Laminating device

Abstract

Provided is a means for suppressing a deterioration in bonding quality.　A control unit 90 of a laminating device 1 starts driving of a lamination roller 50 when a tip end P of a first member 101 reaches a drive start position Q. If a conveying operation (S115) causes the tip end P of the first member 101 to reach the drive start position Q before the first member 101 reaches the next recording position (S114: No), instead of the conveying operation, the control unit 90 causes a first conveying roller 41 to execute a first divided conveying operation for performing: first conveying (S116) for conveying the first member 101 until the tip end P reaches the drive start position Q, and then stopping the conveying; and second conveying (S117) for conveying the first member 101 from the position at which the tip end P reached the drive start position Q to the next recording position, and then stopping the conveying.

Description

Laminating equipment

[0001] The present invention relates to a laminating apparatus for laminating a plurality of members together.

[0002] Conventionally, laminating devices that bond a first member having an image recorded thereon to a second member have been known. For example, in the device described in Patent Document 1, a recording medium wound around a recording medium roll is removed, and a print image is formed on the removed recording medium in a printing unit. The recording medium with the print image formed thereon is cut to a predetermined length in a first cutting unit and transported to a laminating unit. Meanwhile, a laminating member is unwound from a laminating member roll and is superimposed on the recording medium by a pair of guide rolls in the laminating unit. The recording medium and laminating member are then heated by a pair of pressure and heating rolls. The recording medium corresponds to the first member, and the laminating member corresponds to the second member.

[0003] Japanese Patent Application Laid-Open No. 2003-211593

[0004] As described above, if the first member (recording medium) on which an image has been recorded in the recording unit is cut to a predetermined length and then transported to the laminating unit, the time required to form the finished laminated product will be long. Therefore, it is conceivable that in the laminating device, while recording is being performed on the first member in the recording unit, two types of members are laminated together using laminating rollers.

[0005] In order to record on the first member in the recording unit, the first member needs to be transported intermittently. However, when the laminating roller starts to drive, the intermittently transported first member does not necessarily stop at a position suitable for lamination. This can cause a large amount of slack in the first member, which can degrade lamination quality.

[0006] The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a means for suppressing deterioration in bonding quality.

[0007] (1) The laminating device of the present invention includes a conveying roller that conveys a first member in a conveying direction, a recording unit that records an image on the first member conveyed by the conveying roller, a laminating roller that bonds the first member on which the image has been recorded by the recording unit to a second member, and a control unit. The control unit causes the recording unit to perform a recording operation to record an image on the first member, causes the conveying roller to perform a conveying operation to convey the first member to a next recording position and stop it, and starts driving the laminating roller when the leading edge of the first member reaches a drive start position, and if the leading edge of the first member reaches the drive start position before the first member reaches the next recording position as a result of the conveying operation, causes the conveying roller to perform a first divided conveying operation instead of the conveying operation, which includes a first conveying operation to convey the first member until the leading edge of the first member reaches the drive start position and stop it, and a second conveying operation to convey the first member from the position where the leading edge of the first member reaches the drive start position to the next recording position and stop it.

[0008] According to the laminating device described above, when the leading edge of the first member reaches the drive start position when the conveying operation is performed, the conveying roller is made to perform the first divided conveying operation instead of the conveying operation, so that the first member is stopped temporarily at a position suitable for bonding before the bonding roller starts to be driven, thereby suppressing a deterioration in bonding quality.

[0009] (2) Preferably, the drive start position may be a position where the leading end of the first member abuts against the laminating roller and where the first member is deflected by a predetermined amount or less.

[0010] (3) Preferably, the laminating device further includes a sensor that detects the leading edge of the first member, and when the sensor detects the leading edge of the first member while the conveying roller is performing the conveying operation, the control unit causes the conveying roller to perform the currently performed conveying operation to the end, calculates a third conveying distance by subtracting a second conveying distance between the sensor and the stop position of the leading edge of the first member from a first conveying distance between the sensor and the drive start position, and, when the conveying distance of the next conveying operation is less than the third conveying distance, causes the conveying roller to perform the conveying operation, and, when the conveying distance of the next conveying operation is equal to or greater than the third conveying distance, causes the conveying roller to perform the first divided conveying operation.

[0011] (4) Preferably, the control unit causes the recording unit to perform either a first recording operation in which an image is recorded in the maximum range possible during one movement in an intersecting direction intersecting the transport direction, or a second recording operation in which an image is recorded in the maximum range during multiple movements in the intersecting direction, and the transport distance caused by the transport operation may be either the distance in the transport direction of the maximum range when the recording unit performs the first recording operation, or the distance in the transport direction of the range in which an image is recorded during one movement in the intersecting direction when the recording unit performs the second recording operation.

[0012] (5) Preferably, the laminating device further includes a sensor that detects the leading edge of the first member, and the control unit may cause the conveying roller to perform a second divided conveying operation that performs a third conveying operation at least twice, in which the first member is conveyed a fifth conveying distance that is shorter than the fourth conveying distance and then stopped, if the conveying distance by the conveying operation is longer than the fourth conveying distance, before the sensor detects the leading edge of the first member, and may cause the conveying roller to perform the conveying operation even if the conveying distance by the conveying operation is longer than the fourth conveying distance, after the sensor detects the leading edge of the first member.

[0013] (6) Preferably, when the sensor detects the leading edge of the first member while the transport roller is performing the third transport, the control unit causes the transport roller to complete the third transport that is currently being performed, calculates a seventh transport distance by subtracting a sixth transport distance between the sensor and a stop position of the leading edge of the first member due to the third transport from a first transport distance between the sensor and the drive start position, and, when the fifth transport distance is less than the seventh transport distance, causes the transport roller to perform the third transport. When the fifth transport distance is equal to or greater than the seventh transport distance, the control unit may cause the transport roller to perform the first divided transport operation, instead of the third transport, which includes a fourth transport that transports the first member until the leading edge of the first member reaches the drive start position and stops it, and a fifth transport that transports the first member from a position where the leading edge of the first member reaches the drive start position to a next recording position and stops it.

[0014] (7) Preferably, when the sensor detects the leading edge of the first member while the transport roller is performing the third transport, the control unit causes the transport roller to perform the third transport that is currently being performed to the end, calculates a seventh transport distance by subtracting a sixth transport distance between the sensor and a stop position of the leading edge of the first member by the third transport from a first transport distance between the sensor and the drive start position, and, when an eighth transport distance that is the remaining transport distance in the second divided transport operation is less than the seventh transport distance, causes the transport roller to perform the second divided transport operation to the end, and, when the eighth transport distance is equal to or greater than the seventh transport distance, causes the transport roller to perform the first divided transport operation that performs a fourth transport that transports and stops the first member until the leading edge of the first member reaches the drive start position and then stops it, and a fifth transport that transports and stops the first member from a position where the leading edge of the first member reaches the drive start position to a next recording position and then stops it.

[0015] (8) Preferably, the laminating device further includes a sensor that detects the leading edge of the first member, and when the sensor detects the leading edge of the first member while the conveying roller is performing the conveying operation, the control unit compares a first conveying distance between the sensor and the drive start position with a second conveying distance between the sensor and a stop position of the leading edge of the first member, and when the first conveying distance is equal to or less than the second conveying distance, causes the conveying roller to perform the conveying operation, and when the first conveying distance is longer than the second conveying distance, causes the stop position to be changed to the drive start position and causes the conveying roller to perform the first divided conveying operation that includes a sixth conveying operation in which the first member is conveyed until the leading edge of the first member reaches the drive start position and is stopped there, and a seventh conveying operation in which the first member is conveyed from the position where the leading edge of the first member reaches the drive start position to a next recording position and is stopped there.

[0016] (9) Preferably, if the recording unit has completed recording of the image on the first member before the leading end of the first member reaches the laminating roller, the control unit may cause the conveying roller to perform an eighth conveyance to convey the first member until the leading end of the first member reaches the laminating roller; and if the recording unit has not completed recording of the image on the first member before the leading end of the first member reaches the laminating roller, the control unit may cause the conveying roller to perform either the conveying operation or the first divided conveying operation.

[0017] (10) Preferably, when the recording unit has not completed recording of the image on the first member after the leading end of the first member reaches the laminating roller, the control unit causes the recording unit to perform the recording operation and causes the conveying roller to perform the conveying operation; and when the first member reaches a first cutting position where a part of the first member including the leading end is cut off before the first member reaches a next recording position, instead of the conveying operation, the control unit causes the conveying roller to perform a third divided conveying operation which performs a ninth conveying of the first member to the first cutting position and stopping it, and a tenth conveying of the first member from the first cutting position to a next recording position and stopping it.

[0018] (11) Preferably, the laminating device further includes a first sensor that detects the leading edge of the first member, and a second sensor that is located upstream of the first sensor in the conveying direction and detects the leading edge of the first member, and the control unit may execute the following processes: detect the leading edge position of the first member based on an output signal of the second sensor; if the recording unit has completed recording of an image on the first member before the first sensor detects the leading edge of the first member, have the conveying rollers convey the first member so that the detected leading edge position is located between the detection position of the first sensor and the laminating rollers; detect and update the leading edge position of the first member based on the output signal of the first sensor; and, after the first sensor has detected the leading edge of the first member, have the conveying rollers convey the first member based on the updated leading edge position.

[0019] (12) A laminating apparatus of the present invention includes a conveying roller that conveys a first member in a conveying direction, a recording unit that records an image on the first member conveyed by the conveying roller, a laminating roller that bonds the first member on which the image has been recorded by the recording unit to a second member, and a control unit. The control unit causes the conveying roller to perform intermittent conveyance that repeats a first conveying operation of conveying the first member after the image has been recorded on the first member in a first portion of the recording unit, starts driving the laminating roller when the leading edge of the first member reaches a drive start position, and, if the leading edge of the first member reaches the drive start position while the conveying roller is repeating the first conveying operation over the first conveying distance, instead of the intermittent conveyance, conveys the first member a second conveying distance that is shorter than the first conveying distance over which the leading edge of the first member reaches the drive start position, and then causes the recording unit to record the image on the first member only in a second portion smaller than the first portion.

[0020] According to the laminating device, when the leading edge of the first member reaches the drive start position during the conveying operation, the conveying rollers are caused to perform the first divided conveying operation instead of the conveying operation, so that the first member is stopped temporarily at a position suitable for lamination before the laminating rollers are driven, thereby preventing a deterioration in lamination quality. Also, after the first member is stopped temporarily, an image can be partially recorded using a part of the recording unit.

[0021] According to the present invention, it is possible to suppress deterioration in bonding quality.

[0022] FIG. 1(A) is an external perspective view of a laminating apparatus 1 according to an embodiment of the present invention, and FIG. 1(B) is a schematic cross-sectional view of a finished laminated product 100 produced by the laminating apparatus 1. FIG. 2 is a longitudinal cross-sectional view of the laminating apparatus 1. FIG. 3 is a block diagram of the laminating apparatus 1. FIG. 4 is a diagram showing a cutting position of a first member 101 in the laminating apparatus 1. FIG. 5 is a flowchart of a laminating process executed by the control unit 90 of the laminating apparatus 1. FIG. 6 is a flowchart of a process executed by the control unit 90 of the laminating apparatus 1 to convey the first member 101 to the next recording position. FIG. 7 is a flowchart of a process executed by the control unit 90 of the laminating apparatus 1 to convey the first member 101 to the third trailing edge cutting position. FIG. 8(A) is a flowchart of a process executed by the control unit 90 of the laminating apparatus 1 to convey the first member 101 to the rewinding position. FIG. 8B is a flowchart of the process of conveying the sheet to the second trailing edge cutting position, which is executed by the control unit 90 of the laminating apparatus 1. FIG. 9 is a flowchart of the leading edge detection post-processing, which is executed by the control unit 90 of the laminating apparatus 1. FIG. 10A is a diagram showing an example of the first divided conveying operation by the control unit 90 of the laminating apparatus 1. FIG. 10B is a diagram showing the drive start position Q of the laminating apparatus 1. FIG. 11 is a diagram showing an example of the first divided conveying operation in the case of small amount conveying by the control unit 90 of the laminating apparatus 1. FIG. 12A is a diagram showing the case where dx>d1 in the laminating apparatus 1. FIG. 12B is a diagram showing the first conveying method executed by the control unit 90 of the laminating apparatus 1 when dx>d1. FIG. 12C is a diagram showing the first conveying method executed by the control unit 90 of the laminating apparatus 1 when dx>d1. FIG. 12(D) is a diagram showing another conveying method executed by the control unit 90 of the laminating apparatus 1 when dx>d1. FIG. 13 is a flowchart of the leading edge detection post-processing executed by the control unit 90 of the laminating apparatus 1 when dx>d1. FIG. 14(A) is the same as FIG. 12(A). FIG. 14(B) is a diagram showing a second conveying method executed by the control unit 90 of the laminating apparatus 1 when dx>d1. FIG. 15(A) is a diagram showing a first conveying method in the case of skip conveying executed by the control unit 90 of the laminating apparatus 1. FIG. 15(B) is a diagram showing a second conveying method in the case of skip conveying executed by the control unit 90 of the laminating apparatus 1.FIG. 16 is a diagram showing an image recording area in a laminating device according to a first modified example.

