WO2022118597A1

WO2022118597A1 - Mask production method and production apparatus

Info

Publication number: WO2022118597A1
Application number: PCT/JP2021/040472
Authority: WO
Inventors: 正人廣安
Original assignee: 株式会社瑞光
Priority date: 2020-12-02
Filing date: 2021-11-03
Publication date: 2022-06-09

Abstract

The present invention makes it possible for individual pieces, which are sequentially cut from a continuous mask body formed so that sections slated to become masks are connected and which are conveyed from the continuous mask body, to be received and delivered to a subsequent process in a stable state, even at high conveyance speeds.　In the present invention, a continuous mask body (2) is formed so that sections slated to become masks are connected, the continuous mask body (2) is sequentially cut while being conveyed to form individual pieces (4) composed of the respective sections slated to become masks, the cut individual pieces (4) are conveyed using a main conveyor (12) and then discharged from the main conveyor (12), an individual piece (4s) discharged from the main conveyor (12) is received and conveyed by an auxiliary conveyor (16), and the conveyance speed of the individual piece (4s) is reduced while being conveyed, whereafter the individual piece (4s) is ejected from the auxiliary conveyor (16), the individual piece (4s) ejected from the auxiliary conveyor (16) is received at a prescribed position (15), and the received individual piece (4s) is withdrawn from the prescribed position (15) before a following individual piece (4t) reaches the prescribed position (15).

Description

Mask manufacturing method and manufacturing equipment

The present invention relates to a mask manufacturing method and a manufacturing apparatus, and more particularly to a technique of sequentially cutting a mask continuum in which a portion to be a mask is connected to manufacture a mask.

Conventionally, a mask in which a pair of sheet-shaped ear hooks are joined to the mask body has been proposed. For example, FIG. 4 is a plan view of such a mask 110, showing a state in which an unused mask 110 is viewed from the skin surface side. As shown in FIG. 4, in the mask 110, an ear hook sheet 130a forming a pair of ear hook portions 130 is joined to the mask main body 120.

The pair of ear hook portions 130 have a joint portion 131 and an annular portion 132, respectively. The joint portion 131 is joined to the end region 121 of the mask body 120 via a joint point 122 by fusion. The annular portions 132 of the pair of ear hook portions 130 are joined to each other at the joint portion 134. Ear hook holes 133 are formed inside the joint portion 131 and the annular portion 132. When using the mask 110, the pair of ear hooks 130 are separated at the joint 134 and the ears are inserted into the respective ear hook holes 133.

FIG. 5 is an explanatory diagram of the manufacturing process of the mask 110. As shown in FIG. 5, each mask main body 120 is conveyed in the direction of the arrow 140 while being held by the sheet holding surface 142 of the holding roll 141. At the same time, the sheet holding surface 124 of the die cutter 123 conveys the sheet continuum 121b forming the portion to be the ear hook sheet 130a in the direction indicated by the arrow 220. Then, the mask body 120 on the holding roll 141 and the portion of the sheet continuum 121b to be the ear hook portion 130 are overlapped and joined to each other and then cut to form individual pieces of the mask 110 (for example,). , Patent Document 1).

Japanese Patent No. 5762804

The mask 110 in which the ear hook portions 130 joined to each other are arranged on the mask main body 120 as described above can be manufactured at a higher speed by improving the manufacturing method.

For example, a mask continuum in which the parts to be masks are connected is continuously formed, and then the mask continuum being transported is sequentially cut to form individual pieces of the mask, which are handed over to a subsequent process.

When manufacturing a mask while transporting the mask continuum in this way, the higher the transport speed of the mask continuum, the more the number of masks manufactured per unit time can be increased.

However, if the transport speed of the mask continuum is increased, the individual pieces cut from the mask continuum are also transported at high speed, which makes it difficult to receive the individual pieces of the mask in a stable state, which hinders the subsequent process. Occurs.

