JP4359303B2 - Construction board manufacturing apparatus and manufacturing method - Google Patents

Description

  The present invention relates to an apparatus and a method for manufacturing a building plate material in which a decorative sheet is bonded to a base material made of plywood or the like. The production apparatus and production method of the present invention are suitably used for production of flooring materials for flooring, ceiling materials, wall materials, and the like.

  As flooring materials for flooring in a house or a store, a material in which a decorative sheet is bonded to the surface of a base material made of plywood or the like and the surface thereof is further coated (see, for example, Patent Document 1). As such a flooring for flooring, there is conventionally a flooring 100 having a plurality of rectangular regions 102 having different colors or patterns on the surface of a decorative sheet, like the flooring 100 shown in FIG.

  When a floor is formed using the floor material 100, as shown in FIG. 4, the positions of the square regions 102 of the adjacent floor material 100 are aligned (not shifted), that is, the adjacent floor material 100 is located. It is necessary that the boundary 104 of the rectangular region 102 is a straight line.

  Further, in order to align the positions of the rectangular regions 102 of the adjacent floor materials 100 as described above, the positions of the regions 102 are the same in all the floor materials 100 forming the floor, that is, all the floor materials 100. It is necessary that the bonding position of the predetermined region of the decorative sheet with respect to the substrate is constant.

  On the other hand, as a flooring manufacturing apparatus in which a decorative sheet is bonded to a base material made of plywood or the like, conventionally, a laminating apparatus that bonds the base material and the decorative sheet, and a base material supply apparatus that supplies the base material to the laminating apparatus And a decorative sheet supply device that supplies the decorative sheet to the laminating device, and in the laminating device, the decorative sheet supplied from the decorative sheet supply device is continuously supplied to the base material supplied at regular intervals from the base material supply device. There is something to paste. In this floor material manufacturing apparatus, the bonding position of the decorative sheet to the base material is made constant by matching the base material feed rate (pitch) and the sheet feed rate.

JP 2003-184287 A JP 2005-104051 A

  However, in the above-described conventional floor material manufacturing apparatus, by combining the feeding speed (pitch) of the base material and the feeding speed of the sheet, the bonding position of the decorative sheet to the base material can be made substantially constant, In all flooring materials, the bonding position of the decorative sheet to the base material could not be made exactly constant.

  The present invention has been made in view of the above-described circumstances, and is a manufacturing apparatus and a manufacturing method for a building board material in which a base material and a decorative sheet are bonded together, and the decorative sheet for the base material in all the building board materials An object of the present invention is to provide a manufacturing apparatus and a manufacturing method of a building plate material capable of accurately making the bonding position of the plate.

In order to achieve the above object, the present invention provides
An apparatus for manufacturing a building plate material in which a base material and a decorative sheet are bonded together,
A laminating device for bonding the base material and the decorative sheet;
A substrate supply device for supplying the substrate to the laminating device at a predetermined feed rate;
An infeed roll that conveys the decorative sheet at a predetermined feed speed, a dancer roll installed in the conveying path of the decorative sheet, a pressurizing means that applies a predetermined pressure to the dancer roll, and a dancer roll position detection that detects the position of the dancer roll And a decorative sheet supply device that supplies the decorative sheet to the laminating device at a predetermined feed rate,
A base material detecting means for detecting a predetermined location of the base material supplied to the laminating apparatus;
A decorative sheet detecting means for detecting a mark provided on the decorative sheet supplied to the laminating apparatus;
By controlling the feeding speed of one or both of the decorative sheet and the base material based on the detection results of the base material detecting means and the decorative sheet detecting means, A control unit that adjusts the position of the decorative sheet, and a control unit that controls the rotational speed of the infeed roll so that the dancer roll is held at a fixed position based on a detection signal of the dancer roll position detection means; An apparatus for manufacturing a building board material is provided.

  Moreover, this invention provides the manufacturing method of the board | plate material for construction characterized by using the decorative sheet in which the mark was provided in the predetermined location, and bonding a base material and a decorative sheet using the manufacturing apparatus of the said invention. To do.

