FRONT MEMBER AND BUTTON PRODUCT MANUFACTURING DEVICE

Abstract

A front member configured to be included in a button member, the button member constituting a button product together with a printing medium, the front member includes: a plate-shaped front member body having one surface and the other surface; and a spacer protruding to the one surface of the front member body.

Claims

1. A front member configured to be included in a button member, the button member constituting a button product together with a printing medium, the front member comprising: a plate-shaped front member body having one surface and the other surface; and a spacer protruding to the one surface of the front member body.

2. The front member according to claim 1, wherein the front member body has a circular shape in a plan view, a diameter of the one surface is 31 mm or more and 58 mm or less, and a thickness of the spacer is 3.5 mm or more and 4.5 mm or less.

3. The front member according to claim 1, wherein a compressive residual strain of the spacer measured in accordance with JIS K 6401 is 7.9% or less.

4. The front member according to claim 1, wherein a pressure when a compressive strain of the spacer is 25% at the time of compressing the spacer in accordance with JIS K 6254 is 0.02 MPa or more and 0.05 MPa or less.

5. A button product manufacturing device that manufactures a button product by connecting the front member according to claim 1 and a back member, the device comprising: a die set including a lower die configured to support the front member and an upper die configured to separate the front member from the lower die; and a front member feeder accommodating a plurality of the front members in a stacked state and configured to feed the front member to the lower die.

6. The button product manufacturing device according to claim 5, wherein the front member feeder includes a front member slope configured to guide the front member toward the lower die.

7. The button product manufacturing device according to claim 6, wherein the front member slope includes: support portions provided on both sides in a direction intersecting a feed direction of the front member to the lower die; and an escape groove located between one support portion and the other support portion of the support portions and lower than the support portions, and the front member slope is configured to guide the front member toward the lower die so that the escape groove and the spacer do not come into contact with each other.

8. The button product manufacturing device according to claim 5, wherein a dynamic friction coefficient between the lower die and the spacer is 0.3 or more and 0.5 or less.

9. The button product manufacturing device according to claim 5, wherein the die set further includes a back member lower die to which the back member is configured to be fed, and the die set is configured to connect the back member supported by the back member lower die and the front member held by the upper die and provided with the spacer.

10. The front member according to claim 1, configured to be used in a button product manufacturing device, the button product manufacturing device manufactures a button product by connecting the front member and a back member, the button product manufacturing device includes: a die set including: a lower die configured to support the front member; and an upper die configured to separate the front member from the lower die, and a front member feeder accommodating a plurality of the front members in a stacked state and configured to feed the front member to the lower die, wherein the front member is configured to be accommodated in the front member feeder.

11. The front member according to claim 1, configured to be used in a button product manufacturing device, the button product manufacturing device manufactures a button product by connecting the front member and a back member, the button product manufacturing device includes: a die set including: a lower die configured to support the front member; and an upper die configured to separate the front member from the lower die, and a front member feeder accommodating a plurality of the front members in a stacked state, configured to feed the front member to the lower die, and the front member feeder having a front member slope configured to guide the front member toward the lower die, wherein the front member is configured to be guided to the front member slope.

12. The front member according to claim 1, configured to be used in a button product manufacturing device, the button product manufacturing device manufactures a button product by connecting the front member and a back member, the button product manufacturing device includes: a die set including: a lower die configured to support the front member; and an upper die configured to separate the front member from the lower die, and a front member feeder accommodating a plurality of the front members in a stacked state, configured to feed the front member to the lower die, and the front member feeder including support portions provided on both sides in a direction intersecting a feed direction of the front member to the lower die, and an escape groove located between one support portion and the other support portion of the support portions and lower than the support portions, the front member feeder being a front member slope that is configured to guide the front member toward the lower die, wherein the front member is configured to be guided toward the lower die so that the escape groove and the spacer do not come into contact with each other.

13. The front member according to claim 1, configured to be used in a button product manufacturing device, the button product manufacturing device manufactures a button product by connecting the front member and a back member, the button product manufacturing device includes: a die set including: a lower die configured to support the front member; and an upper die configured to separate the front member from the lower die, and a front member feeder accommodating a plurality of the front members in a stacked state, configured to feed the front member to the lower die, and the front member feeder including a front member slope configured to guide the front member toward the lower die, wherein a dynamic friction coefficient between the lower die and the spacer is 0.3 or more and 0.5 or less.

14. The front member according to claim 1, configured to be used in a button product manufacturing device, the button product manufacturing device manufactures a button product by connecting the front member and a back member, the button product manufacturing device includes: a die set including: a lower die configured to support the front member; an upper die configured to separate the front member from the lower die; and a back member lower die to which the back member is configured to be fed, and a front member feeder accommodating a plurality of the front members in a stacked state and configured to feed the front member to the lower die, wherein the front member is configured to be connected to the back member supported by the back member lower die after being held by the upper die.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0006] FIG. 1 is a perspective view illustrating a button product manufacturing device that manufactures a button product using a front member.

[0007] FIG. 2 is a plan view of the button product manufacturing device in FIG. 1.

[0008] FIG. 3 is a block diagram illustrating a configuration of a control system of the button product manufacturing device in FIG. 1.

[0009] FIG. 4A is a perspective view of the front member.

[0010] FIG. 4B is a perspective view of the front member viewed from a direction different from that of FIG. 4A.

[0011] FIG. 5 is a perspective view illustrating a configuration of a front member feed unit.

[0012] FIG. 6 is a diagram illustrating a state where the front member is fed to a lower die by the front member feed unit in FIG. 5.

[0013] FIG. 7A is a plan view illustrating a printing medium.

[0014] FIG. 7B is a plan view illustrating a white film.

[0015] FIG. 8A is a perspective view of a die set.

[0016] FIG. 8B is a perspective view of the die set viewed from a direction different from that of FIG. 8A.

[0017] FIG. 9 is a sectional view of the button product manufactured by caulking the front member in FIG. 4A and a back member.

[0018] FIG. 10 is a flowchart illustrating a flow of processing by the button product manufacturing device.

DESCRIPTION

[0019] Hereinafter, a front member according to an embodiment of the present invention and a button product manufacturing device that manufactures a button product using the front member will be described with reference to the drawings. The front member and the button product manufacturing device to be described below is merely an embodiment of the present invention. Accordingly, the present invention is not limited to the following embodiment, and can be added, deleted, or modified without departing from the scope of the present invention.

