JP6419141B2 - Method for manufacturing piece for assembly toy - Google Patents

Description

The present invention relates to a method of manufacturing a piece for assembling toys. More particularly, a method of manufacturing a very small design is good toy building for copy scan.

  There are various assembly toys such as jigsaw puzzles and block toys. For example, in a jigsaw puzzle, paper, etc. on which a pattern such as paintings, photographs, figures, symbols, characters, characters, etc. is drawn is divided into several pieces, and pieces separated separately are fitted together to restore the pattern. This is a fun toy. The block toy is a toy that can assemble a block in which a plurality of cylindrical protrusions are attached to a rectangular parallelepiped base into various three-dimensional shapes.

  Each piece of the jigsaw puzzle is a deformed polygonal flat plate such as a quadrangle, and a substantially circular engaging male portion or engaging female portion is formed on the side surface thereof. The engaging male part of one piece can be fitted to the engaging female part of another adjacent piece. In addition, the engaging female part of one piece is fitted into the engaging male part of another adjacent piece. A jigsaw puzzle piece is manufactured by cutting out a cardboard or a synthetic resin plate as a material with, for example, a plurality of punching blades arranged in parallel in the vertical direction and a plurality of punching blades arranged in parallel in the horizontal direction.

  The punching blade for manufacturing each piece of the jigsaw puzzle is formed by bending a metal plate so that the engaging male part and the engaging female part can be cut off. The punching blade is required to have a certain thickness in order to punch a cardboard or a synthetic resin plate having a predetermined thickness, and there is a limit to the size that can be bent. For this reason, there is a limit to the size with which the pieces are inevitably cut from cardboard or synthetic resin plates. In other words, it was not possible to create extremely small pieces. Further, since it is difficult to bend the punching blade into the same shape, it is difficult to make a punching blade of the same shape, and it is difficult to make pieces of the same shape.

  In addition, block toys that can be played by making a three-dimensional shape are manufactured. In particular, the number of block toys in recent years that can make various three-dimensional shapes such as animals and plants, dinosaurs, buildings or vehicles is increasing so that even adults can play. Such a block toy is composed of extremely small blocks in order to make a very precise three-dimensional shape. The block of such a block toy is manufactured by injection molding, and a very small 7 m × 7 m size is manufactured. Furthermore, a conventional technique will be described based on patent literature for an assembled toy.

  The present applicant has proposed a jigsaw puzzle that is manufactured using a laminate that is manufactured by applying only pressure without applying an adhesive (see Patent Document 1). As a three-dimensional puzzle, an assembly block toy for assembling various three-dimensional shapes by connecting flat block members via joint members has been proposed (see Patent Document 2). Similarly, a block toy has been proposed in which a plurality of types of blocks having a unit length of several millimeters and different shapes can be combined and assembled into precise shapes of various shapes. (For example, patent document 3).

JP 2012-249851 A Japanese Patent No. 4165897 JP 2010-172568 A

  However, since the jigsaw puzzle pieces described in Patent Document 1 are formed by being cut out with a punching blade, the size of each piece is relatively large at 13 mm × 13 mm. Moreover, since the block toy described in Patent Document 2 or 3 manufactures the block in units of one by injection molding, there is a problem that it takes time and is not good in productivity and tends to increase the manufacturing cost. there were.

  The present invention was created in order to solve the conventional problems as described above, and achieves the following object. An object of the present invention is to provide an assembling toy piece having a very small appearance with a good design and a wide range of design choices. Another object of the present invention is to provide an assembly toy piece that is easy to produce, improves productivity, and reduces costs.

The present invention takes the following means in order to achieve the object. The manufacturing method of the assembled toy piece according to the first aspect of the present invention is a manufacturing method of the assembled toy piece that is assembled by engaging the engaging portion and the engaged portion, and extruding the synthetic resin melted by extrusion molding into a sheet shape A resin sheet manufacturing process for manufacturing a soft and elastically deformable resin sheet, and when the resin sheet is in an uncured state that is not completely cured after the extrusion, a picture, a photograph, a figure, a symbol, A printing step on which a pattern including one type selected from characters and characters is printed is pressed and bonded together to produce a laminated sheet, and the laminated sheet is cut to form a base sheet having a predetermined length. A cutting step for manufacturing, and a shearing step for punching the base sheet to manufacture a piece for assembling toy, wherein the shearing step includes one shearing die composed of a die and a punch, and another shearing step. Preparing the one shearing mold by moving the base sheet so as to be applied to the first location and punching out the first location by shearing; A shearing die is applied to the second location and the second location is punched out by shearing, and then the base sheet is moved to match the one shearing die to the third location. Applying and punching out the third location by shearing, then applying the other shearing mold in accordance with the fourth location and punching out the fourth location by shearing; It is characterized by including .