  In the present invention, the feeding speed of one or both of the decorative sheet and the base material is controlled based on the detection result of the predetermined portion of the base material by the base material detection means and the detection result of the mark on the decorative sheet by the decorative sheet detection means. By adjusting the position of the decorative sheet with respect to the base material at the bonding position between the base material and the decorative sheet of the laminating apparatus, the bonding position of the decorative sheet with respect to the base material is accurately made constant in all building boards. Is possible.

  In the present invention, the configuration of the base material detection means, the decorative sheet detection means, and the control unit is not limited, but the base material detection means detects the tip of the base material supplied to the laminating apparatus with an optical sensor and outputs a detection signal. The decorative sheet detecting means transmits the detection signal to the control unit by detecting the mark of the decorative sheet supplied to the laminating apparatus with an optical sensor. The time difference between the time when the optical sensor of the detection means detects the tip of the base material and the time when the decorative sheet detection means detects the mark on the decorative sheet is read as the distance difference between the base material and the decorative sheet, and the distance difference is zero. It is preferable to accelerate or decelerate the feeding speed of one or both of the decorative sheet and the substrate.

In the present invention, the decorative sheet supply apparatus includes an infeed roll that conveys the decorative sheet at a predetermined feed speed, a dancer roll installed in the conveyance path of the decorative sheet, and a pressurizing unit that applies a predetermined pressure to the dancer roll, Dancer roll position detecting means for detecting the position of the dancer roll, and the controller controls the rotation speed of the infeed roll based on the detection signal of the dancer roll position detecting means so that the dancer roll is held at a fixed position. you control. In this case, as will be described later, fluctuations in the tension of the decorative sheet in the decorative sheet supply apparatus can be suppressed.

  According to the present invention, it is possible to make the bonding position of the decorative sheet to the base material accurately constant.

  Hereinafter, embodiments of the present invention will be described with reference to the drawings. However, the present invention is not limited to the following examples. FIG. 1 is a schematic front view showing an embodiment of a building board manufacturing apparatus according to the present invention.

  In the manufacturing apparatus of this example, 10 is a base material supply apparatus, 12 is a decorative sheet supply apparatus, 14 is a laminating apparatus, 16 is a decorative sheet cutting apparatus, 18 is a conveyor, and 20 is a re-pressing apparatus.

  The base material supply device 10 is a conveyor device for supplying the base material to the laminating device 14 at a predetermined feed rate.

  The decorative sheet supply device 12 supplies the decorative sheet 24 wound around the decorative sheet roll 22 to the laminating device 14 at a predetermined feed rate. The decorative sheet supply device 12 is installed in the conveyance path of the decorative sheet 24 by being rotated by a driving motor and transporting the decorative sheet 24 at a predetermined feed speed, and is oscillated and displaced to displace the decorative sheet 24. A dancer roll 28 for absorbing slack and elongation is provided. The dancer roll 28 is attached to a support arm 30 that supports the dancer roll 28 in a swingable manner. A low friction cylinder (air cylinder) 32 serves as a pressurizing unit that applies a predetermined pressure to the dancer roll 28. Is attached. The decorative sheet supply device 12 is provided with a precision positioner (not shown) as dancer roll position detecting means for accurately detecting the position of the dancer roll 28.

  In the base material supply device 10 and the decorative sheet supply device 12, the drive system is driven by a servo motor so that the base material feed speed and the decorative sheet feed speed are accurately synchronized with an error of about 1/10000 second ( This speed is called “synchronization speed”).

  The laminating device 14 superimposes the decorative sheet 24 on the base material coated with an adhesive on the surface by an adhesive coating device (not shown), and the superposed base material and the decorative sheet 24 are placed between the press rolls 36. By passing through, the base material and the decorative sheet 24 are bonded together. A bonding point between the base material and the decorative sheet 24 is indicated by a reference numeral 38.

  In addition, the apparatus of this example includes a base material detection unit, a decorative sheet detection unit, and a CPU as a control unit. The base material detection means detects the tip of the base material supplied to the laminating apparatus 14 with the optical sensor 40 and transmits a detection signal to the control unit. The decorative sheet detecting means detects the mark of the decorative sheet 24 supplied to the laminating apparatus 14 by the optical sensor 42 and transmits a detection signal to the control unit. The control unit controls the feeding speed of one or both of the decorative sheet and the base material based on the detection results of the base material detection means and the decorative sheet detection means, thereby bonding the base material and the decorative sheet of the laminating apparatus. The position of the decorative sheet with respect to the base material is adjusted.

