JPS6039011B2 - Method and device for producing multicolor patterned sheets - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention produces a multicolor pattern sheet using a pattern forming material such as arbitrarily colored synthetic resin powder, granular pellets, or a mixture of synthetic resin paste and these powders. The present invention relates to a method and an apparatus for manufacturing the same.

The method for manufacturing a multicolor patterned sheet of the present invention includes a first step of applying an adhesive to the surface of a wide and long base material, and a pattern forming material is sequentially applied to the adhesive-coated surface to form a predetermined pattern and a predetermined number of patterns. The second step is to transfer and spread the pattern, the third step is to heat and press the patterned pattern sheet to compactly bond the pattern material and make the thickness flat, and then the third step is to apply a transparent resin layer to the surface. 4 steps, a 5th step of performing synchronized concave-convex drawing and pressing that matches the pattern in the 2nd step, and a 6th step of cooling the multicolor pattern sheet after applying the drawing press, and the method includes a specific manufacturing method and The apparatus will be described in detail in the following example.

First, an adhesive 4 is applied to the surface of a wide and long base material 1 that is wound into a roll in FIG.

Although FIG. 1 schematically shows a doctor blade type, the amount of coating in this case is adjusted by the distance between the substrate 1 and the doctor blade 3 and the tension between the guide rolls 2 and 5. Other methods such as a reverse roll method are also suitable for this adhesive applicator. Generally, a vinyl chloride resin paste is suitable for the adhesive 4, but a solution type adhesive such as a one-component or two-component polyurethane resin or a vinyl chloride-acrylic resin solution can also be used. However, if it is necessary to heat the adhesive after applying the adhesive on the base layer, passing it through a heating furnace should be used optionally and is not particularly limited, but it may be used to When considering fixability, drying and gelation to the extent that the adhesive surface loses its tackiness should be avoided. Next, one end of the base material,
Alternatively, synchronization marks 6 are attached to both ends by a marking machine 6 to ensure synchronized concavo-convex aperture pressing in a later process. FIG. 1 shows an example of a punching method in which a punching hole is punched in the terminal. In the figure, 7 is a backup rubber roll for facilitating punching. The type of method to use for this tuning mark should be determined in combination with the detection method. If the above-mentioned punched hole 6' is provided, a phototube method is suitable as the detection method, and a paint containing metal powder is used. In the case of the mark line printing method, the metal detection method is suitable. In either case, this synchronization mark is
This matches the repeated pattern of the pattern and the drawing pattern of the uneven drawing and pressing roll, and is an extremely important means for producing multicolor patterned sheets. FIG. 2 shows the base groove structure coated with adhesive. Next, the pattern forming material is sequentially transferred and patterned into a pattern using the transfer patterning machines A, A2, A3, . . . . The structure of this transfer patterning machine will be explained with reference to FIG. A pattern forming material 9 in the form of powder, granules, or pellets is stored in a supply hopper 8 and held by an endless suction belt 14 and a leveling roll 10 located below it. The plate belt 14 is made of thermoplastic urethane, soft vinyl chloride resin, ethylene-
A synthetic resin layer such as acetic acid bee copolymer, a vulcanized rubber layer such as EPT, polyptadiene, polychloroprene, butyl rubber, or a photoactivated resin such as an ultraviolet cured film is laminated, and this resin layer or rubber layer is patterned. A mold hole 14' is formed by punching, and the pattern forming material is filled into the mold hole by the rotation action of the leveling roll 10'. The leveling roll 10 is rotated in a direction opposite to the traveling direction of the plate belt, thereby making it easier to fill the mold cavity. The plate belt, which has filled the pattern forming material into the mold holes in this way, progresses forward, and when it reaches the lower part, it is reversed while being sucked by the suction action of the suction roll 11. The suction roll 11 is provided with a large number of suction holes 11', through which particulate matter on the wire mesh is sucked and fixed. Furthermore, a suction shut-off device 11'' is provided inside the suction roll, and can be arbitrarily adjusted to release this suction/fixing action when the mold cavity reaches a predetermined position, that is, a position parallel to the base material. It has a semi-cylindrical shape that is inscribed on the inner surface of the suction roll. When this suction action is released, the pattern forming material filled in the mold cavity is released by its own weight or by the action of the dropping device 11'''. The pattern is transferred onto the adhesive surface of the base material without destroying the pattern.The falling device 11 shows a method using a blower nozzle in Figure 8, but it is not limited to this method. Mechanical methods such as rolls are also effective.Suction endless plate belt 1
4 is suspended on a roll group consisting of a suction roll 11, guide rolls 12, 12', and a receiving roll 13, and is rotated and moved by the drive of these rolls. In addition, as mentioned above, the surface of the plate belt is composed of a synthetic resin layer or a vulcanized rubber layer, so that the pattern forming material can easily fall from the mold cavity.
In addition, a brush roll 15 is provided for applying a template agent 18 to prevent foreign matter from adhering to the surface of the plate belt other than the mold holes. The mold release agent 18 is placed in a container 17, transferred to a brush roll 15 by a pumping roll 16, and applied to the plate belt.

