Method and apparatus for peeling laminated materials

Abstract

The present invention provides a method and apparatus for peeling laminates that can effectively peel the surface layer from the laminate. [Solution] This method is a method for peeling a surface layer (felt layer 53) from a laminated material (carpet 51) having a surface layer (felt layer 53), comprising: a laminated material holding step of holding the end of the laminated material with a first holding part 1; a surface layer holding step of holding the end of the surface layer with a second holding part 2; and a peeling step of peeling the surface layer from the laminated material by relatively moving the first holding part holding the end of the laminated material and the second holding part holding the end of the surface layer in a direction P away from each other.

Description

Technical Field

[0001] The present invention relates to a method and an apparatus for peeling a laminated material, and more particularly to a method and an apparatus for peeling a surface layer from a laminated material.

Background Art

[0002] Conventionally, as a laminated material, an automotive carpet having a skin material and a felt layer laminated on the back surface of the skin material is generally known. In the manufacturing process of automotive carpets, carpet end materials are generated, but they cannot be recycled while maintaining a multilayer structure having a skin material and a felt layer made of different materials. Therefore, the emergence of a technology that can effectively peel the felt layer from the carpet end material is desired.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] Here, as a conventional method for peeling a laminated material, a method for peeling a rubber material from a rubber sheet material having a cord member aligned with a rubber material has been proposed (see, for example, Patent Document 1). Patent Document 1 discloses a method in which an end portion of a rubber sheet material is held by a material holding device, the rubber sheet material is sandwiched in the thickness direction by a pair of parallel blades constituting a peeling device, and the peeling device is separated from the material holding device to peel the rubber material from the rubber sheet material.

[0005] However, in the peeling method disclosed in Patent Document 1, since the rubber sheet material is configured to be sandwiched in the thickness direction by a pair of parallel blades, the accuracy requirement for the peeling device is high, and the rubber material cannot be effectively peeled from the rubber sheet material.

[0006] This invention has been made in view of the above-mentioned circumstances, and aims to provide a method and apparatus for peeling laminates that can effectively peel off the surface layer from the laminate. [Means for solving the problem]

[0007] The present invention is as follows: 1. A method for peeling a laminated material having a surface layer, wherein the surface layer is peeled off from the laminated material having the surface layer, A laminated material holding step in which the end of the laminated material is held by the first holding part, A surface layer holding step in which the edge of the surface layer is held by a second holding part, A method for peeling a laminate, comprising a peeling step of peeling the surface layer from the laminate by relatively moving the first holding part, which holds the end of the laminate, and the second holding part, which holds the end of the surface layer, in a direction away from each other. 2. The method for peeling a laminate according to 1. above, wherein the direction in which the first holding portion and the second holding portion separate is the direction along the longitudinal direction of the laminate when viewed from the side of the laminate. 3. A cutting step in which notches are formed at the edges of the surface layer, The process further comprises a bending step in which the end of the laminated material is bent starting from the aforementioned cut, The laminated material holding step involves holding the bent end of the laminated material, The method for peeling a laminated material according to 1. above, wherein the surface layer retention step is to retain the portion of the edge of the surface layer including the cut. 4. The method for peeling a laminated material according to 3. above, wherein the second holding portion has a projection that penetrates the surface layer from the end face of the cut. 5. A laminate peeling apparatus for peeling a surface layer from a laminate having a surface layer, A first holding portion that holds the end of the laminated material, A second retaining portion that holds the edge of the surface layer, A peeling device for laminated material, comprising a peeling unit that peels the surface layer from the laminated material by relatively moving the first holding unit, which holds the end of the laminated material, and the second holding unit, which holds the end of the surface layer, in a direction away from each other. [Effects of the Invention]

[0008] According to the present invention, the surface layer can be effectively peeled off the laminate by relatively moving the first holding part, which holds the end of the laminate, and the second holding part, which holds the end of the surface layer, in a direction away from each other. [Brief explanation of the drawing]

