JP3350860B2 - Continuous production method and apparatus for striped color pattern sheet material - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method and an apparatus for continuously manufacturing a sheet material having a unique multicolored striped color pattern.

[0002]

2. Description of the Related Art Conventionally, as a method of producing a sheet material having a striped color pattern, a surface printing method or a multicolor coating material combination method (a plurality of different colors) is used as a means for forming the striped color pattern of the sheet material. From the viewpoint of the sheet material manufacturing process, a batch-type manufacturing method using a mold having a predetermined shape (Japanese Patent Laid-Open No. 4-92045, etc.) and a long-strip base sheet. Is continuously fed to form a pattern sequentially (JP-A-57-160608,
JP-A-57-87319).

[0003]

However, the surface printing method can freely express a multicolored and unique mixed stripe pattern such as a natural stone tone stripe pattern. There was a problem that the pattern had no depth, and if the surface of the sheet material was peeled off or damaged, the background color of the pattern was exposed and became very noticeable.

[0004] In this respect, in the method using the multi-color coating material, it is easy to make the pattern deep, and it is easy to avoid the problem of exposing a non-patterned ground color due to peeling or damage of the sheet material surface.

However, the method of using a multicolor coating material using a mold has a major drawback that the production efficiency is poor because of the batch system, and the continuous method of using the multicolor coating material has good production efficiency, but is optional. There is a drawback that it is difficult to express a striped color pattern.

That is, in the invention of the "method of manufacturing a decorative sheet" according to the above-mentioned Japanese Patent Application Laid-Open No. 57-160608, two or more spray nozzles 3 for applying a colored synthetic resin are used to feed the sheet 1. Since the arrangement is fixed to the spray device 2 provided in a direction perpendicular to the direction, a so-called vertical stripe pattern having no change is obtained.

Further, in the invention of the "method of manufacturing a decorative sheet" according to Japanese Patent Application Laid-Open No. 57-87319, the vertical stripe pattern is made variable by stirring devices 5 and 5 'which perform a predetermined operation. However, the mode of the change is described in the fifth gazette of the publication.
As shown in FIG. 11 and FIG. 11, a regular or geometric pattern was formed, and a unique stripe color pattern such as a natural stone tone stripe color pattern could not be freely expressed.

Therefore, the present invention is a continuous production method with high production efficiency, a combined use method of multicolored coating materials having no trouble such as a surface printing method in a stripe color pattern, and a natural stone tone stripe pattern. An object of the present invention is to provide a method and apparatus for continuously manufacturing a sheet material having a striped color pattern, which freely expresses a unique striped color pattern such as a color pattern.

[0009]

Means for Solving the Problems (Structure of the First Invention) The structure of the first invention of the present application (the invention according to claim 1) for solving the above-mentioned problems is a structure in which a continuous feeding is performed on the machining-in. While moving a plurality of coating material supply means along the direction intersecting the processing line with respect to the surface of the band-shaped base sheet,
A continuous production method of a striped color pattern sheet material, in which sheet materials having a striped color pattern are continuously manufactured by supplying coloring coating materials of different colors from these coating material supply means.

(Structure of the Second Invention) The structure of the second invention (the invention described in claim 2) for solving the above-mentioned problem is as follows.
A continuous production method of a striped color pattern sheet material, wherein the colored coating material in the first invention is a mixture of a colored aggregate or a colored aggregate.

(Structure of Third Invention) The structure of the third invention of the present application (the invention according to claim 3) for solving the above problems is as follows.
In the first invention or the second invention, there is provided a continuous production method of a striped color pattern sheet material, wherein the supply of a plurality of coloring materials having different colors is performed in combination with a coating layer leveling process using a coater. .

(Structure of the Fourth Invention) The structure of the fourth invention of the present application (the invention according to claim 4) for solving the above problems is as follows.
In any one of the first to third inventions, there is provided a method for continuously producing a striped color pattern sheet material, wherein a thermal gelation treatment of a coating material is performed downstream of a processing line.

(Structure of the Fifth Invention) The structure of the fifth invention (the invention described in claim 5) for solving the above problems is as follows.
Feeding means for continuously feeding the long-strip base sheet onto the processing line; and supplying a colored coating material of a different color to the surface of the long-strip base sheet movable along a direction intersecting the processing line. And a plurality of coating material supply means.

[0014]

Operation and effect of the invention] (Operation and effect of the first invention and the fifth invention)
Effect) Since a plurality of coating material supply means are moved along a direction intersecting the processing line, and different color coating materials are supplied to the surface of the long band base sheet continuously fed on the processing line. Stripe color pattern sheet material can be efficiently and continuously manufactured.