Further, the guide roll 12' is provided to prevent the plate belt from being stirred and may be omitted, or on the other hand, if the stirring is large, the number of guide rolls may be increased. The plate belt 14 should be replaced arbitrarily depending on the pattern of the multicolor pattern sheet, and in the case of the present invention, one pattern sheet is composed of a combination of a, a2, and a3, but instead of this, , a',, is 2, a'3...
By replacing the plate belt with a plate belt made of another combination, other pattern sheets can be obtained. This attachment/detachment is relatively easy; narrowing the gap between the suction roll 11 and the guide roll 12 loosens the plate belt, so the plate belt can be pulled out laterally and removed, another plate belt inserted, and the plate belt loosened. The distance between the roll 11 and the guide roll 12 is widened. In this case, it is of course necessary to adjust the marking machine for the synchronization mark so as to match this pattern and to replace the concavo-convex squeeze roll. Furthermore, it requires adjustment of the detector. As another embodiment of the transfer patterning apparatus, as shown in FIG. 9, it is very effective to use a suction type receiving roll 13' as the receiving roll under the supply hopper.

In the method shown in FIG. 8, the weight of the pattern forming material 9 and the leveling roll 1 are
The method shown in FIG. 9 is effective in the case of a pattern-forming material that is filled into the mold cavity by the feeding action of zero, but which tends to cause bridging of granules in the hopper. Suction type receiving roll 13'
is also provided with a suction hole 13'' and a suction shutoff device,
The suction start position and suction release position can be freely adjusted. However, in the case of fluid materials, suction is not necessarily required. A first pattern a. is transferred onto the base material, and then a second pattern a2 is applied to the vacant area other than a by the second transfer patterning machine A2, and a second pattern a2 is further applied to the vacant area other than a,, a2 by the first transfer patterning machine A3. Three patterns a3 are sequentially transferred and patterned.
The number of patterns should be set arbitrarily, and in the case of only a, only a, ten a2, the case of a, ten a2, ten a3, and when there are many colors and patterns, transfer patterning machine It should be added and patterned using the same method. Furthermore, it is effective to implement the present invention to provide an electric heater between each patterning machine for temporarily fusing the pattern material, and this is effective in preventing pattern shift during patterning in the next process. In particular, when the pattern forming material is a fluid material mainly composed of vinyl chloride resin paste mixed with colored particulate matter, it is extremely effective in preventing the patterns from mixing together. However, this heater is omitted in FIG. After patterning a, a2, a3... in this way, these patterned sheets are heated in a heating furnace 20 to soften the pattern forming material to a weldable state and at the same time completely coat the adhesive layer 4. Immediately after the patterned sheet leaves the heating oven,
That is, while the pattern forming material is heated and softened, the pattern forming material is compressed and tightly bonded by passing through the pressure roll devices 21 and 22 while the pattern forming material is heated and softened, and the adhesion with the adhesive is made more complete, and the patterned surface is It smoothes the surface.

Next, the coating device 2
3. Apply a transparent resin layer. The transparent resin layer protects the pattern layer, improves abrasion resistance, prevents contamination, and fills the joints between each pattern (open spaces between patterns) with resin to prevent excessive stress during the subsequent drawing and pressing process. It is applied to prevent pattern bleeding, and can use vinyl chloride resin paste, vinyl chloride resin solution, mixed solution of vinyl chloride resin and acrylic resin, two-component polyurethane resin, etc. alone or in combination, or ultraviolet curable paint. However, it is not particularly limited as long as it fulfills the above purpose. Suitable coating equipment for this transparent resin is a reverse roll coater, flow coater, etc. that can apply a relatively thick coating solution on the patterned sheet and that does not apply excessive stress to the patterned surface. There is. From this point of view, the round blade doctor type is also suitable. FIG. 1 shows an example of a reverse roll coater, where 24 is a transparent resin liquid, 25 is a squeezing roll, 23 is a reverse roll, and 26 is a backup rubber roll. The patterned sheet coated with transparent resin is passed through a heating furnace 27,
Complete drying and gelation of the transparent resin layer and coating with pattern forming material. The cross-sectional structure of the patterned sheet in each step, that is, the cross section along the row 0' line in Figure 1 is shown in Figure 3, the mm' line cross section is shown in Figure 4, the W-W' line cross section is shown in Figure 5, A cross section taken along line V-V' is shown in FIG. The heated patterned sheet leaving the heating furnace 27 is immediately transferred to the synchronized concavo-convex pressing devices 28 and 29.
28', 28 to make a patterned sheet.
The cross-sectional structure along the -W' line of
As shown in the figure, in the case of Fig. 7, the third pattern a3 is a concave part, the first pattern a is a convex part, and the second pattern a2 is an intermediate convex part. However, this should be arbitrarily selected according to the pattern, and is not limited to the three levels of high, medium, and low as shown in FIG. The diaphragm must be pressed in accordance with the synchronized uneven diaphragm pressing patterns a, , a2, and a3. The device first detects the detection mark 6' made by the marking machine 6 by a synchronized mark detector 301 installed immediately or immediately before the squeeze and push devices 27 and 28, and then rotates the squeeze and push roll at the correct position. Control yourself as if you were. This control is normally performed by issuing a slight rotational slowing speed command, since it is sufficient to follow the slight expansion and contraction of the base material during the process. The thus obtained multicolor patterned sheet has patterns a,
, a2, and a3 by changing their colors and patterns,
A variety of design effects can be obtained, and since it has a concave and convex aperture press that matches this pattern, it has the above design effects,
This results in an extremely excellent multicolored patterned sheet with a three-dimensional effect.

