Zipper Manufacturing Method

Abstract

The present invention provides a zipper manufacturing method capable of improving manufacturing efficiency, comprising: a defect detection step for detecting defects in a zipper chain; a defect discrimination step for discriminating whether the defect detected in the defect detection step is a first defect for which subsequent processing can be continued or a second defect for which subsequent processing other than cutting cannot be continued; a first marking step for applying a first mark to a unit chain in the zipper chain containing the first defect when the defect is determined to be the first defect in the defect discrimination step; a second marking step for applying a second mark to a unit chain in the zipper chain containing the second defect when the defect is determined to be the second defect in the defect discrimination step; a mark detection step for detecting the first mark and the second mark; and a first processing skipping step for skipping subsequent processing other than cutting for the unit chain to which the second mark is applied when the second mark is detected.

Description

Technical Field

[0001] The present invention relates to a slide fastener manufacturing method, and more particularly, to a method for continuously manufacturing slide fasteners by conveying a continuous slide fastener chain from upstream to downstream while passing through a plurality of processing mechanisms. Background Art

[0002] In the case of continuously mass-producing a zipper having a synthetic resin element row based on a continuous zipper chain, a synthetic resin element row is injection molded in advance at each relative edge of a pair of left and right long zipper tapes to form a pair of left and right zipper tapes. Next, the following process is performed. That is, a process of partially removing the element row at predetermined intervals in the length direction of the zipper chain in a closed state where the element rows of the left and right zipper tapes are meshed to form a spacing portion (refer to Figure 4 ); a step of bonding an auxiliary film to the front and back surfaces of the zipper chain corresponding to a portion of the spacer portion (refer to Figure 5 ); a process for forming a perforated portion in the auxiliary film of the zipper chain (refer to Figure 6 ); the process of separating the zipper chain after releasing the engagement between the left and right chain teeth (refer to Figure 7 ); the process of passing the slider through the chain teeth of the zipper chain tape on the left and right sides from the perforated portion on one side (refer to Figure 8 ); In the process of injection molding the stopper and the opening member of the zipper chain in the open state (refer to Fig. 9 ); the process of closing the left and right chain teeth of the zipper chain (refer to Fig.10 ); the process of assembling the opening parts of the zipper chain (refer to Fig.11 ); and a step of cutting the continuous zipper chain from the perforated portion. The zipper is continuously manufactured through the above steps (refer to Fig.12 ).

[0003] In this specification, the above-mentioned processing, treatment, adjustment, etc. performed on the zipper chain in the manufacturing process of the zipper are collectively referred to as "processing". The following situation exists: in the manufacturing process of the above-mentioned zipper, the zipper chain is defective due to dirt, damage, processing errors, etc. In addition, there is also the following situation: due to changing batches, two zipper chains with different zipper tape colors are connected to form a continuous zipper chain, and the zipper chain is passed through the above-mentioned manufacturing process. The connecting part in such a zipper chain is not included in the final zipper and is discarded. The following technology is disclosed in Japanese Patent Publication No. 2-74205 (Patent Document 1): when a defective part or the above-mentioned connecting part is detected in the zipper chain, a mark is applied to the defective part or the connecting part, and the marked chain part (unit chain) or the connecting part is not subjected to subsequent processing.

[0004] However, if subsequent processing is not performed even when the defect that may occur in the fastener chain during the manufacturing process of the slide fastener is a relatively minor defect such as dirt or damage, there is a problem that the manufacturing efficiency is reduced.

[0005] Prior art literature

[0006] Patent Literature

[0007] Patent Document 1: Japanese Patent Application Laid-Open No. 2-74205 Summary of the invention

[0008] The present invention has been made in view of the above-mentioned problems, and an object of the present invention is to provide a slide fastener manufacturing method capable of improving manufacturing efficiency.

[0009] According to the present invention, there is provided a zipper manufacturing method for manufacturing a zipper by processing a continuous zipper chain while conveying it from upstream to downstream ("processing" also includes handling, adjustment, etc. of the zipper chain). The zipper manufacturing method is characterized in that it comprises: a defect detection step for detecting a defect in the zipper chain; a defect discrimination step for discriminating whether the defect detected in the defect detection step is a first defect for which subsequent processing can be continued or a second defect for which subsequent processing other than cutting cannot be continued; a first marking step for discriminating whether the defect detected in the defect discrimination step is a first defect for which subsequent processing can be continued. The method comprises the following steps: a first marking step, applying a first mark to the unit chain including the first defect in the zipper chain when the zipper chain is judged as the second defect in the defect judging step; a second marking step, applying a second mark to the unit chain including the second defect in the zipper chain when the zipper chain is judged as the second defect in the defect judging step; a marking detection step, detecting the first mark and the second mark; and a first processing skipping step, skipping subsequent processing other than cutting for the unit chain to which the second mark is applied or discharging the unit chain to which the second mark is applied when the second mark is detected.