Overall Configuration of Button Product Manufacturing Device

[0020] First, a button product manufacturing device that manufactures a button product using a front member will be described with reference to the drawings. FIG. 1 is a perspective view illustrating a button product manufacturing device 100 that manufactures a button product using a front member according to the present embodiment. FIG. 2 is a plan view of the button product manufacturing device 100 in FIG. 1. FIG. 3 is a block diagram illustrating a configuration of a control system of the button product manufacturing device 100 in FIG. 1.

[0021] The button product manufacturing device 100 according to the present embodiment is a device that manufactures a button product by connecting a front member and a back member constituting the button product, for example, by caulking the front member and the back member. The button product manufacturing device 100 includes a printing unit 1, a conveying unit 2, a die set 3, a front member feed unit 4, a back member feed unit 5, a pressing unit 6, a take-out unit 7, a collection box 8, and a button product container 9, as illustrated in FIGS. 1 and 2. In FIGS. 1 and 2, directions orthogonal to one another are referred to as a first direction Dx, a second direction Dy, and a third direction Dz. In the present embodiment, for example, the first direction Dx is a front-rear direction of the button product manufacturing device 100, the second direction Dy is a left-right direction of the button product manufacturing device 100, and the third direction Dz is an up-down direction. In this case, a front side of the printing unit 1 is referred to as a front side, a rear side thereof is referred to as a rear side, and left and right sides thereof as viewed from the front are referred to as a left side and a right side. In the following description, Dx is referred to as the front-rear direction, Dy is referred to as the left-right direction, and Dz is referred to as the up-down direction.

[0022] The printing unit 1 is disposed below the die set 3, the front member feed unit 4, the back member feed unit 5, the pressing unit 6, and the take-out unit 7. The printing unit 1 is an inkjet printer that prints an image on a printing medium W (FIG. 7A to be described later) such as a transparent film. The printing unit 1 performs printing on the printing medium W. Specifically, the printing unit 1 includes an ejection head 10, and printing is performed by ink droplets being ejected by the ejection head 10 onto the printing medium W. The printing unit 1 further includes a conveying motor 11 that drives a conveying roller. The ejection head 10 may be of a serial head type or a line head type.

[0023] The printing unit 1 includes a sheet holder (not illustrated) that holds a plurality of printing media W and a plurality of white films F (FIG. 7B to be described later), and the printing media W and the white films F are held on the sheet holder as a bundle in which the printing media W and the white films F are alternately stacked. The white film F is fed to the conveying unit 2 without being printed by the printing unit 1, and the printing medium W is fed to the conveying unit 2 after a predetermined image is formed by the ejection head 10 of the printing unit 1. The predetermined image is an inverted image that becomes a normal image when a user views the image from a surface opposite to a surface on which the image is printed among surfaces of the printing medium W. In the present embodiment, an example in which the printing unit 1 is an inkjet printer has been described, but without being limited thereto, the printing unit 1 may be another printer such as a laser printer or a thermal printer.

[0024] Regarding the conveying unit 2, a part of the conveying unit 2 is disposed in front of the printing unit 1, and the entire conveying unit 2 is disposed in front of the die set 3. The conveying unit 2 conveys, along a conveying direction Dc1 toward the die set 3, the printing medium W and the white film F conveyed from the printing unit 1 onto a front member SE (FIGS. 4A and 4B) which is included in a button member CE to be described later and which is supplied prior to a lower die 30 provided in the die set 3.

[0025] The die set 3 performs, for example, caulking of the front member SE and a back member BE, as an example of connection between the front member SE and the back member BE (FIG. 9) included in the button member CE to be described later. The front member SE is formed of a magnetic material such as a tin-plated steel plate. The back member BE is formed of a magnetic material such as a tin-plated steel plate. The die set 3 includes the lower die 30, a lower die 31, a rotation support table 32, an upper die 33, an upper die lifting motor 34, and a lower die moving motor 140. The lower die 31 corresponds to a back member lower die. The lower die 30 and the lower die 31 are formed in a circular shape in a plan view, and are supported by the rotation support table 32. The lower die 30 and the lower die 31 face each other with a center of the rotation support table 32 as a reference. The upper die 33 is raised or lowered to approach or separate from either the lower die 30 or the lower die 31 in the up-down direction Dz based on an operation of the upper die lifting motor 34.

[0026] The rotation support table 32 rotates around the up-down direction Dz based on an operation of the lower die moving motor 140. By rotating the rotation support table 32, either the lower die 30 or the lower die 31 can be located at a position facing the upper die 33 in the up-down direction Dz (hereinafter, referred to as second die position). A position facing the second die position in the front-rear direction Dx is hereinafter referred to as a first die position. When the lower die 30 is at the first die position, the front member SE is fed to the lower die 30 by the front member feed unit 4. Accordingly, the lower die 30 supports the front member SE. After the white film F is conveyed onto the front member SE by the conveying unit 2, first separation processing to be described later is performed. Accordingly, only a later-described connected portion Fb of the white film F is disposed on the front member SE. Subsequently, second separation processing to be described later is performed after the printing medium W is conveyed onto the connected portion Fb on the front member SE by the conveying unit 2. Accordingly, only a later-described connected portion Wb of the printing medium W is disposed on the connected portion Fb. The front member feed unit is an example of a front member feeder. The conveying unit is an example of a conveyor.

[0027] Next, the lower die 30 at the first die position while supporting the front member SE is located at the second die position by rotating the rotation support table 32. At this time, the lower die 31 at the second die position moves to the first die position. Then, the upper die 33 is lowered, and the front member SE supported by the lower die 30 is held by the upper die 33. Thereafter, the upper die 33 is raised, and the front member SE is separated from the lower die 30 by the upper die 33. At this time, the back member BE is fed to the lower die 31 by the back member feed unit 5. Subsequently, the lower die 31 at the first die position is located at the second die position by rotating the rotation support table 32. Thereafter, the upper die 33 holding the front member SE is lowered toward the lower die 31 supporting the back member BE, so that the back member BE is caulked to the front member SE. In this way, the die set 3 manufactures a button product 200 (FIG. 9) by caulking the back member BE supported by the lower die 31 and the front member SE held by the upper die 31 and provided with a spacer (a contact member) CM. Thereafter, the lower die 31 at the second die position is located at the first die position by rotating the rotation support table 32. Then, the button product 200 supported by the lower die 31 moved to the first die position is taken out by the take-out unit 7. The contact member is an example of a spacer. The back member feed unit is an example of a back member feeder.