  The assembled toy according to the second aspect of the present invention is the first aspect of the present invention, wherein the piece main body processed by the shearing process is punched.

  The assembly toy of the present invention 3 is the present invention 1 or 2, wherein the piece main body is formed by being punched in a state where tension is applied to the resin sheet.

  The assembling toy of the present invention 4 is any one of the present invention 1 to 3, wherein the piece body is punched into a width dimension of 6 to 10 mm and a depth dimension of 6 to 10 mm. It is formed.

  The assembly toy according to a fifth aspect of the present invention is any one of the first to fourth aspects of the present invention, wherein the engaging portion is an engaging male portion formed so as to protrude from an outline of the piece main body, The joint portion is an engaging female portion formed so as to be recessed from the outline of the piece main body, and the inner shape dimension of the engaging female portion and the outer diameter size of the engaging male portion are the same or substantially the same. In addition, at least one of the engaging male part and the engaging female part is formed in the piece body.

  The assembly toy of the present invention 6 is any one of the present invention 1 to 5, and on the front or back surface of the piece body, one kind selected from a picture, a photograph, a figure, a symbol, a character, and a character by inkjet is used. The pattern including the print is printed.

  The assembly toy of the present invention 7 is any one of the present invention 1 to 5, wherein the resin sheet is in an uncured state in which the resin sheet is not completely cured after the extrusion molding. A printing sheet on which a pattern including one type selected from a picture, a photograph, a figure, a symbol, a character, and a character is printed is pressed and pasted.

  The assembly toy of the present invention 8 is the present invention 7, wherein the printed sheet is one selected from paper, non-woven fabric, woven fabric, felt, and a film made of a synthetic resin.

  The manufacturing method of the assembled toy according to the ninth aspect of the present invention is a manufacturing method of an assembled toy composed of pieces for an assembled toy assembled by engaging the engaging portion and the engaged portion, and synthetic resin melted by extrusion molding is used. A resin sheet manufacturing process for manufacturing a soft elastically deformable resin sheet by extruding into a sheet shape, and a shearing process for punching the resin sheet by a shearing process by applying a shearing force with a die and a punch to form a piece body It is characterized by that.

  The method for manufacturing an assembled toy according to the tenth aspect of the present invention is the ninth aspect of the present invention, wherein, in the shearing step, the piece body is formed by being punched in a state where tension is applied to the resin sheet.

  The manufacturing method of the assembly toy of this invention 11 is this invention 9 or 10, Comprising: The pattern which contains 1 type selected from a painting, a photograph, a figure, a symbol, a character, and a character by the inkjet on the surface or back surface of the said piece main body Is added with a printing process for printing.

  The method for producing an assembled toy according to the present invention 12 is the present invention 9 or 10, wherein the resin sheet is in an uncured state that is not completely cured after the extrusion molding, It is characterized by adding a laminating process in which a printing sheet on which a pattern including one type selected from symbols, characters, and characters is printed is pressed and bonded.

  The assembly toy piece of the present invention has a very small appearance with a good design and a wide range of design choices. The assembly toy piece of the present invention is easy to produce, improves productivity, and reduces costs.

FIG. 1 is a diagram showing the dimensions of an assembled toy piece 1, FIG. 1 (a) is a plan view of the assembled toy piece 1, and FIG. 1 (b) is an arrow in FIG. 1 (a). FIG. 1C is a left side view illustrating a state viewed from an arrow α, and FIG. 1C is a front view illustrating a state viewed from an arrow β in FIG. FIG. 2 is an external view showing a plane, a left side, and a front of the assembly toy piece 1 according to the first embodiment of the present invention. FIG. 3 is a plan view showing a state in which nine assembled toy pieces 1 are combined on the same plane.

