CN109383014A - 塑胶地板的立体压纹制程方法及其结构 - Google Patents

塑胶地板的立体压纹制程方法及其结构 Download PDF

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CN109383014A
CN109383014A CN201710653363.9A CN201710653363A CN109383014A CN 109383014 A CN109383014 A CN 109383014A CN 201710653363 A CN201710653363 A CN 201710653363A CN 109383014 A CN109383014 A CN 109383014A
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plastic floor
pattern
printing layer
roll
printing
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CN109383014B (zh
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陆钉毅
赵培东
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Lu Dingyi
Wuxi Boyu Plastic Machinery Co ltd
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Abstract

本发明提供一种塑胶地板的立体压纹制程方法及其结构，其系先将基板及具有空白表面的印刷层利用一辊压单元辊压为一体，并且同时于该印刷层表面成型一立体的形态的压纹图案，再利用一数字打印单元将对应该压纹图案的颜料打印于该压纹图案上。之后再通过一涂布单元将呈融胶状的耐磨层原料涂布于该印刷层上，并将涂布耐磨层原料后的塑胶地板材施以高温烘烤，使耐磨层干燥硬化成型，等待塑胶地板材冷却后，再依所需的尺寸大小裁切成塑胶地板成品。不仅能使塑胶地板的图案更为立体、美观，且也能方便依客户的需求变换不同的图案花纹。