For example, FIG. 3 is an explanatory diagram for receiving the individual piece 80. As shown in FIG. 3, the individual pieces 80 transported in the direction indicated by the arrow 81 are ejected into the air by a transport device (not shown), and as shown by the arrow 86, head toward a predetermined receiving position 82. When the transport speed of the transport device becomes high, as shown by the arrow 88, the individual piece 80 crosses the receiving position 82, hits the backing plate 84, is repelled, and reaches the receiving position 82. When the transport speed of the transport device becomes higher, the individual piece 80 rebounds more at the backing plate 84, and the direction and posture when reaching the receiving position 82 are disturbed, or the position away from the receiving position 82. To reach. If individual pieces are received in such a disordered state, it becomes difficult to arrange and package a predetermined number of pieces in a subsequent process.

In view of such circumstances, the problem to be solved by the present invention is to increase the transport speed of the individual pieces that are sequentially cut and transported from the mask continuum formed so that the parts to be masks are connected. It is to provide a mask manufacturing method and a mask manufacturing apparatus that can be received in a stable state and handed over to a subsequent process.

The present invention provides a method for manufacturing a mask configured as follows in order to solve the above problems.

The mask manufacturing method consists of (i) a mask continuum forming step of forming a mask continuum so that the parts to be masked are connected, and (ii) sequentially cutting the mask continuum while transporting the mask continuum. A cutting step of forming individual pieces of a portion to be a mask, and (iii) a transporting step of transporting the cut individual pieces using a main conveyor and then discharging the individual pieces from the main conveyor. (Iv) An injection step in which the individual pieces discharged from the main conveyor are received and transported by an auxiliary conveyor, the transfer speed of the individual pieces is reduced during transportation, and then the individual pieces are ejected from the auxiliary conveyor. , (V) A receiving step of receiving the individual pieces ejected from the auxiliary conveyor at a predetermined position and retracting the received individual pieces 4s from the predetermined position until the subsequent individual pieces reach the predetermined position. , Equipped with.

According to the above method, even if the transport speed of the individual pieces to be cut becomes high in sequence from the mask continuum, the individual pieces are received in a stable state by decelerating the transport speed of the individual pieces and then ejecting the pieces. be able to.

Preferably, the auxiliary conveyor ejects the individual pieces while transporting the individual pieces at a constant speed for a predetermined time.

In this case, since the injection speed becomes a constant speed, it is possible to receive the individual pieces in a more stable state.

Preferably, the main conveyor conveys the individual pieces while sandwiching them between a pair of endless belts that are rotationally driven. The auxiliary conveyor conveys the individual pieces while sandwiching them between a pair of rotary-driven rolls.

In this case, it is easy to increase the transport speed of individual pieces.

Preferably, the main conveyor conveys the individual pieces at a speed higher than the speed at which the mask continuum is conveyed in the cutting step.

In this case, it is possible to prevent the decelerating individual piece from interfering with the subsequent individual piece in the injection process.

Further, the present invention provides a mask manufacturing apparatus configured as follows in order to solve the above problems.

The mask manufacturing apparatus includes (a) a mask continuum forming mechanism that forms a mask continuum so that portions to be masked are connected, and (b) sequentially cutting the mask continuum while transporting the mask continuum. A cutting mechanism that forms individual pieces of the part to be masked, (c) a main conveyor that receives and conveys the cut pieces, and then discharges the individual pieces, and (d) discharges from the main conveyor. An auxiliary conveyor that receives and conveys the individual pieces, slows down the transfer speed of the individual pieces during transportation, and then ejects the individual pieces, and (e) determines the individual pieces ejected from the auxiliary conveyor. It is provided with a receiving mechanism that receives the received piece at a position and retracts the received piece from the predetermined position until the subsequent piece reaches the predetermined position.

According to the above configuration, even if the transport speed of the individual pieces to be cut becomes high in sequence from the mask continuum, the individual pieces are received in a stable state by decelerating the transport speed of the individual pieces and then ejecting the pieces. be able to.

In this case, it is easy to increase the transport speed of individual pieces.

Preferably, the main conveyor conveys the individual pieces at a speed faster than the speed at which the cutting mechanism conveys the mask continuum.

In this case, it is possible to prevent the decelerating piece on the auxiliary conveyor from interfering with the subsequent piece.

According to the present invention, individual pieces that are sequentially cut and transported from a mask continuum that is continuously formed so that the parts to be masks are connected are stably maintained even at a high transfer speed. It can be received and handed over to a later process.