[0010] In the present invention, in the defect detection step, if a defect in the zipper chain is detected by a sensor, a camera, an operator's visual inspection, etc., then in the defect determination step, the determination unit of the control unit or the operator, etc. determines whether the defect is a first defect in which processing in a mechanism downstream of the mechanism where the defect is detected can be continued or a second defect in which such processing (except for cutting in the cutting mechanism) cannot be continued. Then, in the case where it is determined to be the first defect, in the first marking step, a first mark is automatically or manually applied to the unit chain in the zipper chain where the first defect is detected by a cutter, a puncher, a coder, a marking machine, etc., and in the case where it is determined to be the second defect, in the second marking step, a second mark is similarly applied to the unit chain in the zipper chain where the second defect is detected. Then, in the mark detection step, if the first mark is detected by a sensor, a camera, a code reader, an operator's visual inspection, etc., the subsequent processing is continued. Furthermore, when the second mark is detected in the mark detection step, the control unit skips the subsequent processing (except cutting) for the unit chain with the second mark applied thereto as a first processing skipping step. As a first discharging step, the unit chain with the second mark applied thereto is cut by the cutting mechanism and discharged as a defective product.

[0011] In the present invention, as an example of the first defect, dirt or damage in the zipper tape, auxiliary film, slider, opening piece, upper stop, chain teeth, etc. can be listed, but it is not limited to this. As an example of the second defect, the examples of the spacer, perforated portion, opening piece, upper stop, etc. not being formed as required, the auxiliary film not being bonded, the left and right zipper chain tapes not being opened and closed as required, the slider not being installed on the zipper chain, or the zipper chain not being combined as required can be listed, but it is not limited to this. It can also be said that the first defect is a minor defect that has no effect on the subsequent process, and the second defect is a processing error that makes it impossible to continue the subsequent process (except cutting) while maintaining the original state.

[0012] In the present invention, as a method of applying the first mark to the zipper chain, there can be listed, but it is not limited to, adding an RFID, QR code, barcode, etc., forming a cut or hole in the zipper tape, or pasting a piece of gold tape, etc. As a method of applying the second mark to the zipper chain, there can be listed, but it is not limited to, adding an RFID, QR code, barcode, etc. that can be distinguished from the first mark, adding a cut or hole in the zipper tape that can be distinguished from the first mark, or pasting two pieces of gold tape, etc.

[0013] In the present invention, "unit chain" refers to the final unit chain of a single zipper in a continuous zipper chain. Fig.12 ) is cut off.

[0014] In one embodiment of the present invention, the second marking step includes removing at least a portion of the unit chain containing the second defect. In this embodiment, for example, the lengthwise portion containing the second defect in the zipper chain can be cut off, and the downstream end of the remaining upstream chain and the upstream end of the downstream chain can be connected with a gold tape as an example of the second mark.

[0015] In one embodiment of the present invention, the continuous zipper chain includes a zipper chain formed by connecting a first zipper chain and a second zipper chain having different zipper tape colors, the defect detection step also detects the connecting portion between the first zipper chain and the second zipper chain, the defect discrimination step also discriminates the connecting portion, the zipper manufacturing method includes a third marking step of applying a third mark to the connecting portion, the mark detection step also detects the third mark, and the zipper manufacturing method includes a second processing skipping step of skipping subsequent processing other than cutting for the connecting portion to which the third mark is applied when the third mark is detected. In this embodiment, as a continuous zipper chain, a zipper chain formed by connecting the downstream side end of the first zipper chain having different zipper tape colors and the upstream side end of the second zipper chain is included. The connecting portion between the first zipper chain and the second zipper chain is a portion including the connecting end between the first zipper chain and the second zipper chain, which is ultimately excluded from the unit chain cut as a zipper. Such a connecting portion does not need to be processed, is not included in the final zipper and is discarded. The inventors of the present invention believe that the connecting portion is treated as a defect or as a defect and is treated in roughly the same way as the second defect. Moreover, in the defect detection step, the connecting portion is also detected in addition to the first defect and the second defect. Further, in the defect discrimination step, it is judged whether it is the first defect or the second defect or the connecting portion. Then, in the case where it is judged as a connecting portion, a third mark is applied to the connecting portion in the third marking step. In the case where the third mark is detected in the mark detection step, as a second processing skipping step, the subsequent processing (except cutting) for the connecting portion to which the third mark is applied is skipped. As a second discharge step, the connecting portion to which the third mark is applied is cut in the cutting mechanism and discharged as a defective product.

