JPS5850599B2 - Manufacturing method and equipment for long flooring with mosaic pattern - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a novel method for manufacturing a long flooring material and an apparatus for manufacturing the same. Synthetic resin plate-like molded strips (hereinafter referred to as pellets) having various shapes and colors and having a substantially constant thickness are arranged closely without overlapping to form a consistent mosaic pattern from top to bottom. When manufacturing long flooring materials, pellets are fed through a diaphragm, and then the diaphragm reciprocates in the lateral direction perpendicular to the direction of pellet movement, and the pellets pass above the diaphragm without overlapping. The pellets are aligned at the same density over the entire width of the pellets through guide plates installed in parallel with a gap between them, and then the pellets are adsorbed onto a vacuum drum in this aligned state, and then transferred onto the substrate. By doing so, the present invention provides a method and opening device for continuously manufacturing endless flooring.

There are several known methods for producing flooring with a mosaic pattern. For example, pellets with various tones are mixed, arranged on a flat plate, heated and pressed, and then sliced to a certain thickness to form the product. This is a well-known fact in the manufacturing method of PVC tiles.

Since this method can only produce relatively small products such as rectangular tiles, methods using a roll press are also known in order to obtain long products.

A product with a mosaic pattern like this will have a consistent pattern from top to bottom even if it wears out, but the gaps between the pellets, which are the basis of the mosaic pattern, may become stuck and polymerized. Furthermore, it has the disadvantage of being subject to design constraints, such as the appearance of flow patterns and the inability to use large pellets that are larger than the thickness.

In order to avoid such design constraints, attempts have been made to use vibrators to arrange large pellets, but this has been limited to small products such as square tiles.

There is also a known method (Japanese Patent Publication No. 40-1679) in which amorphous plate-like objects that have been crushed into amorphous shapes are spread on a separately prepared plastic sheet and then pressed, but this method may cause the plate-like objects to overlap. However, there were drawbacks such as large variations in the spacing of the plate-shaped objects, poor production efficiency, and difficulty in obtaining uniform designs.

Furthermore, in the invention of Japanese Patent Publication No. 42-5430, the pellets in the hopper are transferred onto a conveyor net via a diaphragm, but in industrial implementation, it is difficult to arrange the pellets in a homogeneous manner. All the pellets are not arranged in a flat plane, and some pellets are inevitably adsorbed in an upright state, so this is stripped off by the pressure roll and creates a large gap, resulting in a uniform phase change over the entire width. They are not arranged in an array, which has the disadvantage that their commercial value is diminished.

Furthermore, although the beretsu G protruding from the conveyor net can be recycled and reused, this method is also inferior in work efficiency.

The present invention was achieved as a result of long-term research, and relates to a new method and apparatus for manufacturing mosaic pattern flooring that overcomes the drawbacks of conventional manufacturing methods. In addition, in the production of wide flooring, it is possible to arrange pellets of equal density without overlapping over the entire width, and unlike a geometrically aligned state, the pellets are completely natural and irregular. It is possible to adjust the arrangement density according to the shape of the pellet, and it is possible to obtain a product with high commercial value.

Detailed questions are given below. The base materials for flooring materials include cloth, non-woven fabric, asbestos sheets, paper, and PVC sheets.In the case of long flooring materials, the processing process is long, so the tensile force tends to be excessively applied, which causes problems in the final product. Shrinkage, warping, distortion, etc. will reduce the product value by half.

From the above points of view, asbestos sheet is the most suitable base material as it has sufficient strength, heat resistance, heat retention, dimensional stability, and workability during construction. Also preferable are glass fiber mats and asbestos/glass fiber mixed sheets.

As the adhesive applied to the base material, emulsion type, solvent type, paste sol, and other commonly available adhesives can be used.

Conventional methods such as reverse coater, roll coater, bar coater, spray method, etc. are sufficient for applying the adhesive to the base material, and the viscosity of the adhesive can be set arbitrarily according to the manufacturing operating conditions. Considering absorption into the base material and fixation of the pellet, a range of 1,000 centipoise to +10,000 centipoise is appropriate.

