JP2000289015A - Method and apparatus for manufacturing tile unit - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve productivity by filling a synthetic resin of a flowing state in without mold holes from an upper surface side of a mold sheet, removing the sheet and forming a bridge piece of the resin in the hole. SOLUTION: A mold sheet 3 having without mold holes 2 modeled in a shape of a bridge piece to meet a disposition of the piece at a stainless steel plate is superposed on a bearer 1. Then, in the state that a synthetic resin of a flowing state is fully filled between spatula members 40 of a charging means 4, the members 40 are slid in one reciprocation in a mold sheet 3 state, and the resin becoming a raw material of the piece is filled in the holes 2. Then, the sheet 3 is removed from the bearer 1, and the resin in the holes 2 is directly placed on an upper surface of the bearer 1. A tile group is laced on the bearer 1, curing of the resin is executed. According to the constitution, troublesomeness of bringing a mold recess of the bearer 1 into coincidence with the holes 2 of the sheet 3 is eliminated, and hence productivity is improved.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method and an apparatus for manufacturing a tile unit in which a plurality of tiles arranged at predetermined joint intervals are connected by a bridge member made of synthetic resin.

[0002]

2. Description of the Related Art As shown in FIG. 17, each of a plurality of tiles T, T... (Hereinafter, an aggregate of such tiles T, T... Are connected by a synthetic resin bridge piece B, and a tile unit U is known. A conventional method of manufacturing the tile unit U will be described with reference to FIGS.
First, a synthetic resin b (for example, a thermosetting resin such as polyvinyl chloride), which is a material of the bridge piece B, is dropped at the bridge piece placement point on the flat receiving table A with the nozzle N, and the tile group is placed thereon. Then, the synthetic resin b is brought into close contact with the back surface of the tile group, and the hardening treatment of the synthetic resin b is performed as it is (for example, if the synthetic resin b is a thermosetting resin, heating is performed for a predetermined time).

[0003]

The above conventional manufacturing method (hereinafter simply referred to as a nozzle dropping method) has the following problems. Since the soft synthetic resin b before curing is sandwiched between the cradle A and the tile T and crushed, the portion (see S in FIG. 17) becomes thin and the adhesive strength to the tile T becomes insufficient. Since the crushed synthetic resin b sandwiched between the cradle A and the tile T escapes into the gap between the joints, the bridge piece B having a large bulge at the center is formed. Usually, in the construction method using the tile unit U, joints are often adjusted by cutting the bridge pieces B of the tile unit U in the final stage. However, as described above, the bridge pieces B become thicker at the joints. In this case, it is difficult to cut the bridge pieces B and the separated bridge pieces B do not overlap each other smartly, so that it is difficult to adjust the joint width to be small. In addition, the bridge piece B bulging in a kamaboko shape may protrude beyond the thickness of the tile T to the surface, and the appearance is very poor. The ends of the bridge pieces B may enter the separation preventing grooves V formed on the back surface of the tile T, and the effect of preventing the separation of the tile T itself is reduced. Since the tile group rises from the cradle A and is supported by the synthetic resin b, the tile group becomes unstable, and there is a possibility that the arrangement of the tiles may be deviated in the process of moving to the next step. Although the number of the nozzles N required is equal to the number of the bridge pieces B, the cost is high because the unit price per one nozzle N is high. In addition, when the dimensions and arrangement of the tiles T of the tile unit U change, the arrangement of the nozzles N needs to be changed accordingly, which is not suitable for the production of small quantities. Since the shape of the bridge piece B is not constant, the commercial value of the tile unit U is low.

The applicant of the present invention paying attention to the above problem of the nozzle dropping method, as shown in FIGS. 15 and 16, forms a mold recess 100 for forming a bridge piece B on a receiving table 1 on which a group of tiles is mounted. The mold sheet 3 provided with the cutout hole 2 corresponding to the mold concave portion 100 is placed on the cradle 1 (FIG. 15).
See right half. ), Filling the cutout hole 2 from the upper surface side of the mold sheet 3 with a synthetic resin b in a flowing state to be a material of the bridge piece B (see the left half of FIG. 15). The upper portion of the tile group b is made to protrude higher than the upper surface of the receiving table 1 (see the right half of FIG. 16). (Refer to the left half of FIG. 16). In this state, a hardening treatment of the synthetic resin b is performed to form the bridge piece B, and a method for manufacturing the tile unit NU is disclosed in Japanese Patent Application No. Hei 10-100586. No.)