[0023] The following describes a laminating apparatus 1 according to an embodiment of the present invention. The embodiment described below is merely an example of the present invention, and it goes without saying that the embodiment of the present invention can be modified as appropriate without departing from the spirit and scope of the present invention. In the following description, the direction of travel is expressed as the direction from the start point of an arrow to the end point, and the direction of travel on the line connecting the start point and end point of an arrow. Furthermore, the up-down direction 7 is defined based on the state in which the laminating apparatus 1 is installed and ready for use (the state shown in FIG. 1A ). The front-to-back direction 8 is defined with the surface on which the operation unit 12 and display unit 13 are provided as the front. The left-to-right direction 9 is defined when viewing the laminating apparatus 1 from the front. The up-to-down direction 7, the front-to-back direction 8, and the left-to-right direction 9 are perpendicular to one another.

[0024] [Overview of Laminating Apparatus 1] As shown in Fig. 1(A), the laminating apparatus 1 according to this embodiment has a rectangular parallelepiped housing 11. An operation unit 12 and a display unit 13 are located on the front of the housing 11. An outlet 14 is located on the front of the housing 11 below the operation unit 12 and the display unit 13. The laminating apparatus 1 bonds two types of members together to create a finished laminated product 100.

[0025] A tape-like first member 101 and a tape-like second member 102 are supplied to the laminating apparatus 1. As shown in Fig. 2 , the first member 101 is wound around a cylindrical core material 113 to form a first roll 111. The second member 102 is wound around a cylindrical core material 114 to form a second roll 112. The first roll 111 and the second roll 112 are mounted in a first holder 21 and a second holder 22 of the laminating apparatus 1, respectively.

[0026] The first member 101 is, for example, a transparent film. As shown in Fig. 1(B) , the second member 102 is a member having an adhesive layer on at least one surface. The second member 102 is, for example, a backing sheet having a first adhesive layer 103 on one surface of a tape layer 104 (the surface facing the first member 101 in the finished laminate 100) and a second adhesive layer 105 on the other surface of the tape layer 104. A release sheet 106 is provided on the opposite side of the tape layer 104 with the second adhesive layer 105 sandwiched therebetween.

[0027] The first member 101 and the second member 102 may be made of any material. The second member 102 may be made of, for example, a resin material such as PET or PVC (polyvinyl chloride), synthetic paper such as Yupo paper (registered trademark), or a metal material. The second member 102 may be transparent or opaque. The first member 101 and the second member 102 may have an adhesive layer on one surface, an adhesive layer on the other surface, or both surfaces, or neither surface may have an adhesive layer. When a material without an adhesive layer is used, the first member 101 and the second member 102 may be bonded together after an adhesive is applied, or may be bonded together by heat welding, pressure bonding, or the like.

[0028] 2 , the recording surface 107 is the surface of the first member 101 on which an image is recorded. The back surface 108 is the surface of the first member 101 opposite the recording surface 107. The bonding surface 109 is the surface of the second member 102 that has the first adhesive layer 103.

[0029] The laminating device 1 bonds the first member 101 and the second member 102 by bringing the recording surface 107 of the first member 101 into close contact with the bonding surface 109 of the second member 102. The laminating device 1 cuts the bonded members to a predetermined size. This creates a finished laminated product 100 shown in FIG. 1(B). The created finished laminated product 100 is discharged from the discharge port 14.

[0030] As shown in FIG. 2, the laminating apparatus 1 includes a first holder 21, a second holder 22, a recording unit 30, first to third conveying rollers 41 to 43, an intermediate roller 44, a laminating roller 50, a first cutting unit 61, a second cutting unit 62, and member sensors 65 and 66 within a housing 11. Additionally, the laminating apparatus 1 includes a control unit 90 and various motors within the housing 11 (see FIG. 3). Guide members (not shown) that support the first member 101 are provided at necessary positions within the housing 11. This forms a conveying path 15 that runs from the first holder 21 through the recording unit 30, the first cutting unit 61, and the laminating roller 50 to the second cutting unit 62.

[0031] [First holder 21 and second holder 22] The first holder 21 and the second holder 22 are members that can rotate around an axis extending in the left-right direction 9. The thickness of the first holder 21 is equal to the inner diameter of the core material 113 of the first roll 111. The thickness of the second holder 22 is equal to the inner diameter of the core material 114 of the second roll 112. The first holder 21 and the second holder 22 are fixed to the housing 11 or a member fixed to the housing 11.

[0032] The first holder 21 and the second holder 22 are located at positions spaced apart from each other within the housing 11. In the configuration shown in Fig. 2, the first holder 21 is located near the center of the housing 11 in the up-down direction 7 and at the rear of the housing 11 in the front-rear direction 8. The second holder 22 is located at the top of the housing 11 in the up-down direction 7 and forward of the center of the housing 11 in the front-rear direction 8. The positions of the first holder 21 and the second holder 22 within the housing 11 are arbitrary.

[0033] Before the laminating apparatus 1 operates, a first roll 111 is attached to the first holder 21, and a second roll 112 is attached to the second holder 22. The first holder 21 rotatably supports the first roll 111. The second holder 22 rotatably supports the second roll 112. The first member 101 is pulled out from the first roll 111 supported by the first holder 21. The second member 102 is pulled out from the second roll 112 supported by the second holder 22.

[0034] A force acting in a direction to wind up the first member 101 is applied to the first holder 21 from a first roll motor 81 (see FIG. 3 ). A force acting in a direction to wind up the second member 102 is applied to the second holder 22 from a second roll motor 82 (see FIG. 3 ).

[0035] [Recording Unit 30] The recording unit 30 is located downstream of the first roll 111 on the transport path 15. The recording unit 30 is located above the transport path 15 in the up-down direction 7 and between the first roll 111 and the first cutting unit 61 in the front-rear direction 8. The recording unit 30 includes a carriage 31 and a recording head 32. Two guide rails (not shown) are located inside the housing 11, extending in the left-right direction 9 and having both ends fixed to the housing 11 or to members fixed to the housing 11. The carriage 31 is placed on the two guide rails. The carriage 31 receives driving force from a CR motor 85 (see FIG. 3 ) and moves in the left-right direction 9.

[0036] The recording head 32 is mounted on a carriage 31. A plurality of nozzles 33 are formed on the underside of the recording head 32. As the carriage 31 moves, the recording head 32 moves in the left-right direction 9. A platen 34 is located below the range of movement of the carriage 31. While moving in the left-right direction 9, the recording head 32 ejects ink downward from the nozzles 33 based on image data supplied from a control unit 90. As a result, an image based on the image data is recorded on a recording surface 107 of the first member 101 transported over the platen 34.

[0037] [First to third transport rollers 41 to 43 and intermediate roller 44] The first to third transport rollers 41 to 43 and the intermediate roller 44 are located between the first roll 111 and the laminating roller 50. The intermediate roller 44 and the first transport roller 41 are located between the first roll 111 and the recording unit 30 in the front-to-rear direction 8. The second transport roller 42 and the third transport roller 43 are located between the recording unit 30 and the laminating roller 50 in the front-to-rear direction 8. The first transport roller 41 is located in front of the intermediate roller 44 in the front-to-rear direction 8. The third transport roller 43 is located in front of the second transport roller 42 in the front-to-rear direction 8.

[0038] The first conveying rollers 41 include a first roller 411 and a second roller 412. The first roller 411 is located directly above the second roller 412. The first member 101 passes between the first roller 411 and the second roller 412. At this time, the first roller 411 abuts against the recording surface 107 of the first member 101, and the second roller 412 abuts against the back surface 108 of the first member 101. As a result, the first conveying rollers 41 grip the first member 101.

[0039] The second roller 412 receives a driving force from the conveying motor 83 (see FIG. 3 ) and rotates about an axis extending in the left-right direction 9. Accordingly, the first roller 411 also rotates about an axis extending in the left-right direction 9. At this time, a force in a direction pulling the first member 101 from the first roll 111 acts on the first member 101. Furthermore, the second roller 412 receives a driving force in the opposite direction from the conveying motor 83 and rotates in the reverse direction, and accordingly the first roller 411 also rotates in the reverse direction. At this time, a force in a direction moving the first member 101 closer to the first roll 111 acts on the first member 101.

[0040] The second conveyor rollers 42 include a third roller 421 and a fourth roller 422. The third conveyor rollers 43 include a fifth roller 431 and a sixth roller 432. The intermediate rollers 44 include a seventh roller 441 and an eighth roller 442. The configurations and functions of the second conveyor rollers 42, the third conveyor rollers 43, and the intermediate rollers 44 are the same as those of the first conveyor rollers 41, and therefore will not be described here.

[0041] Here, of the two rollers included in the first to third conveyor rollers 41 to 43 and the intermediate roller 44, the lower roller receives driving force from the conveyor motor 83. Alternatively, the upper roller may receive driving force from the conveyor motor 83, or both the upper and lower rollers may receive driving force from the conveyor motor 83. Also, it is not necessary for all of the first to third conveyor rollers 41 to 43 and the intermediate roller 44 to receive driving force from the conveyor motor 83. The first to third conveyor rollers 41 to 43 and the intermediate roller 44 may each receive driving force independently from a different motor, or may receive driving force from a motor that drives a motor other than the motor that drives the first to third conveyor rollers 41 to 43 and the intermediate roller 44.

[0042] [Laminating Roller 50] The laminating roller 50 is located downstream of the recording unit 30 on the conveying path 15. The laminating roller 50 is located between the first cutting unit 61 and the second cutting unit 62 in the front-rear direction 8. The laminating roller 50 includes a first laminating roller 51 and a second laminating roller 52. The first laminating roller 51 is located directly above the second laminating roller 52. The first laminating roller 51 and the second laminating roller 52 grip the first member 101 and the second member 102 with a predetermined force. As a result, the first member 101 and the second member 102 are bonded together to form the finished laminate 100.

[0043] The second member 102 pulled out from the second roll 112 enters between the first laminating roller 51 and the second laminating roller 52. At this time, the laminating surface 109 of the second member 102 faces downward. The first member 101 that has passed through the recording unit 30 and the first cutting unit 61 enters below the second member 102 between the first laminating roller 51 and the second laminating roller 52. At this time, the recording surface 107 of the first member 101 faces upward.

[0044] The second laminating roller 52 receives a driving force from a laminating motor 84 (see FIG. 3 ) and rotates about an axis extending in the left-right direction 9. Accordingly, the first laminating roller 51 also rotates about an axis extending in the left-right direction 9. The first laminating roller 51 and the second laminating roller 52 bond the first member 101 and the second member 102 together by bringing the recording surface 107 of the first member 101 and the laminating surface 109 of the second member 102 into close contact with each other. Note that the first laminating roller 51 may receive a driving force from the laminating motor 84, or both the first laminating roller 51 and the second laminating roller 52 may receive a driving force from the laminating motor 84.

[0045] Furthermore, the laminating roller 50 does not necessarily have to bond the first member 101 and the second member 102. For example, if the laminating apparatus 1 has a section downstream of the laminating roller 50 where thermal welding or pressure bonding is performed, the laminating roller 50 is a roller pair disposed in front of the section and which overlaps the first member 101 and the second member 102.