Description

塑胶地板的立体压纹制程方法及其结构
技术领域
本发明涉及一种塑胶地板，特别系指一种将印刷层的图案花纹在生产线上直接进行的塑胶地板制作方法。
背景技术
按，利用塑胶材料制成地板以取代天然木材，减少对自然资料的破坏，是现今塑胶地板产品开发的趋势，而为了增加塑胶地板产品的外观美感，都会在其印刷层上印刷各式的纹路或图案。由背景技术可知，一般塑胶地板的图案花纹，都是预先印制于该印刷层上，制造时，再一并连同基板与耐磨层辊压成型为一体，就视觉效果而言，印刷层上的花纹图案是平面的，为了增进立体美感，另外于塑胶地板外缘形成压纹图案，然而因为图案花纹是印在印刷层上，而压纹是成型在耐磨层上，产生的视觉效果无法确实呈现一体式的立体的美感，同时也无法印刷图案也无法与压纹准确对应，形成视觉美感的落差。另外一般塑胶地板上的印刷图案都是固定的，无法针对客户需要的图案或花纹量身订作，有加以改善的必要。
发明内容
本发明的主要目的，提供一种塑胶地板的立体压纹制程方法及其结构，其系令塑胶地板的图案花纹能在生产线上以打印方式完成，增进图案花纹多样变化选用的方便性，并且令打印的图案花纹与立体压纹图案在同一层面，以提升立体花纹的美感效果。
为实现上述目的，本发明采用的技术方案是：
一种塑胶地板的立体压纹制程方法，其特征是包括：
A.取得一基板，并将该基板输送至一辊压单元；
B.输送一印刷层，该印刷层表面空白，利用一第二放卷机构将该印刷层输送至辊压单元；
C.辊压成型，利用该辊压单元将该基板及印刷层辊压黏合为一塑胶地板材，同时并在该印刷层表面辊压成型一立体形态的压纹图案；
D.数码打印，利用一数字打印单元将色彩颜料打印于该印刷层的压纹图案上；
E.涂布耐磨层，利用一涂布单元将呈融胶状的耐磨层原料涂布于该印刷层上；
F.定型，将涂布耐磨层原料后的塑胶地板材施以定型处理，使耐磨层干燥硬化成型；
G.分切，等待塑胶地板材冷却后，再依所需的尺寸大小裁切成塑胶地板成品。
所述的塑胶地板的立体压纹制程方法，其中：该基板利用一挤出机挤出成型后，输送至该辊压单元，或利用一第一放卷机构卷绕基板，以放卷方式输送供应至该辊压单元。
所述的塑胶地板的立体压纹制程方法，其中：该辊压单元为五辊式的压延机，其是一机架上设置一定厚辊组、预贴辊组及压合辊组，该定厚辊组由若干辊轮组成，设于该预贴辊组一侧，该预贴辊组由一大辊轮及若干设于该大辊轮外围的导辊构成，而该压合辊组由若干辊轮组成，设于该预贴辊组另一侧，且至少其中一辊轮的轮面上形成有图案刻纹，用以将该基板、印刷层压合成型为一体时，同时在该印刷层表面形成一压纹图案。
所述的塑胶地板的立体压纹制程方法，其中：该数字打印单元是在第一机体上设有一第一平台，对应该第一平台上方设有一打印机构，该打印机构具有一集料座，该集料座一端与供应打印用颜料的来源处相接，另一端凸设有向外输出颜料的出料部，该打印机构受一电控系统控制，当塑胶地板材被输送至特定位置时，由该出料部依预先在电控系统上的图案设定，将颜料打印于该印刷层的压纹图案上。
所述的塑胶地板的立体压纹制程方法，其中：该数字打印单元将颜料打印于该压纹图案上时，预先在该印刷层上依一固定的长度分别设置若干定位原点，当该电控系统感测到定位原点时，即控制该打印机构进行打印，而能准确的将不同色泽的颜料打印于对应的压纹图案上。
所述的塑胶地板的立体压纹制程方法，其中：该涂布单元是一第二机体上设一第二平台，并在对应该第二平台上方设一涂布机构，该涂布机构一端与供应耐磨层原料的来源处相接，另一端向外输出耐磨层原料，该涂布机构受一电控系统控制，当塑胶地板材被输送至特定位置时，将耐磨层原料涂布于该印刷层上。
所述的塑胶地板的立体压纹制程方法，其中：该步骤F.定型，是依不同材质使用不同方式，如PVC耐磨层使用干燥硬化成型，UV耐磨层可以用UV灯照射方式，而干燥硬化可应用烘烤定型，是在塑胶地板的自动化生产线中设一热烘机，该热烘机上缘设有一第三平台，并在对应该第三平台上方设一电热源，该热烘机受电控系统控制，当涂布耐磨层原料的塑胶地板材被输送至该第三平台上时，利用该热电源产生的高温进行烘烤作业。
所述的塑胶地板的立体压纹制程方法，其中：该塑胶地板分切成品后，在相对的二侧形成第一扣部及第二扣部，令相邻的二塑胶地板在装配时，能利用对应的第一扣部及第二扣部连结固定。
一种塑胶地板的立体压纹结构，其特征是包括：
一基板；
一印刷层，该印刷层表面成型有一立体形态的压纹图案，该压纹图案上设有一层颜料；
一耐磨层，是透明材质，形成于该印刷层上；
如此，利用该压纹图案同时在该印刷层上呈现平面图案与立体压纹，使塑胶地板的图案花纹能呈现立体形态的压纹结构。
本发明的优点在于：通过先将基板及具有空白表面的印刷层利用该辊压单元辊压为一体，并且同时于该印刷层表面成型一立体的形态的压纹图案，再利用该数字打印单元将对应该压纹图案的颜料打印于该压纹图案上。之后再通过涂布单元将呈融胶状的耐磨层原料涂布于该印刷层上，并利用该热烘机将涂布耐磨层原料后的塑胶地板材施以高温烘烤，使耐磨层干燥硬化成型，等待塑胶地板材冷却后，再依所需的尺寸大小裁切成塑胶地板成品。如此，利用打印的图案花纹与立体形态的压纹图案位于同一层面上，不仅能使塑胶地板的图案更为立体、美观，且也能方便依客户的需求变换不同的图案花纹，增进产业竞争性。
有关本发明所采用的技术、手段及其功效，兹举一较佳实施例并配合图式详细说明于后，相信本发明上述的目的、构造及特征，当可由的得一深入而具体的了解。
附图说明
图1是本发明制造设备的组成架构平面图。