[0028] The front member feed unit 4 is disposed above the printing unit 1 and to the right of the die set 3. The front member feed unit 4 includes a pusher motor 46. The front member feed unit 4 feeds the front member SE to the lower die 30 by a pusher pushing out the front member SE based on an operation of the pusher motor 46. Details of the front member feed unit 4 will be described later.

[0029] The back member feed unit 5 is disposed above the printing unit 1 and to the left of the die set 3. The back member feed unit 5 includes a pusher motor 56. The back member feed unit 5 feeds the front member SE to the lower die 31 by a pusher pushing out the back member BE based on an operation of the pusher motor 56.

[0030] The pressing unit 6 is disposed in front of the front member feed unit 4 and the back member feed unit 5 and to the left of the die set 3. The pressing unit 6 includes a pressing motor 60. The pressing unit 6 presses the printing medium W and the white film F toward the lower die 30 based on an operation of the pressing motor 60.

[0031] The take-out unit 7 is disposed in front of the front member feed unit 4. The take-out unit 7 includes a take-out motor 70. The take-out unit 7 takes out the button product 200 from the lower die 31 based on an operation of the take-out motor 70, and guides the button product 200 to the button product container 9 disposed in front of the take-out unit 7.

[0032] The button product manufacturing device 100 further includes a control device 110, a first drive circuit 115, a second drive circuit 116, a third drive circuit 117, a fourth drive circuit 118, a fifth drive circuit 119, a sixth drive circuit 120, and a seventh drive circuit 150, as illustrated in FIG. 3. The control device 100 includes an interface 111, a calculation unit 112, and a storage unit 113. The interface 111 receives, as print data, various data such as image data from an external device 114 such as a computer, a camera, a communication network, a recording medium, a display, and a printer. The control device 110 may be implemented by a single device, or may have a configuration in which a plurality of devices are arranged in a distributed manner and cooperate with one another to operate the button product manufacturing device 100.

[0033] The storage unit 113 is a memory accessible from the calculation unit 112, and includes a RAM and a ROM. The RAM temporarily stores various data including data received from the external device 114 such as image data, data converted by the calculation unit 112, and the like. The ROM stores a button product manufacturing program for performing various types of processing, predetermined data, and the like. The button product manufacturing program may be stored in an external storage medium different from the storage unit 113 and accessible from the calculation unit 112, such as a CD-ROM.

[0034] The calculation unit 112 includes at least one circuit, for example, a processor such as a CPU, and an integrated circuit such as an ASIC. The calculation unit 112 executes the button product manufacturing program to control each unit.

[0035] The control device 110 outputs a control signal to the first drive circuit 115. The first drive circuit 115 generates a drive signal based on the control signal and outputs the drive signal to the ejection head 10 of the printing unit 1. The ejection head 10 is driven in response to the drive signal, which causes ink droplets to be ejected from a nozzle. Specifically, the first drive circuit 115 causes the ink droplets to be ejected from the ejection head 10 onto the printing medium W while moving the ejection head 10 in a predetermined movement direction based on the image data acquired from the external device 114. Then, the first drive circuit 115 drives the conveying motor 11 to convey the printing medium W in a conveying direction (not illustrated). The first drive circuit 115 alternately repeats the printing pass and the conveying operation in this way, so that an image based on the image data is printed on the printing medium W.

[0036] The control device 110 outputs a control signal to the second drive circuit 116. The second drive circuit 116 generates a drive signal based on the control signal and controls an operation of a conveying motor 23 provided in the conveying unit 2. In this case, the second drive circuit 116 controls the operation of the conveying motor 23 based on a detection result of a conveying sensor provided in the conveying unit 2. Accordingly, the printing medium W and the white film F from the printing unit 1 are conveyed to the lower die 30 by the conveying unit 2.

[0037] The control device 110 outputs a control signal to the third drive circuit 117. The third drive circuit 117 generates a drive signal based on the control signal and controls operations of the upper die lifting motor 34 and the lower die moving motor 140 provided in the die set 3. In addition, the control device 110 outputs a control signal to the fourth drive circuit 118. The fourth drive circuit 118 generates a drive signal based on the control signal and controls the operation of the pusher motor 46 provided in the front member feed unit 4. Further, the control device 110 outputs a control signal to the fifth drive circuit 119. The fifth drive circuit 119 generates a drive signal based on the control signal and controls the operation of the pusher motor 56 provided in the back member feed unit 5. In addition, the control device 110 outputs a control signal to the sixth drive circuit 120. The sixth drive circuit 120 generates a drive signal based on the control signal and controls the operation of the pressing motor 60 provided in the pressing unit 6. In addition, the control device 110 outputs a control signal to the seventh drive circuit 150. The seventh drive circuit 150 generates a drive signal based on the control signal and controls the operation of the take-out motor 70 provided in the take-out unit 7.

Front Member

[0038] Next, the front member SE according to the present embodiment will be described. FIG. 4A is a perspective view of the front member SE, and FIG. 4B is a perspective view of the front member SE viewed from a direction different from that of FIG. 4A.

[0039] As illustrated in FIGS. 4A and 4B, the front member SE according to the present embodiment is included in the button member CE constituting the button product 200 together with the printing medium W. The front member SE includes a plate-shaped front member body SEb having one surface Sf2 and the other surface Sf1, and the contact member CM protruding to the one surface Sf2 of the front member body SEb. The one surface Sf2 is, for example, a back surface of the front member body SEb, and the other surface Sf1 is, for example, a front surface of the front member body SEb.

[0040] The front member body SEb has a circular shape in a plan view. The front member body SEb is a member whose peripheral edge portion SEa protrudes downward. A thickness of the front member body SEb is, for example, 0.3 mm. A diameter of the one surface Sf2 of the front member body SEb is, for example, 31 mm or more and 58 mm or less. However, the diameter of the one surface Sf2 is not limited to the above-described numerical range.