FIG. 1 is a schematic diagram of a main part of a mask manufacturing apparatus. (Example 1) FIG. 2 is a timing chart. (Example 1) FIG. 3 is an explanatory diagram of receiving individual pieces. (Example 1) FIG. 4 is a plan view of the mask. (Conventional example) FIG. 5 is an explanatory diagram of a mask manufacturing process. (Conventional example)

Hereinafter, embodiments of the present invention will be described with reference to the drawings.

<Example 1> The mask manufacturing method and manufacturing apparatus of the first embodiment will be described with reference to FIGS. 1 and 2.

FIG. 1 is a schematic diagram conceptually showing a configuration of a main part of a mask manufacturing apparatus 10 used in the mask manufacturing method of the first embodiment. As shown in FIG. 1, the mask manufacturing apparatus 10 includes a mask continuum forming mechanism 10a, a cutting mechanism 10b, a main conveyor 12, an auxiliary conveyor 16, and a counting machine 14 as a receiving mechanism. The auxiliary conveyor 16 is arranged between the main conveyor 12 and the counter 14, and the sensor 18 is arranged between the main conveyor 12 and the auxiliary conveyor 16.

The main conveyor 12 is arranged so that the pair of

endless belts

12a and 12b face each other at intervals, and the pair of

endless belts

12a and 12b circulate in a predetermined path in the directions indicated by the

arrows

12p and 12q at the same speed. The main conveyor 12 conveys the pair of

endless belts

12a and 12b while sandwiching the individual pieces 4 between the portions facing each other. The main conveyor 12 may be changed to another type of transport device, but if a transport device for transporting the individual pieces 4 by sandwiching them between the pair of

endless belts

12a and 12b is used, the transport speed of the individual pieces 4 can be increased. It is easy to make it fast.

The sensor 18 detects the individual pieces 4 discharged from the main conveyor 12.

In the auxiliary conveyor 16, a pair of

rolls

16a and 16b facing each other rotate in the directions indicated by

arrows

16p and 16q, and convey the auxiliary conveyor 16 while sandwiching the individual pieces 4s between the pair of

rolls

16a and 16b. As will be described in detail later, the auxiliary conveyor 16 repeats speed fluctuations. The auxiliary conveyor 16 may be changed to another type of conveyor, but if a conveyor is used in which the individual pieces 4s are sandwiched between the pair of

rolls

16a and 16b to convey the individual pieces 4s, the individual pieces 4s can be simply configured. It can be transported while decelerating, and it is easy to miniaturize.

The counter 14 is configured such that a plurality of paddles 14p move at intervals from each other and sequentially pass through a predetermined position 15. When the paddle 14p passes through the predetermined position 15, the individual pieces 4s ejected from the auxiliary conveyor 16 are received by the flat surface 14q of the paddle 14p, and the individual pieces 4s are conveyed in a state of being placed on the flat surface 14q. ..

The counting machine 14 is provided with a stop plate 14k on the opposite side of the auxiliary conveyor 16 with the predetermined position 15 interposed therebetween. When the piece 4s discharged from the auxiliary conveyor 16 hits the stop plate 14k, the piece 4s is repelled and heads for the predetermined position 15.

The mask manufacturing device 10 further includes a control device 11. The control device 11 is connected to a main motor 12m for driving the main conveyor 12, an auxiliary motor 16m for driving the auxiliary conveyor 16, a counter motor 14m for moving the paddle 14p of the counter 14, and a sensor 18. ing. The control device 11 is composed of a motion controller, a motor driver, and the like, and controls the operation of the mask manufacturing device 10 according to a predetermined program.

Next, the mask manufacturing method and the operation of the mask manufacturing apparatus 10 will be described.

(I) In the mask manufacturing apparatus 10, the mask continuum forming mechanism 10a continuously forms the mask continuum 2 so that the portions to be masked are connected, and conveys the mask continuum 2 at the first speed V1. This is a mask continuum forming step.

(Ii) Next, the cutting mechanism 10b sequentially cuts the mask continuum 2 being transported at the position indicated by the chain line 3, to form the individual piece 4 in which the portion to be the mask is divided. This is a cutting process.

