IE73444B1 - A method for producing coated fabric - Google Patents

Abstract

PVC coated fabric is produced by applying a topping PVC material, followed by a foam paste layer, and a laminating material onto a release face of a paper substrate material. A fabric backing layer is applied over the laminating layer to form a composite. The paper substrate is removed from the composite any imperfections are removed and the paper is wound on a reel for recycling. A reel of PVC coated fabric is delivered to a printing station at which, in one oepration, indicia are printed on the exposed face of the fabric backing layer and a desired pattern is printed on the exposed face of the PVC topping layer. A lacquer is then applied and the material is embossed.

Description

A method for producing coated fabric The invention relates to a method for producing P.V.C. coated fabric.

According to the invention there is provided a method for producing PVC coated fabric comprising the steps of: unwinding a substrate material having a release face from a reel; preparing an outer topping material of PVC in a liquid form; applying the liquid topping material to the release face of the substrate; spreading the liquid topping material across the substrate to a desired thickness to form a topping layer on the substrate; heating the substrate with the topping layer applied in a pre-gelling oven at a temperature of from 140°C to 170°C; passing the substrate with the topping layer applied over cooling rollers; preparing a foam paste material; applying the foam paste material to the exposed face of the topping layer; spreading the foam paste material across the topping layer to form a foam paste layer of desired thickness; heating the substrate with the topping layer and the foam paste layer applied in a second oven at a temperature of from 150°C to 180°C; passing the substrate with the topping and foam layers applied over cooling rollers; applying a liquid laminating material over the exposed face of the foam layer; spreading the laminating material over the foam layer to form a laminating layer of desired thickness; stretching a fabric backing material; applying the stretched fabric backing material over the laminating layer to form a composite; first stage heating of the composite in an oven at a temperature of from 180°C to 200°C; second stage heating of the composite in an oven at a temperature of from 190°C to 210°C; third stage heating of the composite in an oven at a temperate of from 195°C to 215°C; passing the heated composite over first stage cooling rollers; » passing the partially cooled composite over second stage cooling rollers; passing the cooled composite over third stage cooling rollers; removing the substrate material from the composite; winding the substrate material onto a roll; recycling the substrate material by unwinding the substrate material from the roll; removing imperfections from the substrate material while unwinding; rewinding the substrate material onto a roll for reuse; trimming the side edges of the composite material; winding the composite material onto a roll; printing indicia on the fabric backing of the composite material; printing on the exposed outer face of the topping layer of the composite; drying the printed composite; embossing the composite; and applying a lacquer to the composite. i In a particularly preferred embodiment of the invention, • the lacquer is applied to the printed composite prior to embossing.

In one embodiment of the invention, the lacquered printed composite is dried prior to embossing.

In a preferred arrangement, the recycling of the substrate material includes the steps of :detecting the alignment of the unwound substrate material; and adjusting the position of a roller on which the substrate material is to be rewound so that the substrate material being rewound is aligned with the rewinding roller.

Preferably, the alignment of the unwound substrate is detected by a location sensor and the position of the rewinding roller is automatically adjusted to correspond with the alignment detected by the sensor. In a preferred embodiment of the invention, the sensor comprises an arm which is pivotally mounted at one end and engages a side edge of the substrate at the other end, the arm being connected to a controller and movement of the arm from a predetermined aligned position causing the controller to effect a corresponding movement in the rewinding roller. Preferably, the rewinding roller is mounted on a track means and is proportionally moved along the track means by a ram means in response to a signal from the controller.

In a preferred embodiment of the invention, the method includes the step of tensioning the substrate material to match the speed of the substrate with the topping layer applied.

In one embodiment of the invention, the method includes the step of leading the substrate material along a settling station prior to spreading the topping material on the substrate. Preferably, the settling station is provided by a settling tray across which the substrate is led prior to spreading of the topping material on the substrate.

In a preferred embodiment of the invention, the foam paste material .is delivered into a hopper from which it is applied to the topping layer. Preferably, the foam paste is introduced into a storage tank equipped with a mixer, agitating the mixture and delivering foam paste from the storage tank on demand. In a preferred arrangement, the storage tank has inclined side walls and an inclined floor to direct the foam paste to an outlet of the tank.

In a particularly preferred embodiment of the invention, the method includes the step of fourth stage cooling of the composite prior to removal of the substrate material.

In a preferred embodiment of the invention the heated composite material from the oven is led through an air space of from 2 to 3 metres prior to application of the cooling rollers.

In one embodiment of the invention, the stretched by first stretching with a first roller and second stretching with a second roller. fabric is stretching stretching The invention also provides PVC coated upholstery material whenever prepared by the method of the invention.