[0009] The present invention will be further described in the following detailed description with reference to the drawings, which refer to several drawings, with the same reference numerals indicating the same parts in several of the drawings. [Figure 1] This is an explanatory diagram of a carpet peeling method according to an embodiment, where (a) and (b) show the carpet setting process, and (c) shows the felt layer cutting process. [Figure 2] This is an explanatory diagram of a carpet peeling method, where (a) and (b) show the carpet bending process, and (c) shows the carpet holding process. [Figure 3] This is an explanatory diagram of a carpet peeling method; (a) and (b) show the felt layer retention process, and (c) shows the felt layer peeling process. [Figure 4] This is an explanatory diagram of the carpet peeling method, where (a) shows a perspective view of the felt layer cutting process and (b) shows a perspective view of the felt layer retention process. [Figure 5] This is an explanatory diagram of a carpet peeling device according to an embodiment. [Figure 6] This is an explanatory diagram of the cutting section that makes up a carpet peeling device. [Figure 7] This is an explanatory diagram of the second holding part that constitutes the carpet peeling device. [Figure 8]It is an explanatory diagram of a method for peeling a carpet according to another form. (a) shows the bending process of the carpet, (b) shows the holding process of the carpet, (c) shows the holding process of the felt layer, and (d) shows the peeling process of the felt layer. [Figure 9] It is an explanatory diagram of a method for peeling a carpet according to still another form. (a) shows the holding process of the carpet, (b) shows the holding process of the felt layer, and (c) shows the peeling process of the felt layer.

Embodiments for Carrying Out the Invention

[0010] The matters shown here are exemplary and for illustratively explaining the embodiments of the present invention, and are described for the purpose of providing an explanation that is considered to be the most effective and easy to understand for the principles and conceptual features of the present invention. In this regard, it is not intended to show the structural details of the present invention more than is necessary for a fundamental understanding of the present invention, and it is to clarify to those skilled in the art how some forms of the present invention are actually implemented by the explanation combined with the drawings.

[0011] Hereinafter, the present invention will be specifically described by way of embodiments with reference to the drawings. In this embodiment, as the "laminated material" according to the present invention, a carpet end material (hereinafter, also simply referred to as "carpet") generated in the manufacturing process of an automotive carpet is exemplified.

[0012] The carpet 51 has a skin material 52 and a felt layer (surface layer) 53 laminated on the back surface of the skin material 52 (see FIG. 5). The skin material 52 has a skin layer 52a and an intermediate layer 52b laminated on the back surface of the skin layer 52a. That is, the carpet 51 has a three-layer structure of a skin layer 52a, an intermediate layer 52b, and a felt layer 53. However, a carpet 51 having a two-layer or four-layer or more multi-layer structure may also be used. The felt layer 53 and the skin layer 52a are formed of polyethylene terephthalate (PET) or the like, and the intermediate layer 52b is formed of polyethylene (PE) or the like. That is, the felt layer 53 and the skin material 52 are formed of different materials.

[0013] <Carpet peeling device> As shown in FIG. 5, the carpet peeling device A according to this embodiment includes a first holding part 1, a second holding part 2, a peeling part 3, a regulating part 5, a pressing part 6, a cutting part 7, a table part 8, and a bending part 9. In FIG. 5, the longitudinal direction of the carpet 51 set at a predetermined set position S on a table 41 (slide bottom plate) described later is defined as the front-rear direction P. Further, the feeding direction of the carpet 51 onto the table 41 is defined as "forward", and the opposite side is defined as "rear" (see FIG. 1(a)).

[0014] The first holding part 1 holds the end of the carpet 51 at the set position S (see FIG. 2(c)). The first holding part 1 has a pair of clamp pieces 1a and 1b that can approach and separate from each other. The direction in which the pair of clamp pieces 1a and 1b approach and separate is the front-rear direction P. Each of the clamp pieces 1a and 1b is formed in a straight ruler shape extending along the width direction of the carpet 51 at the set position S. One of the clamp pieces 1a moves with respect to the other clamp piece 1b by the operation of a fluid cylinder 11 (or a mechanism part including a motor). However, either one of the pair of clamp pieces 1a and 1b may move, or both may move.