  In addition, the apparatus of this example can respond to the change of the thickness, width, and length of the base material (size change for each lot).

  When manufacturing the board | plate material (floor material) for construction using the apparatus of this example, the decorative sheet shown, for example in FIG. 2 is used. FIG. 2 is a plan view showing a part of a continuous decorative sheet. The decorative sheet 24 of this example has margins 52 and 54 on both sides of a portion 50 on which a pattern is printed, and a square fixed position detection mark 56 is printed on one margin 52. One fixed position detection mark 56 is printed for each pitch of the decorative sheet 24 (the length obtained by adding the length of the cutting allowance in the sheet longitudinal direction to the sheet length to be bonded to one base material). . The distance between the tip of the fixed position detection mark 56 and the tip of the fixed position detection mark 56 behind it is equal to the length of the one pitch. In addition, a guideline 58 for bonding the base material and the decorative sheet 24 to each other without shifting in the width direction (meandering) is printed on the inner side of the marginal position detection mark 56.

  When the flooring material is manufactured using the decorative sheet 24 of FIG. 2 using the apparatus of this example, the base material supply apparatus 10 supplies the base material to the laminating apparatus 14 at a predetermined feed speed, and the decorative sheet supply apparatus 12 A decorative sheet 24 is supplied to the laminating apparatus 14 at a predetermined feed rate. As the substrate, for example, a general plywood based on the JAS standard can be used.

  When the base material and the decorative sheet 24 are supplied to the laminating apparatus 14 as described above, the base material detecting means detects the front end of the base material supplied to the laminating apparatus 14 by the optical sensor 40 and outputs a detection signal to the control unit. Send to. The decorative sheet detecting means detects the fixed position detection mark 56 of the decorative sheet 24 supplied to the laminating apparatus 14 by the optical sensor 42 and transmits a detection signal to the control unit.

  Then, the control unit calculates the time difference between the time when the optical sensor 40 of the base material detecting means detects the tip of the base material and the time when the optical sensor 42 of the decorative sheet detecting means detects the mark 56 of the decorative sheet 24. 2 is read as a distance difference between the decorative sheet and the decorative sheet, and the leading edge 60 of the home position detection mark 56 shown in FIG. 2 is accelerated or decelerated so that the distance difference becomes zero. The base material and the decorative sheet are bonded together so that the tip of the base material matches the tip of the base material.

More specifically, the first contact point between the base material to be aligned and the decorative sheet 24 is in the vicinity of the first press roll inlet of the three press rolls 36, and bonding is performed by contact at this point. in which the position of the is determined for the distance difference thereof to detect the position of the mark 56 of the decorative sheet 24 and the leading end position of the next substrate while the substrate is advanced between three press rolls 36 The base sheet and the decorative sheet 24 to be bonded together by accelerating or decelerating the overall feed speed of the base sheet and the decorative sheet 24 being pressed by the press roll 36 and the path in which the dancer roll 28 exists are calculated. Prepare for alignment. Thereby, the bonding position of the decorative sheet 24 with respect to the base material can be made accurately constant in all floor materials.

  That is, in the apparatus of this example, the time difference from when the sensor detects the top of the base material until the sensor detects the mark on the decorative sheet, or the sensor detects the top of the base material after the sensor detects the mark on the decorative sheet. The time difference until the reading is read as a distance difference between each other, and the feeding speed of the decorative sheet and the base material is accelerated or decelerated so as to catch up (or delay) the distance difference. This is performed instantaneously and accurately using a calculation function and fed back to machine control. However, the base material and the decorative sheet may be aligned by accelerating or decelerating the feeding speed of one of the decorative sheet and the base material.

  In the apparatus of this example, as described above, the rough alignment (previous operation) of the base material and the decorative sheet by the conventional mechanical method is performed by the electrical method based on the CPU calculation control which is a new technology (this operation). ), It is possible to realize an accurate pattern matching and continuous reproducibility in pasting the base material and the decorative sheet, which was impossible in the past.

