JP2017226156A - Production method of decorative sheet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a production method of a decorative sheet, which has a degree of freedom in a way of placing a base material on a transportation table and is less likely to generate a positional deviation irrespective of how the base material is placed.SOLUTION: A sheet winding step in which a base material 10 is placed on a transportation table 31 such that one side of the base material 10 becomes substantially parallel with a transportation direction D, and, a gap S is formed between opposing sides 31a of adjacent base materials 10 on the transportation table 31, a relative position of the base materials 10 is fixed while suctioning with a suctioning device 40, so as to contain an entire upper surface 11 of the base material 10 placed on the transportation table 31, and a side edge surface 12 on one side of the base material 10 facing outside on the transportation table 31, a sheet winding device 32 is driven to wind a sheet 18 to adhere, and a cutting step of cutting a part that covers the gap S between the base materials 10 of the sheet 18 wound to the base material 10 so as to separate a space between the base materials 10 are sequentially applied.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a method for manufacturing a decorative plate body by putting a non-rectangular plate-like substrate into a sheet winding device and winding the sheet around the surface of the substrate.

  As a conventional method of manufacturing a decorative board body, Patent Document 1 proposes a method of efficiently forming a decorative surface of a tread board having a non-rectangular plate shape such as a triangle, which is disposed at a corner portion of a curved staircase.

  This method is a method using a sheet winding machine (pressure roller) that operates in a direction orthogonal to the loading direction of the substrate. Specifically, first, for a plurality of non-rectangular plate-like substrates, the nose portions are parallel to the loading direction, the side end surfaces of the nose portions are directed outward, and there are gaps between the substrates. The base material is placed on the tray in such a state. And a sheet | seat is wound with a sheet winding machine, the clearance gap equivalent part of a sheet | seat is cut, and it isolate | separates for every base material with a sheet | seat.

  Thus, this method has restrictions on how to place the base material, but according to that, for example, combining two triangular base materials and arranging them so that their overall shape is generally rectangular, the sheet Can be used without waste for almost the entire length in the width direction.

  In addition, in the above document, a positioning protrusion is provided on the tray so that the base material is not displaced when the sheet is wound by the sheet winding machine, and the base material is provided with a protrusion in which the protrusion is fitted. A place is provided to enable alignment.

JP 2008-133622 A

  However, since it is necessary to perform positioning by fitting the concave and convex portions as described above when placing the base material, accuracy is required to place it reliably, regardless of whether it is an automatic or manual placement method. Desired. In addition, as described above, since it is necessary to place the base material so that one side thereof is parallel to the loading direction, it can be said that there is almost no freedom in the placement position of the base material.

  The present invention has been proposed in view of such circumstances, and there is a degree of freedom in how to place the base material on the transport table, and misalignment occurs regardless of how the base material is placed. It is in providing the manufacturing method of a decorative board body which is hard to carry out.

  In order to achieve the above object, the method for manufacturing a decorative board body of the present invention manufactures a decorative board body by putting a non-rectangular plate-like base material into a sheet winding apparatus and winding the sheet around the surface of the base material. The sheet winding device includes a transport table having a plurality of substrates placed thereon and having opposed edges substantially parallel to the transport direction, and a direction substantially perpendicular to the transport direction of the transport table. A sheet winding machine that performs sheet winding operation, and a suction device that sucks the substrate placed on the conveyance table from the back side, and one side of the substrate is substantially parallel to the conveyance direction. The base material is placed on the transport base so that there is a gap between the adjacent sides of the base materials adjacent to each other on the transport base, and the relative positions of the base materials are fixed while sucking with a suction device. The entire upper surface of the base material placed on the transport table including the gap and the outside on the transport table The sheet winding step of operating the sheet winding machine to wind and stick the sheet so as to include the side end surface on one side of the substrate, and covering the gap among the sheets wound on the substrate. A sheet cutting step of cutting the portions so as to separate the base materials is performed in order.

  Since the method for manufacturing a decorative board body of the present invention has the above-described configuration, there is a degree of freedom in the way of placing the base material on the carriage, and even when the base material is placed in any way, the position shifts. Is unlikely to occur.