[0046] [First Cutting Unit 61 and Second Cutting Unit 62] The first cutting unit 61 is located downstream of the recording unit 30 on the conveying path 15. The first cutting unit 61 is located above the conveying path 15 in the up-down direction 7 and between the second conveying roller 42 and the laminating roller 50 in the front-rear direction 8. The first cutting unit 61 cuts the first member 101 between the second conveying roller 42 and the laminating roller 50. The second cutting unit 62 is located downstream of the laminating roller 50 on the conveying path 15. The second cutting unit 62 is located above the conveying path 15 in the up-down direction 7 and in front of the laminating roller 50 in the front-rear direction 8. The second cutting unit 62 simultaneously cuts the first member 101 and the second member 102 that have been bonded together by the laminating roller 50.

[0047] The first cutting unit 61 has any configuration capable of cutting the first member 101. The second cutting unit 62 has any configuration capable of cutting the first member 101 and the second member 102. The first cutting unit 61 and the second cutting unit 62 may include, for example, a cutter carriage that receives driving force from a cutting motor 86 (see FIG. 3 ) and moves in the left-right direction 9, and a cutter mounted on the cutter carriage, or may include a movable blade that receives driving force from the cutting motor 86 and moves in the up-down direction 7, and a fixed blade facing the movable blade.

[0048] [Component sensors 65, 66] The component sensors 65, 66 detect the leading edge P of the first component 101 being conveyed along the conveying path 15. The component sensor 65 is located above the conveying path 15 in the up-down direction 7, and between the intermediate roller 44 and the first conveying roller 41 in the front-rear direction 8. The component sensor 66 is located above the conveying path 15 in the up-down direction 7, and between the third conveying roller 43 and the laminating roller 50 in the front-rear direction 8. The component sensor 66 is located upstream of the laminating roller 50 in the front-rear direction 8.

[0049] The member sensor 65 includes a light-emitting element (not shown) that emits light toward the recording surface 107 of the first member 101 transported along the transport path 15, and a light-receiving element (not shown) that receives light reflected by the recording surface 107 of the first member 101. When the first member 101 is present below the member sensor 65, the light-receiving element of the member sensor 65 receives light reflected by the recording surface 107 of the first member 101, and the amount of light detected by the light-receiving element is greater than the threshold. On the other hand, when the first member 101 is not present below the member sensor 65, the light-receiving element of the member sensor 65 does not receive light reflected by the recording surface 107 of the first member 101, and the amount of light detected by the light-receiving element is less than the threshold. The member sensor 66 has the same configuration and function as the member sensor 65.

[0050] Here, the member sensors 65, 66, each including a light-emitting element and a light-receiving element, are provided above the transport path 15, but such member sensors 65, 66 may also be provided below the transport path 15. The member sensors 65, 66 may also be contact sensors that are provided on the left or right of the transport path 15 and come into contact with the left or right end of the first member 101 to detect the end of the first member 101. The member sensor 65 may also be a so-called media sensor mounted on the carriage 31.

[0051] [Control Unit 90 and Its Peripheral Parts] As shown in Figure 3, the control unit 90 includes a CPU 91, a ROM 92, a RAM 93, and an EEPROM 94. The ROM 92 stores programs for controlling various operations of the laminating device 1. The EEPROM 94 stores various data used when the above programs are executed. The RAM 93 is used as a storage area for temporarily recording various data used when the CPU 91 executes the above programs, and as an area for expanding data and programs. When the laminating device 1 is powered on, the programs stored in the ROM 92 are copied and transferred to the RAM 93. The CPU 91 executes the programs stored in the RAM 93. This allows the control unit 90 to perform various controls.

[0052] The ASIC 95 is connected to the operation unit 12 and the display unit 13. The operation unit 12 detects when an operation key is pressed and outputs a signal corresponding to the pressed operation key. The control unit 90 identifies the pressed operation key based on the output signal from the operation unit 12. The display unit 13 displays information related to the operation of the laminating device 1 on its screen based on instructions from the control unit 90.

[0053] The recording head 32 is connected to the ASIC 95. The control unit 90 outputs a signal corresponding to image data to the recording head 32 via the ASIC 95. The recording head 32 ejects ink from a plurality of nozzles 33 provided in the recording head 32 in response to the signal output from the control unit 90.

[0054] Component sensors 65 and 66 are connected to the ASIC 95. The component sensors 65 and 66 output signals corresponding to the amount of light detected by the light receiving elements. The control unit 90 detects the leading edge P of the first component 101 being conveyed along the conveying path 15 based on the output signals of the light receiving elements.

[0055] [Various Motors] The first roll motor 81, the second roll motor 82, the conveying motor 83, the laminating motor 84, the CR motor 85, and the cutting motor 86 are connected to the ASIC 95. Drive circuits for controlling these motors are incorporated into the ASIC 95. The control unit 90 outputs drive signals for rotating each motor to the drive circuits corresponding to each motor. The drive circuits output drive currents corresponding to the drive signals output from the control unit 90 to the corresponding motors. This causes the corresponding motors to rotate. Note that some of the above motors may be configured using the same motor.

[0056] The first roll motor 81 generates power to rotate the first roll 111 supported by the first holder 21. The second roll motor 82 generates power to rotate the second roll 112 supported by the second holder 22. The CR motor 85 generates a force to move the carriage 31 in the left-right direction 9. The cutting motor 86 generates a force to operate the first cutting unit 61 and the second cutting unit 62.

[0057] The conveyor motor 83 generates power to rotate the first to third conveyor rollers 41 to 43 and the intermediate roller 44. The power generated by the conveyor motor 83 is applied to the second roller 412, the fourth roller 422, the sixth roller 432, and the eighth roller 442. The second roller 412, the fourth roller 422, the sixth roller 432, and the eighth roller 442 receive power from the conveyor motor 83 and rotate around their central axes in the left-right direction 9. Accordingly, the first roller 411, the third roller 421, the fifth roller 431, and the seventh roller 441 also rotate around their central axes in the left-right direction 9.

[0058] A rotary encoder 87 is attached to the rotation shaft of the second roller 412. The rotary encoder 87 outputs a signal corresponding to the amount of rotation of the second roller 412. The control unit 90 obtains the amount of rotation of the first conveyor roller 41 based on the output signal of the rotary encoder 87. Note that the rotary encoder 87 may be attached to the rotation shaft of the first roller 411. The amount of rotation of the first conveyor roller 41 can be detected by the rotary encoder 87.

[0059] A rotary encoder 88 is attached to the rotation shaft of the eighth roller 442. The rotary encoder 88 outputs a signal corresponding to the amount of rotation of the eighth roller 442. The control unit 90 obtains the amount of rotation of the intermediate roller 44 based on the output signal of the rotary encoder 88. Note that the rotary encoder 88 may also be attached to the rotation shaft of the seventh roller 441. The amount of rotation of the intermediate roller 44 can be detected by the rotary encoder 88.

[0060] The laminating motor 84 is, for example, a stepping motor. The laminating motor 84 generates power to rotate the laminating roller 50. The power generated by the laminating motor 84 is applied to the second laminating roller 52. A torque limiter 89 is interposed between the laminating motor 84 and the laminating roller 50. The torque limiter 89 is attached to, for example, the rotation shaft of the second laminating roller 52. The torque limiter 89 limits the power of the laminating motor 84 and transmits it to the rotation shaft of the second laminating roller 52. The amount of rotation of the laminating roller 50 can be controlled by the stepping motor.

[0061] The control unit 90 drives the conveying motor 83 to rotate the first to third conveying rollers 41 to 43 and the intermediate roller 44, and drives the laminating motor 84 to rotate the laminating roller 50. The control unit 90 drives the first roll motor 81 to apply force to the first roll 111, and drives the second roll motor 82 to apply force to the second roll 112. The control unit 90 drives the CR motor 85 to move the carriage 31, and drives the cutting motor 86 to operate the first cutting unit 61 and the second cutting unit 62.

[0062] In the laminating apparatus 1, the first to third conveying rollers 41 to 43 and the intermediate roller 44 convey the first member 101 in the conveying direction (front-rear direction 8). The recording unit 30 records an image on the first member 101 conveyed by the first to third conveying rollers 41 to 43 and the intermediate roller 44. The laminating roller 50 bonds the first member 101, on which the image has been recorded by the recording unit 30, to the second member 102. The first conveying roller 41 is an example of a conveying roller. The member sensor 66 is an example of a sensor and a first sensor. The member sensor 65 is an example of a second sensor.

[0063] [Cutting Positions of First Member 101] The following describes a case where the laminating apparatus 1 continuously produces multiple finished laminated products 100. The range of the first member 101 that corresponds to one finished laminated product 100 is referred to as the "recording range," and the leading edge P (downstream end) of the first member 101 is referred to as the "leading edge P." For example, when continuously producing three finished laminated products 100, the first member 101 is cut at five cutting positions shown in FIG. 4. In FIG. 4, the horizontal direction of the drawing is the conveyance direction of the first member 101, and the first member 101 is conveyed from left to right within the drawing. The conveyance direction of the first member 101 coincides with the front-rear direction 8.

[0064] The five cutting positions are classified into four types. The leading edge cutting position C0 is located between the most downstream recording area in the conveying direction of the first member 101 (recording area #1 in FIG. 4) and the first margin adjacent to that recording area downstream in the conveying direction. The first trailing edge cutting position C1 is located between two adjacent recording areas in the conveying direction of the first member 101 (recording areas #1 and #2, and recording areas #2 and #3 in FIG. 4). The second trailing edge cutting position C2 is located between the most upstream recording area in the conveying direction of the first member 101 (recording area #3 in FIG. 4) and the second margin adjacent to that recording area upstream in the conveying direction. The third trailing edge cutting position C3 is located upstream of the most upstream recording area in the conveying direction of the first member 101.

[0065] The first cutting unit 61 cuts the first member 101 at the third rear end cutting position C3. The second cutting unit 62 cuts the first member 101 at the leading end cutting position C0, the first rear end cutting position C1, and the second rear end cutting position C2. When the laminating apparatus 1 continuously produces N sheets of laminated finished products 100 (N is an integer of 2 or greater), the number of leading end cutting positions C0, the second rear end cutting positions C2, and the third rear end cutting positions C3 is one each, and the number of first rear end cutting positions C1 is (N-1).

[0066] [Laminating Process by Control Unit 90] The control unit 90 executes the laminating process shown in Figures 5 to 8. The laminating process is executed by the CPU 91 executing a program stored in the RAM 93. Note that the second conveying roller 42 and the third conveying roller 43 play a small role in the laminating process, and therefore, a description of the second conveying roller 42 and the third conveying roller 43 will be omitted below.

[0067] During lamination processing, the control unit 90 updates the count value stored in RAM 93 based on the output signal of the rotary encoder 87 (FIG. 3), and obtains the amount of rotation of the first conveying roller 41 and the position of the leading edge P of the first member 101 on the conveying path 15 based on the count value. Based on the obtained position of the leading edge P, the control unit 90 determines the area on the first member 101 where an image is recorded in one recording, and positions on the conveying path 15 such as the leading edge cutting position C0, the first trailing edge cutting position C1, the second trailing edge cutting position C2, and the third trailing edge cutting position C3.

[0068] Before the lamination process is performed, the first member 101 pulled out from the first roll 111 is held only by the intermediate roller 44, and the leading end P of the first member 101 is located between the intermediate roller 44 and the first conveying roller 41. The leading end of the second member 102 pulled out from the second roll 112 is held by the laminating roller 50. In addition, the laminating roller 50 holds a part of the first member 101 that was generated in the previous lamination process.

[0069] At the beginning of the lamination process, the control unit 90 determines whether a print instruction has been received (S11). If a print instruction has been received (S11: Yes), the control unit 90 proceeds to S12, and if a print instruction has not been received (S11: No), the control unit 90 proceeds to S11.

[0070] Next, the control unit 90 drives the intermediate roller 44 to transport the first member 101 until the leading edge P reaches the first transport roller 41 (S12). Next, the control unit 90 drives the first transport roller 41 to transport the first member 101 to the first recording position (S13). In S13, the control unit 90 transports the first member 101 until the first recording area of ​​the first member 101 (the area where an image is recorded in the first pass) is positioned in the recording area of ​​the recording unit 30.

[0071] Next, the control unit 90 drives the recording unit 30 to record an image in a predetermined range on the first member 101 (S14). In S14, the control unit 90 causes the recording head 32 to eject ink onto the recording surface 107 of the first member 101. As a result, an image is recorded on the portion of the first member 101 facing the recording head 32.