The invention will be more clearly understood from the following description thereof given by way of example only with reference to the accompanying drawings in which:Fig. 1 is a schematic side view of part of a method of producing upholstery material according to the invention; Fig. 2 is a side elevational view of an unreeling station for substrate material; Fig. 3 is a plan view of portion of the station of Fig. ‘ 2; Fig. 4 is a perspective view of a topping station used in the method of the invention; Fig. 5 is a side elevational view of the topping station of Fig. 4; Fig. 6 is a perspective view of a foam applying station used in the method of the invention; Fig. 7 is a side view of the station of Fig. 6; Fig. 8 is a side elevational view of substrate material recycling system used in the method of the invention; Fig. 9 is a plan view of part of the substrate recycling system illustrated in Fig. 8; Fig. 10 is a perspective view of a foam paste mixing and storage tank used in the method of the invention; Fig. 11 is a side elevational view on a reduced scale of the tank of Fig. 10; and Fig. 12 is a front elevational view on a reduced scale of the tank of Fig. 10.

PVC coated fabric is produced by a method according to the invention in which a substrate material 1 of paper material having a release coating on one face is unwound from a reel 2 and passed along guide rollers 3 to a topping applying station 4 at which a topping PVC material is applied to the release layer of the substrate 2 from a container. 5 having a valved outlet 7. The topping material is allowed to settle at a settling station 8 which will be described in more detail below, before spreading at 9 a liquid topping material to the release face of the substrate. The coating head may be a roller over roller arrangement for uniform distribution The substrate with the topping layer applied is then heated in a pre-gelling oven 10 to a temperature of from 140°C to 170°C, preferably approximately 160°C. The substrate with the topping layer applied is then led over cooling rollers 11(a) and guide rollers 11(b) to a foam paste applying station 12 at which the foam paste material is applied to the exposed face of the topping layer on the substrate. The foam paste material is spread across the topping layer at 13 to form a foam paste layer of desired thickness. A screen roller which picks up laminating paste and applies it to the foam layer may be used.

The substrate with the topping layer and foam paste layer applied is then heated in a second stage oven 14 at a temperature from 150°C to 180°C, preferably approximately 170°C. The substrate with the topping and foam layers applied is then passed over cooling rollers 16 and guide rollers 17 to a laminating station 18 at which a liquid laminating material is applied over the exposed space of the foam layer to form a laminating layer of desired thickness. A screen roller which picks up laminating paste and applies it to the foam layer may be used.

A fabric backing material 20 is led from a supply roller 21 and stretched by a first stage stretching roller 22 and a second stage stretching roller 23 before applying the stretched fabric backing material over the laminating layer to form a composite 25. The composite 25 is then heated in the first stage 26 of an oven to from 180°C to 200°C, preferably 190°C and then passed to a second stage 27 of the.oven in which the composite is further heated to a temperature of from 190°C to 210°C before, preferably 200°C, before finally passing to a third stage 28 of the oven in which the composite is heated to from 195°C to 215°C, preferably 205°C.

The heated composite 25 is passed through an air space of between 2 and 3 metres long for pre-cooling and then over a pair of first stage cooling rollers 29. The partially cooled composite is then passed over second and third stage heating rollers 30, 31. The cooled composite is further passed over an additional fourth stage heating roller 32 before the substrate material 1 is stripped off the composite 25 and wound onto a reel 35. The PVC coated fabric with the backing substrate removed is led around guide rollers 37, edge trimmed at 36 and wound onto a reel 38.

The reel 38 of PVC coated fabric is delivered to a printing station at which, in one operation, indicia are printed on the exposed face of the fabric backing layer and a desired pattern is printed on the exposed face of the PVC topping layer. A lacquer is applied over printed surface of the topping layer and the material is dried. After drying, the material is embossed to produce a desired 3-dimensional pattern on the surface of the material.

In more detail and referring particularly to Figs. 2 and 3, the reel 2 of the substrate material 1 is mounted on a shaft 50 having a disc 51 which is engageable by a two-jaw brake 53. The brake 53 is operated in response to the required tension of the substrate material being fed into the pre-gelling oven 10 to ensure that the substrate 1 is correctly tensioned.

Referring particularly to Figs. 4 and 5, the settling station 8 for the liquid topping material is provided by a tray 55 which allows the topping material to spread and settle on the substrate 1 prior to spreading of the topping material by means of a knife 9 to a required thickness.

Referring particularly to Figs. 6 and 7, liquid foam paste is introduced onto the topping layer from a trough defined by an adjustable trough plate 60 and a pair of adjustable side trough plates 61. The trough assists in controlling the flow of liquid foam paste onto the topping layer prior to spreading with the blade 13.

Referring particularly to Figs. 10 to 12, the liquid foam paste is prepared and introduced into a storage tank 65 mounted on support legs 66. The tank 65 is fitted with an agitator for mixing the liquid foam paste and for ensuring complete mixing of the paste, as required. It will be noted that lower side wall portions 67 and a floor 68 of the tank 65 are inclined inwardly downwardly towards an outlet 69 of the tank provided with a valve 70. The liquid foam paste is available from the tank 65 on demand.

Referring particularly to Figs. 8 and 9, the reel 51 of substrate paper is mounted on a frame 70 and unreeled over a table 71 at which imperfections in the material may be removed by splicing out the affected section which is collected on a waste roller 72. The recyclable substrate 7 3 is passed around guide rollers 74 and rewound on a reel 75. The reel 75 is mounted on a support 76 having rollers which run along tracks 78 in response to operation of a ram 8 0.

