JP6722888B2 - Method for manufacturing decorative board - Google Patents

Description

TECHNICAL FIELD The present invention relates to a method for manufacturing a decorative plate body by introducing a non-rectangular plate-shaped base material into a sheet winding device and winding the sheet around the surface of the base material.

As a conventional method for manufacturing a decorative board, Patent Document 1 proposes a method for efficiently forming a decorative surface of a non-rectangular plate-shaped tread arranged in a corner portion of a curved staircase.

This method uses a sheet winding machine (pressure roller) that operates in a direction orthogonal to the feeding direction of the base material. Specifically, first, with respect to a plurality of non-rectangular plate-shaped base materials, the nosing portions are made parallel to each other so that the side end surfaces of the nose portions face outward, and there is a gap between the base materials. The base material is placed on the tray in such a state as described above. Then, the sheet is wound by a sheet winding machine, and a portion corresponding to a gap of the sheet is cut to separate the substrate with the sheet.

Thus, in this method, although there are restrictions on how to place the base material, according to this, for example, if two base materials having a triangular shape are combined and arranged so that their overall shapes are roughly rectangular, a sheet is formed. It is possible to utilize almost the entire length of the width direction without waste.

Further, in the above document, the tray is provided with a positioning protrusion so that the base material is not displaced when the sheet is wound by a sheet winding machine, while the base material has a concave portion into which the protrusion fits. A place is provided so that alignment can be performed.

JP, 2008-133622, A

However, when mounting the base material, it is necessary to perform the alignment by the concave-convex fitting as described above, and therefore the accuracy is not accurate for sure mounting regardless of whether the mounting method is automatic or manual. Desired. Moreover, since it is necessary to mount the base material so that one side thereof is parallel to the loading direction as described above, it can be said that there is almost no degree of freedom in the mounting position of the base material.

The present invention has been proposed in consideration of such a situation, and there is a degree of freedom in how to place a base material on a carrier, and a position shift occurs regardless of how the base material is placed. It is to provide a manufacturing method of a decorative board that is difficult to do.

In order to achieve the above object, the method for producing a decorative sheet according to the present invention is to produce a decorative sheet by introducing a non-rectangular plate-shaped substrate into a sheet winding device and winding the sheet around the surface of the substrate. The sheet winding apparatus has a plurality of suction ports, and a plurality of base materials are placed on the transport table having opposing edges substantially parallel to the transport direction, and the suction ports are individually provided. The suction mechanism that is held in a closed state and opens the suction port located below the substrate when the substrate is placed on the transport table, and the sheet along the direction substantially orthogonal to the transport direction of the transport table. A sheet winding machine that performs a winding operation and a suction device that sucks a base material placed on a transport base from a back side through a suction port, and one side of the base material is in a transport direction. The base material is placed on the carrier so that it is substantially parallel to the base material, and a gap is formed between the opposing sides of the base materials that are adjacent to each other on the carrier. A sheet winding machine having a fixed relative position and including the entire upper surface of the base material placed on the carrier, including the gap, and the side end surface on one side of the base material facing outward in the carrier. A sheet winding step of wrapping and adhering the sheet by operating the sheet, and a sheet cutting step of cutting the portion of the sheet wound around the base material covering the gap so as to separate the base materials. , Are executed in order.

Since the method for manufacturing a decorative board of the present invention has the above-described configuration, there is a degree of freedom in how to place the base material on the carrier table, and the position shift occurs no matter how the base material is placed. Is less likely to occur.

It is explanatory drawing of the manufacturing method of the decorative board which concerns on one Embodiment of this invention. (A) is a partial schematic plan view showing one mode of sheet winding by the sheet winding device. (B) is a partial schematic enlarged side sectional view of the sheet winding device. FIG. 1A is a schematic cross-sectional view corresponding to the line AA in FIG. FIG. 2B is a schematic vertical cross-sectional view of the suction mechanism of the portion B of FIG. It is a figure which shows the schematic procedure of the manufacturing method of a decorative board. (A)-(e) is an example of the material for treads which can be manufactured by this manufacturing method and is arrange|positioned at the corner part of a curved staircase. (A)-(i) is another example of the footboard material which can be manufactured by this manufacturing method and which is arranged at the corner portion of the curved staircase.