[0072] Next, the control unit 90 determines whether or not to end image recording (S15). In S15, the control unit 90 determines that image recording is to end when images have been recorded in all recording areas corresponding to the finished laminate product 100 to be created. If the control unit 90 does not end image recording (S15: No), it proceeds to S16. In this case, the control unit 90 executes a process ( FIG. 6 ) of driving the first conveyance roller 41 to convey the first member 101 to the next recording position (S16). In S16, the control unit 90 conveys the first member 101 until the next recording area of ​​the first member 101 (the area where an image will be recorded in the next pass) is positioned in the recording area of ​​the recording unit 30. Next, the control unit 90 proceeds to S14.

[0073] If the control unit 90 determines in S15 that the image recording is to be completed (S15: Yes), the control unit 90 proceeds to S17. In this case, the control unit 90 executes a process (FIG. 7) in which the control unit 90 drives the first conveying roller 41 to convey the first member 101 until the third trailing end cutting position C3 reaches the cutting position of the first cutting unit 61 (S17).

[0074] Next, the control unit 90 executes a process (FIG. 8A) in which the first conveyance roller 41 is driven to convey the upstream side of the first member 101 cut at the third trailing end cutting position C3 until the leading edge P reaches the rewinding position (S21). In parallel with this, the control unit 90 executes a process (FIG. 8B) in which the laminating roller 50 is driven to convey the downstream side of the first member 101 cut at the third trailing end position C3 until the second trailing end cutting position C2 reaches the cutting position of the second cutting unit 62 (S22). The rewinding position is a position where the first member 101 is rewound until the leading edge P reaches this position, and is located between the intermediate roller 44 and the first conveyance roller 41. After executing S21 and S22, the control unit 90 proceeds to S23.

[0075] Next, the control unit 90 determines whether recording can be started (S23). In S23, the control unit 90 determines whether both the first conveying roller 41 and the laminating roller 50 can execute the next print instruction based on output signals from sensors (not shown) etc. If recording can be started (S23: Yes), the control unit 90 proceeds to S11, and if recording cannot be started (S23: No), the control unit 90 proceeds to S23.

[0076] [Process of Conveying to the Next Printing Position] At the beginning of the process of conveying to the next printing position ( FIG. 6 ), the control unit 90 starts driving the first conveying rollers 41 (S31). Thereafter, the conveyance of the first member 101 is controlled by the first conveying rollers 41. Next, the control unit 90 determines whether the first member 101 has reached the next printing position (S32).

[0077] If the first member 101 has not reached the next recording position (S32: No), the control unit 90 proceeds to S33. In this case, the control unit 90 determines whether the member sensor 66 has detected the tip P of the first member 101 (S33).

[0078] If the member sensor 66 detects the leading edge P (S33: Yes), the control unit 90 proceeds to S34. In this case, the control unit 90 switches the method for acquiring the position of the leading edge P of the first member 101 (S34). In S34, the control unit 90 resets the count value, which is updated based on the output signal of the rotary encoder 87. From this point on, the control unit 90 determines the amount of rotation of the first conveyance roller 41, i.e., the conveyance amount of the first member 101, based on the count value after the reset. Therefore, the control unit 90 performs future conveyance and position control based on the more accurate position of the leading edge P of the first member 101 detected by the member sensor 66. Next, the control unit 90 proceeds to S32.

[0079] If the member sensor 66 does not detect the tip P of the first member 101 in S33 (including a state after the tip P has already been detected) (S33: No), the control unit 90 proceeds to S35. In this case, the control unit 90 determines whether the tip cutting position C0 of the first member 101 has reached the cutting position of the second cutting unit 62 (S35).

[0080] If the leading edge cutting position C0 has reached the second cutting unit 62 (S35: Yes), the control unit 90 proceeds to S36. In this case, the control unit 90 stops driving the first conveyor roller 41 (S36). This stops the first member 101. Next, the control unit 90 drives the second cutting unit 62 to cut the stopped first member 101 at the leading edge cutting position C0 (S37). Next, the control unit 90 proceeds to S31.

[0081] If the leading edge cutting position C0 has not reached the second cutting unit 62 in S35 (S35: No), the control unit 90 proceeds to S38. In this case, the control unit 90 determines whether the first trailing edge cutting position C1 of the first member 101 has reached the cutting position of the second cutting unit 62 (S38).

[0082] If the first trailing end cutting position C1 has reached the second cutting unit 62 (S38: Yes), the control unit 90 proceeds to S39. In this case, the control unit 90 stops the conveyance of the first conveyance roller 41 (S39). This stops the first member 101. Next, the control unit 90 drives the second cutting unit 62 to cut the stopped first member 101 at the first trailing end cutting position C1 (S40). Next, the control unit 90 proceeds to S31.

[0083] If the first trailing end cutting position C1 has not reached the second cutting unit 62 in S38 (S38: No), the control unit 90 proceeds to S41. In this case, the control unit 90 determines whether the leading end P of the first member 101 has reached the drive start position Q (see FIG. 10 ) (S41). The drive start position Q is the position at which the control unit 90 starts driving the laminating roller 50 when the leading end P of the first member 101 reaches that position.

[0084] If the leading edge P of the first member 101 has reached the drive start position Q (S41: Yes), the control unit 90 proceeds to S42. In this case, the control unit 90 stops driving the first conveying roller 41 (S42). This stops the first member 101. Next, the control unit 90 starts driving the laminating roller 50 (S43). Next, the control unit 90 proceeds to S31. If the leading edge P of the first member 101 has not reached the drive start position Q in S41 (S41: No), the control unit 90 proceeds to S32.

[0085] After the laminating roller 50 starts to be driven in S43, when the first conveyance roller 41 starts to be driven in S31, the laminating roller 50 is in a state of gripping the first member 101. Therefore, the first member 101 is in a state of straddling the first conveyance roller 41 and the laminating roller 50. When driving the laminating roller 50 in S31, the control unit 90 applies a driving force to the laminating roller 50 such that the laminating roller 50 conveys the first member 101 at a speed faster than the conveyance speed at which the first conveyance roller 41 conveys the first member 101. The laminating roller 50 is provided with a torque limiter 89 so that the laminating roller 50 cannot convey the first member 101 faster than the conveyance speed at which the first conveyance roller 41 conveys the first member 101. As a result, the first member 101 is conveyed such that the conveyance position is controlled by the first conveyance roller 41 while maintaining tension on the first member 101 between the first conveyance roller 41 and the laminating roller 50.

[0086] If the first member 101 reaches the next recording position in S32 (S32: Yes), the control unit 90 proceeds to S44. In this case, the control unit 90 stops driving the first conveying roller 41 (S44). This stops the first member 101. Next, the control unit 90 ends the process of conveying the first member 101 to the next recording position.

[0087] [Process for Conveying to the Third Trailing End Cutting Position] At the beginning of the process for conveying the first member 101 to the third trailing end cutting position C3 ( FIG. 7 ), the control unit 90 starts driving the first conveyance rollers 41 (S51). Thereafter, the conveyance of the first member 101 is controlled by the first conveyance rollers 41. Next, the control unit 90 determines whether the third trailing end cutting position C3 of the first member 101 has reached the cutting position of the first cutting unit 61 (S52).

[0088] If the third rear end cutting position C3 has not reached the first cutting unit 61 (S52: No), the control unit 90 proceeds to S53. In this case, the control unit 90 determines whether the leading end cutting position C0 of the first member 101 has reached the cutting position of the second cutting unit 62 (S53).

[0089] If the leading edge cutting position C0 has reached the second cutting unit 62 (S53: Yes), the control unit 90 proceeds to S54. In this case, the control unit 90 stops driving the first conveyor roller 41 (S54). This stops the first member 101. Next, the control unit 90 drives the second cutting unit 62 to cut the stopped first member 101 at the leading edge cutting position C0 (S55). Next, the control unit 90 proceeds to S51.

[0090] If the leading edge cutting position C0 has not reached the second cutting unit 62 in S53 (S53: No), the control unit 90 proceeds to S56. In this case, the control unit 90 determines whether the first trailing edge cutting position C1 of the first member 101 has reached the cutting position of the second cutting unit 62 (S56).

[0091] If the first trailing end cutting position C1 has reached the second cutting unit 62 (S56: Yes), the control unit 90 proceeds to S57. In this case, the control unit 90 stops the conveyance of the first conveyance roller 41 (S57). This stops the first member 101. Next, the control unit 90 drives the second cutting unit 62 to cut the stationary first member 101 at the first trailing end cutting position C1 (S58). Next, the control unit 90 proceeds to S51.

[0092] If the first trailing end cutting position C1 has not reached the second cutting unit 62 in S56 (S56: No), the control unit 90 proceeds to S59. In this case, the control unit 90 determines whether the leading end P of the first member 101 has reached the drive start position Q (S59).

[0093] If the leading edge P of the first member 101 has reached the drive start position Q (S59: Yes), the control unit 90 proceeds to S60. In this case, the control unit 90 stops driving the first conveying roller 41 (S60). This stops the first member 101. Next, the control unit 90 starts driving the laminating roller 50 (S61). Next, the control unit 90 proceeds to S51. If the leading edge P of the first member 101 has not reached the drive start position Q in S59 (S59: No), the control unit 90 proceeds to S52.

[0094] After the laminating roller 50 starts to be driven in S61, when the first conveyance roller 41 starts to be driven in S31, the laminating roller 50 is in a state of gripping the first member 101. Therefore, the first member 101 is in a state of straddling the first conveyance roller 41 and the laminating roller 50. When driving the laminating roller 50 in S61, the control unit 90 applies a driving force to the laminating roller 50 such that the laminating roller 50 conveys the first member 101 at a speed faster than the conveyance speed at which the first conveyance roller 41 conveys the first member 101. The laminating roller 50 is provided with a torque limiter 89 so that the laminating roller 50 cannot convey the first member 101 faster than the conveyance speed at which the first conveyance roller 41 conveys the first member 101. As a result, the first member 101 is conveyed such that the conveyance position is controlled by the first conveyance roller 41 while maintaining tension on the first member 101 between the first conveyance roller 41 and the laminating roller 50.

[0095] If the third trailing end cutting position C3 has reached the first cutting unit 61 in S52 (S52: Yes), the control unit 90 proceeds to S62. In this case, the control unit 90 stops driving the first conveying roller 41 (S62). Next, the control unit 90 stops driving the laminating roller 50 (S63). This stops the first member 101. Next, the control unit 90 drives the first cutting unit 61 to cut the stopped first member 101 at the third trailing end cutting position C3 (S64). Next, the control unit 90 ends the process of conveying the first member 101 to the third trailing end cutting position C3.

[0096] [Process for Conveying to Rewind Position] At the beginning of the process for conveying to the rewind position ( FIG. 8A ), the control unit 90 starts driving the first conveyance roller 41 (S71). In S71, the control unit 90 drives the first conveyance roller 41 in the reverse direction. After this, the first member 101 (the upstream side of the first member 101 cut at the third trailing end cutting position C3) is rewound toward the first roll 111.

[0097] Next, the control unit 90 determines whether the tip P of the first member 101 has reached the rewinding position (S72). If the tip P has reached the rewinding position (S72: Yes), the control unit 90 proceeds to S73, and if the tip P has not reached the rewinding position (S72: No), the control unit 90 proceeds to S72.

[0098] Next, the control unit 90 stops driving the first transport roller 41 (S73), thereby stopping the first member 101. Next, the control unit 90 ends the process of transporting the sheet to the rewinding position.

[0099] [Process of Conveying to Second Trailing End Cutting Position] At the start of the process of conveying to the second trailing end cutting position C2 ( FIG. 8B ), the control unit 90 starts driving the laminating roller 50 (S80). Thereafter, the conveyance of the first member 101 is controlled by the laminating roller 50. Next, the control unit 90 determines whether the second trailing end cutting position C2 of the first member 101 (downstream of the first member 101 cut at the third trailing end cutting position C3) has reached the cutting position of the second cutting unit 62 (S81).

[0100] If the second rear end cutting position C2 has not reached the second cutting unit 62 (S81: No), the control unit 90 proceeds to S82. In this case, the control unit 90 determines whether the leading end cutting position C0 of the first member 101 has reached the cutting position of the second cutting unit 62 (S82).

