Manufacturing System

Abstract

To provide a manufacturing system for manufacturing a prescribed product by performing printing and applying of a coating agent to a base material formed of a resin or the like which can simplify the creation work of data for manufacturing the product by a user.SOLUTION: In a coating applicator 3 of a manufacturing system 1, a linear coating agent being a coating agent in a linear shape with the first direction as the longitudinal direction is applied to a base material when a nozzle jetting the coating agent is moved once in the first direction. A higher-level control device 7 creates application data for applying the coating agent to the base material by the coating applicator 3 on the basis of the image data being the data of the image printed on the base material by a printer 4. The application data comprises: data of the jetting range of the coating agent from a nozzle in the first direction for applying the linear coating agent to the base material; and data of the application interval of the linear coating agent in the second direction.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a manufacturing system for manufacturing a predetermined product by printing and applying a coating agent to a substrate made of resin or the like. [Background technology]

[0002] Conventionally, a decorative structure is known that includes a base material made of a resin or the like, a plurality of convex portions formed on one side of the base material, and an overcoat layer that covers the convex portions (see, for example, Patent Document 1). In the decorative structure described in Patent Document 1, the convex portions are formed, for example, by printing an ink for the convex portions by an inkjet method, and then curing the printed ink for the convex portions. The overcoat layer is formed, for example, by applying a coating agent by a spray method or an inkjet method, and then curing the applied coating agent. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2014-213247 A Summary of the Invention [Problem to be solved by the invention]

[0004] The present inventor has developed a manufacturing system for manufacturing a predetermined product by printing and applying a coating agent to a substrate made of resin or the like. This manufacturing system includes a printing mechanism for printing on the substrate and an application mechanism for applying a coating agent to the substrate. The application mechanism applies a coating agent to the substrate, for example, to form a coating layer that protects the print on the substrate. As described in Patent Document 1, spray and inkjet methods are conventionally known as methods for applying a coating agent to a substrate. In the case of the inkjet method, however, when the viscosity of the coating agent becomes high, the coating agent cannot be ejected from the inkjet head.

[0005] That is, when the viscosity of the coating agent becomes high, the inkjet method is no longer able to apply the coating agent to the substrate. Therefore, when the inkjet method is adopted as a method for applying a coating agent to a substrate, the coating agent that can be used is limited, and the versatility of the application mechanism is reduced. On the other hand, in the case of the spray method, it is possible to apply the coating agent to the substrate even if the viscosity of the coating agent becomes high. Therefore, the inventors of the present application decided to adopt a spray method in which the coating agent is sprayed from a nozzle as a method for applying a coating agent to a substrate.

[0006] When manufacturing a product using this manufacturing system, print data for printing on a substrate by the printing mechanism and application data for applying a coating agent to the substrate by the application mechanism are required. In other words, in this manufacturing system, data including at least print data and application data must be created as data for manufacturing a product, but it is preferable for the user to easily create this data.

[0007] Therefore, an object of the present invention is to provide a manufacturing system for producing a specified product by printing and applying a coating agent to a substrate formed of resin or the like, which can simplify the user's work of creating data for manufacturing the product. [Means for solving the problem]

[0008] In order to solve the above problems, the manufacturing system of the present invention includes a printing mechanism that prints on a substrate, an application mechanism that applies a coating agent to the substrate, and a host control device to which the printing mechanism and the application mechanism are electrically connected, and if a predetermined direction perpendicular to the up-down direction is defined as a first direction and a direction perpendicular to the up-down direction and the first direction is defined as a second direction, the application mechanism includes a nozzle that sprays the coating agent downward toward the substrate, a table on which the substrate is placed, a carriage on which the nozzle is mounted, a first moving mechanism that moves the carriage back and forth relatively to the table in the first direction, and a second moving mechanism that moves the carriage back and forth relatively to the table in the second direction, and the nozzle that sprays the coating agent is disposed in the first moving mechanism. When the mechanism moves once relative to the table in a first direction, a linear coating agent, which is a linear coating agent with the first direction as its longitudinal direction, is applied to the substrate, and a coating layer is formed on the substrate by multiple linear coating agents applied at regular intervals in the second direction, and the upper control device creates application data for applying the coating agent to the substrate by the application mechanism based on image data, which is data of an image printed on the substrate by the printing mechanism, the application data including data of the spray range of the coating agent from the nozzle in the first direction for applying the linear coating agent to the substrate and data of the application interval of the linear coating agent in the second direction.

[0009] In the manufacturing system of the present invention, the host control device creates application data for applying a coating agent to a substrate by the application mechanism based on image data, which is data of an image printed on the substrate by the printing mechanism, the application data including data of a spray range of the coating agent from the nozzle in a first direction for applying a linear coating agent to the substrate and data of an application interval of the linear coating agent in a second direction. That is, in the present invention, the host control device automatically creates the application data based on the image data, and the user does not need to create the application data. Therefore, the manufacturing system of the present invention can simplify the user's work of creating data for manufacturing products.

[0010] In the present invention, it is preferable that the thickness of the substrate can be input to the upper control device, and the upper control device creates application data based on the substrate thickness and image data input to the upper control device. Since the distance between the substrate and the nozzle varies depending on the substrate thickness, a change in the substrate thickness may cause a change in the width of the linear coating agent in the second direction, and thus may cause a change in the appropriate application interval of the linear coating agent in the second direction. However, with this configuration, even if the substrate thickness changes, appropriate application data can be created in the upper control device.

[0011] In the present invention, it is preferable that the host control device is capable of selecting the type of nozzle, and the host control device creates application data based on the selected type of nozzle and image data. Although the width of the linear coating agent in the second direction may vary depending on the type of nozzle, and the appropriate application interval of the linear coating agent in the second direction may vary depending on the type of nozzle, this configuration allows the host control device to create appropriate application data even if the type of nozzle changes.