It is explanatory drawing of the manufacturing method of the decorative board body which concerns on one Embodiment of this invention. (A) is the partial schematic plan view which showed the one aspect | mode of the sheet winding by a sheet winding apparatus. (B) is a partial schematic enlarged side sectional view of the sheet winding apparatus. (A) is a schematic cross section corresponding to the AA line in Fig.1 (a). (B) is a typical longitudinal cross-sectional view of the suction mechanism of the B part of Fig.2 (a). It is a figure which shows the schematic procedure of the manufacturing method of a decorative board body. (A)-(e) is an example of the step board material arrange | positioned by the corner part of the curved staircase which can be manufactured by this manufacturing method. (A)-(i) is another example of the step board material arrange | positioned by the corner part of the curved staircase which can be manufactured by this manufacturing method.

  Embodiments of the present invention will be described below with reference to the accompanying drawings. First, a basic procedure of a method for manufacturing a decorative board body according to the following embodiment (hereinafter simply referred to as a manufacturing method) will be described.

  This manufacturing method is a method for manufacturing the decorative plate body 1 by putting the non-rectangular plate-like base material 10 into the sheet winding device 30 and winding the sheet 18 around the surface of the base material 10. The sheet winding device 30 includes a conveyance table 31 on which a plurality of base materials 10 are placed and having opposed edges substantially parallel to the conveyance direction, and a sheet along a direction substantially orthogonal to the conveyance direction of the conveyance table 31. A sheet winding machine 32 that performs a winding operation and a suction device 40 that sucks the base material 10 placed on the conveyance table 31 from the back side are provided. And this manufacturing method performs the following procedures (process) in order (refer FIGS. 1-3).

  Sheet winding step: First, the base material 10 is formed so that one side of the base material 10 is substantially parallel to the transport direction and a gap S is formed between the opposing sides of the base materials 10 adjacent on the transport base 31. Is placed on the transport table 31 and the relative positions of the base materials 10 are fixed while being sucked by the suction device 40. And the sheet | seat is included so that the whole upper surface 11 of the base material 10 mounted in the conveyance stand 31 including the clearance gap S and the side end surface 12 of the one side of the base material 10 which faced the outer side in the conveyance stand 31 may be included. The winding machine 32 is operated to wind and attach the sheet 18.

  Sheet cutting step: A portion of the sheet 18 wound around the base material 10 covering the gap S is cut so as to separate the base materials 10. Furthermore, it is desirable to cut and remove the sheet protruding portion 18a (see FIG. 3) protruding to the side of the substrate 10 along the end surface.

  According to such a manufacturing method, since the sheet 10 is wound while the substrate 10 on the conveyance table 31 is sucked by the suction device 40 in the sheet winding step, a winding mistake due to misalignment hardly occurs. Furthermore, since the base material 10 is held at a fixed position with respect to the conveyor 31, it is possible to prevent the gap S between the base materials 10 from fluctuating. Further, if the suction can be performed at a number of locations on the transport table 31, the substrate 10 can be placed at various positions. That is, the degree of freedom of the placement method is improved. Therefore, efficient manufacture of the decorative board 1 can be realized.

  Next, the details of this manufacturing method will be described by taking the tread material 1 used for each step of the corner portion 51 of the curved staircase 50 as an example. First, the shape and usage of the tread board material 1 will be described with reference to FIGS. 4 and 5. The arrows in FIGS. 4 and 5 indicate the ascending direction.

  This tread board material 1 is a non-rectangular plate-like board disposed as a tread board material 1 in each step of a square corner portion 51 in plan view in the middle of a curved staircase 50 as shown in FIG. Is the body.

  The footboard material 1 is configured by winding a decorative sheet 18 around a base material 10. As the base material 10, various plate materials such as plywood, MDF, and particle board are used. A synthetic resin material or the like may be used.

  The corner 51 of the left turn shown in FIG. 4A is composed of three stages. As shown in FIG. 4B, the shapes of these treads (tread material 1) are triangular, non-rectangular (not trapezoidal), and triangular in order from the bottom. On the upper surface of the nosing part 1 a of each tread board material 1, a groove 1 b formed by a non-slip groove 13 formed on the base material 10 appears. That is, the base material 10 is a plate material in which the front and back surfaces (upper and lower surfaces) are distinguished.