[0101] If the leading edge cutting position C0 has reached the second cutting unit 62 (S82: Yes), the control unit 90 proceeds to S83. In this case, the control unit 90 stops driving the laminating roller 50 (S83). This stops the first member 101. Next, the control unit 90 drives the second cutting unit 62 to cut the stopped first member 101 at the leading edge cutting position C0 (S84). Next, the control unit 90 proceeds to S81.

[0102] If the leading edge cutting position C0 has not reached the second cutting unit 62 in S82 (S82: No), the control unit 90 proceeds to S85. In this case, the control unit 90 determines whether the first trailing edge cutting position C1 of the first member 101 has reached the cutting position of the second cutting unit 62 (S85).

[0103] If the first trailing end cutting position C1 has reached the second cutting unit 62 (S85: Yes), the control unit 90 proceeds to S86. In this case, the control unit 90 stops driving the laminating roller 50 (S86). This stops the first member 101. Next, the control unit 90 drives the second cutting unit 62 to cut the stopped first member 101 at the first trailing end cutting position C1 (S87). Next, the control unit 90 proceeds to S81. If the first trailing end cutting position C1 has not reached the second cutting unit 62 in S85 (S85: No), the control unit 90 proceeds to S81.

[0104] If the second trailing end cutting position C2 has reached the first cutting unit 61 in S81 (S81: Yes), the control unit 90 proceeds to S88. In this case, the control unit 90 stops driving the laminating roller 50 (S88). This stops the first member 101. Next, the control unit 90 drives the second cutting unit 62 to cut the stopped first member 101 at the second trailing end cutting position C2 (S89). Next, the control unit 90 ends the process of conveying the first member 101 to the second trailing end cutting position C2.

[0105] In the laminating process, the control unit 90 causes the recording unit 30 to perform a recording operation to record an image on the first member 101 (S14), and causes the first conveying roller 41 to perform a conveying operation to convey and stop the first member 101 to the next recording position (S16). When the leading edge P of the first member 101 reaches the drive start position Q (S41, S59: Yes), the control unit 90 stops driving the first conveying roller 41 (S42, S60), and after stopping the first member 101, starts driving the laminating roller 50 (S43, S61).

[0106] 9 after the member sensor 66 detects the leading edge P of the first member 101 (after S33: Yes), in order to stop the first member 101 at a position where the leading edge P is located at the drive start position Q. In the leading edge detection post-processing, if the leading edge P of the first member 101 reaches the drive start position Q by the transport operation before the first member 101 reaches the next recording position, the control unit 90 causes the first transport roller 41 to perform a first divided transport operation that performs a first transport and a second transport instead of the transport operation.

[0107] More specifically, in the control (S16) for conveying the first member 101 to the next recording position, the first conveyance roller 41 starts conveying the first member 101 (S31), and when the leading edge P of the first member 101 reaches the drive start position Q (S41: Yes) before the first member 101 reaches the next recording position (S32: No), the driving of the first conveyance roller 41 is stopped (S42). These operations constitute the first conveyance. After the first conveyance, the first conveyance roller 41 resumes conveying the first member 101 (S31), and when the first member 101 reaches the next recording position (S32: Yes), the first conveyance roller 41 is stopped (S44). These operations constitute the second conveyance. In other words, the control that does not perform S42 between S31 and S44 constitutes the conveyance operation, and the control that performs S42 between S31 and S44 constitutes the first divided conveyance operation.

[0108] The following describes a case where it is not necessary to stop conveying during the conveying operation and the first divided conveying operation. In other words, a case where, during the operation of conveying to the next recording position (S16), the leading edge cutting position C0 does not reach the second cutting section 62 and the first trailing edge cutting position C1 does not reach the second cutting section 62 (S35, S38: No) will be described.

[0109] Hereinafter, the distance along the conveying path 15 is referred to as the "conveying distance," and the conveying distance between the member sensor 66 and the drive start position Q is denoted as d1, and the conveying distance in the next conveying operation is denoted as dx (see FIG. 10). Here, it is assumed that the conveying distance dx is equal to or less than the conveying distance d1.

[0110] At the beginning of the leading edge detection post-processing, the control unit 90 causes the first conveyance roller 41 to complete the ongoing conveyance operation (S111). Next, the control unit 90 acquires the conveyance distance d1 between the member sensor 66 and the drive start position Q, the conveyance distance d2 between the member sensor 66 and the stop position of the leading edge P of the first member 101, and the conveyance distance dx of the next conveyance operation (S112). Next, the control unit 90 calculates the conveyance distance d3 by subtracting the conveyance distance d2 from the conveyance distance d1 (S113).

[0111] Next, the control unit 90 determines whether the conveying distance dx is less than the conveying distance d3 (S114). If the conveying distance dx is less than the conveying distance d3 (S114: Yes), the control unit 90 proceeds to S115. In this case, the leading edge P of the first member 101 will not reach the drive start position Q by the next conveying operation. Therefore, the control unit 90 drives the first conveying roller 41 to convey the first member 101 from the current position to the next recording position (S115). In S115, the control unit 90 sets the conveying amount to dx and drives the first conveying roller 41, thereby conveying the first member 101 from the current position to the next recording position and stopping it. Next, the control unit 90 proceeds to S112.

[0112] If the conveying distance dx is equal to or greater than the conveying distance d3 in S114 (S114: No), the control unit 90 proceeds to S116. In this case, the leading edge P of the first member 101 will reach or pass the drive start position Q in the next conveying operation. Therefore, the control unit 90 drives the first conveying rollers 41 to convey the first member 101 from the current position to a position where the leading edge P reaches the drive start position Q (S116). In S116, the control unit 90 sets the conveying amount to d3 and drives the first conveying rollers 41 to convey the first member 101 from the current position to a position where the leading edge P reaches the drive start position Q, and then stops the first member 101.

[0113] Next, the control unit 90 drives the first conveyance roller 41 to convey the first member 101 from the position where the leading edge P reaches the drive start position Q to the next recording position (S117). In S117, the control unit 90 sets the conveyance amount to (dx-d3) and drives the first conveyance roller 41 to convey the first member 101 from the position where the leading edge P reaches the drive start position Q to the next recording position and stop the first member 101. Next, the control unit 90 ends the leading edge detection post-processing.

[0114] Although not shown in Figure 9, after executing S116, the control unit 90 drives the laminating roller 50, and after executing S115 or S117, drives the recording unit 30 to record an image in a predetermined range of the first member 101.

[0115] An example of the first divided conveying operation will be described with reference to Fig. 10. In the example shown in Fig. 10, the conveying distance dx is less than the conveying distance d1. Also, assume that the leading edge P of the first member 101 passes the position of the member sensor 66 by the Nth conveying operation and passes the drive start position Q by the (N+1)th conveying operation.

[0116] At the beginning of the leading edge detection post-processing, the control unit 90 causes the first conveyance roller 41 to execute the Nth conveyance operation to the end. Next, the control unit 90 acquires the conveyance distances d1, d2, and dx and calculates the conveyance distance d3. Because the conveyance distance dx is equal to or greater than the conveyance distance d3, the control unit 90 causes the first conveyance roller 41 to execute a first divided conveyance operation that performs a first conveyance and a second conveyance, instead of the (N+1)th conveyance operation. In the first conveyance, the control unit 90 sets the conveyance amount to d3 and drives the first conveyance roller 41, stopping the first member 101 at a position where the leading edge P is located at the drive start position Q. In the second conveyance, the control unit 90 sets the conveyance amount to (dx-d3) and drives the first conveyance roller 41, stopping the first member 101 at the next recording position.

[0117] 10B , the drive start position Q is located a predetermined amount forward of the laminating roller 50 in the front-rear direction 8 (a predetermined amount downstream in the conveying direction). The drive start position Q is a position where the leading edge P of the first member 101 contacts the laminating roller 50 and where a deflection 121 of a predetermined amount or less is formed in the first member 101. Note that the drive start position Q does not necessarily have to be located a predetermined amount forward of the laminating roller 50 in the front-rear direction 8. In other words, the drive start position Q may be located a predetermined amount rearward of the laminating roller 50 in the front-rear direction 8 (a predetermined amount upstream in the conveying direction). In this case, the drive start position Q may be a position where the leading edge P of the first member 101 does not contact the laminating roller 50.

[0118] The transport distances d1, d2, and d3 are examples of the first transport distance, the second transport distance, and the third transport distance, respectively. S115, S116, and S117 are examples of the transport operation, the first transport, and the second transport, respectively.

[0119] [Divided Conveyance of First Member 101 (Small-Amount Conveyance)] The first conveyance roller 41 may convey the first member 101 by a standard conveyance amount or by a smaller conveyance amount. Hereinafter, the former is referred to as "normal conveyance" and the latter is referred to as "small-amount conveyance." During normal conveyance, the first member 101 is conveyed in increments of the size of the nozzle region of the recording head 32 in the conveyance direction (hereinafter referred to as "head size"). In this case, the recording unit 30 records an image in the maximum range in which it can be recorded during one movement in the left-right direction 9.

[0120] The first member 101 is conveyed by small-amount conveyance in increments of an amount smaller than the head size. The first member 101 is conveyed by small-amount conveyance in increments of, for example, 1 / A of the head size. In this case, the recording unit 30 records an image in the maximum range while moving multiple times in the left-right direction 9. The control unit 90 switches between normal conveyance and small-amount conveyance to be performed by the first conveyance roller 41 at any timing. Note that small-amount conveyance includes single conveyance, multi-pass conveyance, etc.

[0121] The control unit 90 executes the leading edge detection post-processing ( FIG. 9 ) not only in the case of normal conveyance but also in the case of small-amount conveyance. An example of the first divided conveyance operation in the case of small-amount conveyance will be described with reference to FIG. 11 . In the example shown in FIG. 11 , the conveyance distance dx is less than the conveyance distance d1, and the leading edge P of the first member 101 passes the position of the member sensor 66 by the Nth conveyance operation and passes the drive start position Q by the (N+10)th conveyance operation.

[0122] At the beginning of the leading edge detection post-processing, the control unit 90 causes the first conveyance roller 41 to perform the Nth conveyance operation to the end. Before each conveyance operation, the control unit 90 acquires conveyance distances d1, d2, and dx and calculates conveyance distance d3. Before the (N+1)th to (N+9)th conveyance operations, the conveyance distance dx is less than the conveyance distance d3, so the control unit 90 sets the conveyance amount to dx and drives the first conveyance roller 41. During the (N+1)th to (N+9)th conveyance operations, the control unit 90 conveys the first member 101 to the next recording position and stops it.

[0123] Before the (N+10)th conveying operation, the conveying distance dx is greater than the conveying distance d3, so the control unit 90 causes the first conveying roller 41 to execute a first divided conveying operation that performs a first conveying and a second conveying, instead of the (N+10)th conveying operation. In the first conveying, the control unit 90 sets the conveying amount to d3 and drives the first conveying roller 41, and stops the first member 101 at a position where the leading edge P of the first member 101 is located at the drive start position Q. In the second conveying, the control unit 90 sets the conveying amount to (dx-d3) and drives the first conveying roller 41, and stops the first member 101 at the next recording position.

[0124] The printing operation during standard conveyance is an example of a first printing operation. The printing operation during small conveyance is an example of a second printing operation. The head size is an example of the distance in the conveyance direction within which an image is printed in one printing operation during the first printing operation.

[0125] [Divided Conveyance of First Member 101 (When dx>d1)] The following describes the case where the conveying distance dx is greater than the conveying distance d1. When dx>d1, the leading edge P of the first member 101 may exceed both the position of the member sensor 66 and the drive start position Q in a single conveying operation (see FIG. 12A). In this case, even if the leading edge detection post-processing shown in FIG. 9 is performed without any special ingenuity, the first member 101 cannot be stopped at a position where the leading edge P is located at the drive start position Q. Below, two types of conveying methods that solve this problem will be described.

[0126] The first conveying method is a method in which the conveying distance dx is divided to make the conveying distance dx equal to or less than d1. In FIG. 12B , the conveying distance dy, which is half of the conveying distance dx, is assumed to be less than d1. The control unit 90 causes the first conveying rollers 41 to perform a second divided conveying operation in which the third conveying operation is performed twice until the member sensor 66 detects the leading edge P of the first member 101. In the third conveying operation, the control unit 90 sets the conveying amount to dy and drives the first conveying rollers 41 to convey the first member 101 by the conveying distance dy at a time.