In moving the plurality of coating material supply means, they may be moved integrally, may be moved independently of each other, or some of them may be moved integrally and the other may be moved independently. It is possible to arbitrarily change the moving speed, the moving direction, and the relative moving position of each coating material supply means by appropriately selecting such a mode of movement, so that a natural stone tone striped color pattern can be obtained. It is possible to freely realize a striped color pattern of an arbitrary pattern including a unique striped color pattern.

In addition, since the method is a multicolor coating material combined method in which a plurality of types of colored coating materials are applied, it is easy to give depth to the pattern, and the non-pattern ground color is exposed due to peeling or damage of the sheet material surface. can avoid. Furthermore, since it is a continuous type, manufacturing efficiency is good.

(Function / Effect of the Second Invention) In the second invention, since a colored aggregate or a colored aggregate is blended as a coloring means of the colored coating material, a striped color pattern having a more natural texture is obtained. be able to.

(Function / Effect of the Third Invention) In the third invention, the supply of the colored coating material is performed in combination with the coating layer leveling treatment by the coater, so that the leveled striped color pattern is obtained. Sheet material can be manufactured continuously.

(Function / Effect of the Fourth Invention) In the fourth invention, since the thermal gelation treatment of the coating material is performed downstream of the processing line, the striped color pattern sheet material is solidified and completed continuously and quickly. be able to.

[0020]

Next, embodiments of the first invention to the sixth invention will be described. In the following, simply "the present invention"
When it says, it refers to 1st invention-6th invention collectively.

[Striped color pattern sheet material] The type and use of the striped color pattern sheet material are not limited, and the inner and outer walls, columns, beams, eaves, ceilings, floors, etc. of houses, buildings and other buildings. Finishing is included without limitation.

The color of the striped color pattern and the pattern of the pattern are not limited either, and may be an irregular striped color pattern of a natural stone tone such as a sandstone tone, a marble tone or the like, or a creative striped color of an arbitrary pattern. A pattern and a standard striped color pattern such as a stripe pattern are also included.

The striped color pattern sheet material may have a single color base coating material layer between the striped color pattern layer made of a colored coating material and the long band base sheet. Such a base coating material layer can be easily formed by providing, for example, a fixed base coating material supply means upstream of the coating material supply means for supplying the colored coating material on the processing line.

Further, a clear layer may be further formed on the surface of the striped color pattern sheet material, or the clear layer may be formed after polishing the surface. In forming clear or transparent color clear, roll coater,
The coating can be dried and formed by an air curtain coater, airless spray coating or the like. As the resin for the clear layer, synthetic resin solutions such as acrylic ester copolymer resin, styrene-acryl copolymer resin, urethane resin, acrylic-urethane copolymer resin, silicone-acryl copolymer resin, fluororesin, etc., which have excellent weather resistance Alternatively, any of synthetic resin emulsions can be used.

[Long Strip Base Sheet] The long strip base sheet can be used without limitation as long as it is suitable for continuous feeding, for example, a long strip sheet material that is flexible enough to be rolled. In addition, both those that are used directly as a substrate of the striped color pattern sheet material and those that are peeled and removed after the completion of the striped color pattern sheet material are included.

The long-strip base sheet may be any of woven fabric, non-woven fabric, mesh, etc. made of inorganic fiber, organic fiber, etc. Specific examples include glass fiber, carbon fiber, silicon carbide fiber, acrylic fiber, vinylon fiber, and the like. There are polyester fibers, aramid fibers, etc., and in addition, there are various synthetic resin sheets such as vinyl chloride sheets and polyethylene sheets, various paper material sheets, microcell polymer sheets, etc., which are filled with resin or paint. Alternatively, there may be mentioned those not applied.

[Coloring Coating Material] As the coloring coating material, a mixture of at least a coloring means and an aggregate in various known coating material binders is used.

As the coating material binder, for example, vinyl acetate resin, vinyl acetate copolymer resin, ethylene / vinyl acetate copolymer resin, acrylate ester copolymer resin, styrene / acryl copolymer resin, urethane resin, acrylic / urethane copolymer resin, A synthetic resin solution such as a silicone-acrylic copolymer resin, a fluororesin, or the like, a synthetic resin emulsion, an alkali silicate solution, an alkali silicate dispersion, or the like can be arbitrarily used, but a synthetic resin emulsion is particularly preferable.

In consideration of the relationship with the fourth invention, the coating material binder preferably has a thermosensitive gelling property, but may have a property of solidifying by a process other than heating. Various additives such as water, a thickener, a preservative, and an activator can be arbitrarily compounded in the coating material binder.

As a coloring means, a pigment may be used separately from the aggregate. However, when a colored aggregate (particularly natural stone particles or the like) or a colored aggregate is mixed with the coloring coating material, the aggregate also serves as the coloring means. This case is more preferable in realizing a natural stone-tone striped color pattern having a natural texture.

Examples of the aggregate include aggregates such as natural stone particles such as silica sand and cold water sand, natural crushed stones and the like, crushed ceramics, glass particles, resin fragments and the like, which originally have a specific color, and specific aggregates. Can be used.