Any plastic pellet can be used, but a vinyl chloride compound is most preferred in terms of cost, manufacturing technology, and product properties.

Pellets can be produced by conventional methods such as cutting an extruded product or cutting a sheet of a certain thickness into small pieces, or depending on the desired shape, they can be produced by punching a sheet of a certain thickness. It is also possible to do so.

The shapes of pellets are triangular, square, pentagonal, hexagonal, etc.
...It can be a geometric shape such as a circle, or it can be intentionally amorphous to give it a natural feel, and in some cases it can be designed in the shape of a flower or bird. You can also do it.

There is no particular restriction on the size of the pellets, but the thickness should be in the range of 0.5 to 2 mm, and as uniform as possible, and the average diameter should be 3 to 30 mm for design purposes. preferable.

Also, although pellets of the same shape may be used, it is more effective to mix large pellets and small pellets at a constant ratio in order to achieve a natural alignment of the pellets.

Further, although these pellets may be of a single color, it is effective to use a mixture of inverted pellets or to arrange a marble pattern on the pellets to increase the commercial value and create a luxurious decorative appearance.

To prepare the pellets, separate sheets of the desired color can be fed into a grinder at a fixed rate and shredded all at once, or pellets can be prepared by predetermined shape or color. You can also prepare them and mix them in a certain ratio before use.

Pellets with a marble pattern can be easily obtained by making a sheet with a marble pattern in a conventional manner using a calendar roll or the like, and then crushing this sheet.

It is also possible to embed pulverized microchips in the gaps between the pellets, and in such a case, it is appropriate that the microchips have a size of 3 or less.

Arranging the pellets uniformly and irregularly on a substrate is a main element of the present invention, and will be explained below with reference to the drawings.

The base material 20-1 is continuously supplied from the unwinding roll 1,
Adhesive 19 is applied with Coke-2.

The base material 20-2 coated with adhesive is sent to the heating furnace 4 in a state 20-3 in which pellets are transferred from the pellet aligning machine 3 so that the pellets are arranged at equal density without overlapping over the entire width, and immediately crushed by the roll press 5. As a result, the base material and the pellet are firmly bonded to each other (20-4).

By the way, the basic configuration of the sorting machine 3 is a hopper 10 and a transverse diaphragm 13, and the purpose can be achieved by combining the angular variation, width, length, etc. of this diaphragm as desired. Considering stability of operation, improvement of production speed, reduction of production loss, etc., the vertical vibration plate 12a,
12b.

12c, a guide plate 14 for preventing the pellets from overlapping, and a drum 16 for transferring the pellets (22-4) arranged at equal density onto the base material 20-2, making it possible to make a wide range of adjustment, and to continuously transfer the pellets at equal density. Pellets can be arranged in the same state.

Since the pellets (22-1) stored in the hopper sometimes cause a bridging phenomenon, it is desirable to install a rotary feeder in consideration of the shape and opening of the hopper.

Vertical vibration plate 12a. 12b and 12c have electromagnetic pie break-23a.

23b and 23c are installed in single or multiple pieces,
It serves to remove the overlap while moving the pellets (22-2) that have become heavy due to slight vibrations forward.

The most efficient values can be arbitrarily selected for the frequency, amplitude, angular variation, length, and width of the diaphragms 12a, 12b, and 12c.

Regarding the diaphragm 12a, in order to adjust the forward movement of the pellets almost uniformly in terms of quantity, it is preferable to combine two or more diaphragms for each width.

The tip of the diaphragm 12b is raised with respect to the horizontal installation of the diaphragm 12a using this as a reference plane, and the inclination angle at this time is set to 3 to 5.

Furthermore, the diaphragm 12c is adjusted to the diaphragm 12a according to the amount of movement of the pellet.
The angle of inclination is adjusted within the range of 5-10 degrees based on .

It is preferable that the frequency of each vibration is 1800 to 3600 times/min, and the amplitude is kept within a range of 11 m or less.