The cut pieces 4 are further conveyed toward the main conveyor 12 at the first speed V1. When the mask continuum 2 is formed so that the portions to be masks are connected without any gap, there is no waste of material.

(Iii) Next, the main conveyor 12 receives the cut pieces 4 and conveys them, and then discharges the pieces 4. This is a transport process.

In the main conveyor 12, when the individual pieces 4 are sandwiched between the pair of

endless belts

12a and 12b on one side 12u of the main conveyor 12, the main conveyor 12 sandwiches the individual pieces 4 between the pair of

endless belts

12a and 12b. It is conveyed at the second speed V2 up to 12v on the other side of the. The individual pieces 4 are discharged from the other side 12v of the main conveyor 12 and head toward the auxiliary conveyor 16.

The second speed V2 is preferably faster than the first speed V1. As will be described later, since the individual pieces 4s are decelerated while being conveyed by the auxiliary conveyor 16, it is necessary to prevent the decelerated individual pieces 4s from interfering with the subsequent individual pieces 4t. When the main conveyor 12 conveys the individual pieces 4 at a second speed V2 faster than the first speed V1, the distance between the individual pieces 4 before and after the main conveyor 12 conveys widens, so that the front and rear pieces are conveyed by the auxiliary conveyor 16. You can prevent the pieces from interfering.

If the mask continuum formed so that the parts to be masks are connected at intervals is cut and the parts other than the parts to be masks are removed, the second velocity V2 is the same as the first velocity V1. Even if the second speed V2 is slower than the first speed V1, it is possible to prevent the front and rear pieces from interfering with each other on the auxiliary conveyor 16.

(Iv) Next, the auxiliary conveyor 16 receives and conveys the individual pieces 4s discharged from the main conveyor 12, slows down the transfer speed of the individual pieces 4s during transportation, and then ejects the individual pieces 4s. This is the injection process.

The sensor 18 detects the individual piece 4 when the individual piece 4 discharged from the main conveyor 12 passes through the detection position 18p, and transmits the detection signal to the control device 11.

When the tip of the piece 4 discharged from the main conveyor 12 reaches between the pair of

rolls

16a and 16b of the auxiliary conveyor 16, the piece 4 is conveyed while being sandwiched between the pair of

rolls

16a and 16b. The control device 11 controls the auxiliary motor 16m so that the rotation speed of the pair of

rolls

16a and 16b decreases during the transfer and the transfer speed of the individual piece 4 is decelerated.

The piece 4s conveyed by the auxiliary conveyor 16 is ejected into the air at a third speed V3 when the rear end of the piece 4s passes between the pair of

rolls

16a and 16b of the auxiliary conveyor 16 and is predetermined. Move towards position 15. The third speed V3 is a speed at which the individual pieces 4s can be received in a stable state at a predetermined position 15.

(V) Next, the counter 14 receives the piece 4s ejected from the auxiliary conveyor 16 at the predetermined position 15, and receives the received piece 4s at the predetermined position until the subsequent piece 4t reaches the predetermined position 15. Evacuate from 15. This is the receiving process.

In the counting machine 14, each paddle 14p moves in conjunction with the timing when the piece 4s ejected from the auxiliary conveyor 16 reaches the predetermined position 15, and the paddle 14p receives the piece 4s at the predetermined position 15. ..

For example, the paddle 14u waiting at the standby position 15a before the predetermined position 15 moves to the predetermined position 15 at the timing when the individual pieces 4s reach the predetermined position 15, receives the individual pieces 4s, and receives the subsequent individual pieces. By the time the piece 4t reaches the predetermined position 15, it moves to the retracted position 15b. While the paddle 14u moves from the standby position 15a to the retracted position 15b, the next paddle 14v moves to the standby position 15a.

FIG. 2 is a time chart when the mask manufacturing apparatus 10 operates. FIG. 2A shows the detection signal 18x of the sensor 18. FIG. 2B shows a control signal 12x of the main motor 12m. FIG. 2C shows a control signal 16x of the auxiliary motor 16m. FIG. 2D shows a control signal 14x of the counter motor 14m.