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 according to the following embodiment (hereinafter, simply referred to as a manufacturing method) will be described.

The present manufacturing method is a method for manufacturing the decorative sheet 1 by introducing the non-rectangular plate-shaped 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 which has opposing edges substantially parallel to the conveyance direction, and a sheet along a direction substantially orthogonal to the conveyance direction of the conveyance table 31. It has a sheet winding machine 32 that performs a winding operation, and a suction device 40 that sucks the base material 10 placed on the transport table 31 from the back side. Then, this manufacturing method sequentially executes the following steps (processes) (see FIGS. 1 to 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 conveyance direction and a gap S is formed between the opposite sides of the base materials 10 adjacent to each other on the conveyance table 31. Are arranged on the carrier 31 and the relative positions of the base materials 10 are fixed while suctioning with the suction device 40. The sheet includes the entire upper surface 11 of the substrate 10 placed on the carrier 31 including the gap S and the side end surface 12 on one side of the substrate 10 facing outward in the carrier 31. The winding machine 32 is operated to wind and attach the sheet 18.

Sheet cutting step: The portion of the sheet 18 wound around the base material 10 that covers the gap S is cut so as to separate the base materials 10. Further, it is desirable to cut and remove the sheet protruding portion 18a (see FIG. 3) protruding to the side of the base material 10 along the end face.

According to such a manufacturing method, in the sheet winding step, the base material 10 on the conveyance table 31 is wound while being sucked by the suction device 40, so that a winding error due to a positional deviation is unlikely to occur. Furthermore, since the base material 10 is held at a fixed position with respect to the conveyor 31, it is possible to prevent the size of the gap S between the base materials 10 from varying. Further, if the suction can be performed at a large number of points on the carrier table 31, the base material 10 can be placed at various positions. That is, the degree of freedom in the placement method is improved. Therefore, the efficient manufacture of the decorative plate body 1 can be realized.

Next, details of the present 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 material 1 will be described with reference to FIGS. 4 and 5. The arrows in FIGS. 4 and 5 indicate the rising direction.

This tread material 1 is a non-rectangular plate-shaped plate that is arranged as the tread material 1 at each step of the corner portion 51 having a square shape in plan view, which is located in the middle of the curved staircase 50 as shown in FIG. 4A. It is the body.

The tread material 1 is formed by winding a makeup 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 left-handed corner portion 51 shown in FIG. 4A has three stages. As shown in FIG. 4B, the shape of these treads (stepping material 1) is a triangle, a quadrangle that is not a rectangle (not a trapezoid), and a triangle in order from the bottom. On the upper surface of the nose portion 1a of each tread material 1, a groove 1b formed by an anti-slip groove 13 formed on the base material 10 appears. That is, the base material 10 is a plate material whose front and back surfaces (upper and lower surfaces) are distinguished.

As shown by the chain double-dashed line in FIG. 4(a), when the corner portion 51 is bent to the right, FIG. 4(b), which has a symmetrical shape to that of FIG. 4(b), corresponds to FIG. 4(b). The shape of c) is mentioned.

Further, FIGS. 4D and 4E are examples in which each of a plurality of steps (two steps) forming the corner portion 51 has the triangular tread material 1, and in any case, the corner portion 51 is formed. The plan view shape of the two tread materials 1 is a right-angled isosceles triangle having the same outer shape.

As shown in these drawings, the tread material 1 at the corner 51 has a shape obtained by dividing a square into a plurality of parts. 4B and 4C, the outer shape of the first step tread 3L1 of FIG. 4B is the same as that of the third step tread 3R3 of FIG. Since the corresponding sides are different, the overall shape including the groove 1b is not the same. Similarly, the outer shape of the third step tread 3L3 of FIG. 4(b) and the first step tread 3R1 of FIG. 4(c) are the same, but the sides corresponding to the nose portion 1a are different, so these Not the same shape. Although the second step treads 3L2 and 3R2 have the same outer shape, they do not have the same shape because the sides corresponding to the nose section 1a are different.