[0012] In the present invention, the nozzle begins spraying the coating agent when the moving speed of the carriage in the first direction becomes constant, and a coating deviation correction value can be input to the upper control device for correcting a deviation in the first direction between the spray position of the coating agent from the nozzle in the first direction and the application position of the coating agent to the substrate in the first direction, and it is preferable that the upper control device creates coating data based on the coating deviation correction value and image data input to the upper control device.

[0013] With this configuration, the nozzle starts spraying the coating agent when the moving speed of the carriage in the first direction becomes constant, making it possible to suppress variations in the applied thickness of the linear coating agent in the first direction. Furthermore, when the nozzle sprays the coating agent while the carriage moves in the first direction, the spray position of the coating agent from the nozzle in the first direction and the application position of the coating agent on the substrate in the first direction are misaligned in the first direction, but with this configuration, the upper control device creates application data based on an application misalignment correction value for correcting the misalignment between the spray position of the coating agent from the nozzle in the first direction and the application position of the coating agent on the substrate in the first direction and image data, making it possible to suppress the misalignment of the application position of the linear coating agent in the first direction.

[0014] In the present invention, for example, the printing mechanism and the coating mechanism are separate devices, and the number of coating mechanisms is less than the number of printing mechanisms.

[0015] In the present invention, for example, the printing mechanism and the application mechanism are separate devices, and the application mechanism applies a coating agent to the substrate after printing has been performed by the printing mechanism, and the printing mechanism prints an alignment mark on the substrate for aligning the substrate in the application mechanism. In this case, even if the printing mechanism and the application mechanism are separate devices, it is possible to align the substrate in the application mechanism using the alignment mark. Therefore, it is possible to suppress misalignment between the portion of the substrate on which printing has been performed and the portion of the substrate on which the coating agent is applied.

[0016] In the present invention, for example, the printing mechanism prints on the substrate with inks of multiple colors, and the application mechanism applies a monochromatic coating agent to the substrate. Also, in the present invention, for example, the application mechanism applies a transparent coating agent to the substrate. Also, in the present invention, for example, the printing mechanism prints on the substrate with ultraviolet-curable ink, and the application mechanism applies an ultraviolet-curable coating agent to the substrate.

[0017] In the present invention, the manufacturing system includes a cutting mechanism that cuts the substrate after the coating agent has hardened into a predetermined shape, and the cutting mechanism is preferably electrically connected to a host control device, which creates cutting data for cutting the substrate with the cutting mechanism based on image data. In this configuration, the host control device automatically creates the cutting data based on image data, and the user does not need to create the cutting data. Therefore, even when the substrate after the coating agent has hardened is cut into a predetermined shape by the cutting mechanism, it is possible to simplify the user's work of creating data for manufacturing the product.

[0018] In the present invention, it is preferable that the host control device creates the application data based on the cutting data, which simplifies the data creation process in the host control device compared to a case where the host control device creates the application data without using the cutting data. In the present invention, for example, software for creating image data is installed in the host control device, and the image data is created by the host control device. Effect of the Invention

[0019] As described above, the present invention makes it possible to simplify the work of a user creating data for manufacturing a product in a manufacturing system for producing a specified product by printing and applying a coating agent to a substrate made of resin or the like. [Brief description of the drawings]

[0020] [Figure 1]1 is a block diagram of a manufacturing system according to an embodiment of the present invention. [Diagram 2] FIG. 2 is a diagram for explaining the configuration of the coating apparatus shown in FIG. [Diagram 3] FIG. 3 is a cross-sectional view for explaining the configuration of the nozzle shown in FIG. 2. [Figure 4] FIG. 3 is a diagram for explaining that, when a coating agent is applied by the application device shown in FIG. 2, a deviation occurs in the first direction between the position at which the coating agent is sprayed from the nozzle in the first direction and the position at which the coating agent is applied to the substrate in the first direction. [Diagram 5] 2 is a diagram showing an example of a display on a display of the upper control device shown in FIG. 1. [Figure 6] 2 is a diagram showing an example of an image etc. printed on a substrate by the printing device shown in FIG. 1. [Figure 7] 2 is a diagram for explaining a method of creating application data in the upper control device shown in FIG. 1. [Figure 8] 2 is a diagram for explaining a method of creating application data in the upper control device shown in FIG. 1. [Figure 9] 2 is a diagram for explaining a method of creating application data in the upper control device shown in FIG. 1. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0021] Hereinafter, an embodiment of the present invention will be described with reference to the drawings.

[0022] (Outline of manufacturing system configuration) FIG. 1 is a block diagram of a manufacturing system 1 according to an embodiment of the present invention.

[0023] The manufacturing system 1 of this embodiment is a system for manufacturing a predetermined product using a base material 2 (see FIG. 2). In the manufacturing system 1, for example, a plate for a key holder used in a key holder is manufactured. The base material 2 is formed of various materials such as resin, metal, glass, paper, or fabric. The base material 2 of this embodiment is formed of a hard resin such as acrylic resin or ABS resin. Moreover, the base material 2 of this embodiment is formed in a flat plate shape.

[0024] The manufacturing system 1 includes an application device 3 as an application mechanism that applies a coating agent to a substrate 2, a printing device 4 as a printing mechanism that prints on the substrate 2, a curing device 5 that hardens the coating agent applied to the substrate 2, a cutting device 6 as a cutting mechanism that cuts the substrate 2 into a predetermined shape after the coating agent has hardened, and a PC (personal computer) 7 as a host control device to which the application device 3, the printing device 4, and the cutting device 6 are electrically connected. In this embodiment, the printing device 4 prints on the substrate 2 before the coating agent is applied by the application device 3. That is, the application device 3 applies the coating agent to the substrate 2 after printing is performed by the printing device 4. In this embodiment, the application device 3, the printing device 4, the curing device 5, and the cutting device 6 are separate devices.