[0016] Effects of the Invention

[0017] In the present invention, it is determined whether the defect detected in the zipper chain is the first defect or the second defect. In the case of the first defect, subsequent processing is continued, and in the case of the second defect, subsequent processing other than cutting is skipped, thereby improving the manufacturing efficiency of the zipper. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] Figure 1This is a block diagram schematically showing a synthetic resin slide fastener manufacturing apparatus.

[0019] Figure 2 This is a flowchart showing the processing steps performed by a synthetic resin slide fastener manufacturing apparatus.

[0020] Figure 3 It is a top view showing a continuous zipper chain.

[0021] Figure 4 It is a plan view which cuts out and shows the slide fastener chain in the state where the spacer part is formed.

[0022] Figure 5 It is a plan view which cuts out and shows the slide fastener chain in the state where the auxiliary film is bonded.

[0023] Figure 6 It is a plan view which shows the state which cut|disconnected the slide fastener chain in which the perforation part was formed.

[0024] Figure 7 It is a plan view showing a state where the fastener chain is divided after the engagement between the left and right element rows is released.

[0025] Figure 8 This is a plan view of a slide fastener chain cut out and showing a state in which a slider is passed through one side of the fastener stringer on the left side.

[0026] Fig. 9 It is a plan view of a slide fastener chain cut out and showing a state where an opening piece and a top stop are injection molded.

[0027] Fig.10 It is a top view showing a zipper chain cut out and changing from an open state to a closed state.

[0028] Fig.11 This is a plan view of a slide fastener chain cut out and showing a state in which a socket body with a socket rod and an insert rod are combined.

[0029] Fig.12 This is a top view showing the completed zipper.

[0030] Fig.13 It is a flowchart about the defect detection in the zipper manufacturing method of the present invention.

[0031] Fig.14 This is a block diagram schematically showing an example of a control structure for performing a failure determination step.

[0032] Fig.15 It is a top view which illustrates the slide fastener chain to which the 1st mark was given.

[0033] Fig.16 It is a top view which illustrates the slide fastener chain in which the second defect is detected.

[0034] Fig.17 It is a plan view showing a state where the second mark is applied to the fastener chain.

[0035] Fig.18 It is a top view which shows the fastener chain which connected the 1st fastener chain on the upstream side and the 2nd fastener chain on the downstream side which have fastener tapes of different colors.

[0036] Fig.19 This is a flow chart about the mark detection in the zipper manufacturing method of the present invention.

[0037] Fig. 20 is schematically shown in Figure 1 A block diagram of the structure after the mark sensing mechanism is assembled in the zipper manufacturing device.

[0038] Fig.21 is Figure 2 Flowchart of the processing steps after the mark sensing mechanism is added to the flowchart.

[0039] Fig. 22 It is a top view which shows another example of the 1st mark with respect to a slide fastener chain.

[0040] Fig.23 It is a top view which shows another example of the 2nd mark with respect to a slide fastener chain.

[0041] Fig.24 It is a top view which shows another example of the 3rd mark with respect to a slide fastener chain.

[0042] Fig.25 It is a top view which shows still another example of the 1st mark with respect to a slide fastener chain.