图2是本发明辊压单元搭配挤出机的组合平面图。
图3是本发明辊压单元搭配放卷机构的组合平面图。
图4是本发明塑胶地板材完成步骤C的组合剖面图。
图5是本发明塑胶地板材完成步骤D的组合剖面图。
图6是本发明塑胶地板材完成步骤E的组合剖面图。
图7是本发明塑胶地板成品的立体图。
图8是本发明塑胶地板利用第一扣部与第二扣部连结的使用示意图。
附图标记说明：塑胶地板1；塑胶地板材1’；基板10；印刷层20；第二放卷机构21；压纹图案22；耐磨层30；辊压单元40；机架41；定厚辊组42；辊轮421；预贴辊组43；大辊轮431；导辊432；压合辊组44；辊轮441；图案刻纹442；数字打印单元50；第一机体51；第一平台52；打印机构53；集料座 531；出料部532；感应元件533；涂布单元60；第二机体61；第二平台62；涂布机构63；热烘机70；第三平台71；电热源72；电控系统80；挤出机91；第一放卷机构92；第一扣部93；第二扣部94；颜料95。
具体实施方式
请参阅图1-图8所示，本发明塑胶地板的立体压纹制程方法及其结构其系将一基板10、印刷层20及耐磨层30利用一辊压单元40、数字打印单元50、涂布单元60、热烘机70及电控系统80等设备的辅助，在塑胶地板的自动化生产线中，以线上打印的方式成型不同的图案花纹，同时将印刷层的平面图案与立体型态的压纹成型于同一层面上，其制程包括：
取得基板10，并将该基板10输送至辊压单元40，该基板10可利用一挤出机91挤出成型后，再输送至该辊压单元40，或如图3，利用一第一放卷机构92 卷绕基板10，以放卷方式输送供应至该辊压单元40。
B.输送印刷层20，该印刷层20表面空白，利用一第二放卷机构21将该印刷层20输送至辊压单元40。
C.辊压成型，利用该辊压单元40将该基板10及印刷层20辊压黏合为一塑胶地板材1’，同时并在该印刷层20表面辊压成型一立体形态的压纹图案22。该辊压单元40可为五辊式的压延机，其是一机架41上设置一定厚辊组42、预贴辊组43及压合辊组44，该定厚辊组42由二辊轮421相邻设置组成，设于该预贴辊组43一侧，该预贴辊组43由一大辊轮431及若干设于该大辊轮431外围的导辊432构成；而该压合辊组44由若干辊轮441组成，设于该预贴辊组43 另一侧，且至少其中一辊轮441的轮面上形成有图案刻纹442，用以将该基板 10、印刷层20压合为一体时，同时于该印刷层20表面形成预设的压纹图案22。
D.数码打印，利用该数字打印单元50将色彩颜料95，打印于该印刷层20 的压纹图案22上。该数字打印单元50是第一机体51上设有一第一平台52，对应该第一平台52上方设有一打印机构53，该打印机构53具有一集料座531，该集料座531一端与供应打印用颜料95的来源处相接，另一端凸设有向外输出颜料95的出料部532，该打印机构53可受该电控系统80控制，当塑胶地板材 1’被输送至特定位置时，由该出料部532依预先于电控系统50上的图案设定，将颜料95打印于该印刷层20的压纹图案22上。且该数字打印单元50将颜料 95打印于该压纹图案22上时，可预先于该印刷层20上依一固定的长度分别设置若干定位原点，二定位原点间的距离，约略等于成型有图案刻纹442的辊轮 441的直径，且二定位原点之间也可再设置若干确认点，用以确认打印的行程是否和预先在系统中的设定相同；又该打印机构53上设有一感应元件533，该感应元件533与电控系统50电性连接，当该电控系统50利用该感应元件533感测到定位原点时，即控制该打印机构53进行打印，准确的将不同色泽的颜料打印于对应的压纹图案22上，呈现对花的图案效果。
E.涂布耐磨层，利用一涂布单元60将呈融胶状的耐磨层原料涂布于该印刷层20上，该耐磨层原料可为UV，或由PVC加可塑剂、稳定剂、助剂所组成的树酯糊等构透材质，并可再视需要添加防霉抗菌原料及抗刮原料。又该涂布单元60是一第二机体61上设一第二平台62，并在对应该第二平台62上方设一涂布机构63，该涂布机构63一端与供应耐磨层原料的来源处相接，另一端可向外输出耐磨层原料；该涂布机构63可受电控系统80控制，当塑胶地板材1’被输送至特定位置时，可将耐磨层原料涂布于该印刷层20上。
F.定型，将涂布耐磨层原料后的塑胶地板材1’施以定型处理，使耐磨层30 干燥硬化成型；而定型的制程，可依不同材质使用不同方式，PVC耐磨层30使用干燥硬化成型，UV耐磨层可以用UV灯照射方式，其中干燥硬化可应用烘烤定型，可于塑胶地板的自动化生产线中设一热烘机70，该热烘机70上缘设有一第三平台71，并在对应该第三平台71上方设一电热源72，该热烘机70可受电控系统80控制，当涂布耐磨层原料的塑胶地板材1’被输送至该第三平台71上时，系利用该热电源72产生的高温进行烘烤作业。
G.分切，热烘完成后的塑胶地板材1’常温冷却后，再依所需的尺寸大小裁切成塑胶地板1成品。且若为硬质的塑胶地板1，可于相对的二侧形成第一扣部 93及第二扣部94，令相邻的二塑胶地板10在装配时，能利用对应的第一扣部 93及第二扣部94连结固定。
如此，利用上述塑胶地板1的花纹图案利用线上打印方式成型，不仅能方便依客户的需求作不同图案花纹的变换，同时利用打印的图案花纹与立体形态的压纹图案22位于同一个印刷层20上，能使塑胶地板1的图案更为立体、美观，增进产业竞争性。
以上说明对本发明而言只是说明性的，而非限制性的，本领域普通技术人员理解，在不脱离权利要求所限定的精神和范围的情况下，可作出许多修改、变化或等效，但都将落入本发明的保护范围之内。