[0025] The printing device 4 is an inkjet printer. The printing device 4 includes, for example, an inkjet head that ejects ink toward the substrate 2, a carriage on which the inkjet head is mounted, a carriage drive mechanism that moves the carriage in the main scanning direction, a table on which the substrate 2 is placed, and a movement mechanism that moves the carriage in the sub-scanning direction relative to the table. The printing device 4 also includes a control unit that controls the printing device 4. This control unit is electrically connected to the PC 7, and controls the printing device 4 based on a control command from the PC 7. The printing device 4 prints on the substrate 2 with inks of multiple colors. The printing device 4 also prints on the substrate 2 with ultraviolet-curable ink.

[0026] In addition, in the printing device 4, various inks can be used, such as aqueous inks (water-based inks) such as aqueous pigment ink, latex ink, and pigment-containing resin dispersion ink, evaporation-drying inks such as solvent inks (solvent inks) that use organic solvents as a solvent, ultraviolet-curing inks (UV inks), and energy-ray-curing inks such as solvent-added UV inks (solvent UV inks, SUV inks), but ultraviolet-curing inks are preferably applied to the resin substrate 2, so the ink used in the printing device 4 is preferably ultraviolet-curing ink. In addition, it is more preferable that the ink used in the printing device 4 is a radical polymerization or cationic polymerization ultraviolet-curing ink.

[0027] Furthermore, when the substrate 2 is an acrylic resin, the ink used in the printing device 4 is preferably an ink using acrylic monofunctional and polyfunctional monomers or oligomers. Furthermore, when the coating agent applied by the application device 3 is an acrylic coating agent, the ink used in the printing device 4 is more preferably an ink with a high ratio of polyfunctional monomers and oligomers. Examples of inks with a high ratio of polyfunctional monomers and oligomers include ultraviolet-curing inks such as LH-100 and LUS-120 manufactured by Mimaki Engineering Co., Ltd.

[0028] The cutting device 6 is a laser cutter that cuts the base material 2 with a laser beam. The cutting device 6 includes, for example, a laser emitting unit that emits a laser beam toward the base material 2, a table on which the base material 2 is placed, and a moving mechanism that moves the laser emitting unit relative to the table in two directions that are perpendicular to the up-down direction (vertical direction) and perpendicular to each other. The cutting device 6 also includes a control unit that controls the cutting device 6. This control unit is electrically connected to the PC 7 and controls the cutting device 6 based on a control command from the PC 7. The cutting device 6 also includes an optical detection mechanism (not shown) for detecting a later-described alignment mark M printed on the base material 2. The cutting device 6 may cut the base material 2 with a cutter blade. In this case, the cutting device 6 includes a cutter blade instead of the laser emitting unit.

[0029] The coating device 3 applies a coating agent at least on the printing applied to the substrate 2 in order to protect the printing applied to the substrate 2 by the printing device 4. The coating device 3 applies a single-color coating agent to the substrate 2. In this embodiment, the coating device 3 applies a transparent coating agent to the substrate 2. The coating device 3 also applies an ultraviolet-curing coating agent to the substrate 2. For example, the coating device 3 applies a radical polymerization type or cationic polymerization type ultraviolet-curing coating agent to the substrate 2. Furthermore, when the substrate 2 is formed of acrylic resin, the coating device 3 applies an acrylic-based coating agent. A more specific configuration of the coating device 3 will be described later.

[0030] The curing device 5 includes an ultraviolet irradiator that irradiates ultraviolet light onto the coating agent applied to the substrate 2. The ultraviolet irradiator irradiates ultraviolet light from above the substrate 2 onto which the coating agent has been applied. The coating agent cured by the curing device 5 becomes a coating layer. That is, when the coating agent applied to the substrate 2 is irradiated with ultraviolet light, a coating layer is formed on the substrate 2. The thickness of the coating layer formed on the substrate 2 is 10 to 40 μm. In this embodiment, a coating layer with a relatively high hardness is formed on the substrate 2.

[0031] The time required for applying a coating agent to one substrate 2 by one coating device 3 is less than half the time required for printing on one substrate 2 by one printing device 4. For this reason, the manufacturing system 1 of this embodiment is configured, for example, as shown in Fig. 1, with two printing devices 4, one coating device 3, one curing device 5, and one cutting device 6, and the substrate 2 printed by the two printing devices 4 is supplied to the one coating device 3. That is, in the manufacturing system 1, the number of coating devices 3 is smaller than the number of printing devices 4.

[0032] (Configuration of Coating Equipment) Fig. 2 is a diagram for explaining the configuration of the coating apparatus 3 shown in Fig. 1. Fig. 3 is a cross-sectional view for explaining the configuration of the nozzle 13 shown in Fig. 2.

[0033] The coating device 3 includes a table 12 on which the substrate 2 is placed, a nozzle 13 that sprays the coating agent downward toward the substrate 2, a coating head 14 to which the nozzle 13 is attached, a carriage 15 on which the nozzle 13 and the coating head 14 are mounted, and a Y bar 16 that movably holds the carriage 15. The coating device 3 also includes a control unit that controls the coating device 3. This control unit is electrically connected to the PC 7 and controls the coating device 3 based on a control command from the PC 7. The coating device 3 applies the coating agent to the substrate 2 by a spray method in which the coating agent is sprayed from the nozzle 13. In the following description, the Y direction in FIG. 2 that is perpendicular to the up-down direction (Z direction in FIG. 2) is defined as the left-right direction, and the X direction in FIG. 2 that is perpendicular to the up-down direction and the left-right direction is defined as the front-rear direction.