[0041] The contact member CM is provided on the one surface Sf2 of the front member body SEb as described above. In this case, the contact member CM may be fixed to the one surface Sf2 of the front member body SEb by, for example, an adhesive or an adhesive seal. The contact member CM is provided, for example, at the center of the one surface Sf2 of the front member body SEb. The contact member CM has, for example, a rectangular parallelepiped shape or a cubic shape. A lowermost end of the contact member CM provided on the one surface Sf2 of the front member body SEb is located below a lowermost end of the peripheral edge portion SEa of the front member body SEb. A thickness of the contact member CM is, for example, 3.5 mm or more and 4.5 mm or less. However, the thickness of the contact member CM is not limited to the above-described numerical range.

[0042] The contact member CM is a member that contracts when a pressure is applied to the contact member CM, and is made of, for example, urethane foam. A compressive residual strain of the contact member CM measured in accordance with JIS K 6401 is 7.9% or less. Specifically, in JIS K 6401, the compressive residual strain is acquired as follows. First, after the thickness of the contact member CM is measured, the contact member CM is compressed to a thickness of 75% of the original thickness thereof in a state of being clamped by jigs. Then, the compressed contact member CM is left in an atmosphere of 70 C. for 22 hours. Thereafter, the contact member CM is taken out from the jig, and the thickness of the contact member CM is measured again. Then, the compressive residual strain is acquired by [{(thickness of contact member CM before compression)(thickness of contact member CM after compression)}/(thickness of contact member CM before compression)]100 based on the thicknesses of the contact member CM before and after compression. However, the compressive residual strain of the contact member CM is not limited to the above-described numerical range.

[0043] A pressure when a compressive strain of the contact member CM is 25% at the time of compressing the contact member CM in accordance with JIS K 6254 is 0.02 MPa or more and 0.05 MPa or less. Specifically, in JIS K 6254, the pressure when the compressive strain is 25% is acquired as follows. First, the thickness of the contact member CM having, for example, a prismatic shape is measured. Then, the contact member CM is placed in a test device under an atmosphere of a temperature of 23 C. and a humidity of 50% RH (relative humidity), and the contact member CM is compressed using a load cell at a speed of 10 mm/min until the compressive strain of the contact member CM reaches 25%. A pressure of the load cell at this time is acquired. The compressive strain can be obtained by dividing the thickness of the contact member CM after compression by the thickness of the contact member CM before compression. However, the pressure on the contact member CM is not limited to the above-described numerical range.

Front Member Feed Unit

[0044] Hereinafter, the front member feed unit 4 will be described. FIG. 5 is a perspective view illustrating a configuration of the front member feed unit 4. FIG. 6 is a diagram illustrating a state where the front member SE is fed to the lower die 30 by the front member feed unit 4 in FIG. 5.

[0045] The front member feed unit 4 feeds the front member SE to the lower die 30 provided in the die set 3. The front member feed unit 4 is disposed above the printing unit 1 and to the right of the die set 3. The front member feed unit 4 includes a front member stocker 40, a front member slope 43, a pusher 45, and the pusher motor 46, as illustrated in FIG. 5. The front member stocker 40 accommodates a plurality of front members SE in a state of being stacked in the up-down direction Dz. The front member stocker 40 is formed in a cylindrical shape. The front member stocker 40 is erected such that an axial center thereof is oriented in the up-down direction, and a slit 40a extending in the up-down direction is formed at a portion close to the lower die 30. The slit 40a has a width dimension smaller than a diameter dimension of the front member SE, and is formed in a portion from an upper end to a lower end of the front member stocker 40. The user can visually recognize the front member SE accommodated in the front member stocker 40 through the slit 40a of the front member stocker 40. That is, the user can grasp the remaining number of the front member SE. When the remaining number is small, the user can newly replenish the front member SE from the upper end of the front member stocker 40. The front member slope 43 is provided with a front member sensor S1 which is, for example, a contact sensor. When the remaining number of the front member SE in the front member stocker 40 is, for example, zero based on a detection result by the front member sensor S1, the control device 110 displays, on a display unit (not illustrated) provided in the button product manufacturing device 100, a message prompting replenishment of the front member SE to the front member stocker 40. Accordingly, the user can grasp the remaining number of the front member SE in the front member stocker 40, and can replenish a new front member SE to the front member stocker 40. The front member sensor S1 is not limited to a contact sensor, and another sensor such as a photoelectric sensor or a laser sensor may be adopted as the front member sensor S1.

[0046] A space having a dimension equal to or slightly larger than a thickness dimension of one front member SE is provided between the lower end of the front member stocker 40 and an upper surface of the front member slope 43. The pusher 45 pushes out the front member SE on the front member slope 43 toward the lower die 30. The pusher 45 is disposed on a side opposite to the lower die 30 with respect to the front member stocker 40. That is, the front member stocker 40 is disposed between the lower die 30 and the pusher 45. The pusher 45 has, for example, a plate-shaped pusher body 45a and a rack gear 45b connected to the pusher body 45a and extending in a predetermined feed direction Dk1. The rack gear 45b is engaged with a pinion gear 47 connected to a rotary shaft of the pusher motor 46. The pusher motor 46 is rotationally driven, so that the rack gear 45b moves in the feed direction Dk1 and a direction opposite thereto, and the pusher body 45a moves on the front member slope 43 in the feed direction Dk1 and the opposite direction along with the movement. In this case, when the pusher body 45a moves in the feed direction Dk1, a distal end of the pusher body 45a passes below the front member stocker 40 and reaches the vicinity of the lower die 30. Accordingly, one front member SE fed from the front member stocker 40 onto the front member slope 43 is pushed out by the pusher body 45a and sent out in the feed direction Dk1 toward the lower die 30. Accordingly, the lower die 30 supports the front member SE. In this case, when the pusher body 45a moves and retracts in the direction opposite to the feed direction Dk1, the distal end of the pusher body 45a retreats from below the front member stocker 40 toward the outer side. Accordingly, one front member SE is moved downward from the front member stocker 40 and fed onto the front member slope 43.