In the compounding of the coloring coating material in which these are combined, the resin solid content ratio can be arbitrarily combined from 3 to 50%. Further, the setting of the viscosity of the coloring coating material is not limited.
The viscosity difference may be arbitrarily set within a range of 00 to 20000 cps (measured value at 20 ° C. by a No. 1 rotor type viscometer).

[Coating Material Supplying Means] A plurality of coating material supplying means for supplying coloring materials of different colors to the surface of the long strip base sheet are processed in the processing line direction, ie, the continuous feeding direction of the long strip base sheet. Is provided so as to be movable along a direction intersecting with.

Here, the "intersecting direction" does not necessarily need to be a direction perpendicular to the processing line, but may be an oblique intersecting direction. Further, "a plurality of coating material supply means are movable" means that the coating material supply means can be moved integrally, that they can be independently moved, and that some coating material supply means are movable. Moving together and other things can move independently.
In order for one coating material supply means to be movable independently of the other, they must be held by separate operating mechanisms.

The type of the operation mechanism is not limited. For example, a form in which a plurality of coating material supply hoppers (or coating material supply tanks) each having a coating nozzle which is independently movably held, or a fixed type is provided. A plurality of coating nozzles respectively connected to a plurality of coating material supply hoppers (or coating material supply tanks) via flexible feed hoses are independently movably held. be able to.

The method of holding the coating material supply means, ie, the coating material supply hopper (or the coating material supply tank) and the coating nozzle movably, is not limited. For example, a rail is installed in a direction crossing the processing line. The method may be such that the coating material supply means is moved along the rail, or the coating material supply means is moved using an appropriate link mechanism or cam mechanism.

A program for moving the coating material supply means, that is,
The timing of movement of each coating material supply means, the speed of movement, the direction of movement, the relative position of each coating material supply means at any time when moving independently of each other, determine the pattern of the striped color pattern. This is arbitrarily set according to a desired striped color pattern. When the above program is complicated, the driving of the actuator in the operation mechanism of the plurality of coating material supply means may be controlled by a computer program.

It is desirable that the coating material supply section (for example, a coating nozzle) in the coating material supply means be capable of opening and closing and adjusting the opening diameter at the time of opening. As a result, by stopping / continuing the supply of a specific coloring coating material, or increasing or decreasing the supply amount,
Variations are possible in which the width of a specific striped stripe is changed or the striped stripe is eliminated halfway with a natural feeling. This adjustment can also be controlled by the computer program. Further, the opening shape of the coating nozzle is arbitrary, and may be a circle, an ellipse, a square, a star, or a shape obtained by dividing the shape into two or more by a rim crossing the opening.

[Coater etc.] The striped color pattern layer formed on the surface of the long strip base sheet by the coating material supply means usually has some surface irregularities. Although the surface irregularities may be intentionally left from the viewpoint of design, the coating layer may be leveled by a coater immediately after supplying the colored coating material on the processing line or to some extent downstream. As a coater,
A knife coater is typical, but other types of coaters such as a roll coater and an air curtain coater can be used arbitrarily.

When the coloring coating material has a heat-sensitive gelling property, it is preferable to provide a heating furnace downstream of the processing line and to solidify the coating material layer by the heat-sensitive gelation treatment of the coating material. Depending on the type of the coloring coating material, other coating material layer solidifying means may be used.

Before such a coating material layer solidification treatment, from the lower surface side of the long band base sheet on which the stripe color pattern layer is formed,
A vibration process using a vibrator may be performed. Since this process is a short-time process for a long-strip base sheet that is continuously fed, the degree of the effect is limited, but a certain amount is applied to the familiarity between the respective coloring coating materials constituting the striped color pattern layer. The effect can be expected.

The completed striped color pattern sheet material may be wound on a winding roll, or may be cut to a predetermined size by a cutter downstream of the processing line.

[0043]

Next, an embodiment of the present invention will be described.

( A continuous production apparatus for a striped color pattern sheet material and its
Example of Use ) In the continuous production apparatus 1 for striped color pattern sheet material shown in FIG. 1, a long-strip base sheet 3 (using a coated nonwoven fabric) having a predetermined width wound around a feeding roll 2 is
After passing through the intermediate rolls 4, they are sequentially fed to the processing line.

In the processing line, a single color base coating material 6 (base coating material A described later) is first applied to the surface of the base sheet 3 with a fixed single nozzle 5 to a substantially uniform predetermined thickness. The applied base coating material layer was leveled by the knife coater 7.

Next, colored coating materials of different colors were applied to the leveled surface of the base coating material layer by using a nozzle device described later to form a striped color pattern layer. At that time, each nozzle device is independently moved along a direction intersecting the processing line by an operation mechanism not shown, or stopped at a specific time, and further, by changing the opening diameter of the nozzle opening. The formation of a specific striped color pattern was performed.