[0015] The second holding part 2 holds the end of the felt layer 53 of the carpet 51 at the set position S (see FIG. 3(b)). The second holding part 2 has a pair of clamp pieces 2a and 2b that can approach and separate from each other. The direction in which the pair of clamp pieces 2a and 2b approach and separate is the up-down direction Q. One of the clamp pieces 2a is formed in a long shape extending along the width direction of the carpet 51 at the set position S. Also, one of the clamp pieces 2a moves with respect to the other clamp piece 2b by the operation of a fluid cylinder 12 (or a mechanism part including a motor). However, either one of the pair of clamp pieces 2a and 2b may move, or both may move. The other clamp piece 2b has a pyramid-shaped protrusion 14 that pierces into the felt layer 53 (specifically, near the boundary with the skin material 52 of the felt layer 53) from the end face of a cut 37 described later of the felt layer 53 of the carpet 51 at the set position S.

[0016] Multiple projections 14 are arranged in a row along the width direction of the carpet 51 (see Figure 7). Multiple substantially V-shaped grooves 15 (or recesses) are formed on the clamping surface of each projection 14, and multiple protrusions 16 (or protrusions) that can engage with the grooves 15 via the felt layer 53 are formed on the clamping surface of one clamping piece 2a. However, the shape, size, number, etc., of the grooves 15 and protrusions 16 are not particularly limited as long as they can engage with each other. Furthermore, a pair of clamping pieces 2a and 2b having flat clamping surfaces without grooves 15 and protrusions 16 may also be used.

[0017] The peeling unit 3 peels the felt layer 53 from the carpet 51 by relatively moving the first holding unit 1, which holds the edge of the carpet 51, and the second holding unit 2, which holds the edge of the felt layer 53, in a direction away from each other (specifically, in the front-rear direction P) (see Figure 3(c)). The peeling unit 3 has a first slider 21 to which the first holding unit 1 is provided, and a second slider 22 to which the second holding unit 2 is provided. The first slider 21 is slidable in the front-rear direction P relative to the fixed base 23. The first slider 21 moves by the operation of a fluid cylinder 25 (or a mechanism including a motor). The second slider 22 is slidable in the front-rear direction P relative to the fixed base 24. The second slider 22 moves by the operation of a fluid cylinder 26 (or a mechanism including a motor).

[0018] The regulating unit 5 regulates the leading edge position of the carpet 51 as it is fed onto the table 41, thereby positioning the carpet 51 at the set position S (see Figures 1(a) and 1(b)). The regulating unit 5 has a regulating member 31 that is movable between a regulating position and a retracted position that restricts the leading edge of the carpet 51. The regulating member 31 moves by the operation of a fluid cylinder 32 (or a mechanism including a motor). The regulating member 31 is also formed in an elongated shape that extends along the width direction of the carpet 51 at the set position S.

[0019] The pressing section 6 presses the edge of the carpet 51 at the set position S against the table 41 (see Figure 1(c)). The pressing section 6 has a pressing member 34 that is movable between a pressing position and a retracted position. The pressing member 34 moves by the operation of a fluid cylinder 35 (or a mechanism including a motor). The pressing member 34 is formed in an elongated shape that extends along the width direction of the carpet 51 at the set position S. Furthermore, a pair of pressing members 34 are provided spaced apart in the front-rear direction P. However, a configuration with only one pressing member 34 is also possible.

[0020] The cutting unit 7 forms a notch 37 at the edge of the felt layer 53 of the carpet 51 at the set position S (see Figure 1(c)). The cutting unit 7 has a cutting blade 38 that moves in the lateral direction of the carpet 51 between a pair of pressing members 34 to form the notch 37. The cutting blade 38 moves by the operation of a fluid cylinder 39 (or a mechanism including a motor). More specifically, the cutting blade 38 moves in a predetermined sequence in the lateral direction R (horizontal direction) and vertical direction of the carpet 51 to perform the cutting operation (see Figure 6). The notch 37 may be formed by a heat cutter or a laser cutter instead of the cutting blade 38.

[0021] The table section 8 supports and releases (unsupports) the end of the carpet 51 in the set position S (see Figures 1(c) and 2(a)). The table section 8 has a table 41 that is movable between a support position that supports the end of the carpet 51 and a release position that releases the end of the carpet 51. The table 41 moves by the operation of a fluid cylinder 42 (or a mechanism including a motor).