When the mask manufacturing device 10 is started, the control device 11 outputs a control signal 12j for rotating the stopped main motor 12m at a steady speed as shown by the reference numeral 12i, and also outputs a control signal 12j as shown by the reference numeral 16i. A control signal 16j for rotating the stopped auxiliary motor 16m at a steady speed is output. The counter motor 14m remains stopped, as indicated by reference numeral 14w.

When the mask manufacturing apparatus 10 is activated, a mask continuum is formed, and individual pieces are cut from the mask continuum and conveyed.

As indicated by reference numeral 18p, when the sensor 18 detects the tip of the first piece 4s, the control device 11 decelerates the auxiliary motor 16m as indicated by reference numeral 16r after the lapse of the _first predetermined time t1. Then, the constant speed is maintained for a predetermined time as indicated by the reference numeral 16s, and then the control signal 16x is output so as to return to the steady speed after increasing the speed as indicated by the reference numeral 16t.

In the first predetermined time t ₁ , the main conveyor 12 starts decelerating at the same time when the tip of the first piece 4s reaches between the pair of

rolls

16a and 16b of the auxiliary conveyor 16. It is determined in advance according to the transfer speed, that is, the steady speed of the main motor 12 m.

Further, while the auxiliary conveyor 16 maintains a constant speed after deceleration, the rear end of the first piece 4s passes through the auxiliary conveyor 16 and the first piece 4s is ejected from the auxiliary conveyor 16. After that, by the time the tip of the second piece 4t reaches the auxiliary conveyor 16, the auxiliary conveyor 16 accelerates and the transfer speed of the auxiliary conveyor 16 returns to the second speed V2. The time during which the auxiliary motor decelerates, the time during which the auxiliary motor 16m maintains a constant speed after deceleration, and the time during which the auxiliary motor 16m returns from a constant speed to a steady speed are predetermined. The constant speed after deceleration of the auxiliary motor 16 m is determined in advance so that the individual pieces 4s ejected from the auxiliary conveyor 16 reach the predetermined position 15.

As indicated by reference numeral 18q, when the sensor 18 detects the tip of the second piece 4t, the control device 11 also starts decelerating the auxiliary motor 16m after the first predetermined time t ₁ has elapsed. Then, the control signal 16x is output to the auxiliary motor 16m so as to maintain a constant speed for a predetermined time, then increase the speed of the auxiliary motor 16m and then return to the steady operation speed. The same control is repeated for the third and subsequent pieces 4.

Further, when the sensor 18 detects the tip of the first piece 4s, the control device 11 starts the counter motor 14m as indicated by reference numeral 14i after the second predetermined time t ₂ has elapsed, and counts. A control signal 14j for rotating the machine motor 14m at a steady speed is output.

After the counter motor 14m has rotated at a steady speed, the control device 11 checks whether the rotation phase of the counter motor 14m matches the timing of receiving the

pieces

4s, 4t, 4 at the predetermined position 15, and is necessary. Accordingly, the deviation of the rotational phase of the counter motor 14 m is corrected.

The control device 11 checks the rotation phase of the counter motor 14m before the first piece 4s reaches the predetermined position 15, for example, when the first piece 4s reaches the predetermined position 15. If it is predicted that the rotation phase of the counter motor 14m is advanced, the rotation of the counter motor 14m is temporarily slowed down as shown by reference numeral 14s, and then returned to the steady speed to return to the steady speed of the first piece. When the piece 4s reaches the predetermined position 15, the phase shift is eliminated.

Further, the control device 11 checks the rotation phase of the counter motor 14m before the second piece 4t reaches the predetermined position 15, for example, the second piece 4t reaches the predetermined position 15. If it is predicted that the rotation phase of the counter motor 14m is delayed at that time, the rotation of the counter motor 14m is temporarily increased as shown by reference numeral 14t and then returned to the steady speed for the second sheet. When the individual piece 4t reaches the predetermined position 15, the phase shift is eliminated.