  As shown by a two-dot chain line in FIG. 4 (a), when the corner portion 51 is right-turned, it corresponds to FIG. 4 (b) and is symmetrical to FIG. 4 (b). The shape of c) is mentioned.

  4D and 4E are examples in the case where each of a plurality of steps (two steps) constituting the corner portion 51 has the triangular tread material 1, and in either case, the corner portion 51 is shown. The two tread board materials 1 in plan view have a right-angled isosceles triangle having the same outer shape.

  As shown in these drawings, the tread material 1 of the corner portion 51 has a shape obtained by dividing a square into a plurality of pieces. 4B and 4C, the first step plate 3L1 in FIG. 4B and the third step plate 3R3 in FIG. 4C have the same outer shape. Since the corresponding sides are different, the overall shape including the groove 1b is not the same. Similarly, the third step tread 3L3 in FIG. 4B and the first step tread 3R1 in FIG. 4C have the same outer shape, but the sides corresponding to the nose portion 1a are different. They are not the same shape. The second step plates 3L2 and 3R2 have the same outer shape, but since the sides corresponding to the nose portion 1a are different, they are not the same shape.

  Further, between FIGS. 4D and 4E, the second step plates 2L2 and 2R2 have the same outer shape and sides corresponding to the nose portion 1a, and thus have the same shape. On the other hand, the first step tread 2L1 in FIG. 4 (d) and the first step tread 2R1 in FIG. 4 (e) have the same outer shape, but since the sides corresponding to the nose portion 1a are different, they have the same shape. is not.

  5 (a) to 5 (d) are other examples of the corner portion 51 composed of two steps, and each corner portion 51 is a combination of a triangular tread board material 1 and a trapezoidal tread board material 1. FIG. It becomes more. FIG. 5E is a diagram showing an example of the corner portion 51 using the four-step tread material 1.

  Furthermore, the planar view shape of the corner portion 51 in FIGS. 5F to 5I is a rectangle formed by arranging two squares. Each of the corner portions 51 in FIGS. 5 (f) and 5 (g) is a combination of a total of four tread board materials 1 including two triangular tread board materials 1 and two trapezoid tread board materials 1. 5 (h) and 5 (i), the corner portions in FIG. 5 (h) and (i) are a total of five tread board materials 1, two non-rectangular tread board materials 1, and a regular triangular tread board material 1. Composed of a combination of sheets.

  The tread material 1 having various shapes illustrated in FIGS. 4 and 5 can be manufactured by this manufacturing method. Hereinafter, a specific manufacturing method will be described with reference to a manufacturing method example in the case where six tread materials 1 shown in the two examples of FIGS. 4B and 4C are manufactured collectively.

  1 and 2 are explanatory views of a specific manufacturing method for manufacturing the six tread materials 1 shown in FIGS. 4 (b) and 4 (c), particularly showing the sheet winding process in detail. It is explanatory drawing. FIG. 3 is a diagram showing the flow of all the steps of this manufacturing method.

  First, equipment in this manufacturing method will be described with reference to FIGS.

  A loading device 20 for sequentially loading the base material 10 into the sheet winding device 30 is installed on the upstream side of the conveying table 31 (see FIG. 1A). The feeding device 20 may have any configuration as long as the base material 10 can be transported and fed from the preparation stage (not shown) of the previous process to the transport base 31 using an operable arm (not shown).

  As described above, the sheet winding device 30 is a sheet that performs sheet winding operation along a conveyance table 31 on which a plurality of base materials 10 are placed and conveyed, and a direction substantially orthogonal to the conveyance direction D of the conveyance table 31. A winding machine 32 and a suction device 40 for sucking the base material 10 placed on the transport table 31 from the back side are provided.

  In the example of FIG. 1, the transport table 31 is a conveyor 31, and both opposing edges 31 a in a direction orthogonal to the transport direction D (the width direction of the conveyor 31) are substantially parallel. As shown in FIG. 1B, the conveyor 31 is formed by connecting a plurality of conveyor members 31b in a caterpillar shape.