FIG. 4 is an external view showing a plane, a left side surface, and a front surface in a state where two pieces for assembling toy 1 are assembled at right angles. FIG. 5 is an external view showing a plane, a right side surface, and a back side of two assembled toy pieces 1 assembled at a right angle. FIG. 6 is a flowchart showing a manufacturing process of the assembled toy piece 1 according to the manufacturing method 1 of the assembled toy piece of the present invention. FIG. 7 is a schematic diagram of a production line for producing the assembly toy piece 1. FIG. 8 is a partial cross-sectional view showing a shearing process in which the piece body 10 is punched from the resin sheet.

FIG. 9 is an external view showing a plane, a left side, and a front surface of the assembly toy piece 1 ′ according to the second embodiment of the present invention. FIG. 10 is a flowchart showing a manufacturing process of the assembled toy piece 1 ′ according to the manufacturing method 2 of the assembled toy piece of the present invention. FIG. 11 is a schematic view of a production line for producing the assembled toy piece 1 ′. FIG. 12 is a plan view showing the order of punching out the base sheet 110 '.

[Embodiment 1]
Embodiment 1 of the present invention will be described below with reference to the drawings. FIG. 1 is a diagram showing the dimensions of an assembled toy piece 1, FIG. 1 (a) is a plan view of the assembled toy piece 1, and FIG. 1 (b) is an arrow in FIG. 1 (a). FIG. 1C is a left side view illustrating a state viewed from an arrow α, and FIG. 1C is a front view illustrating a state viewed from an arrow β in FIG.

  FIG. 2 is an external view showing a plane, a left side, and a front of the assembly toy piece 1 according to the first embodiment of the present invention. FIG. 3 is a plan view showing a state in which nine assembled toy pieces 1 are combined on the same plane. FIG. 4 is an external view showing a plane, a left side surface, and a front surface in a state where two pieces for assembling toy 1 are assembled at right angles. FIG. 5 is an external view showing a plane, a right side surface, and a back side of two assembled toy pieces 1 assembled at a right angle.

  The assembled toy piece 1 is a composition in which an elastically deformable thermoplastic synthetic resin, a thermoplastic elastomer, and a foaming agent are blended. The piece 1 for assembling toys is formed of a foamed synthetic resin having a porous shape in which the foamed pores are finely dispersed and the pores are independent or the pores are continuous. The assembled toy piece 1 is soft and elastically deformable and lightweight. The assembly toy piece 1 is made of a foamable synthetic resin, does not have an inexpensive impression like cardboard, can express a high-quality appearance with excellent design, and has a wide range of design possibilities Is also getting wider.

  As shown in FIG. 3, the assembled toy piece 1 can be formed in a pattern (star-shaped pattern) drawn, or as shown in FIG. 4, each piece is plain and without a pattern. . In other words, as shown in FIG. 3, like a jigsaw puzzle, it may be possible to play by combining differently drawn pieces on the toy piece 1 on a plane, and by combining pieces of different colors Alternatively, a three-dimensional shape may be formed and played. In this example, the assembly toy piece 1 is described as being colored in various colors, but it may be transparent or translucent so that light can be transmitted.

  As shown in FIGS. 1 and 2, the assembled toy piece 1 is formed of a piece main body 10, an engaging female portion 20, and an engaging male portion 30. The piece body 10 is formed in a rectangular parallelepiped shape having a predetermined thickness. As shown in FIG. 1A, the piece body 10 has a width dimension 10W of 6.0 mm and a depth dimension 10D of 6.0 mm. As shown in FIGS. 1B and 1C, the piece body 10 has a height dimension 10H of 2.0 mm. Thus, the piece main body 10 has an extremely small rectangular parallelepiped shape.

  On the side surface of the piece body 10, an engaging female portion 20 is formed that is cut out in a bay shape so as to be recessed in the inside of the piece body 10. As shown in FIG. 1A, one engagement female portion 20 is formed on each of the left side surface and the right side surface of the piece body 10. As shown to Fig.1 (a), the width dimension 20W of the engagement female part 20 is formed in 2.0 mm. The width dimension 21W of the opening 21 which is an opening portion in which the side surface of the piece main body 10 is cut out is formed to be 1.5 mm. A depth dimension 20D of the engaging female portion 20 is 2.0 mm.

  On the side surface of the piece main body 10, an engaging male portion 30 is formed so as to protrude outward from the piece main body. As shown in FIG. 1A, one engagement male portion 30 is formed on each of the upper side surface and the lower side surface of the piece body 10. As shown to Fig.1 (a), the width dimension 30W of the engagement male part 30 is formed in 2.0 mm. The width 31W of the neck 31 which is a part connecting the piece body 10 and the engaging male part 30 is formed to be 1.5 mm. The depth dimension 30D of the engaging male part 30 is 2.0 mm.