Belen) 22 in which the overlap of pellets has been almost completely removed
-3 is moved to the transverse diaphragm 13 and is tightly packed by reciprocating the entire plate in the transverse direction by an eccentric cam via a motor.

At this time, depending on the shape of the pellets and the strength of the movement of the lateral vibration plate 13, the pellets may overlap again, but the guide plate 1
This can be prevented by having 4.

The guide plates are provided in parallel above the transverse vibration plate 13 with a gap large enough to allow the pellets to pass through without overlapping.

The material may be any material, but a transparent glass plate is preferred because it allows the arrangement of the pellets to be seen.

The amplitude of the transverse diaphragm is between 0.5 and 1.5, and the inclination angle is 10
A selection in the range of ~15 mm facilitates diagonal advancement while preventing dense arrays and re-overlapping, regardless of the shape of the pellets.

In this case, the guide plate 14 is used to prevent re-overlapping, and the role of the lateral vibration plate is to move the pellets forward without disturbing the state while densely packing the pellets, and to maintain the arrangement state when riding on the transfer roll. This is accomplished by two information boards.

The pellets 22-4 in a densely arranged state are sucked and spread on the transfer drum 16 having a large number of holes 22-5, and are transferred to the base material 2.
20-3 is transferred to 0-2 to create a mosaic pattern,
The transfer drum 16 has a part A that is connected to an exhaust fan or the like and has a degree of vacuum to prevent the sucked pellets from falling, and a part B that returns to normal pressure or is slightly pressurized at the time the pellets are transferred. It consists of

The transfer drum may be directly connected to a motor 18 that is electrically controlled so that the feeding speed of the base fabric matches the circumferential speed, or it may be a set of net conveyors in which the screen 15 is endlessly wound through a drive roll 17. I don't mind.

The pellets arranged densely on the base material and integrated with the base material in this way are filled with a transparent or opaque liquid material 21 into the gaps between the pellets using a doctor knife 6 20
-5° This material is selected from urethane, epoxy, polyester, vinyl chloride sol, etc., but vinyl chloride sol is advantageous in terms of cost and composition, which can vary from soft to hard.

Vinyl chloride sol usually uses vinyl chloride paste resin or vinyl chloride-vinyl acetate copolymer paste resin, but it is also possible to use it in combination with suspension type legal vinyl chloride resin, acrylic resin, or urethane resin. In addition, it is composed of commonly used compounding agents such as plasticizers, fillers, stabilizers, solvents, pigments, and lubricants.

Next, the mosaic flooring is completed when it is gelled in the heating furnace 7, but if it is necessary to make the surface even more,
The surface can be removed by the polishing machine 8, or a surface treatment agent can be applied to improve surface brightness and abrasion resistance, but in addition to these methods,
It is possible to add methods that can increase the product value depending on the purpose and use.

The obtained long flooring material is wound up into a product by a winding machine.
An example of a cross-sectional view of the product is shown in FIG.

The mosaic pattern appearing on the surface runs from the top surface to the bottom surface, resulting in a flooring material with an excellent feature that the pattern does not easily disappear even when used in cases where there is frequent walking.

Detailed questions will be asked below using examples.

The following compositions were kneaded separately in a Banbury mixer, formed into sheets with a thickness of 1.5 mm using a calendar roll, and formed into square and hexagonal pellets 14f'14 using a continuous punching machine.

The pellets were prepared in the form of a rectangle of 1010 x 10.7 x 7 squares and a hexagon with a side length of 6 squares and 4 squares for each of (1) and (2).

Mixtures (1) to (6) were prepared by mixing these pellets in the following weight proportions using a ribbon blender.

The color mixture was transferred to a hopper, and the pellets were moved forward by a vertical vibrator 12a.

Four vibrators were arranged in the width direction, and the amount of movement of each was adjusted while checking the pellet supply status on the vibrators.

The overlap of pellets on the vibrator gradually disappears12
In c, there were hardly any overlapping pellets, and a uniform amount was supplied over the entire width.