  As the sheet winding machine 32, for example, a sheet feeding roller 33 that feeds the sheet 18 in the transport direction D on the operating conveyor 31 and a sheet winding operation that performs a sheet winding operation along a direction orthogonal to the transport direction D while being transported. The thing with the roller 34 is mentioned.

  The sheet feeding roller 33 is disposed on the downstream side of the feeding device 20 for the base material 10 in FIG. 1A, and the pasting roller 34 is further disposed on the downstream side. As shown in FIG. 2A, the pasting roller 34 includes a side end surface 12 facing outward and a part of the back surface continuous to the side end surface 12 with respect to the base material 10 placed on the conveyor 31. Thus, the operation of winding the sheet 18 is performed. The pasting roller 34 may be further movable along the longitudinal direction of the conveyor 31.

  Further, the sheet winding machine 32 may have a configuration in which the application roller 34 is wound around the plurality of target base materials 10 while taking out the sheet 18 in the width direction of the conveyor 31. The sheet winding machine 32 may apply the sheet 18 in a state where the conveyor 31 is stopped, restart the operation of the conveyor 31, and wind the sheet on the substrate 10 to be conveyed by the pasting roller 34. In other words, the sheet winding machine 32 only needs to perform a sheet winding operation along the direction substantially orthogonal to the conveyance direction D with respect to the base material 10 on the conveyor 31.

  The suction device 40 is configured to suck (adsorb) the base material 10 placed at an appropriate position on the conveyor 31. The conveyor 31 has a large number of suction ports 31c for suction. Specifically, as shown in FIG. 1B, the suction device main body 41 is disposed below the conveyor 31, and a number of suction mechanisms 42 (FIG. 1A) attached to the conveyor 31 are provided. In this way, the substrate 10 on the conveyor 31 is sucked through the suction port 31c.

  As shown in FIG. 2 (b), each suction mechanism 42 is incorporated in the conveyor 31, and has a cylindrical body 43 having a suction port made of a circular hole 43a on the top surface, and an upper and lower provided in the cylinder body 43. It has an elastic body 45 that compresses and returns in the direction, and a sphere 44 that is larger in diameter than the circular hole 43a.

  When the elastic body 44 is in the return state, the upper portion of the sphere 44 protrudes above the conveyor 31 as shown in the left diagram of FIG. When the base material 10 is placed on the conveyor 31 in this state, the sphere 44 is pushed downward by the weight of the base material 10 as shown in the right diagram of FIG. . Then, when the spherical body 44 is moved downward, the suction port 31c of the conveyor 31 and the circular hole 42b of the suction mechanism 42 are both opened, and the base material 10 is sucked. If the base material 10 is removed from the conveyor 31, the elastic body 45 will return and will be in the state of the left figure of FIG.2 (b). The suction device 40 also determines the presence / absence of the base material 10 on the transport table 31 by the configuration of the suction mechanism 42 as described above.

  As described above, since the suction mechanism 42 is incorporated in the conveyor 31, the position changes as the conveyor 31 is conveyed. That is, the relative position of the base material 10 placed on the conveyor 31 with respect to the suction mechanism 42 below is not changed even if the conveyor 31 performs a circulating operation.

  As long as the base material 10 is placed on the conveyor 31, the suction mechanism 42 on the lower side of the base material 10 determines that “the base material is present”, and the base material 10 is sucked downward. The suction mechanism 42 at the portion where nothing is placed on the conveyor 31 determines that “there is no base material” and does not perform the suction operation on the base material 10. In addition, it is good also as a structure which discriminate | determines the presence or absence of the base material 10 with another sensor.

  Further, the sheet cutting device 25 used in the sheet cutting step is installed on the side of the conveyor 31 as shown in FIG. The sheet cutting device 25 may be moved along the longitudinal direction of the conveyor 31 or may have an arm (not shown), and the arm may be moved in any direction on the upper surface side of the conveyor 31. The sheet cutting device 25 may be arranged so that the cutting operation can be performed at least on the portion where the pasting operation by the pasting roller 34 has been performed.