[0005] Although the method of manufacturing the tile unit according to the above-mentioned prior application has achieved the intended results, as a result of further testing and research, the mold recess 100
Was found to be feasible even without the.

[0006]

SUMMARY OF THE INVENTION The present invention has been made in view of the above, and is directed to a method of manufacturing a tile unit in which tiles of a group of tiles are connected to each other by a bridge piece made of a synthetic resin to form a tile unit. A cradle on which the tile group is placed, a mold sheet having a cutout hole in the shape of the bridge piece in accordance with the arrangement of the bridge piece, and a filling means for filling the cutout hole with a synthetic resin in a flowing state. Use
A method for manufacturing a tile unit satisfying the following requirements is provided. The mold sheet is placed on the receiving table, and the cutout hole is filled with a synthetic resin in a flowing state as a material of the bridge piece from the upper surface side of the mold sheet by filling means. The mold sheet is removed, and the synthetic resin in the cutout hole is directly placed on the upper surface of the receiving table. The back surface of the tile group is brought into close contact with the synthetic resin by placing the tile group face up on the upper surface of the receiving stand. In this state, a curing process is performed on the synthetic resin to form a bridge piece.

According to the above manufacturing method, since the synthetic resin is directly mounted on the upper surface of the receiving base, the mold recess 100 of the receiving base 1 and the cutout hole 2 of the die sheet 3 are different from the prior invention.
Does not need to be matched, and since the bridge piece B is easily separated from the cradle 1, the productivity is improved.
Since there is no need to form the mold concave portion 100 in the receiving base 1, the manufacturing cost of the receiving base 1 can be significantly reduced.

On the other hand, in contrast to the conventional nozzle dropping method, in the nozzle dropping method, the central portion of the synthetic resin b dropped from the nozzle N (see reference sign W in FIG. 18A) has a mountain height. In contrast to the thick bulging phenomenon at the joints, the present invention makes it possible to form the synthetic resin uniformly and accurately in the cutout holes of the mold sheet, so that the thick bulging phenomena at the joints hardly occur. Further, since an expensive nozzle N is not required, the cost is low, and furthermore, since only the mold sheet needs to be changed in response to a change in the arrangement and dimensions of the tiles of the tile unit, it is possible to flexibly cope with small-volume products.

According to a second aspect of the present invention, when the bridge portion of each tile of the tile group is formed with a stolen portion for receiving the synthetic resin directly mounted on the upper surface of the pedestal, the pushing portion is pushed by the tile. Since the amount of the crushed synthetic resin is drastically reduced, a swelling phenomenon at the joint portion is more unlikely to occur.

According to a third aspect of the present invention, a supporting member for setting the tile group at a position higher than the upper surface of the receiving table is formed so as to be detachable or retractable on the receiving table and the setting position of the tile group by the supporting member. If the thickness is set to be lower than the thickness of the synthetic resin, and the support member is installed on a receiving table before the tile group is placed after removing the mold sheet,
Even if the tile itself is not subjected to any processing, the swelling phenomenon of the joint portion is less likely to occur as in the second aspect.

[0011]

FIG. 1 shows a first embodiment of the present invention.
This will be described with reference to FIGS. 1 is an exploded perspective view showing a main part of a tile unit manufacturing apparatus, FIG. 2 is a rear view of the tile unit, FIG. 3 is a longitudinal sectional view of the tile unit,
FIG. 4 is a longitudinal sectional view of a receiving table and a mold plate, FIG. 5 is a longitudinal sectional view showing a state in which a cutout hole of the mold plate is filled with a synthetic resin, and FIG. 6 is a view showing a state where the mold plate is removed from FIG. FIG. 7 is a longitudinal sectional view showing a state in which a group of tiles is placed on a receiving stand.