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

5(a) to 5(d) are other examples of the corner portion 51 configured in two steps, and each corner portion 51 is a combination of a triangular tread material 1 and a trapezoidal tread material 1. Consists of. Further, FIG. 5( e) is a diagram showing an example of the corner portion 51 using the four-step tread material 1.

Further, the plan 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. 5F and 5G is made up of a combination of four tread plate materials 1 including two triangular tread material 1 and two trapezoid tread materials 1. Each of the corner portions in FIGS. 5(h) and (i) has a total of a total of 5 pieces of two tread plate materials 1 having a triangular shape, two tread board materials 1 having a rectangular shape that is not rectangular, and a tread plate material 1 having an equilateral triangle shape. It consists of a combination of sheets.

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

1 and 2 are explanatory views of a specific manufacturing method for manufacturing the six tread material 1 shown in FIGS. 4B and 4C, and particularly show the sheet winding step in detail. FIG. Further, FIG. 3 is a diagram showing the flow of all steps of this manufacturing method.

First, the equipment in this manufacturing method will be described with reference to FIGS. 1 and 2.

The loading device 20 for sequentially loading the base material 10 into the sheet winding device 30 is installed on the upstream side of the transport table 31 (see FIG. 1A). The loading device 20 may have a configuration capable of transporting and loading the base material 10 from the preparation table (not shown) of the previous step to the transfer table 31 using, for example, an operable arm (not shown).

As described above, the sheet winding device 30 includes the conveyance table 31 on which a plurality of base materials 10 are placed and conveyed, and the sheet performing the sheet winding operation along a direction substantially orthogonal to the conveyance direction D of the conveyance table 31. It has a winding machine 32 and a suction device 40 for sucking the base material 10 placed on the carrier 31 from the back side.

The carrier 31 is the conveyor 31 in the example of FIG. 1, and both opposing edges 31a in the direction orthogonal to the carrying direction D (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.

Examples of the sheet winding machine 32 include a sheet feeding roller 33 that feeds the sheet 18 in the conveying direction D on an operating conveyor 31, and a sheet winding operation that conveys the sheet along a direction orthogonal to the conveying direction D while being conveyed. And a roller 34.

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

Further, the sheet winding machine 32 may be configured such that the pasting roller 34 winds the sheet 18 in the width direction of the conveyor 31 while winding the sheet 18 around a plurality of target base materials 10. A sheet winding machine 32 may be used in which the sheet 18 is applied while the conveyor 31 is stopped, the operation of the conveyor 31 is restarted, and the sheet is wound around the conveyed substrate 10 by the sticking roller 34. In this way, the sheet winding machine 32 may be configured to perform the sheet winding operation on the base material 10 on the conveyor 31 along a direction substantially orthogonal to the transport direction D.

Further, the suction device 40 is configured so as to be able to suck (adsorb) the base material 10 placed at a proper position on the conveyor 31. The conveyor 31 has a large number of suction ports 31c for suction. Specifically, as the suction device 40, as shown in FIG. 1( b ), a suction device main body 41 is arranged below the conveyor 31, and a large number of suction mechanisms 42 (FIG. 1( a)) attached to the conveyor 31. (See), the base material 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 formed by a circular hole 43 a on the top surface, and a vertical body provided inside the cylindrical body 43. It has an elastic body 45 that compresses and returns in the direction, and a spherical body 44 having a diameter larger than that of the circular hole 43a.

When the elastic body 44 is in the returning state, the upper portion of the spherical body 44 projects 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 down by the weight of the base material 10 and the elastic body 45 is in a compressed state, as shown in the right diagram of FIG. 2B. .. Then, the suction port 31c of the conveyor 31 and the circular hole 42b of the suction mechanism 42 are opened by the downward movement of the sphere 44, and the substrate 10 is sucked. When the base material 10 is removed from the conveyor 31, the elastic body 45 returns to the state shown in the left diagram of FIG. 2B. The suction device 40 also determines the presence/absence of the base material 10 on the carrier 31 by the structure of the suction mechanism 42.