Claims (9)

1.一种塑胶地板的立体压纹制程方法，其特征是包括：
A.取得一基板，并将该基板输送至一辊压单元；
B.输送一印刷层，该印刷层表面空白，利用一第二放卷机构将该印刷层输送至辊压单元；
C.辊压成型，利用该辊压单元将该基板及印刷层辊压黏合为一塑胶地板材，同时并在该印刷层表面辊压成型一立体形态的压纹图案；
D.数码打印，利用一数字打印单元将色彩颜料打印于该印刷层的压纹图案上；
E.涂布耐磨层，利用一涂布单元将呈融胶状的耐磨层原料涂布于该印刷层上；
F.定型，将涂布耐磨层原料后的塑胶地板材施以定型处理，使耐磨层干燥硬化成型；
G.分切，等待塑胶地板材冷却后，再依所需的尺寸大小裁切成塑胶地板成品。
2.根据权利要求1所述的塑胶地板的立体压纹制程方法，其特征在于：该基板利用一挤出机挤出成型后，输送至该辊压单元，或利用一第一放卷机构卷绕基板，以放卷方式输送供应至该辊压单元。
3.根据权利要求1所述的塑胶地板的立体压纹制程方法，其特征在于：该辊压单元为五辊式的压延机，其是一机架上设置一定厚辊组、预贴辊组及压合辊组，该定厚辊组由若干辊轮组成，设于该预贴辊组一侧，该预贴辊组由一大辊轮及若干设于该大辊轮外围的导辊构成，而该压合辊组由若干辊轮组成，设于该预贴辊组另一侧，且至少其中一辊轮的轮面上形成有图案刻纹，用以将该基板、印刷层压合成型为一体时，同时在该印刷层表面形成一压纹图案。
4.根据权利要求1所述的塑胶地板的立体压纹制程方法，其特征在于：该数字打印单元是在第一机体上设有一第一平台，对应该第一平台上方设有一打印机构，该打印机构具有一集料座，该集料座一端与供应打印用颜料的来源处相接，另一端凸设有向外输出颜料的出料部，该打印机构受一电控系统控制，当塑胶地板材被输送至特定位置时，由该出料部依预先在电控系统上的图案设定，将颜料打印于该印刷层的压纹图案上。
5.根据权利要求4所述的塑胶地板的立体压纹制程方法，其特征在于：该数字打印单元将颜料打印于该压纹图案上时，预先在该印刷层上依一固定的长度分别设置若干定位原点，当该电控系统感测到定位原点时，即控制该打印机构进行打印，而能准确的将不同色泽的颜料打印于对应的压纹图案上。
6.根据权利要求1所述的塑胶地板的立体压纹制程方法，其特征在于：该涂布单元是一第二机体上设一第二平台，并在对应该第二平台上方设一涂布机构，该涂布机构一端与供应耐磨层原料的来源处相接，另一端向外输出耐磨层原料，该涂布机构受一电控系统控制，当塑胶地板材被输送至特定位置时，将耐磨层原料涂布于该印刷层上。
7.根据权利要求1所述的塑胶地板的立体压纹制程方法，其特征在于：该步骤F.定型，是依不同材质使用不同方式，如PVC耐磨层使用干燥硬化成型，UV耐磨层可以用UV灯照射方式，而干燥硬化可应用烘烤定型，是在塑胶地板的自动化生产线中设一热烘机，该热烘机上缘设有一第三平台，并在对应该第三平台上方设一电热源，该热烘机受电控系统控制，当涂布耐磨层原料的塑胶地板材被输送至该第三平台上时，利用该热电源产生的高温进行烘烤作业。
8.根据权利要求1所述的塑胶地板的立体压纹制程方法，其特征在于：该塑胶地板分切成品后，在相对的二侧形成第一扣部及第二扣部，令相邻的二塑胶地板在装配时，能利用对应的第一扣部及第二扣部连结固定。
9.一种塑胶地板的立体压纹结构，其特征是包括：
一基板；
一印刷层，该印刷层表面成型有一立体形态的压纹图案，该压纹图案上设有一层颜料；
一耐磨层，是透明材质，形成于该印刷层上；
如此，利用该压纹图案同时在该印刷层上呈现平面图案与立体压纹，使塑胶地板的图案花纹能呈现立体形态的压纹结构。
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WO2020211389A1 (zh) * 2019-04-19 2020-10-22 浙江晶通塑胶有限公司 一种塑胶地板表面处理方法
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CN112848587A (zh) * 2020-12-31 2021-05-28 浙江晶通塑胶有限公司 生产抗菌塑胶地板的方法
CN113798135A (zh) * 2021-08-25 2021-12-17 佛山市顺德区普瑞特机械制造有限公司 一种耐磨耐刮地板及其制备方法和生产线

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