First, a finished product of the tile unit NU will be described. As shown in FIGS. 2 and 3, the tile unit N
U is formed by connecting the respective tiles T, T ... constituting the tile group by bridge pieces B, B ... made of synthetic resin. The bridge piece B has an elastic band structure formed of, for example, polyvinyl chloride which is a thermosetting resin, and is attached to a portion of the tile T other than the separation preventing groove V on the back side of the tile T, and the tiles T, T ... connecting each other. Note that, as described above, the tile group is an aggregate of a plurality of tiles T, T... Arranged at predetermined joint intervals.

Next, a method of manufacturing the tile unit NU will be described. In the manufacturing method of the present invention, as shown in FIG. 1, a receiving table 1 on which a group of tiles are placed, a mold sheet 3 having a cutout die hole 2, and a flowable synthetic resin b are filled in the cutout die hole 2. And a filling unit 4 to be used as a main component.

As shown in FIG. 1, the cradle 1 is a flat metal plate having a sufficient size for mounting the tile unit NU, and a flat upper surface such as a fluororesin or a silicone resin. A coating of a synthetic resin having excellent mold performance is formed. The cradle 1 slides on a roller conveyor (not shown), for example, and moves between steps as appropriate.

The mold sheet 3 is provided with cutout mold holes 2, 2,... In the shape of the bridge piece B in accordance with the arrangement of the bridge piece B on a stainless steel plate having a thickness of about 1 mm to 1.5 mm. One end is pivotally mounted on a fixed member such as a support frame of the roller conveyor, or is mounted so as to swing freely, or is mounted so as to move up and down at a fixed position by a suitable lifting device.

The filling means 4 includes a pair of rubber spatula members 40, 40 slidably contacting the upper surface of the mold sheet 3, and a flow state between the spatula members 40, 40 serving as a material of a bridge piece B. Supply device 41 for supplying (pouring) synthetic resin b
And drive means (not shown) for reciprocating the spatula members 40, 40 on the mold sheet 3.

First, the cradle 1 moving on the roller conveyor is stopped at a predetermined position corresponding to the mold sheet 3 as shown in FIG.
Layer. Next, as shown in FIG.
The spatula members 40, 40 are slid one reciprocally on the mold sheet 3 in a state where the synthetic resin b in the flowing state is filled between 0, 40. Then, the cutout holes 2, 2,... Are filled with the synthetic resin b serving as the material of the bridge piece B at a uniform thickness.
As shown in the figure, by forming the pair of spatula members 40, 40, it is possible to reliably fill the synthetic resin b in the forward stroke and the backward stroke. The synthetic resin b is a thermosetting resin (polyvinyl chloride) and has fluidity at room temperature. Next, the mold sheet 3 is removed from the pedestal 1 and the pedestal 1 as shown in FIG.
The synthetic resin b in the cutout hole 2 is directly placed on the upper surface.

On the other hand, tiles T, T... Are arranged in another place to form a tile group, which is sucked and conveyed and stopped above the pedestal 1 as shown by the two-dot chain line in FIG. It is lowered as it is and is placed face up on the upper surface of the cradle 1 as shown in FIG. Then, the back surfaces of the tiles T, T... In the figure, the thickness of the synthetic resin b is exaggerated for easy understanding, but the thickness of the synthetic resin b is very thin, 1 mm to 1.5 mm, whereas the thickness of the tile T is 7 mm.

Next, the hardening process of the synthetic resin b is executed in the state shown in FIG. In the embodiment, since the synthetic resin b is thermosetting resin polyvinyl chloride, the pedestal 1 is transported and put into a heating furnace at 140 ° C. ×
What is necessary is just to heat for 15 minutes. By doing so, the synthetic resin b is cured to become a bridge piece B, and at the same time, the bridge piece B is attached to the back surface of the tile T to connect the tiles T, T. When a thermosetting resin is used as the material of the bridge piece B, there is an advantage that the bridge piece B does not peel even when the temperature of the completed tile unit NU is increased by leaving it in the hot sun.

The curing treatment of the synthetic resin b naturally depends on the type of the synthetic resin b. For example, when a photosensitive resin is used as the material of the bridge piece B, the synthetic resin b is cured by irradiating light (ultraviolet light).