As shown in FIG. 1, the above nozzle device comprises a plurality of nozzle arms 8a, 8b, 8c. These are supported by a plurality of arm supports (not shown) which can be operated independently in a direction intersecting with the processing line direction so as to be able to swing substantially horizontally within a predetermined angle range. .

The nozzle arm 8a is provided with three nozzles 9a1, 9a2, 9a3.
The nozzle b is provided with nozzles 9b1, 9b2, 9b3, and the nozzle arm 8c is provided with nozzles 9c1, 9c2, 9c3.
Each of these nozzles 9a1 to 9c3 has a certain range (for example, 2 to 9 mmφ, 2 to 5 mmφ, 3 to 8 mmφ).
) Is controlled so that the aperture diameter can be changed.

In this embodiment, a color coating material a described later is supplied from the nozzles 9a1, 9b1, 9c1, 9a2, 9b2 and 9c2, and a color coating material b described later is supplied to the nozzles 9a3, 9b3 and 9c3.
Supplied from

The formed striped color pattern layer was leveled by a doctor roll 10. Support rolls 11 and 12 are provided opposite to the knife coater 7 and the doctor roll 10 to ensure leveling across the base sheet 3. The doctor roll 10 is the same as the support roll 12. Although it rotates in the line traveling direction, its rotation speed is set to approximately ／ of that of the support roll 12.

The unsolidified striped color pattern sheet material that has passed through the doctor roll 10 is then subjected to a vertical vibration process by a vibrator 13, and then subjected to a solidification process by thermal gelation and a drying process in a heating furnace 14. After being applied and cooled in a cooling zone 15 by a known appropriate mechanism, it was taken up on a take-up roll 18 via an intermediate roll 16 and a tension adjusting device 17.

( Example of continuous production of striped color pattern sheet material) The continuous production of striped color pattern sheet material was performed using the continuous production apparatus for striped color pattern sheet material as described above. The composition and color of the base coating material A, the coloring coating material a, and the coloring coating material b used are shown in Table 1 at the end, and the contents of each composition of these coating materials are shown in Table 2 at the end.

The weight of the thus-prepared striped color pattern sheet material after drying was 3.5 kg per square meter, and the thickness was 3.1 mm.
The pattern was apparently smooth with random red-brown and brown random stripes formed on a beige ground. A plan photograph of the fragment is shown in FIG.

The striped color pattern sheet material was cut into a 450 mm square as an example of use, combined with the striped color pattern so as to be random, and attached to a wall surface, and finished design was evaluated. Because of the texture of the stone and the natural feeling of the striped pattern, it could be used as a new decorative finishing material without getting tired.

[0055]

[Table 1]

[0056]

[Table 2]

[Brief description of the drawings]

FIG. 1 is a diagram conceptually showing an embodiment of a continuous manufacturing apparatus for a striped color pattern sheet material.

FIG. 2 is a view showing a plan photograph of an example of a striped color pattern sheet material.

[Description of Signs] 3 Base sheet 5, 8 Nozzle 6 Base coating material 7, 10 Knife coater 9 Colored coating material 14 Heating furnace

Continuation of front page (56) References JP-A-4-349973 (JP, A) JP-A-59-65157 (JP, A) JP-A-10-34073 (JP, A) JP-A-57-160608 (JP) , A) Japanese Patent Publication No. 7-22734 (JP, B2) Japanese Patent Publication No. 46-42462 (JP, B1) Japanese Utility Model Publication No. 54-3187 (JP, Y2) (58) Fields surveyed (Int. Cl. ⁷ , DB) Name) B05D 1/00-7/26

Claims (4)

(57) [Claims] 1. A plurality of coating material supply means are provided on a surface of a long strip base sheet continuously fed on a processing line along a direction intersecting the processing line and at least one of the plurality of coating material supply means. Partly independent of other coating material supply means,
While moving, it is a coloring coating material of a different color from these coating material supply means and at least aggregate is mixed.
And continuously producing a sheet material having a striped color pattern by supplying the same. 2. The method according to claim 1, wherein said coating material supply means adjusts a coating material supply amount.
Knots are possible and can be used in the supply of the coating material.
Stripe color by stopping / continuing the supply or increasing / decreasing the supply amount
The method for continuously producing a striped color pattern sheet material according to claim 1, wherein the pattern has a variation . 3. A color coating material of a plurality of different colors.
Striped color pattern according to claim 1 or claim 2 comprising a supply of those obtained by blending at least aggregate, characterized by being carried out in combination with Nuriso Hitoshitaira process by coater A continuous production method for sheet materials. 4. The method for continuously producing a striped color pattern sheet material according to claim 1, wherein a thermal gelation treatment of the coating material is performed downstream of the processing line.