[0127] 13 after the member sensor 66 detects the leading edge P of the first member 101. In the leading edge detection post-processing, if the leading edge P of the first member 101 reaches the drive start position Q by the third conveyance before the first member 101 reaches the next recording position, the control unit 90 causes the first conveyance roller 41 to perform a first divided conveyance operation that performs a fourth conveyance and a fifth conveyance instead of the third conveyance.

[0128] At the beginning of the leading edge detection post-processing, the control unit 90 causes the first conveyance rollers 41 to complete the currently executing third conveyance (S211). Next, the control unit 90 acquires the conveyance distance d1 between the member sensor 66 and the drive start position Q, the conveyance distance d6 between the member sensor 66 and the stop position of the leading edge P of the first member 101 by the third conveyance, and the conveyance distance dx of the next conveyance operation (S212). Next, the control unit 90 calculates the conveyance distance d7 by subtracting the conveyance distance d6 from the conveyance distance d1 (S213).

[0129] Next, the control unit 90 determines whether the conveying distance dy is less than the conveying distance d7 (S214). If the conveying distance dy is less than the conveying distance d7 (S214: Yes), the control unit 90 proceeds to S215. In this case, the control unit 90 sets the conveying amount to dy and drives the first conveying roller 41 to convey the first member 101 from the current position to the next stop position by the third conveyance and stop the first member 101 (S215). Next, the control unit 90 proceeds to S212.

[0130] If the conveying distance dy is equal to or greater than d7 in S214 (S214: No), the control unit 90 proceeds to S216. In this case, the control unit 90 sets the conveying amount to d7 and drives the first conveying roller 41 to convey and stop the first member 101 from the current position to a position where the leading edge P reaches the drive start position Q (S216).

[0131] Next, the control unit 90 sets the transport amount to (dy-d7) and drives the first transport roller 41 to transport the first member 101 from the position where the leading edge P reaches the drive start position Q to the next recording position, where the first member 101 stops (S217). Next, the control unit 90 ends the leading edge detection post-processing. After the leading edge detection post-processing is completed, the control unit 90 causes the first transport roller 41 to execute a transport operation. In the transport operation, the control unit 90 sets the transport amount to dx and drives the first transport roller 41 to transport the first member 101 by a transport distance dx. By the first transport method, the first member 101 is transported while stopping in order at positions Pa, Pm, Q, Pb, and Pc shown in FIG. 12B.

[0132] The first conveying method described above is a method of dividing the conveying distance dx to make it equal to or less than the conveying distance d1. Here, the conveying distance in the first conveying using the conveying distance dy is dy1, and the conveying distance in the second conveying is dy2. Control may be changed depending on whether the leading edge P of the first member 101 reaches the drive start position Q after the first conveying using the conveying distance dy1 or the leading edge P of the first member 101 reaches the drive start position Q after the second conveying using the conveying distance dy2. When the leading edge P of the first member 101 reaches the drive start position Q after the first conveying, the control unit 90 may set the conveying amount to (dx - d7) in S217 and convey the first member 101.

[0133] More specifically, when the conveying distance dy is used, there are cases where the leading edge P of the first member 101 exceeds the drive start position Q by an even-numbered conveying operation (a conveying operation using the conveying distance dy1) ( FIG. 12B ), and cases where the leading edge P of the first member 101 exceeds the drive start position Q by an odd-numbered conveying operation (a conveying operation using the conveying distance dy2) ( FIG. 12C ). In the former case, the control unit 90 sets the conveying amount to (dy-d7) in S217. In the latter case, the control unit 90 sets the conveying amount to (dx-d7) in S217. As a result, the first member 101 is conveyed while the leading edge P is stopped in order at positions Pa, Q, Pb, and Pc shown in FIG. 12C .

[0134] Note that, when the leading edge P of the first member 101 passes the drive start position Q by the first transport operation, the control unit 90 may, in S217, set the transport amount to (dy1-d7) and drive the first transport rollers 41 to transport and stop the first member 101 to the stop position by the third transport, and after S217, set the transport amount to dy and drive the first transport rollers 41 to transport and stop the first member 101 from the stop position by the third transport to the next recording position. As a result, the first member 101 is transported while stopping in order at positions Pa, Q, Pm, Pb, and Pc shown in FIG. 12(D).

[0135] In the first conveying method, the conveying distance dx may be divided into three or more portions. In this case, the control unit 90 causes the first conveying roller 41 to perform a second divided conveying operation in which the third conveying operation is performed at least twice until the member sensor 66 detects the leading edge P of the first member 101. S215, S216, and S217 are examples of the third conveying operation, the fourth conveying operation, and the fifth conveying operation, respectively. Conveying distances d1, dy, d6, and d7 are examples of the fourth conveying operation, the fifth conveying operation, the sixth conveying operation, and the seventh conveying operation, respectively.

[0136] The second transport method is a method in which the transport target position is changed when the member sensor 66 detects the leading end P of the first member 101. The transport target position is a position to which the leading end P of the first member 101 should reach by the transport operation. Note that in the second transport method, the transport distance dx is not changed. The transport target position is an example of a stop position.

[0137] Fig. 14A shows the same content as Fig. 12A. As shown in the upper part of Fig. 14B, the control unit 90 starts driving the first conveyance roller with a conveyance amount of dx in the Nth conveyance operation. The target conveyance position at this time is position T that is dx away downstream in the conveyance direction from the current position of the leading edge P of the first member 101.

[0138] When the member sensor 66 detects the leading edge P of the first member 101 during the Nth transport operation, the control unit 90 compares the transport distance d1 with the remaining transport distance d2. If the transport distance d1 is equal to or less than the transport distance d2, the control unit 90 causes the first transport roller 41 to perform the Nth transport operation currently being performed. If the transport distance d1 is longer than the transport distance d2, the control unit 90 changes the transport amount of the Nth transport operation currently being performed from dx to d1 and continues the transport (middle part of FIG. 14B ). As a result, the transport target position is changed from position T to drive start position Q.

[0139] If the conveyance distance d1 is longer than the conveyance distance d2, the control unit 90 changes the conveyance target position to the drive start position Q and causes the first conveyance roller 41 to execute a first divided conveyance operation that performs a sixth conveyance and a seventh conveyance. In the sixth conveyance, the control unit 90 causes the first conveyance roller 41 to convey the first member 101 from the current position until the leading edge P of the first member 101 reaches the drive start position Q and then stop the first member 101. In the seventh conveyance, the control unit 90 causes the first member 101 to be conveyed from the position where the leading edge of the first member 101 reaches the drive start position Q to the next recording position and then stop the first member 101. By the second conveyance method, the first member 101 is conveyed while stopping in order at positions Pa, Q, Pb, and Pc shown in the lower part of FIG. 14B .

[0140] [Divided Conveyance of First Member 101 (in the Case of Skip Conveyance)] When image data supplied to the recording unit 30 includes a blank area having a certain length in the conveyance direction, it is not necessary to stop the first member 101 at a position where the blank area is located in the recording area of ​​the recording unit 30. Therefore, the control unit 90 detects the blank area included in the image data and conveys the first member 101 so as to skip the blank area. Hereinafter, this conveyance will be referred to as "skip conveyance," and the conveyance distance by skip conveyance will be denoted as ds. The control unit 90 switches the conveyance performed by the first conveyance roller 41 to skip conveyance at any timing.

[0141] If the conveying distance ds is greater than the conveying distance d1, the leading edge P of the first member 101 may exceed the position of the member sensor 66 and the drive start position Q in one skip conveyance. In this case, even if the leading edge detection post-processing shown in FIG. 9 is performed without any special measures, the first member 101 cannot be stopped at a position where the leading edge P is located at the drive start position Q. As with the case where dx>d1, this problem can be solved by using two types of conveying methods.

[0142] The first conveying method is a method of dividing the conveying distance ds to make it equal to or less than the conveying distance d1. In the example shown in FIG. 15A, the conveying distance ds is divided into conveying distances d1 each. The control unit 90 causes the first conveying rollers 41 to perform a second divided conveying operation in which the third conveying is performed at least twice until the member sensor 66 detects the leading edge P of the first member 101. In the third conveying, the control unit 90 sets the conveying amount to d1 and drives the first conveying rollers 41 to convey the first member 101 by the conveying distance d1 each time.

[0143] When the member sensor 66 detects the leading edge P of the first member 101, the control unit 90 executes the same leading edge detection post-processing as in Fig. 13. The leading edge detection post-processing in this case is the same as the leading edge detection post-processing shown in Fig. 13 except that the conveying distance d1 is used instead of the conveying distance dy. By the first conveying method, the first member 101 is conveyed while stopping in order at positions Pa, Pb, Q, and Ps shown in Fig. 15(A).

[0144] The second conveying method is a method in which the conveyance target position is changed when the member sensor 66 detects the leading edge of the first member 101. In the Nth conveying operation, the control unit 90 starts driving the first conveying roller 41 with a conveyance amount ds (upper part of FIG. 15B ). The conveyance target position at this time is a position Ps that is separated by ds downstream in the conveying direction from the current position of the leading edge P of the first member 101.

[0145] When the member sensor 66 detects the leading edge P of the first member 101 during the Nth transport operation and the transport distance d1 is longer than the transport distance d2, the control unit 90 changes the transport amount of the Nth transport operation being performed from ds to d1 (middle part of FIG. 15B). As a result, the transport target position is changed from position Ps to drive start position Q. By the second transport method, the first member 101 is transported while stopping in order at positions Pa, Q, and Ps shown in the bottom part of FIG. 15B.

[0146] So far, we have described the divided conveyance of the first member 101 in the cases of normal conveyance, small amount conveyance, dx>d1, and skip conveyance. If the conveyance distance in the next conveyance operation is equal to or less than the conveyance distance d1 between the member sensor 66 and the drive start position Q, the control unit 90 executes the leading edge detection post-processing shown in Figures 9 and 13, and if the conveyance distance in the next conveyance operation is greater than the conveyance distance d1, the control unit 90 executes the first drive method or the second drive method described above. The content of the processing executed by the control unit 90 is the same regardless of whether normal conveyance, small amount conveyance, or skip conveyance is being performed.

[0147] [Conveying the first member 101 to the laminating roller 50] In the laminating apparatus 1, the recording unit 30 may complete recording of an image on the first member 101 before the leading edge P of the first member 101 reaches the laminating roller 50. In this case, it is necessary to convey the first member 101 until the leading edge P reaches the laminating roller 50. Therefore, if the recording unit 30 completes recording of an image on the first member 101 before the leading edge P of the first member 101 reaches the laminating roller 50, the control unit 90 causes the first conveyance roller 41 to perform an eighth conveyance, which conveys the first member 101 until the leading edge P of the first member 101 reaches the laminating roller 50.

[0148] In addition, if the recording unit 30 has not completed recording of the image on the first member 101 before the tip P of the first member 101 reaches the lamination roller 50, the control unit 90 causes the first conveying roller 41 to perform either a conveying operation or a first divided conveying operation.

[0149] [Divided Conveyance Related to Leading Edge Cutting Position C0] The control unit 90 stops the first member 101 not only at a position where the leading edge P is located at the drive start position Q, but also at a position where the leading edge cutting position C0 is located at the cutting position of the second cutting unit 62. Therefore, the control unit 90 performs the same process for the leading edge cutting position C0 as for the drive start position Q. Hereinafter, the position of the first member 101 when the leading edge cutting position C0 of the first member 101 is located at the cutting position of the second cutting unit 62 will be referred to as the "first cutting position." The first cutting position is a position where a portion of the leading edge is cut off.

[0150] If the recording unit 30 has not completed recording an image on the first member 101 after the tip P of the first member 101 reaches the laminating roller 50, the control unit 90 causes the recording unit 30 to perform the recording operation and the first conveying roller 41 to perform the conveying operation.

[0151] If the first member 101 reaches the first cutting position before reaching the next recording position, the control unit 90 causes the first conveying roller 41 to perform a third divided conveying operation, instead of a conveying operation, which includes a ninth conveying operation in which the first member 101 is conveyed to the first cutting position and stopped there, and a tenth conveying operation in which the first member 101 is conveyed from the first cutting position to the next recording position and stopped there.