[0047] The front member slope 43 guides the front member SE, which is pushed out by the pusher 45, toward the lower die 30 in the feed direction Dk1. The front member slope 43 is disposed below the front member stocker 40, and extends from a predetermined position adjacent to the lower die 3 through below the front member stocker 40. The front member slope 43 has a pair of support portions 42 and a slope body 41 whose cross section is formed in, for example, a concave shape. The pair of support portions 42 are provided on both sides of a bottom portion of the slope body 41 in a direction (that is, width direction) orthogonal to the feed direction Dk1. Accordingly, an escape groove 44, which is a portion located between one support portion 42 and the other support portion 42 of the pair of support portions 42 and lower than a height of the support portion 42, is formed in an inner bottom surface of the slope body 41. The front member SE is supported by the pair of support portions 42 of the front member slope 43 when being fed from the front member stocker 40 toward the front member slope 43.

[0048] The front member slope 43 has a notch 43a at a downstream end of the feed direction Dk1 of the front member SE. The notch 43a has an arc shape cut out in a convex shape in the direction opposite to the feed direction Dk1. By providing the notch 43a in the front member slope 43, an upstream end of the front member SE (that is, end on side opposite to side where lower die 30 is present) is less likely to be caught by the front member slope 43 when the front member SE is fed from the downstream end of the front member slope 43 to the lower die 30, as illustrated in FIG. 6. Therefore, the front member SE can be fed to the lower die 30 with high accuracy.

[0049] A dynamic friction coefficient between the lower die 30 and the contact member CM is, for example, 0.3 or more and 0.5 or less. In this case, when the front member SE is fed from the front member slope 43 to the lower die 30, the contact member CM provided on the front member SE can be brought into contact with the lower die 30. Accordingly, it is possible to prevent a situation in which the front member SE protruding from the front member slope 43 deviates from a predetermined position (that is, holding surface) of the lower die 30 and projects from the lower die 30. Therefore, the feed accuracy of the front member SE to the lower die 30 is improved. The dynamic friction coefficient between the lower die 30 and the contact member CM is not limited to the above-described numerical range.

Printing Medium and White Film

[0050] Next, the printing medium W and the white film F conveyed from the printing unit 1 toward the lower die 30 by the conveying unit 2 will be described. FIG. 7A is a plan view illustrating the printing medium W, and FIG. 7B is a plan view illustrating the white film F.

[0051] The printing medium W constitutes the button product 200 together with the button member CE (front member SE and back member BE), and is, for example, a transparent sheet. As illustrated in FIG. 7A, the printing medium W has a rectangular shape. The printing medium W has one end We1 in a direction D1 parallel to the conveying direction Dc1 when being conveyed toward the die set 3 by the conveying unit 2, and the other end We2 opposite to the one end We1. In the conveying direction Dc1, the one end We1 of the printing medium W corresponds to a downstream end, and the other end We2 corresponds to an upstream end.

[0052] The printing medium W includes the sheet-shaped connected portion Wb connected to the front member SE and the back member BE by the die set 3, a sheet-shaped remaining portion Wa different from the connected portion Wb, and a plurality of coupling portions Wc coupling the connected portion Wb and the remaining portion Wa. The remaining portion Wa surrounds the connected portion Wb. Accordingly, the remaining portion Wa has the one end We1 and the other end We2 in the direction D1. The printing medium W includes the plurality of coupling portions Wc and cut portions Wf each located between the adjacent coupling portions Wc, at a boundary between the connected portion Wb and the remaining portion Wa. Accordingly, the connected portion Wb and the remaining portion Wa are cut and not coupled between the adjacent coupling portions Wc. The connected portion Wb has, for example, a circular shape in a plan view and is located closer to the one end We1 than to the other end We2. That is, the connected portion Wb is unevenly distributed toward the one end We1 with respect to the remaining portion Wa. The connected portion Wb has a size the same as the connected portion Fb or larger than the connected portion Fb.

[0053] The printing medium W further includes a linear weak portion Wd extending from an edge portion Wh of the one end We1 to the connected portion Wb. The coupling portion Wc and the linear weak portion Wd form a weak portion having lower strength than the connected portion Wb and the remaining portion Wa. Specifically, the linear weak portion Wd and combination of the coupling portion Wc and the cut portion Wf are formed by perforations having the same thickness as the connected portion Wb and the remaining portion Wa but are partially cut. As another example, the coupling portion Wc and the linear weak portion Wd are recesses or the like having a thickness thinner than that of the connected portion Wb and the remaining portion Wa.

[0054] The coupling portion Wc includes a coupling portion Wc1, a coupling portion Wc2, and a coupling portion Wc3. The coupling portion Wc1 couples the connected portion Wb and the remaining portion Wa at a predetermined position Pw1 on the boundary between the connected portion Wb and the remaining portion Wa. The coupling portion Wc2 couples the connected portion Wb and the remaining portion Wa at a position Pw2 on the boundary different from the position Pw1. The coupling portion Wc3 couples the connected portion Wb and the remaining portion Wa at a position Pw3 on the boundary different from the positions Pw1 and Pw2. The connected portion Wb is pressed against the lower die 30 by the pressing unit 6.

[0055] The coupling portion Wc is provided at the predetermined position Pw3 on the boundary between the connected portion Wb and the remaining portion Wa, the number of the coupling portion Wc at the position Pw3 being larger than the number of the coupling portion Wc at the positions Pw1 and Pw2. That is, the number of the coupling portion Wc3 is larger than the total number of the coupling portion Wc1 and the coupling portion Wc2. The two coupling portions Wc present on a straight line orthogonal to the conveying direction Dc1 and passing through a center Cw of the connected portion Wb may be included in the coupling portion Wc1 and the coupling portion Wc2, or may be included in the coupling portion Wc3.

[0056] A configuration of the white film F is basically the same as the configuration of the printing medium W. Similarly to the printing medium W, the white film F constitutes the button product 200 together with the front member SE and the back member BE as the button member CE. As illustrated in FIG. 7B, the white film F has a rectangular shape. The white film F has one end Fe1 in the direction D1 and the other end Fe2 on a side opposite to the one end Fe1. In the conveying direction Dc1, the one end Fe1 of the white film F corresponds to a downstream end, and the other end Fe2 corresponds to an upstream end.