Furthermore, unlike printed products, this sheet is composed of a pattern-forming material in which each pattern layer is the same throughout, so when used for flooring, etc., the same pattern will continue to appear one after another even as it wears out. The pattern effect will not be lost. In addition, since it has a protective layer on its surface, it has excellent stain resistance and abrasion resistance, and can be waxed easily.

[Brief explanation of the drawing]

The drawings show an embodiment of the multicolor pattern sheet manufacturing apparatus according to the present invention, in which FIG. 1 is a schematic side view, FIG. 2 is a sectional view taken along the line 1-1' in FIG. Fig. 1 0-0' sectional view,
Figure 4 is a sectional view taken along line m-m' in Figure 1, and Figure 5 is a sectional view taken along line W-- in Figure 1.
W' line sectional view, Figure 6 is Figure 1 V-V' line sectional view, Figure 7
The figure is a sectional view taken along the line W-W' in Figure 1, and Figure 8 is a perspective view of the main parts.
FIG. 9 is a longitudinal sectional side view of a portion of the same. 1... Wide and long base material, 3... Adhesive applicator, 6...
...Marking machine, 21, 22...Press roll device,
23... Coating device, 24... Transparent resin layer, 28... Synchronized concavo-convex squeeze device, 30... Mark detector, A,,
A2... Transfer patterning machine. Figure 1 Figure 2 Figure 3 Figure 4 Figure 5 Figure 6 Figure 7 Figure 8 Figure 9

Claims (1)

[Scope of Claims] 1. During the transport path of a long base material coated with an adhesive on its back surface, the pattern forming material supplied to the desired punching pattern formed on the endless belt is forced by a suspended suction roll of the endless belt. When the suction reaches the base material, the suction action is released and the pattern-forming material is transferred onto the base material, and a pattern-forming material of a color different from the pattern is further transferred onto the base material by the same operation as described above. Transfer, then press the pattern on the base material, make the thickness uniform at the same time, and then layer a transparent resin layer on the entire top surface.
A method for producing a multicolor patterned sheet, which is then passed through a heating furnace to gel and dry it, and immediately after leaving the furnace, it is squeezed into irregularities that match the pattern, and then cooled. 2. A detection mark for synchronized aperture pressing is attached to the base material coated with adhesive on the back side, and the detection mark is detected by a synchronization detector immediately or just before the synchronized concavo-convex aperture pressing process, and a synchronized concave-convex aperture press that matches the pattern is detected. A method for producing a multicolor patterned sheet according to claim 1. 3 During the transport route of the wide and long base material 1, the adhesive applicator 3
, a marking machine 6 for synchronization detection marks, a transfer pattern making machine A_1, A_2, etc. using an endless suction belt type, a heating furnace 20 for softening the pattern forming material to a weldable state, and a heating furnace 20 for softening the pattern forming material in the softened state. Press roll devices 21 and 22 for compression
A multicolor patterned sheet characterized by being provided with a coating device 23 for a transparent resin layer 24, a synchronized concavo-convex squeeze device 28, and a tuning mark detector 30 immediately after or just before the squeeze device. Manufacturing equipment. 4 The transfer pattern forming machines A_1, A_2... transfer the pattern forming material 9
A suction endless plate belt 14 having a punching die hole 14' for filling and storing the pattern forming material 9 in a pattern, and a suction roller 1 for supplying the hopper 8 and the leveling roll 10.
4. The multicolor pattern sheet manufacturing apparatus according to claim 3, wherein the multicolor pattern sheet manufacturing apparatus is removably suspended from a roll group consisting of 1, guide rolls 12, 12', and receiving roll 13. 5. The multicolor pattern sheet manufacturing apparatus according to claim 3, wherein a suction shielding device 11'' is provided inside the suction roll 11. 6. The receiving roll 13 has a suction hole 13', and the suction shielding device 11'' is provided inside the suction roll 11. 4. The method for producing a multicolor patterned sheet according to claim 3, wherein the suction type receiving roll has a blocking device 13''.