[0152] The ninth conveyance in the third divided conveyance operation is the same as the first conveyance (S116) in the first divided conveyance operation, and the tenth conveyance in the third divided conveyance operation is the same as the second conveyance (S117) in the first divided conveyance operation, so detailed explanation of the third divided conveyance operation will be omitted here.

[0153] [Transporting the first member 101 to the member sensor 65] As described above, the laminating apparatus 1 is equipped with member sensors 65, 66 that detect the leading edge P of the first member 101. The member sensor 65 is located upstream in the transport direction of the member sensor 66. When the first member 101 is transported along the transport path 15, the member sensor 66 detects the leading edge P of the first member 101, and then the member sensor 65 detects the leading edge P of the first member 101.

[0154] The control unit 90 executes a process of detecting the leading edge P of the first member 101 based on the output signal of the member sensor 66, and a process of detecting and updating the leading edge P of the first member 101 based on the output signal of the member sensor 65. After the member sensor 66 detects the leading edge P of the first member 101, the control unit 90 executes a process of causing the first conveyance rollers 41 to convey the first member 101 based on the updated position of the leading edge P of the first member.

[0155] In the laminating apparatus 1, the recording unit 30 may complete recording of an image on the first member 101 before the member sensor 66 detects the leading edge P of the first member 101. In this case, the control unit 90 executes a process of causing the first conveying roller 41 to convey the first member 101 so that the position of the leading edge P of the first member 101 detected by the member sensor 65 is located between the detection position of the member sensor 66 and the laminating roller 50.

[0156] [Effects of the embodiment] As described above, the laminating apparatus 1 according to the present embodiment includes the recording unit 30, the first conveying roller 41 (conveying roller), the laminating roller 50, the control unit 90, the member sensor 66 (sensor, first sensor), and the member sensor 65 (second sensor). The control unit 90 causes the recording unit 30 to perform a recording operation (S14), causes the first conveying roller 41 to perform a conveying operation (S16), and starts driving the laminating roller 50 (S43, S61) when the leading edge P of the first member 101 reaches the drive start position Q (S41, S59: Yes). If the tip P of the first member 101 reaches the drive start position Q (S114: No) before the first member 101 reaches the next recording position through the conveying operation (S115), the control unit 90 causes the first conveying roller 41 to perform a first divided conveying operation that performs a first conveying operation (S116) and a second conveying operation (S117) instead of the conveying operation.

[0157] Therefore, according to the laminating device 1 of this embodiment, when the leading end P of the first member 101 reaches the drive start position Q when the conveying operation is performed, the first conveying roller 41 performs the first divided conveying operation instead of the conveying operation, thereby stopping the first member 101 at a position suitable for bonding and then starting to drive the bonding roller 50, thereby suppressing a deterioration in bonding quality.

[0158] The drive start position Q is a position where the leading end P of the first member 101 contacts the laminating roller 50 and where a deflection 121 of a predetermined amount or less is formed in the first member 101 (FIG. 10B). Therefore, by temporarily stopping the first member 101 at a position where an appropriate amount of deflection is formed, it is possible to prevent a deterioration in the lamination quality of the finished laminate 100.

[0159] Furthermore, when the member sensor 66 detects the leading end P of the first member 101 while the first conveyance roller 41 is performing a conveyance operation, the control unit 90 causes the first conveyance roller 41 to complete the ongoing conveyance operation (S111), calculates a conveyance distance d3 (third conveyance distance) by subtracting the conveyance distance d2 (second conveyance distance) from the conveyance distance d1 (first conveyance distance), and, when the conveyance distance dx of the next conveyance operation is less than the conveyance distance d3 (S114: Yes), causes the first conveyance roller 41 to perform the conveyance operation (S115), and when the conveyance distance dx is equal to or greater than the conveyance distance d3, causes the first conveyance roller 41 to perform the first divided conveyance operation (S116, S117). Therefore, by calculating the conveyance distance d3 and comparing it with the conveyance distance dx of the next conveyance operation, it is possible to select whether to perform the conveyance operation or the first divided conveyance operation.

[0160] Furthermore, the control unit 90 causes the recording unit 30 to perform either a recording operation during standard transport (first recording operation) or a recording operation during small-amount transport (second recording operation) as a recording operation, and the transport distance dx of the transport operation is either the head size (the distance in the transport direction within the range where an image is recorded in one recording during the first recording operation) or 1 / A of the head size (the distance in the transport direction within the range where an image is recorded in one recording during the second recording operation). Therefore, whether the recording unit 30 performs a recording operation during standard transport or a recording operation during small-amount transport, the first member 101 can be temporarily stopped at a position suitable for lamination, thereby preventing a deterioration in the lamination quality of the finished laminate product 100.

[0161] In addition, when the control unit 90 executes the first conveying method shown in Figure 12 (B), before the member sensor 66 detects the tip P of the first member 101, if the conveying distance dx by the conveying operation is longer than the conveying distance d1 (fourth conveying distance), the control unit 90 causes the first conveying roller 41 to execute a second divided conveying operation in which the third conveying is performed at least twice, in which the first member 101 is conveyed a conveying distance dy (fifth conveying distance) shorter than the conveying distance dx and then stopped, and after the member sensor 66 detects the tip P of the first member 101, the control unit 90 causes the first conveying roller 41 to execute the conveying operation even if the conveying distance dx by the conveying operation is longer than the conveying distance d1. Therefore, before the component sensor 66 detects the leading edge P of the first component 101, if the conveying distance dx is long, the first component 101 can be conveyed a shorter conveying distance dy and then stopped, thereby temporarily stopping the first component 101 at a position suitable for lamination and suppressing a deterioration in the lamination quality of the finished laminate 100. After the component sensor 66 detects the leading edge P of the first component 101, even if the conveying distance dx is long, the first component 101 can be conveyed without delay by the conveying operation. The same applies when the control unit 90 executes the first conveying method shown in FIG. 15(A).

[0162] Furthermore, when the control unit 90 executes the first conveying method shown in FIG. 12 (B), if the member sensor 66 detects the leading end P of the first member 101 while the first conveying roller 41 is executing the third conveying, the control unit 90 causes the first conveying roller 41 to execute the currently executing third conveying to the end (S211), calculates the conveying distance d7 (seventh conveying distance) by subtracting the conveying distance d6 (sixth conveying distance) from the conveying distance d1 (S213), and if the conveying distance dy is less than the conveying distance d7 (S214: Yes), causes the first conveying roller 41 to execute the third conveying (S215). If the conveying distance dy is equal to or greater than the conveying distance d7 (S214: No), causes the first conveying roller 41 to execute a first divided conveying operation in which a fourth conveying (S216) and a fifth conveying (S217) are executed instead of the third conveying. Therefore, when the leading edge P of the first member 101 reaches the drive start position Q, the first conveyance roller 41 is caused to perform the first divided conveyance operation instead of the third conveyance, thereby stopping the first member 101 at a position suitable for lamination and preventing a decrease in the lamination quality of the finished laminate 100. The same applies when the control unit 90 executes the first conveyance method shown in Fig. 15(A).

[0163] After calculating the conveying distance d7, the control unit 90 may execute the second divided conveying operation to the end if the eighth conveying distance, which is the remaining conveying distance in the second divided conveying operation, is less than the conveying distance d7, or may execute the first divided conveying operation, which includes the fourth and fifth conveying operations, on the first conveying rollers 41 if the eighth conveying distance is equal to or greater than the conveying distance d7. This provides a similar effect.

[0164] 14B , when the component sensor 66 detects the leading edge P of the first component 101 while the first conveyor roller 41 is performing the conveying operation, the control unit 90 compares the conveying distance d1 with the conveying distance d2, and if the conveying distance d1 is equal to or less than the conveying distance d2, causes the first conveyor roller 41 to perform the conveying operation. If the conveying distance d1 is greater than the conveying distance d2, the control unit 90 changes the conveying target position (stop position) to the drive start position Q and causes the first conveyor roller 41 to perform the first divided conveying operation, which performs the sixth and seventh conveyances. Therefore, when the leading edge P of the first component 101 reaches the drive start position Q, the control unit 90 changes the conveying target position to the drive start position Q and causes the first conveyor roller 41 to perform the first divided conveying operation, thereby stopping the first component 101 at a position suitable for lamination and preventing a deterioration in the lamination quality of the finished laminate 100.

[0165] Furthermore, if the recording unit 30 has completed recording of an image on the first member 101 before the leading edge P of the first member 101 reaches the laminating roller 50, the control unit 90 causes the first conveyance roller 41 to perform the eighth conveyance (conveyance of conveying the first member 101 until the leading edge P reaches the laminating roller 50), and if the recording unit 30 has not completed recording of an image on the first member 101 before the leading edge P of the first member 101 reaches the laminating roller 50, the control unit 90 causes the first conveyance roller 41 to perform either the conveyance operation or the first divided conveyance operation. Therefore, even if the recording of an image on the first member 101 has completed before the leading edge P of the first member 101 reaches the laminating roller 50, the control unit 90 causes the first conveyance roller 41 to perform the eighth conveyance, so that the first member 101 can be conveyed until the leading edge P of the first member 101 reaches the laminating roller 50.

[0166] Furthermore, if the recording unit 30 has not completed recording of the image on the first member 101 after the leading edge P of the first member 101 has reached the laminating roller 50, the control unit 90 causes the recording unit 30 to perform a recording operation and causes the first conveyance roller 41 to perform a conveying operation. If the leading edge cutting position C0 of the first member 101 reaches the cutting position of the second cutting unit 62 (the first member reaches the first cutting position where a part including the leading edge is cut off) before the first member 101 reaches the next recording position, the control unit 90 causes the first conveyance roller 41 to perform a third divided conveying operation that performs a ninth conveyance and a tenth conveyance instead of the conveying operation. Therefore, if the conveying operation would cause the first member 101 to reach the first cutting position, the control unit 90 causes the first conveyance roller 41 to perform the third divided conveying operation instead of the conveying operation. This stops the first member 101 at a position suitable for cutting, allowing the first member 101 to be neatly cut.

[0167] In addition, the control unit 90 executes a process of detecting the position of the tip P of the first member 101 based on the output signal of the member sensor 66, and if the recording unit 30 has completed recording of the image on the first member 101 before the member sensor 66 detects the tip P of the first member 101, the control unit 90 executes a process of causing the first conveying roller 41 to convey the first member 101 so that the position of the detected tip P is located between the detection position of the member sensor 66 and the laminating roller 50, a process of detecting and updating the position of the tip P of the first member 101 based on the output signal of the member sensor 66, and a process of causing the first conveying roller 41 to convey the first member 101 based on the updated position of the tip P after the member sensor 66 detects the tip P of the first member 101. Therefore, if the recording of the image on the first member 101 is completed before the member sensor 66 detects the tip P of the first member 101, the first member 101 is transported so that the tip P of the first member 101 reaches the detection position of the member sensor 65, and the first member 101 can then be transported accurately based on the position of the tip P detected based on the output signal of the member sensor 66.

[0168] [First Modification] In the laminating apparatus 1 according to this embodiment, when the leading edge P of the first member 101 reaches the drive start position Q, the control unit 90 causes the first conveyance roller 41 to perform a first divided conveyance operation, which includes a first conveyance and a second conveyance, and then causes the recording unit 30 to perform a recording operation. In the laminating apparatus according to the first modification, when the leading edge P of the first member 101 reaches the drive start position Q, the control unit 90 causes the first conveyance roller 41 to perform the first conveyance instead of the first divided conveyance operation, and then causes the recording unit 30 to perform a partial recording operation. Thereafter, the control unit 90 causes the first conveyance roller 41 to perform the conveyance operation and causes the recording unit 30 to perform a recording operation. The recording operation is an operation of recording an image in the recording unit 30 using the entire recording head 32. The partial recording operation is an operation of recording an image in the recording unit 30 using the upstream side of the recording head 32.

[0169] In FIG. 16 , the conveying distance dx is equal to the head size (the size of the nozzle region of the recording head 32 in the conveying direction), and hatching indicates the portion of the recording head 32 used to record an image. In the example shown in FIG. 16 , the control unit 90 causes the recording unit 30 to perform a recording operation and record an image in recording region #1 of the first member 101 ( FIG. 16A ). Next, the control unit 90 causes the first conveying roller 41 to perform a conveying operation and convey the first member 101 by the conveying distance dx. Next, the control unit 90 causes the recording unit 30 to perform a recording operation and record an image in recording region #2 of the first member 101 ( FIG. 16B ). The size of recording regions #1 and #2 in the conveying direction is dx. The recording unit 30 uses the entire recording head 32 to record images in recording regions #1 and #2, respectively.