[0043] Description of Reference Numerals

[0044] 1 Zipper tape

[0045] 2 chain teeth

[0046] 3 Slider

[0047] 10 Zipper Chain

[0048] 10C Unit Chain

[0049] 10A No.1 zipper chain

[0050] 10B 2nd zipper chain

[0051] 10a Zipper chain strap

[0052] 11. Partition

[0053] 12 Auxiliary membrane

[0054] 13. Perforation

[0055] 20 Socket body with socket bar

[0056] 21 Insert rod

[0057] 22 Top stop

[0058] 30 Zipper

[0059] 100 Synthetic resin zipper manufacturing device

[0060] 110 1st Equipment

[0061] 110A 1st equipment control unit

[0062] 111 Interval generation mechanism

[0063] 112 film bonding mechanism

[0064] 113 Perforation mechanism

[0065] 120 Second Equipment

[0066] 120A Second equipment control unit

[0067] 121 Chain splitter

[0068] 122 Slider single-side penetration mechanism

[0069] 123 Upper stop and opening part injection molding mechanism

[0070] 130 3rd Equipment

[0071] 130A 3rd equipment control unit

[0072] 131 Chain combination mechanism

[0073] 132 Cutting mechanism

[0074] 160 Control Department

[0075] 161 Storage

[0076] 162 Judgment Department

[0077] 163 Sensors

[0078] 164 Cameras

[0079] 165 Monitor

[0080] 166 Marking Device

[0081] 170A, 170B, 170C Mark sensing mechanism

[0082] C Connection

[0083] M1 1st Mark

[0084] M2 2nd Mark

[0085] M3 3rd Mark

[0086] S, Sa, Sb dirt DETAILED DESCRIPTION

[0087] Figure 1 It is a block diagram schematically showing a synthetic resin zipper manufacturing apparatus (hereinafter also simply referred to as a “zipper manufacturing apparatus”) 100 . Figure 2 1 is a flowchart showing a processing step performed by the zipper manufacturing apparatus 100 . Figure 3 It is a top view showing a continuous slide fastener chain 10 in section. Figure 4 It is a plan view which shows the slide fastener chain 10 in a state where the spacer part 11 is formed. Figure 5 It is a plan view which shows the state which adhered the auxiliary film 12 in the slide fastener chain 10 cut out. Figure 6 It is a plan view showing a state in which the fastener chain 10 with the perforated portion 13 formed therein is cut out. Figure 7 It is a plan view showing a state in which the fastener chain 10 is divided after the engagement between the left and right element rows 2 is released. Figure 8 It is a plan view which cuts out the fastener chain 10 and shows the state in which the slider 3 is passed through the fastener stringer 10a on the left side on one side. Fig. 9 It is a plan view showing a state where a socket body 20 with a socket bar as an opening member, an insert bar 21, and an upper stopper 22 are injection molded in a cutout manner of the slide fastener chain 10. Fig.10 It is a plan view showing the slide fastener chain 10 cut out and changed from an open state to a closed state. Fig.11 It is a plan view of the slide fastener chain 10 cut out and showing the state where the socket body 20 with the socket bar and the insert bar 21 are combined. Fig.12 It is a top view which shows the completed slide fastener 30.

[0088] The zipper manufacturing apparatus 100 is used to zipper a pair of long strips of zipper tapes 1 (see Figure 3 The continuous fastener chain 10 formed by injection molding the synthetic resin element rows 2 at the respective relative edges of the fastener chain 10 is subjected to various processing described later, thereby continuously manufacturing Fig.12 The slide fastener 30 as a finished product is shown. The slide fastener chain 10 includes a pair of left and right fastener tapes 10a each having fastener element rows 2 at the opposing edge portions of the pair of left and right fastener tapes 1. Figure 1The zipper manufacturing apparatus 100 includes a first device 110, a second device 120, and a third device 130. In addition, the zipper manufacturing apparatus 100 includes a conveying mechanism for conveying the zipper chain 10 to the first device 110, then to the second device 120, and then to the third device 130. Next, the side ( Figure 1 The right side in the paper (in the drawing) is referred to as the “downstream” in the conveying direction, and the side opposite to the downstream in the conveying direction is referred to as the “upstream”. Figure 3 to Figure 11 The fastener chain 10 shown is basically conveyed from top to bottom in the paper plane of each figure, so the top in the paper plane of each figure corresponds to the upstream, and the bottom corresponds to the downstream. In addition, there is also a situation where the fastener chain 10 temporarily moves to the upstream side of the conveying direction during the manufacturing process.

[0089] In the zipper manufacturing apparatus 100, a first buffer 140 is provided between the first device 110 and the second device 120, and a second buffer 150 is provided between the second device 120 and the third device 130. The first buffer 140 allows the fastener chain 10 to be retained between the first device 110 and the second device 120 having different processing cycles, and adjusts the supply of the fastener chain 10 to the second device 120, so that the first device 110 and the second device 120 are linked. Similarly, the second buffer 150 allows the fastener chain 10 to be retained between the second device 120 and the third device 130 having different processing cycles, and adjusts the supply of the fastener chain 10 to the third device 130, so that the second device 120 and the third device 130 are linked.

[0090] 1st Equipment

[0091] The zipper chain 10 with the element rows 2 of the left and right zipper tapes 10a in an engaged state (closed state) is introduced into the first device 110, but the left and right zipper tapes 10a with the element rows 2 in an unengaged state (open state) can also be made to be engaged (closed state) in the first device 110. The first device 110 is provided with a spacing generating mechanism 111, a film bonding mechanism 112 and a punching mechanism 113 in order from upstream to downstream. The spacing generating mechanism 111 is used to partially remove the element rows 2 at predetermined intervals in the length direction of the zipper chain 10 to form a spacing portion 11 between the relative edge portions of the left and right zipper tapes 1. The film bonding mechanism 112 is used to form a spacing portion 11 between the upstream side ( Figure 5 The auxiliary film 12 is bonded to the front and back surfaces corresponding to approximately half of the upper portion of the paper surface. Figure 5In the embodiment, the auxiliary film 12 is bonded to the respective zipper tapes of the left and right zipper tapes 1 in a divided state, but the auxiliary film 12 before division may be bonded to the left and right zipper tapes 1 and then divided in a post-process. The perforating mechanism 113 is used to perforate the downstream side ( Figure 6 In the first device 110, the spacer 11, the auxiliary film 12 and the perforated portion 13 are processed in the meshing state of the zipper chain 10, so that the left and right zipper tapes 1 will not be offset during transportation.