  Next, a more specific and detailed procedure of this manufacturing method will be described with reference to FIGS. In addition, FIG. 3 is a figure which showed the schematic procedure of the manufacturing method, In this figure, the outline state was written together about the example (2 sheet combination) of the base material 10 corresponding to each process.

(A) Material input process (see Fig. 1)
A total of six base materials 10 of each of the three tread board materials 1 constituting each corner portion 51 shown in FIGS. 4B and 4C are input by the input device 20 shown in FIG. . That is, the base material 10 is the base material 10 corresponding to the treads 3L1, 3L2, and 3L3 in FIG. 4B and the base material 10 corresponding to the treads 3R3, 3R2, and 3R1 in FIG. Are input in the above order. 1A is a diagram in which the base material 10 is placed on the conveyor 31. In order to show the correspondence with the tread material 1 shown in FIG. .. Etc. are also shown.

  As shown in FIG. 1 (a), the substrate 10 has a side corresponding to the nose portion 13 (side on which the anti-slip groove 14 is formed on the surface) substantially parallel to the transport direction D. And it arrange | positions on the conveyor 31 with the clearance gap S opened between the opposing sides of the adjacent base material 10. FIG. Further, the base material 10 is placed so that the side corresponding to the nose 13 protrudes outward from the side end in the width direction of the conveyor 31 so that the sheet 18 is correctly wound around the base material 10. It is desirable.

  As described above, when the base material 10 is sequentially put into the conveyor 31 as described above, the base material 10 is placed on the conveyor 31 and is weighted. As shown in the right diagram of FIG. Is pushed down to open the suction port 31c and the circular hole 42b, and the base material 10 is adsorbed to the conveyor 31 by the suction operation of the suction machine body 41. Therefore, in the state of FIG. 10 is in a sucked state.

(B) Sheet winding process (see FIGS. 1 to 3)
After feeding the substrate 10 into the conveyor 31, the sheet feeding roller 33 performs a sheet feeding operation, and the sheet 18 is placed on the substrate 10 as shown in FIG. Then, in accordance with the conveyance, the pasting roller 34 operates in order from the top base material 10 to perform the operation of winding the sheet 18 around the base material 10.

  The sheet 18 is wound on the entire upper surface 11 of the base material 10, the side end face 12 on the nose portion 13 side, and a part of the back face continuous from the side end face 12. For example, with respect to a portion where the base materials 10 corresponding to the treads 3L1 and 3L2 are arranged in the width direction (A-A line in FIG. 1A), as shown in FIG. On the other hand, the sheet 18 is wound (attached). In order to stick the sheet 18, an adhesive may be applied to the surface of the substrate 10 in advance. In addition, this process does not need to be implemented after all the 6 base materials 10 are thrown in, and should just be implemented after discriminating having thrown into the conveyor 31 for every base material 10. FIG.

(C) Sheet cutting step (see FIGS. 1 and 3)
After the winding of the sheet 18 to the base material 10 is completed, the sheet cutting device 25 is operated, and the base material 10 in which the nose 13 is arranged on one side end side in the width direction of the conveyor 31 and the other side The sheet 18 is cut along the broken line in FIG. In addition, this process does not need to be performed after all the six base materials 10 are sheet-wound, and may be performed for each base material 10 after determining that the sheet winding is completed.

(D) Sheet cutting (exact cutting) step (see FIG. 3)
After the sheet cut of (C), the base material 10 with the sheet 18 is transferred from the conveyor 31 to another work table (not shown). Then, on the work table, for each base material 10, the sheet protruding portion 18 a that protrudes to the side of the base material 10 is cut along the edge of the base material 10 with the exact size, and the tread material 1 is formed. Is done. Note that the sheet protruding portion 18a may be folded and attached to the side end face 12 instead of cutting at an exact size.

  Since the side end surfaces 12 on the sides other than the nose portion 13 are not exposed after the construction, it is desirable to cut and remove the sheet protruding portion 18a in this way. Therefore, in order to perform an efficient sheet cutting operation, the sheet cutting device 25 may be used to cut along the edge of one substrate 10 to separate the substrates 10. Further, the sheet 18 that covers the gap S is formed on the conveyor 31 by using a sheet cutting apparatus that can simultaneously perform exact cutting along both opposing edges of both base materials 10 arranged through the gap S. You may make it remove. That is, as indicated by a broken line arrow in FIG. 3, after the sheet winding process, a sheet cutting (exact cutting) process that also serves as a separation cut between the base materials 10 may be performed on the conveyor 31.