[0022] The bending section 9 bends the end of the carpet 51 at the set position S by approximately 90 degrees, starting from the cut 37 (see Figure 2(b)). However, the bending angle of the end of the carpet 51 is not limited to 90 degrees and can be selected as appropriate. The bending section 9 has a bending member 44 that is movable between a bending position where the end of the carpet 51 is bent and a retracted position. The bending member 44 moves by the operation of a fluid cylinder 45 (or a mechanism including a motor). In addition, multiple bending members 44 are provided along the width direction of the carpet 51 at the set position S.

[0023] The control processing for each of the above-mentioned functional units 1-3 and 5-9 may be implemented by either hardware or software, and is preferably implemented by a control unit equipped with peripheral circuits such as an input / output interface, centered on a microcontroller (microcomputer) that includes a CPU, memory device (ROM, RAM, etc.), input / output circuits, etc.

[0024] <How to remove carpet> Next, a method for peeling carpet using the carpet peeling device A configured as described above will be explained. In this embodiment, the carpet 51 is made from carpet scraps generated in the manufacturing process of one automobile carpet, which are divided into multiple sections (for example, four sections) to form a substantially straight shape.

[0025] The carpet 51 is fed onto the table 41 with the felt layer 53 facing upward (see Figure 1(a)), and the leading edge of the carpet 51 is brought into contact with the regulating member 31 to set the carpet 51 in the set position S (see Figure 1(b)). Next, the ends of the carpet 51 are pressed against the table 41 by a pair of pressing members 34, and a notch 37 is formed in the felt layer 53 between the pair of pressing members 34 by the cutting operation of the cutting blade 38 (see Figure 6) (see Figure 1(c)). At this time, the notch 37 may be formed in a single cutting operation of the cutting blade 38, but from the viewpoint of ease of notch formation, it is preferable to form the notch 37 with the cutting blade 38 by repeating the cutting operation multiple times (for example, three times).

[0026] Next, the table 41 is moved backward to release the support of the edge of the carpet 51 from the table 41 (see Figure 2(a)). Then, the bending member 44 is lowered to fold the edge of the carpet 51 by approximately 90 degrees starting from the notch 37 (see Figure 2(b)). At this time, the notch 37 in the felt layer 53 opens and its end face is exposed forward. Next, the pair of clamp pieces 1a and 1b are brought close together and the first holding part 1 holds the edge of the carpet 51 (see Figure 2(c)).

[0027] Next, the second holding part 2 is moved backward to pierce the projection 14 into the felt layer 53 from the end face of the notch 37 (see Figure 3(a)). At this time, the projection 14 may be pierced into the felt layer 53 in a single piercing motion, but from the viewpoint of the piercing ability of the projection 14, it is preferable to pierce the projection 14 into the felt layer 53 by repeating the piercing motion multiple times (for example, three times). Then, the pair of clamp pieces 2a and 2b are brought close together and the second holding part 2 holds the portion of the felt layer 53 including the notch 37 at the end (see Figure 3(b)). After that, the first holding part 1 is moved backward to pull the surface material 52 backward, and the second holding part 2 is moved forward to pull the felt layer 53 forward, thereby peeling the felt layer 53 from the carpet 51, that is, separating the surface material 52 and the felt layer 53 (see Figure 3(c)).

[0028] Subsequently, the pair of clamp pieces 1a and 1b are separated to release the first holding unit 1 and place the surface material 52 onto a conveyor (not shown), and the pair of clamp pieces 2a and 2b are separated to release the second holding unit 2 and place the felt layer 53 onto a conveyor (not shown). The surface material 52 and felt layer 53 are collected at each collection unit (not shown) by each conveyor. The collected surface material 52 and felt layer 53 are then recycled as raw materials by fiber manufacturers and the like.

[0029] Here, when peeling the felt layer 53 from the carpet 51, the first and second holding parts 1 and 2 may start moving simultaneously. However, from the viewpoint of the peelability of the felt layer 53, it is preferable to move the first holding part 1 after a predetermined time has elapsed since the start of movement of the second holding part 2. Furthermore, the movement speed of the first holding part 1 and / or the second holding part 2 may be kept constant. However, from the viewpoint of the peelability of the felt layer 53, it is preferable to change the movement speed according to the distance traveled. For example, the movement speed can be slowed down when the distance traveled exceeds a set value.