[0092] The spacing generating mechanism 111 partially removes the left and right element rows 2 in the closed state at predetermined intervals in the longitudinal direction of the fastener chain 10. Thus, a spacing portion 11 penetrating the front and back is formed between the respective opposing edge portions of the left and right fastener tapes 1. Figure 4 , in the spacer 11, a thicker core 1a as a reinforcement portion remains at the relative edges of each zipper tape 1. The core 1a serves to increase the adhesion strength of the chain element row 2 formed on the zipper tape 1 by injection molding or the like. The presence or absence of the chain element row 2, the spacer 11, the perforated portion 13, etc. become the reference for the alignment position of the subsequent process, and are detected by sensors not shown in the figure. The film bonding mechanism 112 bonds the auxiliary film 12 from both the front and back sides of the zipper chain 10. The auxiliary film 12 serves the following functions: to increase the adhesion of the molten resin during the injection molding of the socket body 20 with the socket rod and the plug rod 21, and to improve the operability by strengthening the two ends in the length direction of the single zipper 30 as the final product. Refer to Figure 6 When forming the perforated portion 13 , the perforating mechanism 113 simultaneously perforates two through holes 14 in total in each of the opposing edges of the left and right fastener tapes 1 on the upstream side of the perforated portion 13 in the auxiliary film 12 , for a total of four through holes 14 .

[0093] Second Equipment

[0094] The zipper chain 10 processed with the spacer 11, the auxiliary film 12, the perforated portion 13, etc. by the first device 110 is retained by the first buffer portion 140 and supplied to the second device 120. The second device 120 includes: a chain splitting mechanism 121, which releases the meshing state between the chain element rows 2 of the left and right zipper chain tapes 10a in the closed state and splits the zipper chain 10; a slider single-side penetration mechanism 122, which is used to penetrate the slider 3 from the perforated portion 13 on one side to the left and right sides ( Figure 8 On the chain tooth row 2 of the zipper tooth chain tape 10a (on the left side in the figure); an upper stop and opening piece injection molding mechanism 123, which is used to injection mold the socket body 20 with the socket rod and the insertion rod 21 and the two upper stops 22 on the zipper 30 with the slider 3 passing through one side; and a chain closing mechanism 124, which is used to close the chain tooth rows 2 of the left and right zipper tooth chain tapes 10a in the opened state.

[0095] 3rd Equipment

[0096] The third device 130 includes: a chain assembly mechanism 131 for assembling the socket body 20 with the socket rod and the insertion rod 21; and a cutting mechanism 132 for cutting the zipper chain 10 along the width direction at a position corresponding to the perforated portion 13. Fig.10 The socket body 20 with the socket rod and the insert rod 21 separated in the state are combined. The continuous zipper chain 10 is cut at the position corresponding to the perforated portion 13 by the cutting mechanism 132, so that a plurality of zippers 30 can be continuously obtained. Since it is cut from the perforated portion 13, the auxiliary film portion 12a as a part of the auxiliary film 12 remains at the upper end of the left and right zipper stringers 10a of the zipper 30, and the auxiliary film portion 12b remains at the lower end of the zipper stringer 10a.

[0097] Fig.13 It is a flowchart about the defect detection in the zipper manufacturing method of the present invention. Fig.13 The defect detection step S1 in the embodiment is a step of detecting whether the zipper chain 10 has defects. The defect detection step S1 is performed in the gap generating mechanism 111, the film bonding mechanism 112, the punching mechanism 113, the chain segmenting mechanism 121, the slider one-side passing mechanism 122, the upper stopper and opening member injection molding mechanism 123, the chain closing mechanism 124, the chain combining mechanism 131, and the cutting mechanism 132 in the first device 110, the second device 120, and the third device 130 of the zipper manufacturing apparatus 100. In the following description, unless otherwise specified, the abbreviation "mechanism" or "each mechanism" refers to one or more mechanisms among the gap generating mechanism 111, the film bonding mechanism 112, the punching mechanism 113, the chain segmenting mechanism 121, the slider one-side passing mechanism 122, the upper stopper and opening member injection molding mechanism 123, the chain closing mechanism 124, the chain combining mechanism 131, and the cutting mechanism 132. The first device 110, the second device 120, and the third device 130 include a first control unit 110A, a second control unit 120A, and a third control unit 130A (see Fig.21). In addition, sensors, cameras, measuring instruments, etc. for monitoring whether each process is performed as specified are provided in each mechanism in the first device 110, the second device 120, and the third device 130. For example, in the upper stop and opening piece injection molding mechanism 123, it is configured to always monitor the supply amount and supply pressure of the molten resin supplied to the molding mold. If an abnormal value caused by resin leakage or the like is sensed, the second device control unit 120A (or a control unit under its control) stops the upper stop and opening piece injection molding mechanism 123 and sounds an alarm. As long as no defect is detected in the zipper chain 10 in each mechanism, normal processing continues.