  The width dimension 20W of the engaging female part 20 and the width dimension 30W of the engaging male part 30 are the same, and the width dimension 21W of the opening 21 and the width dimension 31W of the neck part 31 are the same. Further, the depth dimension 20D of the engaging female part 20 and the depth dimension 30D of the engaging male part 30 are the same. For this reason, as shown in FIG. 3, the engagement male part 30 of one piece can be engaged with the engagement female part 20 of another piece. As shown in FIG. 3, one assembled toy piece 1 can be combined with another assembled toy piece 1 on the same plane. In addition, since one assembled toy piece 1 and the other assembled toy piece 1 have the same width dimension 10W and depth dimension 10D, as shown in FIG. 3, they are continuous in the width direction or the depth direction. Can be arranged side by side to form a plane.

  As will be described later, the assembled toy piece 1 is processed by shearing. For this reason, it is thought that the side surface of the engaging female part 20 and the engaging male part is formed with a sloping surface, a sheared surface, and a fractured surface, and fine irregularities are formed. When the engaging female part 20 and the engaging male part 30 are engaged, the fine irregularities are elastically deformed. Therefore, the side surfaces of the engaging female part 20 and the engaging male part 30 are in contact with each other, and the friction force Is expected to increase. For this reason, the engagement male part 30 and the engagement female part 20 are firmly engaged on the same plane without falling off.

  One assembled toy piece 1 and another assembled toy piece 1 can be combined so as to be positioned at right angles, as shown in FIGS. The engagement male part 30 and the engagement female part 20 are elastically deformed, and the engagement male part 30 and the engagement female part 20 are maintained in an engaged state firmly because their side surfaces contact each other. . In this way, one piece of assembled toy piece 1 can be combined not only on the same plane as the other assembled toy piece 1 but also three-dimensionally.

[Production method 1 for assembled toy pieces]
Next, the manufacturing method 1 of the piece for assembly toys is demonstrated based on drawing. The assembly toy piece manufacturing method 1 is a method for manufacturing the assembly toy piece 1 described in the first embodiment. FIG. 6 is a flowchart showing a manufacturing process of the assembled toy piece 1 according to the manufacturing method 1 of the assembled toy piece of the present invention. FIG. 7 is a schematic diagram of a production line for producing the assembly toy piece 1. FIG. 8 is a partial cross-sectional view showing a shearing process in which the piece body 10 is punched from the resin sheet.

  First, the outline of the manufacturing process of the assembly toy piece 1 will be described with reference to the flowchart shown in FIG. In the extrusion step S <b> 1, the resin sheet 100 is extrusion molded with the extrusion molding machine 200. In the adjustment step S2, the resin sheet 100 is passed through the adjustment device 400. In the cutting step S3, the resin sheet 100 is cut to manufacture a base sheet 110 having a predetermined length.

  In the shearing step S4, the base sheet 110 is punched out by shearing to manufacture the assembly toy piece 1. In the printing step S5, the assembly sheet 120 is assembled and printed thereon. In the disassembling step S6, the printed assembly sheet 120 is disassembled into pieces. The assembly toy piece 1 is completed by taking the above manufacturing steps.

  Next, the steps until the assembly toy piece 1 is manufactured will be specifically described with reference to the schematic diagram shown in FIG. The assembly toy piece 1 manufacturing system includes an extrusion molding machine 200, take-up rollers 301 and 302, an adjustment device 400, a cutting device 500, a shearing device 600, and a printing device 700. Is manufactured.

<Extrusion process S1>
The extrusion step S1 is a step of manufacturing the resin sheet 100 using the extrusion molding machine 200. The extrusion molding machine 200 is an extrusion molding apparatus for molding the resin sheet 100 that becomes each resin layer of each piece of the assembly toy piece 1. The material of the resin sheet 100 is a thermoplastic synthetic resin, a thermoplastic elastomer, a foaming agent, or the like. As the thermoplastic synthetic resin, any one of polyvinyl chloride, polypropylene, polyethylene, polystyrene, polyethylene terephthalate, or the like, or a mixture thereof is used.