Next, the tile group is removed from the cradle 1 by suction or by hand. Then, the bridge piece B is stuck to the tile group side and peeled off from the cradle 1. At this time, if a coating of a synthetic resin having excellent release performance is formed on the pedestal 1 as described above, the operation of peeling off the bridge pieces B can be performed very smoothly.

[0022]

Second Embodiment FIGS. 8 and 9 show a second embodiment of the present invention. Both figures are enlarged cross-sectional views of a main portion showing a state where a tile is placed on a receiving stand.

The manufacturing apparatus according to the second embodiment is the same as that according to the first embodiment, but is characterized in that steal portions 50 and 51 are formed at the fixing portions of the bridge pieces B of the tiles T. Specifically, a chamfered meat stealing portion 50 is formed around the back surface of the tile T as shown in FIG. 8, or a stepped meat stealing portion 51 is formed around the back surface of the tile T as shown in FIG. . These meat stealing portions 50 and 51 receive the synthetic resin b placed directly on the upper surface of the cradle 1 and, when the group of tiles are placed on the upper surface of the cradle 1, as shown in FIGS. The abdominal surfaces of the portions 50 and 51 and the synthetic resin b are securely adhered. By providing the meat stealing portions 50 and 51, the amount of the synthetic resin b crushed by the tile T is drastically reduced, so that the swelling at the joint portion is suppressed to the same level as in the invention of the prior application. It is not necessary to form the meat stealing portions 50 and 51 all around the back surface of the tile T, and they may be provided partially in accordance with the positions of the bridge pieces B.

[0024]

Third Embodiment FIGS. 10 to 13 show a third embodiment of the present invention. FIGS. 10 and 11 are partially cutaway plan views showing a state where a group of tiles are placed on a pedestal. FIG. FIG. 13 is an exploded perspective view showing the support member, and FIG. 13 is an enlarged cross-sectional view taken along line XX of FIG.

The manufacturing apparatus according to the third embodiment is characterized in that the supporting member 6 is detachably mounted on the upper surface of the receiving table 1. That is, as shown in FIG. 12, the support member 6 is formed by forming a tile seat 61 at a corner of a prism 60, and the height of the tile seat 61 is directly mounted on the upper surface of the cradle 1. The pedestal 1 is set lower than the thickness of the resin b and has a joint pin 62 protruding from the bottom surface of the prism 60.
It is loosely fitted in the receiving hole 63 formed on the side.

Thus, the present manufacturing apparatus provides the mold sheet 3 on the flat upper surface of the receiving table 1 before the support member 6 is attached.
Are filled with the synthetic resin b by the filling means 4, and the mold sheet 3
, And the synthetic resin b in the cutout hole 2 is directly mounted on the receiving table 1, and then the joint pin 62 as shown in FIG.
The supporting member 6 is attached to the receiving base 1 by fitting the receiving base 1
Further, the group of tiles is placed on the tile seat 61 of the support member 6. As described above, the height of the tile seat 61 of the support member 6 is set lower than the thickness of the synthetic resin b. Will adhere.

Then, after the hardening process of the synthetic resin b is performed in this state, the tile group is removed from the receiving table 1, and the support member 6 is also removed from the receiving table 1 to return to the first step.

The supporting member 6 of the third embodiment may be formed by combining a large number of discrete parts as described above, or may be formed in a single plate as shown in FIG. That is, the support member 6 is formed by punching a window hole 65 which is located at a position corresponding to the synthetic resin b and is larger than the plate 64 having a size substantially equal to that of the receiving table 1. Partition ribs 66 are protruded in the vertical and horizontal directions in accordance with the arrangement. This partition rib 6
6 mainly has a function of positioning the tiles T, but also has a reinforcing function of preventing the plate 64 from warping.

The thickness of the plate 64 is smaller than the thickness of the synthetic resin b. For example, if the thickness of the synthetic resin b is 1.5 mm, the thickness of the plate 64 is set to 1 mm. With the member 6 installed, a small amount of the synthetic resin b protrudes from the window hole 65.