[0030] As described above, the carpet peeling method of this embodiment comprises a carpet holding step of holding the edge of the carpet 51 with a first holding part 1, a felt layer holding step of holding the edge of the felt layer 53 with a second holding part 2, and a peeling step of peeling the felt layer 53 from the carpet 51 by relatively moving the first holding part 1, which is holding the edge of the carpet 51, and the second holding part 2, which is holding the edge of the felt layer 53, in a direction away from each other. This makes it possible to effectively peel the felt layer 53 from the carpet 51.

[0031] Furthermore, in the carpet peeling method of this embodiment, the direction in which the first holding part 1 and the second holding part 2 separate is along the longitudinal direction of the carpet 51 when viewed from the side. This allows the felt layer 53 to be peeled off by utilizing the space along the longitudinal direction of the carpet 51.

[0032] Furthermore, the carpet peeling method of this embodiment further includes a cutting step of forming a notch 37 at the edge of the felt layer 53, and a bending step of bending the edge of the carpet 51 starting from the notch 37. The laminated material holding step holds the bent edge of the carpet 51, and the surface layer holding step holds the portion of the edge of the felt layer 53 including the notch 37. As a result, the edge of the carpet 51 can be easily bent, and the edge of the carpet 51 can be easily and firmly held by the first holding part 1. Furthermore, the edge of the felt layer 53 can be easily and firmly held by the second holding part 2.

[0033] Furthermore, in the carpet peeling method of this embodiment, the second holding part 2 has a projection 14 that penetrates the felt layer 53 from the end face of the cut 37. This allows the second holding part 2 to hold the end of the felt layer 53 more easily and firmly.

[0034] Furthermore, in the carpet peeling method of this embodiment, the peeling step involves moving the first and second holding parts 1 and 2 respectively to peel off the felt layer 53. This allows for shorter movement strokes of the first and second holding parts 1 and 2, and thus reduces the size of their power sources (e.g., fluid cylinders 25 and 26), compared to a configuration in which only one of the first and second holding parts 1 and 2 is moved to peel off the felt layer 53.

[0035] Furthermore, the carpet peeling device A of this embodiment includes a first holding part 1 for holding the edge of the carpet 51, a second holding part 2 for holding the edge of the felt layer 53, and a peeling part 3 that peels the felt layer 53 from the carpet 51 by relatively moving the first holding part 1, which holds the edge of the carpet 51, and the second holding part 2, which holds the edge of the felt layer 53, in a direction away from each other. This makes it possible to effectively peel the felt layer 53 from the carpet 51.

[0036] Furthermore, the present invention is not limited to the above embodiments, and various modified embodiments can be made within the scope of the present invention depending on the purpose and application. That is, although the above embodiments illustrate a form that includes a cutting step as a method for peeling off the carpet 51, the invention is not limited to this, and a form without a cutting step may be used, for example, as shown in Figure 8. In this embodiment, the edge of the carpet 51 is bent with the bending member 44 (see Figure 8(a)), the bent edge of the carpet 51 is held by the first holding part 1 (see Figure 8(b)), the edge of the felt layer 53 is held by the second holding part 2 (see Figure 8(c)), and the first and second holding parts 1 and 2 are moved away from each other to peel off the felt layer 53 from the carpet 51 (see Figure 8(d)).

[0037] Furthermore, although the above embodiment exemplifies a configuration that includes a cutting step and a bending step as a method for peeling off the carpet 51, it is not limited to this, and a configuration without a cutting step and a bending step may be used, for example, as shown in Figure 9. In this configuration, the edge of the carpet that has not been bent is held by the first holding part 1 (see Figure 9(a)), the edge of the felt layer is held by the second holding part 2 (see Figure 9(b)), and the first and second holding parts 1 and 2 are moved away from each other to peel off the felt layer 53 from the carpet 51 (see Figure 9(c)).