[0034] The coating head 14 is held by the carriage 15 so as to be able to move back and forth in the up and down direction relative to the carriage 15. The Y bar 16 is formed in a generally rectangular parallelepiped shape that is elongated in the left and right direction. The carriage 15 is held by the Y bar 16 so as to be able to move back and forth in the left and right direction relative to the Y bar 16. The nozzle 13, the coating head 14, the carriage 15 and the Y bar 16 are disposed above the table 12. The Y bar 16 is able to move relatively in the front and rear directions with respect to the table 12.

[0035] The coating device 3 includes a lifting mechanism 20 that raises and lowers the coating head 14 relative to the carriage 15. The coating device 3 also includes a moving mechanism 21 that reciprocates the carriage 15 in the left-right direction relative to the Y bar 16, and a moving mechanism 22 that reciprocates the Y bar 16 in the front-rear direction relative to the table 12. That is, the coating device 3 includes a moving mechanism 21 that reciprocates the carriage 15 in the left-right direction relative to the table 12, and a moving mechanism 22 that reciprocates the carriage 15 in the front-rear direction relative to the table 12. The left-right direction (Y direction) in this embodiment is a first direction that is a predetermined direction perpendicular to the up-down direction, and the front-rear direction (X direction) is a second direction that is a direction perpendicular to the up-down direction and the first direction. The moving mechanism 21 in this embodiment is a first moving mechanism, and the moving mechanism 22 is a second moving mechanism.

[0036] The coating device 3 also includes a laser pointer (not shown) for aligning the substrate 2 placed on the table 12. This laser pointer is mounted on the carriage 15. The lifting mechanism 20 includes a drive source such as a motor, and a power transmission mechanism such as a ball screw for transmitting the power of the drive source to the coating head 14. The moving mechanism 21 includes a drive source such as a motor, and a power transmission mechanism such as a pulley and a belt for transmitting the power of the drive source to the carriage 15. The moving mechanism 22 includes a drive source such as a motor, and a power transmission mechanism such as a ball screw for transmitting the power of the drive source to the Y bar 16.

[0037] The nozzle 13 is an external mixing type two-fluid nozzle that mixes the coating agent and compressed air externally and sprays them. As shown in FIG. 3, a supply path 13a for the coating agent and a supply path 13b for the compressed air are formed inside the nozzle 13. The supply path 13b is formed, for example, in a ring shape surrounding the supply path 13a. A compressed air supply source (not shown) such as a compressor that supplies compressed air is connected to the supply path 13b. The nozzle 13 is detachably attached to the coating head 14. In this embodiment, various types of nozzles can be used as the nozzle 13, such as a round nozzle 13 with a circular nozzle or a flat nozzle 13 with an oval or elliptical nozzle or the like.

[0038] The vertical distance (gap) between the upper surface of the substrate 2 placed on the table 12 and the lower end surface of the nozzle 13 is set to 2 to 30 mm. However, the distance between the upper surface of the substrate 2 and the lower end surface of the nozzle 13 is preferably set to 5 to 20 mm. The nozzle 13 starts spraying the coating agent when the moving speed of the carriage 15 (specifically, the moving speed in the left-right direction) becomes constant after the stopped carriage 15 starts moving. In other words, the nozzle 13 starts spraying the coating agent when the moving speed of the nozzle 13 becomes constant after the stopped nozzle 13 starts moving together with the carriage 15. The viscosity of the coating agent supplied to the nozzle 13 is 15 to 150 mPa.

[0039] In order to ensure the thickness (film thickness) of the coating layer formed on the substrate 2, the amount of coating agent sprayed from the nozzle 13 per unit time is 0.1 ml / min or more. However, the amount of coating agent sprayed from the nozzle 13 per unit time is preferably 0.5 ml / min or more, and more preferably 1.0 ml / min or more. Also, in order to minimize overflow of the coating agent, the amount of coating agent sprayed from the nozzle 13 per unit time is 30 ml / min or less. However, the amount of coating agent sprayed from the nozzle 13 per unit time is preferably 10 ml / min or less, and more preferably 5 ml / min or less.

[0040] In the coating device 3, when the nozzle 13 that sprays the coating agent moves once in the left-right direction relative to the table 12 by the moving mechanism 21 together with the carriage 15, a linear coating agent CA, which is a linear coating agent with the left-right direction as its longitudinal direction, is applied to the substrate 2. The linear coating agent CA is applied at a position shifted in the front-rear direction from the linear coating agent CA applied immediately before. In this embodiment, a coating layer is formed on the substrate 2 by a plurality of linear coating agents CA applied at regular intervals in the front-rear direction. The width of the linear coating agent CA in the front-rear direction is 1 mm to 30 mm. However, the width of the linear coating agent CA in the front-rear direction is preferably 5 mm to 20 mm.

[0041] In addition, the amount of coating agent sprayed from the nozzle 13 per unit time varies depending on the viscosity of the coating agent sprayed from the nozzle 13, provided that the supply pressure of the coating agent to the nozzle 13 is constant. In addition, the viscosity of the coating agent sprayed from the nozzle 13 varies depending on the temperature of the coating agent sprayed from the nozzle 13. In other words, the amount of coating agent sprayed from the nozzle 13 per unit time varies depending on the temperature of the coating agent sprayed from the nozzle 13, provided that the supply pressure of the coating agent to the nozzle 13 is constant. In this embodiment, the supply pressure of the coating agent supplied to the nozzle 13 is controlled based on the detection result of a temperature sensor that measures the temperature of the coating agent and a database previously stored in the PC 7 so that the amount of coating agent sprayed from the nozzle 13 per unit time is constant, regardless of the temperature of the coating agent sprayed from the nozzle 13.