[0098] exist Fig.13 In the defect determination step S2 in the process, when the zipper chain 10 is detected as defective in S1, it is determined whether the defect is a first defect that allows the subsequent processing to continue or a second defect (or the connecting portion C described later) that prevents the subsequent processing (except for the cutting in the cutting mechanism 132). Then, if it is determined to be a first defect, a first mark M1 is applied to the zipper chain 10 in the first marking step S3a (refer to Fig.15 If it is determined to be a second defect, a second mark M2 is applied to the zipper chain 10 in the second marking step S3b (refer to Fig.17 wait).

[0099] Fig.14 This is a block diagram schematically showing an example of a control structure for performing the defect determination step S2. In the storage unit 161 of the control unit 160, numerical data, image data, threshold data, etc. associated with defects that have occurred in the past or may occur in each mechanism are stored and accumulated in advance. Then, based on the defect detection signal from the sensor 163 or the camera 164, etc., the determination unit 162 of the control unit 160 refers to the various data in the storage unit 161 to determine whether the defect is the first defect or the second defect (or the connecting portion C described later). The control unit 160 outputs the determination result to the monitor 165, and drives the marking device 166 in the first marking step S3a and the second marking step S3b. The marking device 166 includes a cutter, a puncher, a coding machine, etc. that can automatically apply a mark to the zipper chain 10. The control unit 160 can also be in the first control unit 110A, the second control unit 120A, and the third control unit 130A (see the control unit 160) described later. Fig.21 ). In addition, it can also be independent of the first control unit 110A, the second control unit 120A, and the third control unit 130A.

[0100] Fig.15 1 is a top view of the slide fastener chain 10 to which the first mark M1 is applied. The slide fastener chain 10 is in the following state: the left side ( Fig.15 The zipper tape 1 (shown below the paper) is detected as a first defective dirt S, and accordingly, a semicircular cut M1 is provided as an example of a first mark M1 at the left edge of the zipper tape 1 near the dirt S or the dirt S. The cut M1 (and the cuts M2 and M3 described later) are automatically provided by a cutter, a puncher, etc. not shown. Fig.15 The reference numeral 10U in the figure represents a unit chain. The unit chain 10U is a unit in the length direction of the zipper chain 10 that is cut as a single zipper 30 in the cutting mechanism 132, and a plurality of unit chains 10U are arranged along the length direction in the zipper chain 10. The first mark M1 is a mark that allows subsequent processing to continue, and the unit chain 10U including the first mark M1 is discarded after being cut as a single zipper 30 in the cutting mechanism 132.

[0101] Fig.16 1 is a top view showing a zipper chain 10 in which the second defect is detected. A processing error as the second defect, that is, the slider 3 is not attached to the slider one-side insertion mechanism 122, is detected in the zipper chain 10. In response to the detection of the second defect, a second mark M2 is added to the zipper chain 10. Fig.17 1 is a plan view showing a state where the second mark M2 is applied to the slide fastener chain 10. In the slide fastener chain 10, a portion R in the longitudinal direction of the unit chain 10U in which the second defect is detected (see Fig.16 ) is cut off, and the upstream remaining portion 10Ua and the downstream remaining portion 10Ub of the unit chain 10U are further welded by the welding portion W. Fig.17 A total of two cutouts M2 are provided as an example of the second mark M2 at the upper and lower edges of the paper. The cutout of a portion R of the unit chain 10U and the subsequent welded portion W can also be set as a part of the second mark M2 and be the subject of mark detection described later.