For correct alignment of the recycled substrate 73 with the rewind roller 75, an alignment sensor 80 is provided. The sensor 80 includes an arm 81 which is pivotally mounted at an upper end thereof to hang downwardly to engage a side edge of the sheet 73 of substrate material. If the sheet 73 moves out of alignment, the arm 81 moves which sends a signal to a controller 85 which in turn causes the ram 79 to operate proportionately to the position of the sensor 80 to correctly align the roller with the substrate 73.

The invention is not limited to the embodiments hereinbefore described which may be varied in both construction and detail.

Claims (18)

1. A method for producing PVC coated fabric comprising the steps of: unwinding a substrate material having a release 5 face from a reel; preparing an outer topping material of PVC in a liquid form; applying the liquid topping material to the release face of the substrate; 10 spreading the liquid topping material across the substrate to a desired thickness to form a topping layer on the substrate; hearing the substrate with the topping layer applied in a pre-gelling oven at a temperature 15 of from 140°C to 170°C; passing the substrate with the topping layer applied over cooling rollers; preparing a foam paste material; applying the foam paste material to the exposed 20 face of the topping layer; spreading the foam paste material across the topping layer to form a foam paste layer of desired thickness; heating the substrate with the topping layer and the foam paste layer applied in a second oven at a temperature of from 150°C to 180°C; passing the substrate with the topping and foam layers applied over cooling rollers; applying a liquid laminating material over the exposed face of the foam layer; spreading the laminating material over the foam layer to form a laminating layer of desired thickness; stretching a fabric backing material; applying the stretched fabric backing material over the laminating layer to form a composite; first stage heating of the composite in an oven at a temperature of from 180°C to 200°C; second stage heating of the composite in an oven at a temperature of from 190°C to 21O°C; third stage heating of the composite in an oven at a temperate of from 195°C to 215°C; passing the heated composite over first stage cooling rollers; passing the partially cooled composite over second stage cooling rollers; passing the cooled composite over third cooling rollers; stage removing the substrate material from the composite; winding the substrate material onto a roll; recycling the substrate material by unwinding 5 the substrate material from the roll; removing imperfections from the substrate material while unwinding; rewinding the substrate material onto a roll for re-use; 10 trimming the side edges of the composite material; winding the composite material onto a roll; printing indicia on the fabric backing of the composite material; 15 printing on the exposed outer face of the topping layer of the composite; drying the printed composite; embossing the composite; and applying a lacquer to the composite. A method as claimed in claim 1 wherein the lacquer is applied to the printed composite prior to embossing.

2. 3. A method as claimed in claim 2 wherein the lacquered printed composite is dried prior to embossing.

3. 4. A method as claimed in any preceding claim wherein the recycling of the substrate material includes the steps of :detecting the alignment of the unwound substrate material; and adjusting the position of a roller on which the substrate material is to be rewound so that the substrate material being rewound is aligned with the rewinding roller.

4. 5. A method as claimed in claim 4 wherein the alignment of the unwound substrate is detected by a location sensor and the position of the rewinding roller is automatically adjusted to correspond with the alignment detected by the sensor.

5. 6. A method as claimed in claim 5 wherein the sensor comprises an arm which is pivotally mounted at one end and engages a side edge of the substrate at the other end, the arm being connected to a controller and movement of the arm from a predetermined aligned position causing the controller to effect a corresponding movement in the rewinding roller.

6. 7. A method as claimed in claim 6 wherein the rewinding roller is mounted on a track means and is proportionally moved along the track means by a ram means in response to a signal from the controller.

7. 8. A method as claimed in any preceding claim including the step of tensioning the substrate material to match the speed of the substrate with the topping layer applied.

8. 9. A method as claimed in any preceding claim including the step of leading the substrate material along a settling station prior to spreading the topping material on the substrate.

9. 10. A method as claimed in claim 9 wherein the settling station is provided by a settling tray across which the substrate is led prior to spreading of the topping material on the substrate.

10. 11. A method as claimed in any preceding claim wherein the foam paste material is delivered into a hopper from which it is applied to the topping layer.

11. 12. A method as claimed in any preceding claim wherein the foam paste is introduced into a storage tank, agitating the mixture and delivering foam paste from the storage tank on demand.

12. 13. A method as claimed in claim 12 wherein the storage tank has inclined side walls and an inclined floor to direct the foam paste to an outlet of the tank.

13. 14. A method as claimed in any preceding claim including the step of fourth stage cooling of the composite prior to removal of the substrate material.

14. 15. A method as claimed in any preceding claim wherein the heated composite material from the oven is led through an air space of from 2 to 3 metres prior to application of the cooling rollers.

15. 16. A method as claimed in any preceding claim wherein the fabric is stretched by first stretching with a first stretching roller and second stretching with a second stretching roller. 5

16. 17 . A method substantially as hereinbefore described with reference to the accompanying drawings.

17.

18. PVC coated fabric whenever prepared by a method as claimed in any preceding claim.