[0042] (Method of creating image data, coating data and cutting data) Fig. 4 is a diagram for explaining that when the coating agent is applied by the application device 3 shown in Fig. 2, a deviation occurs in the left-right direction between the spray position of the coating agent from the nozzle 13 and the application position of the coating agent on the substrate 2 in the left-right direction. Fig. 5 is a diagram showing an example of a display on the display 24 of the PC 7 shown in Fig. 1. Fig. 6 is a diagram showing an example of an image F etc. printed on the substrate 2 by the printing device 4 shown in Fig. 1. Figs. 7 to 9 are diagrams for explaining a method of creating application data D2 by the PC 7 shown in Fig. 1.

[0043] The PC 7 is equipped with a display 24 such as a liquid crystal display (see FIG. 5). Image creation software is installed on the PC 7 for creating image data D1, which is data for an image F (see FIG. 6) to be printed on the substrate 2 by the printing device 4. The PC 7 also has installed thereon software for coating and cutting, which is used to create application data D2 (see FIG. 7(D)) for applying a coating agent to the substrate 2 by the application device 3, and cutting data D3 for cutting the substrate 2 by the cutting device 6.

[0044] In this embodiment, alignment marks M (see FIG. 6) for aligning the substrate 2 in the coating device 3 and the cutting device 6 are printed on the substrate 2 by the printing device 4. Alignment data D4, which is data for the alignment marks M, is created using software for coating and cutting. In addition, software (printer driver) for controlling the printing device 4, software for controlling the coating device 3, and software for controlling the cutting device 6 are installed in the PC 7.

[0045] The type of coating agent to be applied to the substrate 2, the material of the substrate 2, the type of the nozzle 13, the thickness (film thickness) of the coating layer to be formed on the substrate 2, and the vertical distance between the upper surface of the substrate 2 placed on the table 12 and the lower end surface of the nozzle 13 are stored (registered) in advance as a database in the PC 7, and the PC 7 is capable of selecting this information. The user selects this information while checking the display 24 using the coating / cutting software. The PC 7 is also capable of inputting the thickness of the substrate 2 and a coating offset value for enlarging or reducing the coating range of the coating agent on the substrate 2. The user inputs the thickness of the substrate 2 and the coating offset value while checking the display 24 using the coating / cutting software.

[0046] As described above, the nozzle 13 starts spraying the coating agent when the moving speed of the nozzle 13 in the left-right direction becomes constant, and the coating agent is sprayed from the nozzle 13 moving in the left-right direction at a constant speed. Therefore, as shown in FIG. 4, a left-right deviation ΔY occurs between the spray position of the coating agent from the nozzle 13 in the left-right direction and the application position of the coating agent on the substrate 2 in the left-right direction. A coating deviation correction value for correcting the left-right deviation ΔY between the spray position of the coating agent from the nozzle 13 in the left-right direction and the application position of the coating agent on the substrate 2 in the left-right direction can be input to the PC 7. The user inputs the coating deviation correction value while checking the display on the display 24 using the coating and cutting software. The deviation ΔY is measured in advance by performing a test application of the coating agent to the substrate 2 in the coating device 3. The coating deviation correction value is, for example, half the deviation ΔY.

[0047] The user creates image data D1 on the PC 7 while checking the display on the display 24 using the image creation software, and loads the created image data D1 into the coating / cutting software. The coating data D2 and cutting data D3 are automatically created on the coating / cutting software based on the image data D1. That is, the PC 7 creates the coating data D2 and cutting data D3 based on the image data D1. The alignment data D4 is automatically created on the coating / cutting software based on the cutting data D3, etc. However, the user may create the alignment data D4 while checking the display on the display 24 using the image creation software or the coating / cutting software.

[0048] Further, the PC 7 creates print data for printing on the substrate 2 by the printer 4 based on the image data D1 and the alignment data D4. The print data is automatically created when, for example, a user performs a predetermined operation on the coating / cutting software. Also, for example, when a user performs a predetermined operation on the coating / cutting software, the print data is transferred from the PC 7 to the printer 4, and the printer 4 prints an image F and an alignment mark M on the substrate 2 as shown in FIG. 6. The alignment mark M in this embodiment is a hollow circle. The alignment marks M are printed in four places so as to surround the image F, and when the four alignment marks M are connected in sequence by straight lines in the circumferential direction of the image F, a rectangular frame is formed.

[0049] As shown in FIG. 5, the cutting data D3 is frame-shaped data surrounding the image data D1. When a user inputs a predetermined offset value for cutting on the coating / cutting software, the cutting data D3 is automatically created on the coating / cutting software based on the image data D1. In addition, together with the cutting data D3, provisional coating range setting data D5 for provisionally setting the coating range of the coating agent on the substrate 2 is automatically created on the coating / cutting software. The provisional coating range setting data D5 in this embodiment is the same data as the cutting data D3, and when a user inputs an offset value for cutting on the coating / cutting software, the provisional coating range setting data D5 is automatically created on the coating / cutting software based on the image data D1. Note that in FIGS. 7 to 9, the external shape of the provisional coating range setting data D5 is simplified.

[0050] The coating data D2 is automatically created on the coating and cutting software based on the provisional coating range setting data D5, the preselected type of coating agent, the material of the substrate 2, the type of nozzle 13, the thickness of the coating layer to be formed on the substrate 2, the vertical distance between the upper surface of the substrate 2 placed on the table 12 and the lower end surface of the nozzle 13, and the pre-input thickness of the substrate 2, the coating offset value, and the coating misalignment correction value.