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 the base material 10 does not change even when the conveyor 31 makes a circulation operation.

Further, 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 exists”, 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 “no base material” and does not perform the suction operation on the base material 10. Note that the presence or absence of the base material 10 may be determined by another sensor or the like.

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 configured to move along the longitudinal direction of the conveyor 31 or have an arm (not shown), and the arm can move on the upper surface side of the conveyor 31 in any direction. The sheet cutting device 25 may be arranged at least so as to be able to perform the cutting operation on the portion where the pasting operation is performed by the pasting roller 34.

Next, a more specific and detailed procedure of this manufacturing method will be described with reference to FIGS. Note that FIG. 3 is a diagram showing a schematic procedure of the manufacturing method, and the diagram also shows a schematic state of an example (combination of two sheets) of the substrate 10 corresponding to each step.

(A) Material charging step (see FIG. 1)
A total of six base materials 10 of each of the three tread materials 1 constituting each corner portion 51 shown in FIGS. 4B and 4C are loaded by the loading device 20 shown in FIG. 1A. .. That is, the base material 10 is, with respect to the conveyor 31, the base material 10 corresponding to the step plates 3L1, 3L2, 3L3 of FIG. Are input in the above order. Note that FIG. 1A is a diagram in which the base material 10 is placed on the conveyor 31, and in order to show the correspondence with the tread material 1 shown in FIG. 4, “3L1”..., “3R1” , Etc. are also shown.

As shown in FIG. 1A, the base material 10 has a side corresponding to the nosing portion 13 (a side on which the anti-slip groove 14 is formed on the surface) substantially parallel to the transport direction D. Further, they are arranged on the conveyor 31 with a gap S between the opposite sides of the adjacent base materials 10. Further, in order to properly wind the sheet 18 around the base material 10, the base material 10 is placed so that the side corresponding to the nose portion 13 projects outward from the lateral end of the conveyor 31 in the width direction. Is desirable.

When the base material 10 is sequentially loaded into the conveyor 31 in this manner, the base material 10 is placed on the conveyor 31 and weighted as described above, and the sphere 44 is placed as shown in the right diagram of FIG. 2B. Is pressed 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 main body 41 of the suction machine. Therefore, in the state of FIG. 10 is in a sucked state.

(B) Sheet winding step (see FIGS. 1 to 3)
After the substrate 10 is loaded 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, according to the conveyance, the sticking roller 34 operates in order from the leading base material 10 to wind the sheet 18 around the base material 10.

The sheet 18 is wound around the entire upper surface 11 of the base material 10, the side end surface 12 on the nose portion 13 side, and a part of the back surface continuous from the side end surface 12. For example, as for the portion where the base materials 10 corresponding to the treads 3L1 and 3L2 are arranged in the width direction (line AA in FIG. 1A), as shown in FIG. The sheet 18 is wrapped (attached) with respect to. In order to attach the sheet 18, an adhesive may be applied to the surface of the base material 10 in advance. It should be noted that this step does not have to be performed after all the six base materials 10 have been loaded, and may be performed after it is determined that each of the base materials 10 has been loaded into the conveyor 31.

(C) Sheet cutting process (see FIGS. 1 and 3)
After the winding of the sheet 18 around the base material 10 is completed, the sheet cutting device 25 operates, and the nose portion 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. 1A so as to separate the base material 10 arranged on the side edge side. It should be noted that this step does not have to be performed after all six base materials 10 have been wound into sheets, and may be performed after it is determined that the winding of sheets has been completed for each base material 10.

(D) Sheet cutting (normal size cutting) step (see FIG. 3)
After the sheet is cut in (C), the substrate 10 with the sheet 18 is transferred from the conveyor 31 to another workbench (not shown). Then, on the workbench, for each base material 10, the sheet protruding portion 18a protruding laterally of the base material 10 is cut along the side edge of the base material 10 at a constant size to form the tread material 1. To be done. Note that the sheet protruding portion 18a may be folded and attached to the side end surface 12 instead of being cut to a full size.