The vibration frequency was 3600 rpm, and the vibrator was made of stainless steel with a thickness of 12 mm.

Are there any particular restrictions as long as it has mechanical strength?
Stainless steel with a thickness of 10 mm or more is suitable because of slippage, corrosion, bending, etc. of the pellets.

The inclination angle of the diaphragm is important as well as the frequency in order to eliminate the total amount of pellets to be supplied and overlap.The first diaphragm is set horizontally, and with this as a reference plane, the next diaphragm 12b is set at an ascending angle of 3, 1
2c had an inclination angle of 5 degrees.

The pellets, which were no longer overlapping, were then transferred to a transverse diaphragm.

Between the guide plates provided above the lateral diaphragm, all of the overlapping pellets were broken by the lateral vibration, and the pellets passed through the guide plates without overlapping.

Inside the guide plate, the pellets moved diagonally forward, showing a uniform arrangement of the pellets over the entire width.

The transverse diaphragm is a 12-inch thick aluminum plate, and the amplitude is 1.5.
Adjusted in mm.

The gap between the glass guide plate and the lateral diaphragm was set to 2.

The guide board was made of tempered glass pasted to an iron frame with synthetic resin adhesive so that the alignment of the pellets could be seen.

The transverse diaphragm and the guide plate are parallel, and their inclination angle is 10 degrees with respect to 12a.

When increasing the amount of pellets supplied, the angle of inclination may be increased or the amplitude may be set to an even larger value, but 2 angles or less is appropriate.

The pellets arranged densely by the transverse diaphragm were sequentially suctioned by the transfer roll 16 as they were, and transferred from the transfer roll to the asbestos sheet in a dense state.

Further, a 60-mesh wire mesh was wrapped around the transfer roll.

The asbestos sheet used is 0.7 mm thick mixed with glass fiber, and adhesive (PSH-1) is used in front of the transfer roll.
0100 parts, Dop 60 parts, BaZu stabilizer 3 parts)
was applied onto the base material using a roll coater.

PVC paste sol (PSH-10 100 parts, Dop
45 parts, epoxy soybean oil 3 parts, Ca-Zu stabilizer 3
2 parts of pigment (red)) was filled between the pellets, then heated in a heating furnace at 200°C for about 4 minutes, cooled and solidified, and then the surface was polished using a sander belt type polisher.

The obtained sheet was a long flooring material with a mosaic pattern in which the pellets were arranged evenly and without deformation.

[Brief explanation of the drawing]

FIG. 1 is a process diagram of an example of the method of the present invention, FIG. 2 is a side view of the apparatus of the present invention for use between stations, and FIG. 3 is a perspective view of an example of the product according to the present invention. Hopper...10, Vertical vibration plate...
・12a. 12b, 12c, horizontal vibration plate...13, guide plate...14, transfer drum...16,
Adhesive...19, Base material...2O-(1
~6), Liquid material...21 Pellet...
22-(1-5).

Claims (1)

[Scope of Claims] 1. A long flooring material having a consistent mosaic pattern from top to bottom by arranging synthetic resin pellets of any color and shape in a plane on a long base material coated with a grafting agent. In the production of The pellets are arranged at the same density over the entire width through guide plates installed in parallel with a gap in between, and then the pellets are adsorbed onto a vacuum drum in the same state as they are, and then transferred onto the base material. A method for manufacturing a long flooring material having a mosaic pattern, characterized by: 2. In an apparatus for manufacturing a long flooring material having a consistent mosaic pattern from top to bottom by arranging synthetic resin pellets of any color and shape in a plane on a long base material coated with a grafting agent, A diaphragm that vibrates in the vertical direction in which the pellets move, a diaphragm that vibrates in the lateral direction perpendicular to the direction in which the pellets move, and a guide plate installed above them in parallel with a gap that allows the pellets to pass through without overlapping. An apparatus for manufacturing a long flooring material having a mosaic pattern comprising a series of vacuum drums capable of transferring pellets arranged at equal density over the entire width onto a base material as they are.