  As the thermoplastic elastomer, any one of olefin-based thermoplastic elastomer, styrene-based thermoplastic elastomer and polyester-based thermoplastic elastomer, or a mixture thereof is used. The foaming agent can be used without particular limitation as long as it can be uniformly dispersed and mixed in the resin layer and foams at the melting temperature or higher of the composition. The extruder 200 is supplied with a thermoplastic resin composition in which polypropylene, a thermoplastic olefin-based elastomer, a foaming agent, and the like are mixed.

  The blending ratio and material of polypropylene and thermoplastic elastomer may be appropriately adjusted according to the color, pattern, hardness, etc. of the assembled toy piece. In this example, the resin sheet 100 is adjusted with a pigment or the like so as to have a plain white color. The supplied material is melted and kneaded in a heating cylinder, extruded by a screw, formed into a sheet shape by a die 201 at the tip, and becomes a foamed resin sheet 100. The resin sheet 100 is formed of a foamed synthetic resin having a porous shape in which the foamed pores are finely dispersed and the pores are independent or the pores are continuous.

  Immediately after being extruded by the extrusion molding machine 200, the resin sheet 100 is molded into a sheet shape in an uncured state that is close to solid but not completely cured. At this time, in the case of the resin sheet 100 of a resin composition made of polypropylene and a thermoplastic olefin-based elastomer, the resin sheet 100 is extruded in a state of about 120 ° C to 250 ° C. The resin sheet 100 is formed into a sheet having a predetermined thickness (for example, 2.0 mm) and a predetermined width (for example, 1200 mm) using a rolling roller.

  The resin sheet 100 is taken up by the take-up roller 301 and moves to the adjusting device 400. As shown in FIG. 7, the take-up roller 301 includes a driving roller that is rotationally driven and a nip roller (which may be rotationally driven or may rotate according to the driving roller without being rotationally driven). A take-off roller 302 described later has the same configuration.

<Adjustment step S2>
The adjustment step S2 is a step of adjusting the resin sheet 100 to a flat plane without warping by passing the resin sheet 100 through the adjustment device 400. As shown in FIG. 7, the adjusting device 400 includes adjusting rollers 401 and 402 that release internal stress. The adjustment roller 401 and the adjustment roller 402 are disposed at different heights. As shown in FIG. 7, the resin sheet 100 bends upward when passing the adjustment roller 401, and moves while bending downward when passing the adjustment roller 402.

  The resin sheet 100 passes through the adjustment rollers 401 and 402 arranged at different heights, and is subjected to repeated bending stress to reduce internal stress and is adjusted to a flat plane without warping. The resin sheet 100 that has passed through the adjusting device 400 is taken up by the take-up roller 302 and moves to the cutting device 500.

<Cutting step S3>
The cutting step S <b> 3 is a step of forming the base sheet 110 by cutting the resin sheet 100 with the cutting device 500. As shown in FIG. 7, the cutting device 500 is provided with a cutting blade 501. The resin sheet 100 that has passed through the adjusting device 400 is taken up by the take-up roller 302 and moves to the cutting device 500. The resin sheet 100 is cut into a rectangular shape having a predetermined size by the cutting blade 501 of the cutting device 500 to become the base sheet 110. The base sheet 110 is sent to the shearing device 600 and installed.

<Shearing step S4>
The shearing step S4 is a step of manufacturing the assembly toy piece 1 by punching the base sheet 110 with the shearing device 600. In this example, punching refers to a process of cutting a necessary contour shape from the base sheet 110. As shown in FIG. 7, the shearing device 600 includes a die 601, a punch 602, and a plate press 603. When the base sheet 110 is punched out by the shearing device 600, an extremely small assembly toy piece 1 is formed. As shown in FIG. 8, the die 601 is a tool that supports the base sheet 110, and is a female mold for punching the assembly toy piece 1 from the base sheet 110. The punch 602 is a tool for applying a shear stress to the base sheet 110 and is a male mold for punching the assembly toy piece 1 from the base sheet 110.

  The die 601 and the punch 602 are processed in advance into a shape of a piece body that is a shape to be punched (not shown). In other words, the width dimension 10W and the depth dimension 10D of the assembled toy piece 1 are 6.0 mm, the width dimension 20W and the depth dimension 20D of the engaging female portion 20 are 2.0 mm, and the width dimension of the engaging male portion 30 is. It is good to process so that 30W and depth dimension 30D may be 2.0 mm. The base sheet 110 that is the material of the assembled toy piece 1 is placed on the die 601 and pressed by a plate press 603 or the like, and then punched by punching the punch 602.