[0057] The white film F includes the sheet-shaped connected portion Fb connected to the front member SE and the back member BE by the die set 3, a sheet-shaped remaining portion Fa different from the connected portion Fb, and a plurality of coupling portions Fc coupling the connected portion Fb and the remaining portion Fa. The remaining portion Fa surrounds the connected portion Fb. Accordingly, the remaining portion Fa has the one end Fe1 and the other end Fe2 in the direction D1. The white film F includes the plurality of coupling portions Fc and cut portions Ff each located between the adjacent coupling portions Fc, at a boundary between the connected portion Fb and the remaining portion Fa. Accordingly, the connected portion Fb and the remaining portion Fa are cut and not coupled between the adjacent coupling portions Fc. The connected portion Fb has, for example, a circular shape in a plan view and is located closer to the one end Fe1 than to the other end Fe2. That is, the connected portion Fb is unevenly distributed toward the one end Fe1 with respect to the remaining portion Fa.

[0058] The white film F further includes a linear weak portion Fd extending from the one end Fe1 to the connected portion Fb. The coupling portion Fc and the linear weak portion Fd form a weak portion having lower strength than the connected portion Fb and the remaining portion Fa. Specifically, the linear weak portion Fd and combination of the coupling portion Fc and the cut portion Ff are formed by perforations having the same thickness as the connected portion Fb and the remaining portion Fa but are partially cut. As another example, the coupling portion Fc and the linear weak portion Fd are recesses or the like having a thickness thinner than that of the connected portion Fb and the remaining portion Fa.

[0059] The coupling portion Fc includes a coupling portion Fc1, a coupling portion Fc2, and a coupling portion Fc3. The coupling portion Fe1 couples the connected portion Fb and the remaining portion Fa at a position Pf1 on a boundary between the connected portion Fb and the remaining portion Fa and corresponding to the position Pw1. The coupling portion Fc2 couples the connected portion Fb and the remaining portion Fa at a position Pf2 on the above-described boundary and corresponding to the position Pw2. The coupling portion Fc3 couples the connected portion Fb and the remaining portion Fa at a position Pf3 on the above-described boundary and corresponding to the position Pw3. A portion of the connected portion Fb at the position Pf1 is pressed toward the lower die 30 by a first pressing portion 66e, and a portion of the connected portion Fb at the position Pf2 is pressed toward the lower die 30 by a second pressing portion 66f.

[0060] The coupling portion Fc is provided at the predetermined position Pf3 on the boundary between the connected portion Fb and the remaining portion Fa, the number of the coupling portion Fc at the position Pf3 being larger than the number of the coupling portion Fc at the positions Pf1 and Pf2. That is, the number of the coupling portion Fc3 is larger than the total number of the coupling portion Fc1 and the coupling portion Fc2. The two coupling portions Fc present on a straight line orthogonal to the conveying direction Dc1 and passing through a center Cf of the connected portion Fb may be included in the coupling portion Fe1 and the coupling portion Fc2, or may be included in the coupling portion Fc3.

[0061] After the white film F is conveyed onto the front member SE by the conveying unit 2, the connected portion Fb of the white film F is pressed against the lower die 30 by the pressing unit 6. Then, the white film F is conveyed, by the conveying unit 2, in a conveying direction Dc2 opposite to the conveying direction Dc1 in a state where the connected portion Fb is pressed. By such first separation processing, only the connected portion Fb is disposed on the front member SE, and the remaining portion Fa is conveyed to and collected in the collection box 8 after being separated from the connected portion Fb. The same applies to the printing medium W. That is, after the printing medium W is conveyed by the conveying unit 2 onto the connected portion Fb disposed on the front member SE as described above, the connected portion Wb of the printing medium W is pressed against the lower die 30 by the pressing unit 6. Then, the printing medium W is conveyed in the conveying direction Dc2 by the conveying unit 2 in a state where the connected portion Wb is pressed. By such second separation processing, only the connected portion Wb is disposed on the connected portion Fb on the front member SE, and the remaining portion Wa is conveyed to and collected in the collection box 8 after being separated from the connected portion Wb. By the above processing, the connected portion Fb and the connected portion Wb are disposed in this order on the front member SE.

Die Set

[0062] Next, the die set 3 will be described. FIG. 8A is a perspective view of the die set 3, and FIG. 8B is a perspective view of the die set 3 viewed from a direction different from that of FIG. 8A.

[0063] The die set 3 performs, for example, caulking of the front member SE and the back member BE as connection of the front member SE and the back member BE. The die set 3 includes the lower die 30, the lower die 31, the lower die moving motor 140, the rotation support table 32, the upper die 33, the upper die lifting motor 34, a first gear 35, a second gear 36, a pair of rotary cams 37, and a support plate 38, as illustrated in FIGS. 8A and 8B.

[0064] The lower die 30 and the lower die 31 are formed in a circular shape in a plan view. The lower die 30 and the lower die 31 face each other with a center of the rotation support table 32 as a reference, and are supported by the rotation support table 32 via springs 30s, respectively. In an initial stage, the lower die 30 is disposed in front of the lower die 31. The rotation support table 32 has a substantially circular shape in a plan view. A gear 32a is provided on a side peripheral surface of the rotation support table 32 parallel to an axial direction. The lower die moving motor 140 is provided lateral to the rotation support table 32. A gear 131 is connected to a rotary shaft of the lower die moving motor 140. The gear 131 is engaged with the gear 32a of the rotation support table 32. Accordingly, the lower die moving motor 140 is rotationally driven, so that a driving force thereof is transmitted to the rotation support table 32 via the gears 131 and 32a. Therefore, the rotation support table 32 rotates in the up-down direction Dz. By rotating the rotation support table 32, either the lower die 30 or the lower die 31 can be located at the above-described second die position facing the upper die 33 in the up-down direction Dz. The above-described first die position is a position clamped between the front member slope 43 of the front member feed unit 4 and the back member slope 53 of the back member feed unit 5. When the lower die 30 is at the first die position, the lower die 30 receives the front member SE from the front member feed unit 4. On the other hand, when the lower die 31 is at the first die position, the lower die 31 receives the back member BE from the back member feed unit 5.

[0065] The support plate 38 is erected lateral to the rotation support table 32. The upper die lifting motor 34 is disposed on the support plate 38. A third gear (not illustrated) is connected to a rotary shaft of the upper die lifting motor 34. The third gear is engaged with the first gear 35. The first gear 35 is provided with a fourth gear (not illustrated) coaxially with the first gear 35. The fourth gear is engaged with the second gear 36. The pair of rotary cams 37 are connected to the second gear 36.