Since the side end faces 12 on the sides other than the nose portion 13 are not exposed after 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 one side of the base material 10 to separate the base materials 10. Further, the sheet 18 covering the gap S is mounted on the conveyor 31 by using a sheet cutting device capable of simultaneously performing the normal size cutting along the opposite edges of both the base materials 10 arranged side by side through the gap S. It may be removed. That is, as indicated by a dashed arrow in FIG. 3, after the sheet winding step, a sheet cutting (normal size cutting) step 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 materials 10 on the conveyor 31 are arranged side by side in the width direction, the sheets 18 are wound in a gathered state. It can be used without waste over almost the entire length in the width direction.

Further, since a large number of suction devices 40 are provided side by side with the conveyor 31, it is possible to maintain the base material 10 in a state in which the base material 10 is adsorbed and fixed on the conveyor 31 from the loading of the base material 10 to the sheet cutting. Therefore, it is possible to prevent the substrate 10 from being displaced during conveyance, sheet winding operation, and sheet cutting operation. In particular, in the sheet winding step, the sticking roller 34 operates while pressing the upper surface 11 and the side end surface 12 of the base material 10, so that the operation may easily cause a deviation, but the base material 10 is conveyed by the conveyor 31. Since it is adsorbed on the substrate, the occurrence of displacement can be prevented.

Further, if the suction mechanism 42 is regularly provided at a large number of positions on the conveyor 31 as shown in FIG. 1A, the substrate 10 can be almost surely adsorbed regardless of the position on the conveyor 31. Therefore, the substrate 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 by aligning the side corresponding to the nose portion 13 of the base material 10 with a predetermined position, and it is not necessary to perform complicated alignment, and the insertion device 20 can be freely moved. Placement can be performed.

Further, the loading device 20 may store the placement position of the base material 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.

In the case of manufacturing the footboard material 1 as in the present embodiment, the above-described sheet winding step is executed in the present manufacturing method, so that 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 surface 12 of the side. In other words, the decorative surface can be formed on most of the exposed areas after the construction by the automatic winding of the transport by the manufacturing method. Further, since the sheet 18 can be attached to the nosing portion 13 which must be a makeup surface, the convenience is high.

The tread material 1 has been illustrated above as a decorative board, but the present invention is not limited to this. By this manufacturing method, various non-rectangular plate-shaped decorative board bodies 1 can be manufactured.

1 Tread material (decorative board)
D Conveyance direction 10 Base material 11 Upper surface 12 Side end surface S Gap 18 Sheet 18a Sheet protruding portion 30 Sheet winding device 31 Conveyor (conveyor)
31a Opposite end edge 32 Sheet winding machine 40 Suction device

Claims (2)

A method for producing a decorative board by throwing a non-rectangular plate-shaped substrate into a sheet winding device and winding the sheet around the surface of the substrate,
The sheet winding device has a large number of suction ports, a plurality of the base material is placed, a transport table having opposing edges substantially parallel to the transport direction,
A suction mechanism that holds the suction ports individually, and opens the suction ports located below the substrate when the substrate is placed on the carrier,
A sheet winding machine that performs a sheet winding operation along a direction substantially orthogonal to the conveyance direction of the conveyance table,
A suction device for sucking the base material placed on the carrier from the back side through the suction port ;
It is configured to have
The base material is placed on the transfer table so that one side of the base material is substantially parallel to the transfer direction and a gap is provided between opposing sides of the base materials that are adjacent to each other on the transfer table. Arranged, fixing the relative positions of the base materials while sucking with the suction device, including the gap, the entire upper surface of the base material placed on the transfer table, and the outer side of the transfer table. A sheet winding step in which the sheet winding machine is operated to wind and attach the sheet so as to include the side end surface on the one side of the base material facing the side;
A sheet cutting step of cutting a portion of the sheet wound around the base material that covers the gap so as to separate the base materials from each other. Method. In claim 1,
The base material is a material for a tread arranged at the corner of a curved staircase,
The method for manufacturing a decorative board, wherein the footboard material is arranged such that a side corresponding to a nose of the footboard is parallel to one of the opposite edges of the carrier.

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