  In this way, a part of the base sheet 110 punched out with the die 601 and the punch 602 becomes a plain white assembled toy piece 1 (see FIGS. 1 and 7). In the assembled toy piece 1, the base sheet 110 is pressed by the plate presser 603 and is punched by being applied with a tension, so that the sheared cut is smooth and small is formed. Needless to say, a plurality of assembled toy pieces 1 may be formed by punching a single base sheet 110 at the same time.

  At this time, a plurality of assembly toy pieces 1 may be continuously punched out by moving the base sheet 110 with a feeding device or the like using a pair of dies 601 and punches 602. Alternatively, a plurality of sets of dies 601 and punches 602 may be used at the same time, and a plurality of assembled toy pieces 1 may be punched from the base sheet 110 at a time. The assembled toy piece 1 formed by punching from the base sheet 110 can be manufactured in succession in the same shape according to the shapes of the punch 602 and the die 601.

<Printing step S5>
The printing step S5 is a step of printing a pattern on the assembled toy piece 1. First, the assembling toy piece 1 is assembled so as to be one flat surface to form one assembled sheet 120. In this example, as shown in FIG. 7, the assembly sheet 120 is formed by using nine pieces of assembly toy pieces 1. The assembly sheet 120 is installed in the printing apparatus 700. As shown in FIG. 7, the assembly sheet 120 is formed with a puzzle sheet 130 on which a star pattern is printed by the ink jet printer 701. In this example, the assembly sheet 120 that is a printing medium is not flat but has irregularities on the front surface or the back surface, and thus an ink jet method that directly ejects ink is employed. In addition, ink jetting can reduce the cost per color as compared with other printing methods.

<Disassembly step S6>
The disassembling step S6 is a step of disassembling the printed puzzle sheet 130 into individual assembled toy pieces 1. The assembled toy piece 1 disassembled into pieces is packed and packaged in a package or the like.

  The assembled toy piece 1 manufactured in such a manufacturing process is formed in a very small shape of 6.0 mm square. The engaging female part and the engaging male part 30 are formed in a very small shape of 2.0 mm square. Although the assembled toy piece 1 has such an extremely small shape, a plurality of pieces having the same shape can be manufactured. Since the assembly toy piece 1 is extremely small, a sheet in which the pieces are assembled is also very small. That is, even a sheet having a small width dimension and a depth dimension can be a puzzle including a very large number of pieces. In addition, since the base member is a synthetic resin, the assembled toy piece has a better design and produces a high-class feeling compared to a base member made of cardboard or the like.

[Embodiment 2]
Next, a second embodiment of the present invention will be described. In the second embodiment, a printed layer 11 on which a pattern is printed is bonded to the assembly toy piece 1 made of the foamable synthetic resin of the first embodiment. That is, the second embodiment is a form using the first embodiment. In the description of the second embodiment, the same reference numerals are given to the same components as those of the above-described embodiment, and detailed description thereof is omitted. As shown in FIG. 9, the printed layer 11 is a layer on which a thin coated paper of 0.3 mm is used and is attached to the surface of the assembly toy piece 1 ′, and a pattern is printed thereon.

  The pattern of the printing layer 11 is formed so as to be a pattern including at least one kind selected from a picture, a photograph, a figure, a symbol, a character, and a character by fitting the plurality of piece bodies 10 together. The substrate on which the printing layer is printed is not limited to paper other than coated paper, but may be non-woven fabric, woven fabric or film as long as printing is possible. In this example, the printed layer 11 is bonded only to the surface of the assembly toy piece 1 ′, but it goes without saying that the printed layer 11 may be bonded to the back surface of the assembly toy piece 1.

[Production method 2 for assembled toy pieces]
Next, the manufacturing method 2 of the piece for assembly toys is demonstrated based on drawing. The assembly toy piece manufacturing method 2 is a method of manufacturing the assembly toy piece 1 ′ to which the printed layer 11 described in the second embodiment is bonded. FIG. 10 is a flowchart showing a manufacturing process of the assembled toy piece 1 ′ according to the manufacturing method 2 of the assembled toy piece of the present invention. FIG. 11 is a schematic diagram of a production line for producing the assembled toy piece 1 ′. FIG. 12 is a plan view showing the order of punching out the base sheet 110 ′.