[0051] That is, the PC 7 creates application data D2 based on the provisional application range setting data D5, the preselected type of coating agent, the material of the substrate 2, the type of nozzle 13, the thickness of the coating layer formed on the substrate 2, the vertical distance between the upper surface of the substrate 2 placed on the table 12 and the lower end surface of the nozzle 13, and the preinput thickness of the substrate 2, coating offset value, and application deviation correction value. Also, as described above, the provisional application range setting data D5 is the same data as the cutting data D3, so the PC 7 creates application data D2 based on the cutting data D3.

[0052] Specifically, the PC 7 first creates application range setting data D6 for setting the application range of the coating agent on the substrate 2 based on the application range provisional setting data D5 and the coating offset value (see Figs. 7(A), 8(A), and 9(A)). In this embodiment, in order to reliably protect the image F printed on the substrate 2 with the coating agent, the PC 7 creates the application range setting data D6 so that the application range of the coating agent on the substrate 2 is wider by the coating offset value than the application range provisionally set in the application range provisional setting data D5.

[0053] For example, if the external shape of the provisional coating range setting data D5 is as shown in Fig. 7(A) and Fig. 9(A) (the shape of the hatched portion), the coating range setting data D6 will be frame-shaped data surrounding the provisional coating range setting data D5. Also, for example, if the external shape of the provisional coating range setting data D5 is annular as shown in Fig. 8(A), the coating range setting data D6 will be annular data with a larger outer diameter and a smaller inner diameter than the provisional coating range setting data D5. The coating offset value is, for example, half the coating interval of the linear coating agent CA.

[0054] Thereafter, PC7 creates a plurality of linear line data (hatched lines) D7 in the area specified by the application range setting data D6 at a predetermined interval specified based on the above-mentioned various information preselected by PC7 and the thickness of the substrate 2 pre-inputted to PC7 (see Fig. 7(B), Fig. 8(B), Fig. 9(B)). The line data D7 is data corresponding to the linear coating agent CA. The interval of the line data D7 corresponds to the application interval of the linear coating agent CA in the front-rear direction. The interval of the line data D7 is determined according to the front-rear width of the linear coating agent CA specified based on the various information preselected by PC7 and the thickness of the substrate 2 pre-inputted to PC7.

[0055] Thereafter, PC7 optimizes the trajectory of the line data D7 to minimize the movement amount of the nozzle 13 (see FIG. 7(C)). Specifically, the line data D7 is made into optimal vector data so that the movement amount of the nozzle 13 is minimized. More specifically, the line data D7 is made into vector data so that the vector directions of adjacent line data D7 in a direction perpendicular to the longitudinal direction of the line data D7 are opposite to each other. Thereafter, PC7 moves the line data D7 in the longitudinal direction of the line data D7 by an amount according to the application deviation correction value inputted in advance to PC7 (see FIG. 7(D)). Specifically, the line data D7, which is vector data, is moved in the opposite direction to the vector direction.

[0056] When the line data D7 is moved, creation of the application data D2 is completed. The application data D2 is composed of the multiple line data D7 after movement. The application data D2 created in this manner includes data on the spray range of the coating agent from the nozzle 13 in the left-right direction for applying the linear coating agent CA to the substrate 2, and data on the application interval of the linear coating agent CA in the front-back direction.

[0057] (Production method in manufacturing system) In the manufacturing system 1, as described above, for example, when a user performs a predetermined operation on the coating and cutting software and the print data is transferred from the PC 7 to the printing device 4, the printing device 4 prints the image F and the alignment mark M on the substrate 2. Thereafter, the user carries the substrate 2 on which the image F and the alignment mark M are printed to the coating device 3 and places it on the table 12. Thereafter, the carriage 15 is moved to a position where the light of the laser pointer mounted on the carriage 15 is irradiated onto the alignment mark M, and the position where the light of the laser pointer is irradiated onto the alignment mark M is recognized by the control unit of the coating device 3, thereby causing the control unit of the coating device 3 to recognize the position of the substrate 2 placed on the table 12, and aligning the substrate 2 placed on the table 12. In this embodiment, the control unit of the coating device 3 is caused to recognize the positions where the light of the laser pointer is irradiated onto one, two, or three alignment marks M.

[0058] Thereafter, the user performs a predetermined operation on the coating / cutting software to transfer the coating data D2 from the PC 7 to the coating device 3. When the coating data D2 is transferred to the coating device 3, the coating device 3 applies the coating agent to the substrate 2 based on the coating data D2. Thereafter, the user carries the substrate 2 to which the coating agent has been applied to the curing device 5 and sets it in the curing device 5, and the coating agent applied to the substrate 2 is cured by the curing device 5.

[0059] Thereafter, the user carries the substrate 2 on which the coating agent has hardened to the cutting device 6 and places it on the table of the cutting device 6. Thereafter, the detection mechanism of the cutting device 6 detects the alignment mark M, thereby causing the control unit of the cutting device 6 to recognize the position of the substrate 2 placed on the table, and aligns the substrate 2 placed on the table of the cutting device 6. Thereafter, the user performs a predetermined operation on the coating and cutting software to transfer cutting data D3 from the PC 7 to the cutting device 6. When the cutting data D3 is transferred to the cutting device 6, the cutting device 6 cuts the substrate 2 into a predetermined shape based on the cutting data D3.

[0060] In the coating device 3, the base material 2 placed on the table 12 may be aligned using a detection mechanism similar to that of the cutting device 6. In the cutting device 6, the base material 2 placed on the table of the cutting device 6 may be aligned using a laser pointer similar to that of the coating device 3.