[0102] Fig.18 This is a top view showing a zipper chain 10 formed by connecting the first zipper chain 10A on the upstream side and the second zipper chain 10B on the downstream side of the zipper tape 1 of different colors. The first zipper chain 10A and the second zipper chain 10B are previously formed with left and right chain element rows 2, and are supplied to the zipper manufacturing device 100 in this state. By continuously supplying the first zipper chain 10A and the second zipper chain 10B of different colors of the zipper tape 1 to the same zipper manufacturing device 100, it is possible to continuously manufacture zippers 10 of different colors of the zipper tape 1 without temporarily stopping or replacing the zipper manufacturing device 100. The downstream side end of the first zipper chain 10A and the upstream side end of the second zipper chain 10B are welded by the welding portion Wa. Fig.18The reference numeral C in the figure is a connection portion including the welded portion Wa between the first zipper chain 10A and the second zipper chain 10B. The connection portion C is a portion to be excluded from the unit chain 10U that is finally cut as the zipper 30. Therefore, the connection portion C does not need to be processed and is not included in the final zipper 30 and is discarded. Therefore, the connection portion C can be processed in substantially the same manner as the unit chain 10U including the second mark M2. Fig.13 The connection portion C in the slide fastener chain 10 is detected in the defect detection step S1. Then, it is determined as the connection portion C in the defect determination step S2. Then, the third mark M3 is applied to the connection portion C in the third marking step S3c. Fig.18 In the slide fastener chain 10, the welded portion Wa in the connecting portion C has a width of about ( Fig.18 A total of four cutouts M3 are provided as an example of the third mark M3 at the upper and lower edges of the paper and the left and right edges on the upstream side near the left and right edges. The welded portion Wa of the connection portion C can also be set as a part of the third mark M3 and be the object of the mark detection described later.

[0103] Fig.19 This is a flow chart about the mark detection in the zipper manufacturing method of the present invention. Fig.19 The mark detection step S4 is to detect whether the first mark M1, the second mark M2, and the third mark M3 (refer to Figure 15 to Figure 18 As long as the first mark M1, the second mark M2, and the third mark M3 are not detected in the mark detection step S4, normal processing is continued. In the case where the first mark M1, the second mark M2, and the third mark M3 are detected in the mark detection step S4, it is determined in the mark discrimination step S5 whether the detected mark is one of the first mark M1, the second mark M2, and the third mark M3. Then, in the case where it is determined to be the first mark M1, the panel, the monitor, etc. display that the first mark M1 is detected, and the subsequent processing is continued. In contrast, in the case where it is determined to be the second mark M2 or the third mark M3 in the mark discrimination step S5, the panel, the monitor, etc. display that the second mark M2 or the third mark M3 is detected. Next, in the first skipping step and the second skipping step S6, the processing in the subsequent mechanisms (except for the cutting in the cutting mechanism 132) is skipped for the chain unit 10U including the second mark M2 or the connecting portion C including the third mark M3. In the first skipping step and the second skipping step S6, the first device control unit 110A, the second device control unit 120B, and the third device control unit 130A (see Fig.21) controls each mechanism (except the cutting mechanism 132) in each device 110, 120, 130 so that the processing (except the cutting in the cutting mechanism 132) after the second mark M2 or the third mark M3 is detected is skipped. In the cutting mechanism 132, the chain unit 10U including the second mark M2 or the connecting portion C including the third mark M3 is cut and discharged.

[0104] In the present embodiment, the mark detection step S4 and the mark identification step S5 are performed in the mark sensing mechanisms 170A, 170B, and 170C provided at the most upstream side of the first device 110 , the second device 120 , and the third device 130 , respectively, but the present invention is not limited thereto. Fig. 20 is schematically shown in Figure 1 FIG. 1 is a block diagram of a structure in which mark sensing mechanisms 170A, 170B, and 170C are assembled in the zipper manufacturing device 100. Fig.21 is Figure 2 The flowchart of the processing steps after adding the mark sensing mechanisms 170A, 170B, and 170C to the flowchart. When the zipper chain 10 is introduced into the first device 110, the second device 120, and the third device 130, respectively, the mark sensing mechanisms 170A, 170B, and 170C perform the mark detection step S4 and the mark discrimination step S5. When the zipper chain 10 is introduced into the first device 110, the first defect or the second defect is not detected, so the mark sensing mechanism 170A actually detects the mark M3 of the connecting portion C in the zipper chain 10 formed by connecting the first zipper chain 10A and the second zipper chain 10B of different colors of the zipper tape 1. In this case, the first control unit 110A, the second control unit 120A, and the third control unit 130A display the detected mark M3 on the panel, etc., and control each mechanism of the first device 110, the second device 120, and the third device 130 except the cutting mechanism 132 so that the processing of the connecting part C of the zipper chain 10 is skipped.