  Hereinafter, the outline of the manufacturing process of the assembly toy piece 1 ′ will be described with reference to the flowchart shown in FIG. 10. In the extrusion step S <b> 101, the resin sheet 100 is extrusion molded by the extrusion molding machine 200. In the lamination step S102, the printed sheet 101 is laminated on the resin sheet 100 to produce a laminated sheet 100 '. In the adjustment step S103, the laminated sheet 100 'is passed through the adjustment device 400. In the cutting step S104, the laminated sheet 100 'is cut to produce a base sheet 110' having a predetermined length. In the shearing step S105, the base sheet 110 'is punched to manufacture the assembly toy piece 1'. The assembly toy piece 1 is completed by taking the above manufacturing steps.

  Next, the steps until the assembly toy piece 1 is manufactured will be specifically described with reference to the schematic diagram shown in FIG. 11. The manufacturing system of the assembled toy piece 1 includes an extrusion molding machine 200, a feeding device 800, take-up rollers 301 and 302, a crimping device 850, an adjustment device 400, a cutting device 500, and an NC machine tool 600 ′. The assembled toy piece 1 'is manufactured. Note that the extrusion step S101 and the adjustment step S103 of the manufacturing method 2 for the assembled toy piece 2 are the same as the extrusion step S1 and the adjustment step S2 of the manufacturing method 1 for the assembled toy piece. .

<Lamination process S102>
The lamination step S102 is a step of manufacturing the laminated sheet 100 ′ with the pressure bonding device 850 by bonding the printing sheet 101 to the resin sheet 100. As shown in FIG. 11, the uncured resin sheet 100 formed by the extrusion molding machine 200 is combined with the printing sheet 101 fed from the feeding device 800 and guided to the crimping device 850. The printing sheet 101 is a coated paper that is generally used for commercial printing. In this example, a printing sheet having a thickness of about 0.3 mm is used.

  The printing sheet 101 having the same width as that of the resin sheet 100 is prepared, and is set in the feeding device 800 as a roll 101r by a winding device. The print sheet 101 is fed from the roll 101r toward the pressure bonding device 850 by the feeding device 800. The pressure bonding device 850 is a device for manufacturing the laminated sheet 100 ′ by laminating the printing sheet 101 on the resin sheet 100, and includes a pair of pressure rollers 851 and 852. A nip portion having a predetermined interval (gap) is provided between the pressure rollers 851 and 852 in order to sandwich and pressurize the resin sheet 100 and the printing sheet 101. In this example, the nip portions are formed at intervals of 2.3 mm, for example.

  The back surface of the printing sheet 101 is aligned with the front surface of the resin sheet 100 and guided to the nip portion. In this example, the thickness is about 2.3 mm when the printing sheet 101 and the resin sheet 100 are combined in this order. The printing sheet 101 and the resin sheet 100 are sandwiched between the nip portions, pressed with a predetermined pressure, and bonded together to produce a laminated sheet 100 ′. In this example, the laminated sheet 100 ′ is manufactured by being laminated to a thickness of 2.3 mm.

  That is, the printing sheet 101 is pressed and bonded to the uncured resin sheet 100 at a predetermined pressure at the nip portion. At this time, the uncured resin sheet 100 is within a temperature range of about 50 ° C to 150 ° C. The pressed printing sheet 101 and the resin sheet 100 are in close contact and stacked. Thereafter, when the temperature of the resin sheet 100 is lowered and completely cured, the printed sheet 101 and the resin sheet 100 are laminated so as to be integrated. As described above, the laminated sheet 100 ′ is laminated and manufactured so that the printing sheet 101 is integrated with the resin sheet 100 without requiring an adhesive or the like.

  In this example, the print sheet 101 has been described on the assumption that it is a coated paper, but it goes without saying that it may be a sheet of other paper or film. For example, when the printing sheet 101 is made of a polypropylene sheet, the resin sheet 100 is made of the same kind of material, so that the adhesion state is good and the sheets are laminated so as to be firmly integrated. The printing sheet 101 may be a sheet made of synthetic resin such as polyethylene (PE), polyvinyl chloride (PVC), polyethylene terephthalate (PET), or the like.

<Cutting step S104>
The cutting step S104 is substantially the same as the cutting step S3 of the manufacturing method 1 for the assembled toy piece, and the base sheet 110 ′ is formed by cutting the resin sheet 100 on which the printing sheet 101 is bonded with the cutting device 500. It is a process to do. The base sheet 110 is installed in the shearing device 600.