In this manufacturing apparatus, the mold sheet 3 is stacked on the flat upper surface of the receiving table 1 before the support member 6 is attached, the synthetic resin b is filled by the filling means 4, and the mold sheet 3 is removed. Then, the synthetic resin b in the cutout hole 2 is directly mounted on the receiving table 1, and then the supporting member 6 is mounted on the receiving table 1. At this time, if positioning means 67 (refer to FIG. 11) such as a combination of a boss and a boss hole is provided in the support member 6 and the receiving base 1, the positioning can be performed accurately. The resin “b” surely faces. Although not shown, a suitable clamping means may be provided to temporarily fix the support member 6 to the receiving table 1.

When the group of tiles conveyed in the aligned state is placed on the support member 6, the tiles T are guided by the partition ribs 66, and the tiles T are accurately aligned. , The synthetic resin b is in close contact with the back surface of the tile T. After performing the hardening process of the synthetic resin b in this state, the tile group is removed from the receiving table 1. The feature of the present embodiment is that the tile unit NU is entirely mounted on the support member 6, so that the
The bridge piece B is automatically peeled off from the cradle 1 by the operation of lifting up.

According to the manufacturing apparatus and the manufacturing method of the tile unit of the third embodiment, the amount of the synthetic resin b crushed by the tile T is drastically reduced, as in the above-mentioned prior invention.
There is almost no swelling at the joints. Further, if the support member 6 is provided with a positioning function of the tiles T such as the tile seat portion 61 and the partition rib 66 as in the third embodiment, the tiles T are firmly fixed on the cradle 1. Even if the tile group is moved between the processes while being placed on the receiving table 1, the arrangement of the tiles T is not disturbed.

Although the present invention has been described with reference to the first to third embodiments, the present invention is, of course, not limited to the above embodiments. For example, in the first to third embodiments, the mold sheet 3
Although a stainless steel plate was used for the mold sheet 3, the mold sheet 3 may be made of any material such as a synthetic resin, cloth, wood, and ceramic. Further, in FIGS. 10 and 12 of the third embodiment, the attachment / detachment method in which the support member 6 is fitted to the receiving table 1 is adopted. However, for example, a vertical hole is formed in the receiving table 1 and By moving the support member 6 up and down, the head of the support member 6 may be made to protrude and retract on the receiving table 1. In this case, the synthetic resin b is directly placed with the support member 6 lowered, and the tile T
The support member 6 is made to protrude before placing the.

In the first to third embodiments, the cradle 1 has a flat surface which is completely solid. However, the cradle 1 has a stripe-shaped or lattice-shaped shallow groove on the entire surface, or a hemispherical surface on the entire surface. Innumerable depressions may be provided. Since these shallow grooves and dents have nothing to do with the cutout mold hole 2, the mold recess 10 of the prior application is required.
Different from 0.

The mold sheet 3 of the first to third embodiments has a flat plate shape. For example, as shown in FIG. 14, the mold sheet 3 is formed in a circular drum shape and rotated, and the receiving table 1 is synchronized with the rotation. May be moved in a linear direction. In this case, the filling means 4 is incorporated in the mold sheet 3 in a non-rotational structure, and the spatula member 40 is slid on the inner peripheral surface of the mold sheet 3.

[0036]

According to the present invention, since the synthetic resin is directly mounted on the upper surface of the cradle, first, in comparison with the prior invention, the mold recess of the cradle and the cutout hole of the mold sheet are matched. Since there is no inconvenience, productivity is improved, and since there is no need to form a mold recess in the receiving table, there is an advantage that the manufacturing cost of the receiving table can be greatly reduced.

On the other hand, in comparison with the conventional nozzle dropping method, the nozzle dropping method is the same as the synthetic resin b dropped from the nozzle N.
18 (a), the height of the peak is raised at the joints, which causes a thick swelling at the joints. Can be uniformly and accurately formed, so that the phenomenon of thick swelling at joints is unlikely to occur, and the expensive nozzle N is unnecessary, so that the cost is remarkably low. It only needs to change the mold sheet, so it can be applied to small-volume products, and its value is high because the bridge pieces are accurate and the finish is beautiful.