[0061] (Main effects of this form) As described above, in this embodiment, the PC 7 automatically creates the application data D2 based on the image data D1. Therefore, in this embodiment, the user does not need to create the application data D2. Therefore, in this embodiment, the user can simplify the work of creating data for manufacturing a product in the manufacturing system 1. Also, in this embodiment, the PC 7 automatically creates the cutting data D3 based on the image data D1, and the user does not need to create the cutting data D3. Therefore, in this embodiment, even if the substrate 2 after the coating agent has hardened is cut by the cutting device 6, the user can simplify the work of creating data for manufacturing a product in the manufacturing system 1.

[0062] In this embodiment, since the distance between the substrate 2 and the nozzle 13 varies depending on the thickness of the substrate 2, a change in the thickness of the substrate 2 may cause a change in the width of the linear coating agent CA in the front-rear direction, which may cause a change in the appropriate application interval of the linear coating agent CA in the front-rear direction, but the PC 7 in this embodiment creates application data D2 based on the thickness of the substrate 2 and image data D1 inputted to the PC 7. Therefore, in this embodiment, even if the thickness of the substrate 2 varies, the PC 7 can create appropriate application data D2.

[0063] In this embodiment, the width of the linear coating agent CA in the front-rear direction may vary depending on the type of nozzle 13, and the appropriate application interval of the linear coating agent CA in the front-rear direction may vary, but the PC 7 in this embodiment creates application data D2 based on the type of selected nozzle 13 and image data D1. Therefore, in this embodiment, even if the type of nozzle 13 changes, the PC 7 can create appropriate application data D2.

[0064] In this embodiment, the nozzle 13 starts spraying the coating agent when the moving speed of the carriage 15 in the left-right direction becomes constant. Therefore, in this embodiment, it is possible to suppress the variation in the coating thickness of the linear coating agent CA in the left-right direction. In addition, in this embodiment, since the nozzle 13 sprays the coating agent while moving in the left-right direction, as described above, the spraying position of the coating agent from the nozzle 13 in the left-right direction and the application position of the coating agent on the substrate 2 in the left-right direction are shifted. However, the PC 7 in this embodiment creates the coating data D2 based on the application shift correction value for correcting the shift between the spraying position of the coating agent from the nozzle 13 in the left-right direction and the application position of the coating agent on the substrate 2 in the left-right direction and the image data D1. Therefore, in this embodiment, it is possible to suppress the shift in the application position of the linear coating agent CA in the left-right direction.

[0065] In this embodiment, the printing device 4 prints the alignment mark M on the substrate 2. Therefore, in this embodiment, even if the printing device 4, the coating device 3, and the cutting device 6 are separate devices, it is possible to align the substrate 2 in the coating device 3 and the cutting device 6 using the alignment mark M. Therefore, in this embodiment, it is possible to suppress misalignment between the portion of the substrate 2 where printing is performed, the portion of the substrate 2 where the coating agent is applied, and the portion of the substrate 2 where cutting is performed.

[0066] In this embodiment, the PC 7 creates the application data D2 based on the provisional application range setting data D5, which is the same data as the cutting data D3. Therefore, in this embodiment, it is possible to simplify the data creation process in the PC 7.

[0067] (Other embodiments) The above-described embodiment is one example of a preferred embodiment of the present invention, but the present invention is not limited to this embodiment and various modifications are possible without departing from the spirit and scope of the present invention.

[0068] In the above-described embodiment, the manufacturing system 1 may include one coating device 3 and one printing device 4. That is, the number of coating devices 3 and the number of printing devices 4 included in the manufacturing system 1 may be equal. Also, in the above-described embodiment, an inkjet head that ejects ink toward the substrate 2 may be mounted on the carriage 15 of the coating device 3. That is, the coating mechanism that applies the coating agent to the substrate 2 and the printing mechanism that prints on the substrate 2 may be provided in the same device, and the coating mechanism and the printing mechanism do not have to be separate devices. In this case, the printing device 4 is not necessary.

[0069] Moreover, in the above-described embodiment, an ultraviolet irradiator that irradiates ultraviolet light onto the coating agent applied to the substrate 2 may be mounted on the carriage 15. In this case, the curing device 5 becomes unnecessary. Moreover, in the above-described embodiment, a laser emission unit that emits laser light toward the substrate 2 may be mounted on the carriage 15. In this case, the cutting device 6 becomes unnecessary. Moreover, in the above-described embodiment, if it is not necessary to cut the substrate 2 into a predetermined shape after the coating agent has hardened, the manufacturing system 1 may not be provided with the cutting device 6.

[0070] In the embodiment described above, the application device 3 may apply a coating agent to the substrate 2 before printing is performed by the printing device 4. That is, the printing device 4 may perform printing on a coating layer formed on the substrate 2. In this case, the product manufactured by the manufacturing system 1 may be, for example, a garment such as a T-shirt. In this case, the substrate 2 is made of fabric. In addition, in this case, the substrate 2 is not cut after the coating agent has hardened, so the manufacturing system 1 does not include a cutting device 6. Therefore, the PC 7 does not create cutting data D3.

[0071] Also, in this case, for example, the coating device 3 applies a white coating agent to the substrate 2. In this case, the outer shape of the provisional coating range setting data D5 is smaller than the outer shape of the image data D1 so that the white coating layer does not extend beyond the image F printed by the printing device 4. Also, the outer shape of the provisional coating range setting data D6 is smaller than the outer shape of the provisional coating range setting data D5, for example. That is, the coating offset value becomes a negative value in order to reduce the coating range of the coating agent on the substrate 2.