[0066] The support plate 38 is provided with a plate member 38a extending in the front-rear direction Dx toward above the lower die 31. The upper die 33 is located below the plate member 38a. The upper die 33 includes an inner die 33a and an annular outer die 33b provided below the inner die 33a coaxially with the inner die 33a and having an inner diameter larger than an outer diameter of the inner die 33a. The inner die 33a is provided with a pair of pressed members 33c provided below the plate member 38a and extending in the left-right direction Dy. One rotary cam 37a of the pair of rotary cams 37 presses one of the pressed members 33c downward, and the other rotary cam 37b of the pair of rotary cams 37 presses the other pressed member 33c downward. In such a configuration, the upper die lifting motor 34 is rotationally driven, so that the driving force thereof is transmitted to the second gear 36 via the third gear, the first gear 35, and the fourth gear. Accordingly, the second gear 36 rotates in a rotation direction Dr2, and the pair of rotary cams 37 also rotate in the rotation direction Dr2 accordingly. At this time, the rotary cam 37a pushes down one of the pressed members 33c, and the rotary cam 37b pushes down the other pressed member 33c, so that the inner die 33a can be slid with respect to the outer die 33b and lowered to the lower die 30 or the lower die 31. The upper die 33 can be raised to above the lower dies 30 and 31 by reversely rotating the upper die lifting motor 34.

[0067] FIG. 9 is a sectional view of the button product 200 manufactured by caulking the front member SE and the back member BE. Similarly to the front member SE, the back member BE has a circular shape in a plan view. As described above, the front member SE is a member whose peripheral edge portion SEa protrudes downward, and the back member BE is a member whose peripheral edge portion BEa protrudes upward, as illustrated in FIG. 9. The button product 200 is formed by caulking the front member SE separated and held by the upper die 33, the connected portion Wb of the printing medium W, and the back member BE. The button product 200 is, for example, a button badge. In the button product 200, the peripheral edge portion SEa and the peripheral edge portion BEa are caulked in a state where a peripheral edge portion Fg of the connected portion Fb and a peripheral edge portion Wg of the connected portion Wb disposed on the front member SE to which the contact member CM is fixed are bent and clamped between the peripheral edge portion SEa and the peripheral edge portion BEa.

Flow of Overall Processing

[0068] FIG. 10 is a flowchart illustrating a flow of processing by the button product manufacturing device 100. As illustrated in FIG. 10, first, the control device 110 determines whether the front member SE is present in the front member stocker 40 based on the detection result by the front member sensor S1 (step S1). When the front member SE is present in the front member stocker 40 (Yes in step S1), the control device 110 executes processing of step S2 to be described later. On the other hand, when there is no front member SE in the front member stocker 40 (No in step S1), the control device 110 displays, on a display unit (not illustrated) provided in the button product manufacturing device 100, a message prompting replenishment of the front member SE to the front member stocker 40 (step S15).

[0069] Next, the control device 110 determines whether there is an instruction to produce a button product from a user (step S2). When there is no instruction to produce a button product (No in step S2), the control device 110 waits as it is.

[0070] On the other hand, when there is an instruction to produce a button product (Yes in step S2), the control device 110 causes the front member feed unit 4 to feed the front member SE to the lower die 30 (step S3). Next, the control device 110 causes the conveying unit 2 to convey the white film F onto the front member SE (step S4).

[0071] Next, the control device 110 causes the pressing unit 6 to cut the coupling portion Fc of the white film F (step S5). Then, the control device 110 causes the conveying unit 2 to separate the remaining portion Fa of the white film F from the connected portion Fb and to convey the separated remaining portion Fa to the collection box 8 (step S6).

[0072] Subsequently, the control device 110 causes the conveying unit 2 to convey the printing medium W printed by the printing unit 1 to above the connected portion Fc of the white film F (step S7). Next, the control device 110 causes the pressing unit 6 to cut the coupling portion Wc of the printing medium W (step S8). Then, the control device 110 causes the conveying unit 2 to separate the remaining portion Wa of the printing medium W from the connected portion Wb and to convey the separated remaining portion Wa to the collection box 8 (step S9).

[0073] Next, the control device 110 causes the rotation support table 32 to move the lower die 30 from the first die position to the second die position such that the lower die 30 is located below the upper die 33 in the die set 3, and then causes the upper die 33 to hold the front member SE and the connected portions Wb and Fb held by the lower die 30 (step S10). Then, the control device 110 causes the back member feed unit 5 to feed the back member BE to the lower die 31 moved to the first die position along with the movement of the lower die 30 (step S11).

[0074] Subsequently, the control device 110 causes the rotation support table 32 to move the lower die 31 from the first die position to the second die position such that the lower die 31 is located below the upper die 33 holding the front member SE and the connected portions Wb and Fb, and then lowers the upper die 33 to perform caulking processing (step S12). Accordingly, the button product 200 is manufactured. Thereafter, the control device 110 causes the rotation support table 32 to move the lower die 31 from the second die position to the first die position such that the lower die 31 holding the button product 200 is located at the first die position, and then causes the take-out unit 7 to take out the button product 200 (step S13). Accordingly, the button product 200 is placed into the button product container 9. After taking out of the button product 200 by the take-out unit 7 is finished, the control device 110 causes the rotation support table 32 to move the lower die 30 at the second die position to the first die position.

[0075] Thereafter, the control device 110 determines whether a predetermined number of button products 200 is produced (step S14). When the predetermined number of button products 200 is not produced (No in step S14), the control device 110 returns to the processing of step S3 and repeats the subsequent processing. On the other hand, when the predetermined number of button products 200 is produced (Yes in step S14), the control device 110 ends the button product manufacturing processing.

[0076] As described above, although the front members SE according to the present embodiment are stacked, since the other surface Sf1 of the front member body SEb comes into contact with the contact member CM provided on the other front member body SEb, it is possible to prevent the other surface Sf1 of the front member body SEb from being damaged by the other front member SE.

[0077] In the present embodiment, a diameter of the one surface Sf2 of the front member body SEb is, for example, 31 mm or more and 58 mm or less. Accordingly, the contact member CM having a size enough to be brought into contact with an edge of the lower die 30 is easily fixed to the one surface Sf2.