<Shearing step S105>
The shearing step S105 is a step of manufacturing the assembly toy piece 1 ′ from the base sheet 110 ′ that has already been printed by the NC machine tool 600 ′ controlled by the NC machining program. First, one shearing die is prepared which is composed of two sets of dies and punches and for punching out the A1 to A4 portions shown in FIG. Moreover, it comprises two sets of dies and punches, and prepares another shearing die for punching out the B1 to B4 portions shown in FIG.

  First, the base sheet 110 'is moved, the one shearing die is aligned with the A1 position shown in FIG. 12, and the A1 position is punched by shearing. Next, another shearing die is matched with the B1 location shown in FIG. 12, and the B1 location is punched out by shearing. Next, the base sheet 110 'is moved, the one shearing die is aligned with the A2 location shown in FIG. 12, and the A2 location is punched out by shearing. Next, another shearing die is matched with the B2 location shown in FIG. 12, and the B2 location is punched out by shearing. Similarly, the base sheet 110 'is sequentially moved, and the A3, B3, A4, and B4 locations are punched in order.

  The assembly toy piece manufacturing method 2 uses the NC machine tool 600 ′ to sequentially punch out adjacent pieces, thereby eliminating waste of material compared to the assembly toy piece manufacturing method 1. be able to. Further, the manufacturing method 2 for the assembled toy piece is manufactured because the number of steps is less because it is not necessary to disassemble the assembled toy piece formed at one end after combining the assembled toy piece, as compared to the manufacturing method 2 for the assembled toy piece. Fewer steps are required.

  While various embodiments of the present invention have been described above, the present invention is not limited to these embodiments. Needless to say, changes can be made without departing from the scope and spirit of the present invention. For example, in the embodiment of the present invention, the assembly toy piece in which the engaging male part is formed on the upper and lower sides of the substantially square piece main body and the engaging female part is formed on the left and right has been described. However, without being limited to this shape, the piece main body may be triangular or round. Further, the engagement male part and the engagement female part formed on the piece main body may be provided in a necessary number, or only the engagement male part may be formed on the piece main body, or the engagement female part Only may be formed.

  Moreover, although this invention manufactures the piece for assembly toys by the shearing process which punches out a base sheet, it cannot be overemphasized that other shearing processes may be sufficient. For example, a base sheet that is a material or a piece of assembled toy that has been punched, cut out a part, cut into a single line, cut into a certain width, or closed Needless to say, it may be a process such as a notch for making a cut line.

DESCRIPTION OF SYMBOLS 1 ... Piece for assembly toys 10 ... Piece main body 20 ... Engagement female part 30 ... Engagement male part 100 ... Resin sheet 200 ... Extruder 301, 302 ... Take-off roller 400 ... Adjustment apparatus 500 ... Cutting apparatus 600 ... Shearing apparatus

Claims (1)

An assembly toy piece (1 ') for assembling by engaging an engaging portion and an engaged portion,
A resin sheet manufacturing step (S101) for manufacturing a soft elastically deformable resin sheet (100) by extruding a synthetic resin melted by extrusion molding into a sheet shape;
When the resin sheet (100) is in an uncured state that is not completely cured after the extrusion molding, a pattern including one selected from paintings, photographs, figures, symbols, characters, and characters is printed. Laminating step (S102) for producing a laminated sheet (100 ′) by pressurizing and bonding the printed sheet (101).
Cutting the laminated sheet (100 ′) to produce a base sheet (110 ′) having a predetermined length (S104);
A shearing step (S105) for punching the base sheet (110 ′) to produce a piece for assembling toy (1 ′),
The shearing step includes
Preparing one shear type and another shear type each consisting of a die and a punch;
Moving the base sheet (110 ′) and applying the one shearing mold in conformity with the first location (A1), and punching the first location (A1) by shearing;
Next, the other shearing die is applied in conformity with the second location (B1), and the second location (B1) is punched out by shearing,
Next, the base sheet (110 ′) is moved to apply the one shearing die in conformity with the third location (A2), and the third location (A2) is punched by shearing,
Next, the other shearing die is applied in conformity with the fourth location (B2), and the fourth location (B2) is punched out by shearing,
The manufacturing method of the piece for assembly toys characterized by including this.

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