Between the time when the sensor 18 detects the tip of the piece 4 as shown by the reference numeral 18r and the elapse of the predetermined first time limit t3 _, or as shown by the reference numeral 18s, the sensor 18 is included. When the sensor 18 does not detect a subsequent piece between the detection of the rear end of the piece ₄ and the elapse of the predetermined second time limit t4, the control device 11 indicates by reference numeral 14r. As described above, the rotation of the counter motor 14 m is stopped. At this time, the control device 11 controls the rotation of the counter motor 14 m so that the paddle 14p of the counter 14 stops in a predetermined standby state.

As described above, when the mask is manufactured by using the mask manufacturing apparatus 10, even if the transport speed V1 of the individual pieces 4 sequentially cut and conveyed from the mask continuous body 2 becomes high, the individual pieces 4s The ejection speed V3 when ejected from the auxiliary conveyor 16 can be decelerated by the auxiliary conveyor 16 to a speed at which the individual pieces 4s can be received in a stable state at the predetermined position 15, and as a result, the predetermined position 15 In, the individual pieces 4s can be received in a stable state.

<Summary> As explained above, the individual pieces that are sequentially cut and transported from the mask continuum formed so that the parts to be masked are connected are in a stable state even when the transport speed becomes high. It can be received at and handed over to the subsequent process.

The present invention is not limited to the above embodiment, and can be implemented with various modifications.

2

Mask continuum

4,4s, 4t pieces 10 Mask manufacturing equipment 10a Mask continuum forming mechanism 10b Cutting mechanism 12

Main conveyor

12a, 12b Endless belt 14 Counting machine (receiving mechanism)
15 Predetermined position 16

Auxiliary conveyor

16a, 16b roll

Claims

A mask continuum forming process that forms a mask continuum so that the parts to be masked are connected,
A cutting step in which the mask continuum is sequentially cut while being conveyed to form individual pieces of the portion to be the mask.
A transporting step of transporting the cut pieces using the main conveyor and then discharging the pieces from the main conveyor.
An injection step in which the individual pieces discharged from the main conveyor are received by an auxiliary conveyor and conveyed, the transfer speed of the individual pieces is reduced during transportation, and then the individual pieces are ejected from the auxiliary conveyor.
A receiving step of receiving the individual pieces ejected from the auxiliary conveyor at a predetermined position and retracting the received individual pieces from the predetermined position until the subsequent individual pieces reach the predetermined position.
A method of manufacturing a mask.
The method for manufacturing a mask according to claim 1, wherein the auxiliary conveyor ejects the individual pieces while the individual pieces are being conveyed at a constant speed for a predetermined time.
The main conveyor conveys the individual pieces while sandwiching them between a pair of endless belts that are rotationally driven.
The method for manufacturing a mask according to claim 1 or 2, wherein the auxiliary conveyor conveys the individual pieces while sandwiching them between a pair of rotary-driven rolls.
The method for manufacturing a mask according to any one of claims 1 to 3, wherein the main conveyor conveys the individual pieces at a speed higher than the speed at which the mask continuum is conveyed in the cutting step.
A mask continuum formation mechanism that forms a mask continuum so that the parts to be masked are connected,
A cutting mechanism that sequentially cuts the mask continuum while transporting it to form individual pieces of the portion to be the mask.
A main conveyor that receives and conveys the cut pieces and then discharges the pieces.
An auxiliary conveyor that receives and conveys the individual pieces discharged from the main conveyor, slows down the transfer speed of the individual pieces during transportation, and then ejects the individual pieces.
A receiving mechanism that receives the individual pieces ejected from the auxiliary conveyor at a predetermined position and retracts the received individual pieces from the predetermined position until the subsequent individual pieces reach the predetermined position.
A mask manufacturing device.
The mask manufacturing apparatus according to claim 5, wherein the auxiliary conveyor ejects the individual pieces while conveying the individual pieces at a constant speed for a predetermined time.
The main conveyor conveys the individual pieces while sandwiching them between a pair of endless belts that are rotationally driven.
The mask manufacturing apparatus according to claim 5 or 6, wherein the auxiliary conveyor conveys the individual pieces while sandwiching them between a pair of rotary-driven rolls.
The mask manufacturing apparatus according to any one of claims 5 to 7, wherein the main conveyor conveys the individual pieces at a speed faster than the speed at which the cutting mechanism conveys the mask continuum.