[0078] In the present embodiment, the contact member CM is a member that contracts when a pressure is applied to the contact member CM, and is made of, for example, urethane foam. The compressive residual strain of the contact member CM measured in accordance with JIS K 6401 is 7.9% or less. Accordingly, even when the contact member CM is in a compressed state due to an increase in integrated weight of the plurality of front members SE, it is possible to further improve the reliability that contact between the peripheral edge portion SEa of one front member SE and the peripheral edge portion SEa of the other front member SE does not occur.

[0079] In the present embodiment, the pressure when the compressive strain of the contact member CM is 25% at the time of compressing the contact member CM in accordance with JIS K 6254 is 0.02 MPa or more and 0.05 MPa or less. Accordingly, even when the contact member CM is in a compressed state due to an increase in integrated weight of the plurality of front members SE, it is possible to further improve the reliability that contact between the peripheral edge portion SEa of one front member SE and the peripheral edge portion SEa of the other front member SE does not occur.

[0080] In the present embodiment, the button product manufacturing device 100 includes the front member feed unit 4. Accordingly, the front member SE can be fed to the lower die 30 by the front member feed unit 4 with high accuracy. Although the front members SE according to the present embodiment are stacked and accommodated in the front member stocker 40, since the other surface Sf1 of the front member body SEb comes into contact with the contact member CM provided on the other front member body SEb, it is possible to prevent the other surface Sf1 of the front member body SEb from being damaged by the other front member SE. Further, the thickness of the contact member CM is, for example, 3.5 mm or more and 4.5 mm or less. Accordingly, even when the contact member CM is in a compressed state due to an increase in integrated weight of the plurality of front members SE accommodated in the front member stocker 40, it is possible to prevent the peripheral edge portion SEa of one accommodated front member SE and the peripheral edge portion SEa of the other adjacent front member SE from coming into contact with each other. Therefore, it is possible to prevent the front member SE from being damaged due to contact between the peripheral edge portions SEa.

[0081] In the present embodiment, the front member feed unit 4 has the front member slope 43 that guides the front member SE toward the lower die 30. Accordingly, the front member SE on the front member slope 43 can be easily and accurately guided to the lower die 30 only by pushing out the front member SE by the pusher body 45a of the pusher 45.

[0082] In the present embodiment, the escape groove 44, which is a portion located between one support portion 42 and the other support portion 42 of the pair of support portions 42 and lower than the height of the support portion 42, is formed in the inner bottom surface of the slope body 41. By providing the escape groove 44 in this way, interference between the contact member CM and the front member slope 43 is avoided at the time of pushing out the front member SE.

[0083] In the present embodiment, the dynamic friction coefficient between the lower die 30 and the contact member CM is, for example, 0.3 or more and 0.5 or less. In this case, when the front member SE is fed from the front member slope 43 to the lower die 30, the contact member CM can be brought into contact with the lower die 30. Accordingly, it is possible to prevent a situation in which the front member SE pushed out from the front member slope 43 jumps over the lower die 30. In addition, the dynamic friction coefficient is within the above range, so that the contact member CM provided on the front member body SEb can be brought into contact with the edge of the lower die 30 when the accommodated front member SE is pushed out by the pusher body 45a of the pusher 45 and fed to the lower die 30. That is, the contact member CM can be used as an interference member for the lower die 30. Accordingly, it is possible to prevent a situation in which the front member SE pushed out from the front member slope 43 by the pusher body 45a jumps over the holding surface of the lower die 30. Therefore, the front member SE can be smoothly fed to the lower die 30.

[0084] Further, in the present embodiment, the back member BE supported by the lower die 31 and the front member SE with the contact member CM held by the upper die 33 are caulked in the die set 3. By caulking the front member SE on which the contact member CM is provided to the back member BE in this way, it is possible to prevent the pressure by the upper die 33 from excessively acting on the front member SE during the caulking. In addition, since the contact member CM is clamped between the front member SE and the back member BE to suppress deformation of only the front member SE, deformation of only the back member BE, and deformation of the front member SE and the back member BE, the user can feel the rigidity of the button product 200 at the time of gripping the button product 200. That is, the texture of the front member SE at the time of completion of the button product 200 is improved.

Modifications

[0085] The present invention is not limited to the above-described embodiment, and modifications can be adopted without departing from the gist of the present invention. For example, it is as follows.

[0086] In the above-described embodiment, one contact member CM is provided on the front member SE, but without being limited thereto, two or more contact members CM may be provided on the front member SE.

[0087] In the above-described embodiment, the contact member CM has a rectangular parallelepiped shape or a cubic shape, but without being limited thereto, the contact member CM may have another shape such as a cylindrical shape.

[0088] In the above-described embodiment, the front member body SEb of the front member SE and the back member BE have a circular shape in a plan view, but without being limited thereto, the front member body SEb and the back member BE may have another shape such as an elliptical shape.

[0089] In the above-described embodiment, the connected portion Wb of the printing medium W has a circular shape in a plan view, but without being limited thereto, the connected portion Wb may have another shape such as an elliptical shape.

[0090] In the above-described embodiment, the coupling portions Wc1 and the coupling portions Wc2 are arranged at equal intervals, but without being limited thereto, the coupling portions Wc1 and the coupling portions Wc2 may be arranged at unequal intervals. The coupling portions Wc3 are arranged at unequal intervals, but without being limited thereto, the coupling portions Wc3 may be arranged at equal intervals.

[0091] In the above-described embodiment, a marker may be disposed in the remaining portion Wa of the printing medium W on one side in a direction D2 with a center in the direction D2 as a reference. Accordingly, when a user accommodates the printing medium W in the sheet holder of the printing unit 1, the front and back and the arrangement orientation of the printing medium W are less likely to be wrong. In order to further improve the visibility of the user, it is desirable to provide the marker in a region having a relatively large space in the remaining portion Wa (that is, region away from region where connected portion Wb and coupling portion Wc are provided).

[0092] While the invention has been described in conjunction with various example structures outlined above and illustrated in the figures, various alternatives, modifications, variations, improvements, and/or substantial equivalents, whether known or that may be presently unforeseen, may become apparent to those having at least ordinary skill in the art. Accordingly, the example embodiments of the disclosure, as set forth above, are intended to be illustrative of the invention, and not limiting the invention. Various changes may be made without departing from the spirit and scope of the disclosure. Therefore, the disclosure is intended to embrace all known or later developed alternatives, modifications, variations, improvements, and/or substantial equivalents.