[0105] In the first device 110, when a processing error as a second defect occurs in the zipper chain 10 and the second mark M2 is applied to the zipper chain 10, the first device control unit 110A skips all subsequent processing in the first device 110 to be performed on the unit chain 10U including the second mark M2. Furthermore, when the second mark M2 is detected in the mark sensing mechanisms 170B and 170C in the second device 120 and the third device 130, the second device control unit 120A and the third device control unit 130A skip all subsequent processing (except cutting) in the second device 120 and the third device 130.

[0106] Figure 22 to Figure 24It is a plan view which shows another example of the 1st mark M1, the 2nd mark M2, and the 3rd mark M3 with respect to the slide fastener chain 10. Fig. 22 The damage Sa as the first defect is detected in the fastener chain 10 , and accordingly, a gold-colored tape M1 is attached as the first mark M1 to the fastener tape 1 near the damage Sa. Fig.23 The zipper chain 10 is detected as a second defective processing error in which the slider 3 is not installed in the slider single-side insertion mechanism 122. Correspondingly, a portion of the length direction of the unit chain 10U containing the second defect is cut off, and the upstream side remaining portion 10Ua and the downstream side remaining portion 10Ub are formed by the left and right ( Fig.23 Connect the two pieces of golden tape M2 on the upper and lower sides of the paper. Fig.24 The zipper chain 10 includes a first zipper chain 10A and a second zipper chain 10B having different colors from the zipper tape 1, and the first zipper chain 10A and the second zipper chain 10B are connected by two gold or other adhesive tapes M3 as the third mark M3, and two other gold or other adhesive tapes M3 are further attached near their upstream sides. In addition, by continuously attaching a plurality of adhesive tapes on one side of the zipper tape 1 corresponding to the detected defect, the defect can be judged based on the time length of the read signal of the tape. Fig.25 This is a top view of a zipper chain 10 showing another example of the first mark for the first defect. The zipper chain 10 is detected as a dirt Sb as the first defect, and correspondingly, a portion of the chain element array 2 in the unit chain U10 containing the first defect is removed as the first mark M1. In addition, the defect can be judged based on the length of the detection time of the removed portion or the unremoved chain element array 2 by changing the size of the removed portion of the chain element array 2 corresponding to the detected defect or removing a portion of the chain element array 2 in multiple areas. The first mark M1, the second mark M2, and the third mark M3 are not limited to the above examples, and RFID, QR code, bar code, etc. can also be added.

Claims

1. A zipper manufacturing method for manufacturing a zipper (30) by processing a continuous zipper chain (10) while conveying it from upstream to downstream, the zipper manufacturing method comprising: A defect detection step (S1), detecting defects in the zipper chain (10); A defect determination step (S2) of determining whether the defect detected in the defect detection step (S1) is a first defect (S, Sa, Sb) that allows subsequent processing to continue or a second defect that prevents subsequent processing other than cutting from continuing; a first marking step (S3a), in which, when the first defect (S, Sa, Sb) is determined in the defect determination step (S2), a first mark (M1) is applied to the unit chain (10U) in the zipper chain (10) including the first defect (S, Sa, Sb); a second marking step (S3b), in which, when the second defect is determined in the defect determination step (S2), a second mark (M2) is applied to the unit chain (10U) in the zipper chain (10) including the second defect; a marker detection step (S4), detecting the first marker (M1) and the second marker (M2); and The first process skipping step (S6) skips subsequent processes other than cutting for the unit chain (10U) to which the second mark (M2) is applied when the second mark (M2) is detected.

2. The zipper manufacturing method according to claim 1, characterized in that: The second marking step (S3b) includes removing at least a portion of the unit chain (10U) including the second defect.

3. The zipper manufacturing method according to claim 1 or 2, characterized in that: include: In the first discharging step, when the second mark (M2) is detected, the unit chain (10U) to which the second mark (M2) is applied is cut and discharged.

4. The zipper manufacturing method according to claim 1 or 2, characterized in that: The continuous zipper chain (10) comprises a zipper chain (10) formed by connecting a first zipper chain (10A) and a second zipper chain (10B) of different colors of a zipper tape (1). The defect detection step (S1) also detects the connection portion (C) between the first zipper chain (10A) and the second zipper chain (10B). The defect determination step (S2) also determines the connection portion (C). The zipper manufacturing method includes a third marking step (S3c) of applying a third mark (M3) to the connecting portion (C), The marker detection step (S4) also detects the third marker (M3). The zipper manufacturing method includes a second process skipping step (S6) of skipping subsequent processes other than cutting on the connecting portion (C) to which the third mark (M3) is applied when the third mark (M3) is detected.

5. The zipper manufacturing method according to claim 4, characterized in that: include: The second discharging step is to cut and discharge the connecting portion (C) to which the third mark (M3) is applied when the third mark (M3) is detected.

Images