[0038] Furthermore, in the above embodiment, an example was given in which the edge of the carpet 51 is held by the first holding part 1 and then the edge of the felt layer 53 is held by the second holding part 2. However, the embodiment is not limited to this, and for example, the edge of the felt layer 53 may be held by the second holding part 2 and then the edge of the carpet 51 may be held by the first holding part 1. Moreover, the holding by the first and second holding parts 1 and 2 may be performed substantially simultaneously.

[0039] Furthermore, although the above embodiment illustrates a method of peeling off the felt layer 53 by moving the first and second holding parts 1 and 2 respectively, it is not limited to this, and for example, the felt layer 53 may be peeled off by moving only one of the first and second holding parts 1 and 2.

[0040] Furthermore, although the above embodiment illustrates a configuration in which the first and second holding parts 1 and 2 are separated horizontally to peel off the felt layer 53, the invention is not limited to this, and the first and second holding parts 1 and 2 may be separated in a direction inclined with respect to the horizontal or in a vertical direction to peel off the felt layer 53.

[0041] Furthermore, in the above embodiment, the holding parts 1 and 2 are exemplified as having a pair of clamp pieces 1a, 1b, 2a, and 2b for holding an object, but the embodiment is not limited thereto, and for example, the holding parts 1 and 2 may have a hook portion for locking onto an object, or a suction portion for adsorbing an object.

[0042] Alternatively, a configuration may be used in which multiple carpet peeling devices A of the above embodiment are arranged in the vertical and / or horizontal directions to process multiple carpets 51.

[0043] Furthermore, although automotive carpet 51 was given as an example of the laminated material in the above embodiment, it is not limited to this, and can be used as interior material for vehicles such as automobiles, trains, aircraft, and ships, or as interior material for buildings such as houses and shops. Examples of interior materials for vehicles include carpets, mats, ceiling materials, various trims such as door trims, and surface materials that make up instrument panels, consoles, sun visors, seats, etc. Examples of interior materials for buildings include carpets, mats, ceiling materials, and interior wall materials. Furthermore, the material of the surface layer can be appropriately selected according to the application of the laminated material, and examples include nonwoven fabric layers, woven fabric layers, knitted fabric layers, and foamed fabric layers. [Industrial applicability]

[0044] This invention is widely used as a technique for separating the surface layer from other layers that constitute a laminated material. [Explanation of Symbols]

[0045] 1; 1st holding part 2; 2nd holding part 3; peeled section 7; cut section 9;Bending part 14;Protrusion 51; Carpet (laminated material) 53; Felt layer (surface layer) A: Carpet stripping device

Claims

1. A method for peeling a laminated material having a surface layer, the method for peeling the surface layer from the laminated material having the surface layer, A laminated material holding step in which the end of the laminated material is held by a first holding part, A surface layer holding step in which the edge of the surface layer is held by a second holding part, A method for peeling a laminated material, comprising a peeling step of peeling the surface layer from the laminated material by relatively moving the first holding part, which holds the end of the laminated material, and the second holding part, which holds the end of the surface layer, in a direction away from each other.

2. The method for peeling a laminated material according to claim 1, wherein the direction in which the first holding portion and the second holding portion separate is the direction along the longitudinal direction of the laminated material when viewed from the side.

3. A cutting step of forming a notch at the edge of the surface layer, The process further comprises a bending step in which the end of the laminated material is bent starting from the aforementioned cut, The laminated material holding step involves holding the bent end of the laminated material, The method for peeling a laminated material according to claim 1, wherein the surface layer holding step holds the portion of the edge of the surface layer including the cut.

4. The method for peeling a laminated material according to claim 3, wherein the second holding portion has a projection that penetrates the surface layer from the end face of the cut.

5. A peeling apparatus for a laminated material having a surface layer, which peels off the surface layer from the laminated material having the surface layer, A first holding portion that holds the end of the laminated material, A second retaining portion that holds the edge of the surface layer, A peeling device for laminated material, comprising a peeling unit that peels the surface layer from the laminated material by relatively moving the first holding unit, which holds the end of the laminated material, and the second holding unit, which holds the end of the surface layer, in a direction away from each other.

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