[0072] In the above-described embodiment, two or more nozzles 13 may be mounted on the carriage 15. In this case, the two or more nozzles 13 are arranged in the front-rear direction. Also, in the above-described embodiment, the coating device 3 may apply a thermosetting coating agent to the substrate 2. In this case, the curing device 5 includes a heating mechanism for heating the coating agent applied to the substrate 2.

[0073] In the above-mentioned embodiment, the nozzle 13 may be an internal mixing type two-fluid nozzle that mixes the coating agent and compressed air inside and sprays the mixed mixture. However, when the nozzle 13 is an external mixing type two-fluid nozzle as in the above-mentioned embodiment, scattering of the coating agent sprayed from the nozzle 13 is easily suppressed, so that it becomes possible to apply a constant amount of the coating agent to the intended position of the substrate 2. Also, in the above-mentioned embodiment, the nozzle 13 may be a one-fluid nozzle that sprays only the coating agent. However, when the nozzle 13 is a two-fluid nozzle, it becomes possible to form a coating layer having a relatively thin thickness on the substrate 2.

[0074] In the above-described embodiment, the front-rear direction may be the first direction, and the left-right direction may be the second direction. In this case, the moving mechanism 21 is the second moving mechanism, and the moving mechanism 22 is the first moving mechanism. In the above-described embodiment, the type of substrate 2 used in the manufacturing system 1 may be one type. In the above-described embodiment, the type of coating agent used in the coating device 3 may be one type, and the type of nozzle 13 used in the coating device 3 may be one type.

[0075] In the above-described embodiment, the moving mechanism 22 may reciprocate the table 12 in the front-rear direction relative to the Y bar 16. Also, in the above-described embodiment, the image data D1 may be created in a personal computer other than the PC 7 and read into the PC 7. Furthermore, in the above-described embodiment, the printing device 4 may be a printing device other than an inkjet printer. [Explanation of symbols]

[0076] 1. Manufacturing System 2 Base material 3 Coating device (coating mechanism) 4 Printing device (printing mechanism) 6 Cutting device (cutting mechanism) 7 PC (host control device) 12 Tables 13 Nozzle 15 Carriage 21 Moving mechanism (first moving mechanism) 22 Moving mechanism (second moving mechanism) D1 Image data D2 Application Data D3 Cutting Data M Alignment mark X 2nd direction Y 1st direction Z vertical direction

Claims

1. The printing apparatus includes a printing mechanism that prints on a substrate, a coating mechanism that coats the substrate with a coating agent, and a host control device to which the printing mechanism and the coating mechanism are electrically connected, If a predetermined direction perpendicular to the up-down direction is defined as a first direction, and a direction perpendicular to the up-down direction and the first direction is defined as a second direction, the coating mechanism includes a nozzle that sprays the coating agent downward toward the substrate, a table on which the substrate is placed, a carriage on which the nozzle is mounted, a first moving mechanism that reciprocates the carriage relatively to the table in a first direction, and a second moving mechanism that reciprocates the carriage relatively to the table in a second direction; When the nozzle that sprays the coating agent is moved once relative to the table in a first direction by the first moving mechanism, a linear coating agent that is a linear coating agent having a longitudinal direction in the first direction is applied to the base material, a coating layer is formed on the substrate by the linear coating agent applied at regular intervals in a second direction; The upper control device creates application data for applying the coating agent to the substrate by the application mechanism based on image data, which is data for an image to be printed on the substrate by the printing mechanism, the application data including data on the spray range of the coating agent from the nozzle in a first direction for applying the linear coating agent to the substrate and data on the application interval of the linear coating agent in a second direction.

2. The thickness of the base material can be input to the upper control device, 2. The manufacturing system according to claim 1, wherein the host controller creates the application data based on the thickness of the base material and the image data inputted to the host controller.

3. The host control device is capable of selecting the type of the nozzle, 3. The manufacturing system according to claim 1, wherein the host control device creates the application data based on the selected nozzle type and the image data.

4. the nozzle starts spraying the coating agent when the moving speed of the carriage in the first direction becomes constant; a coating deviation correction value for correcting a deviation in a first direction between a spray position of the coating agent from the nozzle in a first direction and a coating position of the coating agent on the base material in the first direction, 4. The manufacturing system according to claim 1, wherein the host control device creates the application data based on the application deviation correction value and the image data inputted to the host control device.

5. The printing mechanism and the coating mechanism are separate devices, 5. The manufacturing system according to claim 1, wherein the number of the application mechanisms is smaller than the number of the printing mechanisms.

6. The printing mechanism and the coating mechanism are separate devices, The coating mechanism applies the coating agent to the base material after printing has been performed by the printing mechanism, 6. The manufacturing system according to claim 1, wherein the printing mechanism prints, on the base material, an alignment mark for aligning the base material in the coating mechanism.

7. the printing mechanism prints on the substrate with a plurality of colors of ink; The manufacturing system according to claim 1 , wherein the coating mechanism applies the coating agent of a single color to the substrate.

8. The manufacturing system according to claim 7 , wherein the coating mechanism applies the coating agent, which is transparent, to the substrate.

9. The printing mechanism prints on the base material using ultraviolet-curable ink, 9. The manufacturing system according to claim 1, wherein the coating mechanism applies an ultraviolet-curable coating agent to the base material.

10. a cutting mechanism for cutting the substrate into a predetermined shape after the coating agent has hardened; The cutting mechanism is electrically connected to the upper control device, 10. The manufacturing system according to claim 1, wherein the host control device creates cutting data for cutting the base material by the cutting mechanism based on the image data.

11. 11. The manufacturing system according to claim 10, wherein the host control device creates the application data based on the cutting data.

12. The upper level control device has installed therein software for creating the image data, 12. The manufacturing system according to claim 1, wherein the image data is generated by the host control device.

Images