  As described above, according to this manufacturing method, even if the base material 10 on the conveyor 31 is in a state of being aligned in the width direction, the sheet 18 is wound in a state in which they are gathered. It can be used without waste over almost the entire length in the width direction.

  In addition, since a large number of suction devices 40 are provided on the conveyor 31, the base material 10 can be maintained in the state of being adsorbed and fixed to the conveyor 31 from the loading of the base material 10 to sheet cutting. Therefore, it is possible to prevent the base material 10 from being displaced during conveyance, sheet winding operation, or sheet cutting operation. In particular, in the sheet winding process, the sticking roller 34 operates while pressing the upper surface 11 and the side end surface 12 of the base material 10, so that there is a risk that the operation is likely to be displaced. Therefore, it is possible to prevent the occurrence of deviation.

  Furthermore, if the suction mechanism 42 is regularly provided at a number of positions on the conveyor 31 as shown in FIG. 1A, the substrate 10 can be adsorbed almost certainly regardless of the position on the conveyor 31. Therefore, the base material 10 does not have to be placed at a specific position. Therefore, the charging device 20 only needs to place the base material 10 on the conveyor 31 with the side corresponding to the nose portion 13 of the base material 10 set to a predetermined position, and does not need to perform complicated positioning, and can be freely used. Placement at a position can be performed.

  The feeding device 20 may store the placement position of the substrate 10 and provide the position information to the sheet cutting device 25. The sheet cutting device 25 may calculate the sheet cutting position based on the position information and cut the sheet 18 along the sheet cutting position.

  When manufacturing the tread material 1 as in the present embodiment, the sheet winding process as described above is performed in the present manufacturing method. Therefore, the upper surface 11 of the base material 10 corresponds to the nose portion 13 as a matter of course. The sheet 18 can also be attached to the side end face 12 of the side. That is, a decorative surface can be formed on most of the parts exposed after construction by the automatic conveyance winding by the manufacturing method. Moreover, since the sheet | seat 18 can be affixed on the nose part 13 indispensable to be a makeup | decoration surface, it is highly convenient.

  In the above, although the tread board material 1 was illustrated as a decorative board body, it is not limited to this. By this production method, various non-rectangular plate-like decorative board bodies 1 can be produced.

1 Tread board material (decorative board)
D conveying direction 10 base material 11 upper surface 12 side end surface S gap 18 sheet 18a sheet protruding part 30 sheet winding device 31 conveyor (conveying table)
31a Opposing edge 32 Sheet winding machine 40 Suction device

Claims (3)

A method of manufacturing a decorative plate body by putting a non-rectangular plate-like substrate into a sheet winding device and winding the sheet around the surface of the substrate,
The sheet winding apparatus includes a transport table having a plurality of the base materials on which opposite edges that are substantially parallel to the transport direction, and a sheet winding along a direction substantially orthogonal to the transport direction of the transport table. It is configured to have a sheet winding machine that operates, and a suction device that sucks the base material placed on the transport table from the back side,
The base material is placed on the transport table so that one side of the base material is substantially parallel to the transport direction and a gap is formed between opposing sides of the base materials adjacent on the transport table. Arranging and fixing the relative position of the base materials while sucking with the suction device, including the gap, the entire upper surface of the base material placed on the transport table, and the outside of the transport table. A sheet winding step of operating the sheet winding machine to wind and stick the sheet so as to include a side end surface on one side of the base material facing;
A sheet cutting step of cutting a portion covering the gap in the sheet wound around the base material so as to separate the base materials is manufactured in order. Method. In claim 1,
The base material is a tread material disposed at a corner of a curved staircase,
The method for manufacturing a decorative board body, wherein the tread board material is arranged so that a side corresponding to a nose portion is parallel to one opposing end edge of the transport table. In claim 1 or 2,
The method of manufacturing a decorative board, wherein the suction device operates by determining the presence or absence of the base material on the transport table.

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