[0038] Further, by forming a stolen portion for receiving the synthetic resin directly mounted on the upper surface of the pedestal at the bridge piece fixing portion of each tile of the tile group, the amount of the synthetic resin crushed by the tile is reduced. Because of the drastic decrease, a swelling phenomenon at the joint portion is unlikely to occur as in the prior invention.

Further, a support member for setting the tile group at a position higher than the upper surface of the receiving table is formed on the receiving table so as to be detachable or retractable, and the setting position of the tile group by the supporting member is determined by the thickness of the synthetic resin. If the support member is set on the receiving table between the time the mold sheet is removed and the tile group is placed, the amount of the synthetic resin crushed by the tile is drastically reduced. As in the present invention, a swelling phenomenon at joints is unlikely to occur.

[Brief description of the drawings]

FIG. 1 is an exploded perspective view showing a main part of a tile unit manufacturing apparatus.

FIG. 2 is a rear view of the tile unit.

FIG. 3 is a vertical sectional view of a tile unit.

FIG. 4 is a longitudinal sectional view of a receiving stand and a mold plate.

FIG. 5 is a longitudinal sectional view showing a state in which a cutout hole of a mold plate is filled with a synthetic resin.

FIG. 6 is a longitudinal sectional view of the cradle showing a state where a mold plate is removed from FIG. 5;

FIG. 7 is a longitudinal sectional view showing a state where a group of tiles is placed on a cradle.

FIG. 8 is an enlarged cross-sectional view of a main part showing a state where a tile is placed on a cradle.

FIG. 9 is an enlarged cross-sectional view of a main part showing a state where a tile is placed on a cradle.

FIG. 10 is a partially cutaway plan view showing a state where a tile group is placed on a cradle.

FIG. 11 is a partially cutaway plan view showing a state where a group of tiles is placed on a cradle.

FIG. 12 is an exploded perspective view showing a support member.

FIG. 13 is an enlarged sectional view taken along line XX of FIG. 11;

FIG. 14 is a longitudinal sectional view of a main part showing another form of a mold sheet.

FIG. 15 is a longitudinal sectional view for explaining the manufacturing method of the invention of the prior application.

FIG. 16 is a longitudinal sectional view for explaining the manufacturing method of the invention of the prior application.

FIG. 17 is a longitudinal sectional view showing a conventional tile unit.

FIGS. 18A and 18B are vertical cross-sectional views illustrating a conventional method for manufacturing a tile unit.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 ... Cradle 2 ... Cutout hole 3 ... Mold sheet 40 ... Spatula member NU ... Tile unit T ... Tile B ... Bridge piece b ... Synthetic resin

────────────────────────────────────────────────── ───

[Procedure amendment]

[Submission date] May 15, 2000 (2000.5.1)
5)

[Procedure amendment 1]

[Document name to be amended] Statement

[Correction target item name] Claims

[Correction method] Change

[Correction contents]

[Claims]

Claims (2)

[Claims] 1. A tile unit in which a plurality of tiles (hereinafter, such an aggregate of tiles is referred to as a tile group) arranged at predetermined joint intervals are connected by a synthetic resin bridge piece. A method of manufacturing a tile unit, comprising: using a mold sheet having a cutout die hole penetrated in accordance with the arrangement of the bridge pieces, and a spatula member that slides on the mold sheet; By filling the cutout hole of the sheet and sliding the spatula member on the mold sheet, the sheet was cut off, and the mold sheet was removed to form a bridge piece with the synthetic resin in the remaining cutout hole. A method for manufacturing a tile unit. 2. A tile unit is formed by connecting a plurality of tiles (hereinafter referred to as a group of tiles) arranged at predetermined joint intervals with a bridge piece made of synthetic resin. A tile unit manufacturing device, comprising: a mold sheet having a cutout die hole penetrated in accordance with the arrangement of the bridge pieces; and a spatula member sliding on the mold sheet. By filling the cutout hole of the sheet and sliding the spatula member on the mold sheet, the sheet was cut off, and the mold sheet was removed to form a bridge piece with the synthetic resin in the remaining cutout hole. An apparatus for manufacturing a tile unit.