[0170] Next, the control unit 90 determines that the leading edge P of the first member 101 will reach the drive start position Q by the next conveying operation, and causes the first conveying roller 41 to perform the first conveying, thereby conveying the first member 101 by a conveying distance d3 (<dx). Next, the control unit 90 causes the recording unit 30 to perform a partial recording operation, thereby recording an image in recording area #3 of the first member 101 ( FIG. 16C ). The size of recording area #3 in the conveying direction is d3. The recording unit 30 records an image in recording area #3 using the upstream side of the recording unit 30.

[0171] Next, the control unit 90 causes the first transport roller 41 to perform a transport operation, causing the first member 101 to be transported by a transport distance dx. Next, the control unit 90 causes the recording unit 30 to perform a recording operation, causing the recording unit 30 to record an image in recording area #4 of the first member 101 (FIG. 16D). The size of recording area #4 in the transport direction is dx. The recording unit 30 uses the entire recording head 32 to record the image in recording area #4.

[0172] The conveying distances dx and d3 are examples of the first conveying distance and the second conveying distance, respectively. The entire recording head 32 is an example of a first portion of the recording unit 30. The upstream side of the recording head 32 is an example of a second portion of the recording unit 30.

[0173] In the laminating apparatus according to the first modification, the control unit 90 causes the first conveying roller 41 to perform intermittent conveyance (S16), which repeats a first conveying operation of conveying the first member 101 after an image has been recorded on the first member 101 by the entire recording head 32 (first portion of the recording unit 30). When the leading edge P of the first member 101 reaches the drive start position Q (S41, S59: Yes), the control unit 90 starts driving the laminating roller 50 (S43, S61). When the tip P of the first member 101 reaches the drive start position Q while the first conveying roller 41 is repeating the first conveying operation at a conveying distance dx (first conveying distance), instead of intermittent conveying, the control unit 90 conveys the first member 101 by a conveying distance d3 (second conveying distance) that is shorter than the conveying distance dx at which the tip P of the first member 101 reaches the drive start position Q, and then records an image on the first member 101 using only a part of the recording head 32 (the second part of the recording unit 30).

[0174] According to the laminating apparatus of the first modified example, similarly to the laminating apparatus 1, when divided conveyance is performed, when the leading edge P of the first member 101 reaches the drive start position Q, the first conveyance is performed by the first conveyance roller 41 instead of the conveyance operation, and the first member 101 is stopped temporarily at a position suitable for lamination before the laminating roller 50 starts to drive, thereby suppressing a deterioration in lamination quality. Furthermore, after the first member 101 is stopped temporarily, an image can be partially recorded using a part of the recording unit 30.

[0175] [Other Modifications] The laminating apparatus 1 according to this embodiment can be modified in various ways in addition to the above. In the laminating apparatus according to the modification, the control unit 90 may perform the same processing for the drive start position Q and the leading edge cutting position C0 for the first trailing edge cutting position C1, the second trailing edge cutting position C2, and the third trailing edge cutting position C3. The control unit 90 may not perform the same processing for the drive start position Q for the leading edge cutting position C0. When the first conveying method is used during skip conveying, the skip conveying distance ds may be divided into any conveying distances smaller than the conveying distance d1. The control unit 90 may not cause the first conveying rollers 41 to perform small-amount conveying, and may not cause the first conveying rollers 41 to perform skip conveying. The control unit 90 may not cause the first conveying rollers 41 to perform the eighth conveying.

[0176] The laminating apparatus according to the modified example does not need to be equipped with the member sensor 65. In this case, the control unit 90 acquires the position of the leading edge P of the first member 101 based only on the output signal of the rotary encoder 87 until the member sensor 66 detects the leading edge P of the first member 101. The laminating apparatus according to the modified example does not need to be equipped with both member sensors 65 and 66. In this case, the control unit 90 acquires the position of the leading edge P of the first member 101 based only on the output signal of the rotary encoder 87.

[0177] REFERENCE SIGNS LIST 1 laminating device 30 recording unit 41 first conveying roller (conveying roller) 50 laminating roller 65 member sensor (second sensor) 66 member sensor (sensor, first sensor) 90 control unit 101 first member 102 second member 121 deflection P leading end Q drive start position

Claims

1. A recording device comprising: a conveying roller that conveys a first member in a conveying direction; a recording unit that records an image on the first member conveyed by the conveying roller; a laminating roller that bonds the first member on which the image has been recorded by the recording unit to a second member; and a control unit, wherein the control unit: causes the recording unit to perform a recording operation to record an image on the first member; causes the conveying roller to perform a conveying operation to convey the first member to a next recording position and stop the first member; and starts driving the laminating roller when the leading edge of the first member reaches a drive start position; If the conveying operation causes the tip of the first member to reach the drive start position before the first member reaches the next recording position, instead of the conveying operation, the lamination device causes the conveying roller to execute a first divided conveying operation that includes a first conveying operation in which the first member is conveyed until the tip of the first member reaches the drive start position and then stopped, and a second conveying operation in which the first member is conveyed from the position where the tip of the first member reaches the drive start position to the next recording position and then stopped.

2. The laminating apparatus according to claim 1, wherein the drive start position is a position where the leading end of the first member abuts against the laminating roller and where a deflection of a predetermined amount or less is formed in the first member.

3. A lamination device as described in claim 1, further comprising a sensor for detecting the leading edge of the first member, wherein the control unit, when the sensor detects the leading edge of the first member while the conveying roller is performing the conveying operation, causes the conveying roller to perform the conveying operation being performed to the end, calculates a third conveying distance by subtracting a second conveying distance between the sensor and the stop position of the leading edge of the first member from a first conveying distance between the sensor and the drive start position, causes the conveying roller to perform the conveying operation if the conveying distance by the next conveying operation is less than the third conveying distance, and causes the conveying roller to perform the first divided conveying operation if the conveying distance by the next conveying operation is equal to or greater than the third conveying distance.

4. The laminating device of claim 1, wherein the control unit causes the recording unit to execute, as the recording operation, either a first recording operation in which an image is recorded in the maximum range possible during one movement in an intersecting direction intersecting the transport direction, or a second recording operation in which an image is recorded in the maximum range during multiple movements in the intersecting direction, and the transport distance caused by the transport operation is either the distance in the transport direction of the maximum range when the recording unit executes the first recording operation, or the distance in the transport direction of the range in which an image is recorded by the recording unit during one movement in the intersecting direction when the recording unit executes the second recording operation.

5. A lamination device as described in claim 1, further comprising a sensor for detecting the leading edge of the first member, wherein the control unit causes the conveying roller to perform a second divided conveying operation in which, if the conveying distance by the conveying operation is longer than the fourth conveying distance before the sensor detects the leading edge of the first member, the conveying roller performs a third conveying operation in which the first member is conveyed a fifth conveying distance shorter than the fourth conveying distance and then stopped at least twice, and after the sensor detects the leading edge of the first member, the control unit causes the conveying roller to perform the conveying operation even if the conveying distance by the conveying operation is longer than the fourth conveying distance.

6. The lamination device according to claim 5, wherein the control unit, when the sensor detects the leading edge of the first member while the transport roller is performing the third transport, causes the transport roller to perform the third transport being performed to the end, calculates a seventh transport distance by subtracting a sixth transport distance between the sensor and the stop position of the leading edge of the first member by the third transport from a first transport distance between the sensor and the drive start position, and, when the fifth transport distance is less than the seventh transport distance, causes the transport roller to perform the third transport, and, when the fifth transport distance is equal to or greater than the seventh transport distance, causes the transport roller to perform the first divided transport operation, instead of the third transport, a fourth transport in which the first member is transported until the leading edge of the first member reaches the drive start position and then stopped, and a fifth transport in which the first member is transported from the position where the leading edge of the first member reaches the drive start position to a next recording position and then stopped.

7. The lamination apparatus according to claim 5, wherein the control unit, when the sensor detects the leading edge of the first member while the conveying roller is executing the third conveyance, causes the conveying roller to execute the third conveyance being executed to the end, calculates a seventh conveyance distance by subtracting a sixth conveyance distance between the sensor and the stop position of the leading edge of the first member by the third conveyance from a first conveyance distance between the sensor and the drive start position, and, when an eighth conveyance distance which is the remaining conveyance distance in the second divided conveyance operation is less than the seventh conveyance distance, causes the conveying roller to execute the second divided conveyance operation to the end, and, when the eighth conveyance distance is equal to or greater than the seventh conveyance distance, causes the conveying roller to execute the first divided conveyance operation which performs a fourth conveyance in which the first member is conveyed until the leading edge of the first member reaches the drive start position and then stopped, and a fifth conveyance in which the first member is conveyed from the position where the leading edge of the first member reaches the drive start position to a next recording position and then stopped.

8. A laminating apparatus as described in claim 1, further comprising a sensor for detecting the leading edge of the first member, wherein the control unit, when the sensor detects the leading edge of the first member while the conveying roller is performing the conveying operation, compares a first conveying distance between the sensor and the drive start position with a second conveying distance between the sensor and a stop position of the leading edge of the first member, and, when the first conveying distance is equal to or less than the second conveying distance, causes the conveying roller to perform the conveying operation, and, when the first conveying distance is longer than the second conveying distance, changes the stop position to the drive start position and causes the conveying roller to perform the first divided conveying operation which includes a sixth conveying operation in which the first member is conveyed until the leading edge of the first member reaches the drive start position and is stopped there, and a seventh conveying operation in which the first member is conveyed from the position where the leading edge of the first member reaches the drive start position to a next recording position and is stopped there.

9. The lamination apparatus according to claim 1, wherein the control unit, if the recording unit has completed recording of the image on the first member before the leading edge of the first member reaches the laminating roller, causes the transport roller to perform an eighth transport operation to transport the first member until the leading edge of the first member reaches the laminating roller, and, if the recording unit has not completed recording of the image on the first member before the leading edge of the first member reaches the laminating roller, causes the transport roller to perform either the transport operation or the first divided transport operation.

10. The lamination apparatus of claim 1, wherein the control unit, if the recording of the image on the first member by the recording unit has not been completed after the leading edge of the first member reaches the laminating roller, causes the recording unit to perform the recording operation and causes the conveying roller to perform the conveying operation; and, if the first member reaches a first cutting position where a portion including the leading edge is cut off before the first member reaches a next recording position, instead of the conveying operation, causes the conveying roller to perform a third divided conveying operation which includes a ninth conveying operation in which the first member is conveyed to the first cutting position and stopped there, and a tenth conveying operation in which the first member is conveyed from the first cutting position to the next recording position and stopped there.

11. A lamination apparatus as described in claim 1, further comprising a first sensor which detects the leading edge of the first member, and a second sensor which is located upstream of the first sensor in the transport direction and detects the leading edge of the first member, wherein the control unit executes the following processes: detect the leading edge position of the first member based on an output signal of the second sensor; if the recording unit has completed recording of the image on the first member before the first sensor detects the leading edge of the first member, have the transport rollers transport the first member so that the detected leading edge position is located between the detection position of the first sensor and the laminating roller; detect and update the leading edge position of the first member based on the output signal of the first sensor; and after the first sensor detects the leading edge of the first member, have the transport rollers transport the first member based on the updated leading edge position as a reference.

12. A lamination device comprising: a transport roller for transporting a first member in a transport direction; a recording unit for recording an image on the first member transported by the transport roller; a laminating roller for laminating the first member on which the image has been recorded by the recording unit and a second member; and a control unit, wherein the control unit causes the transport roller to perform intermittent transport by repeating a first transport operation of transporting the first member after an image has been recorded on the first member in a first portion of the recording unit, starts driving the laminating roller when the leading end of the first member reaches a drive start position, and if the leading end of the first member reaches the drive start position while the transport roller is repeating the first transport operation over the first transport distance, instead of the intermittent transport, transports the first member a second transport distance shorter than the first transport distance at which the leading end of the first member reaches the drive start position, and then records the image on the first member only in a second portion smaller than the first portion of the recording unit.

Images