  In the apparatus of the present example, the time required for the decorative sheet to move an arbitrary distance difference (correction distance) at the synchronous speed (correction time) is added (or removed) to the above-described time difference, thereby The bonding position with the decorative sheet can be shifted back and forth by the correction distance.

  Moreover, in the conventional floor material manufacturing apparatus, the dancer roll applies a constant tension by a metal spring or the like to a slight tension fluctuation generated in the decorative sheet flowing at a constant speed, so that the decorative sheet at the time of bonding is applied. The generation of wrinkles was prevented. However, in the apparatus of the present example, frequent and severe tension fluctuations occur due to rapid acceleration / deceleration of the decorative sheet, so that the dancer roll cannot follow the tension fluctuations by the above-described conventional method.

  Therefore, in the apparatus of this example, as described above, the low friction cylinder 32 that is the pressurizing means of the dancer roll 28 and the precision positioner that is the dancer roll position detecting means are provided, and a constant pressure by the low friction cylinder 32 is applied to the dancer roll 28. In addition, an accurate tension is applied to the decorative sheet 24, the position of the dancer roll 28 is detected by the precision positioner, and the rotation speed of the infeed roll 26 is controlled by the control unit based on the detection signal of the precision positioner. Therefore, fluctuations in sheet tension are suppressed. That is, a slight change in the position of the dancer roll 28 is fed back to the drive control of the infeed roll 26, and the feeding speed of one or both of the decorative sheet and the base material is accelerated or kept so as to keep the position of the dancer roll 28 at a fixed position. By decelerating, fluctuations in sheet tension are eliminated. The sheet tension is detected by a load cell attached to the sheet roll bearing portion and displayed as a management value.

It is a schematic front view which shows one Embodiment of the manufacturing apparatus of the board | plate material for buildings which concerns on this invention. It is a top view which shows a part of continuous decorative sheet. It is a top view which shows an example of a flooring. It is a top view which shows the state which forms a floor with the flooring of FIG.

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Base material supply apparatus 12 Decorative sheet supply apparatus 14 Laminating apparatus 24 Decorative sheet 26 Infeed roll 28 Dancer roll 32 Low friction cylinder 40 Optical sensor 42 Optical sensor 56 Fixed position detection mark

Claims (3)

An apparatus for manufacturing a building plate material in which a base material and a decorative sheet are bonded together,
A laminating device for bonding the base material and the decorative sheet;
A substrate supply device for supplying the substrate to the laminating device at a predetermined feed rate;
An infeed roll that conveys the decorative sheet at a predetermined feed speed, a dancer roll installed in the conveying path of the decorative sheet, a pressurizing means that applies a predetermined pressure to the dancer roll, and a dancer roll position detection that detects the position of the dancer roll And a decorative sheet supply device that supplies the decorative sheet to the laminating device at a predetermined feed rate,
A base material detecting means for detecting a predetermined location of the base material supplied to the laminating apparatus;
A decorative sheet detecting means for detecting a mark provided on the decorative sheet supplied to the laminating apparatus;
By controlling the feeding speed of one or both of the decorative sheet and the base material based on the detection results of the base material detecting means and the decorative sheet detecting means, A control unit that adjusts the position of the decorative sheet, and a control unit that controls the rotational speed of the infeed roll so that the dancer roll is held at a fixed position based on a detection signal of the dancer roll position detection means; An apparatus for manufacturing a building board, characterized in that: The base material detection means detects the tip of the base material supplied to the laminating apparatus with an optical sensor and transmits a detection signal to the control unit.
The decorative sheet detection means detects the mark of the decorative sheet supplied to the laminating apparatus with an optical sensor and transmits a detection signal to the control unit.
The control unit interprets the time difference between the time when the optical sensor of the base material detection means detects the tip of the base material and the time when the decorative sheet detection means detects the mark of the decorative sheet as the distance difference between the base material and the decorative sheet. 2. The apparatus for manufacturing a building board according to claim 1, wherein the feeding speed of one or both of the decorative sheet and the base material is accelerated or decelerated so that the distance difference is zero. Using a decorative sheet mark is provided at a predetermined position, the manufacturing method of building plate, characterized in that bonding the substrate and the decorative sheet by using the manufacturing apparatus according to claim 1 or 2.

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