JP2000005673A - Roller coater and coating method using the same and material to be coated - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a roller coater equipped with a means by which cleaning of a recessed part on the circumferential face of a transfer roll is effectively performed and thereby a paint film having high design properties and high minuteness is formed on the base material. SOLUTION: The roller coater C is provided with a roll 4 for cleaning which comes into contact with the circumferential face of a transfer roll 2 (rubber layer 11) and cleans coating adhering to the recessed parts on the circumferential face of the transfer roll 2. The roll 4 for cleaning exists on the trailing side apart from a cleaning roll 3 in looking in the direction of rotation of the transfer roll and is arranged in the prescribed position on the leading side apart from a mesh roll 1. Thereby, cleaning of the recessed parts on the circumferential face of the transfer roll 2 is effectively performed by the roll 4 for cleaning. Therefore, paint films 32 having high design properties and high minuteness are formed.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a roll coater, a coating method using the same, and an object to be coated. More specifically, a roll coater having a cleaning roll and a transfer roll, which can apply a highly-designed coating film to a substrate having an uneven surface or a substrate having a smooth surface with high accuracy, The present invention relates to a coating method using the roll coater, and an object on which a substrate is coated with a coating film using the roll coater.

[0002]

2. Description of the Related Art In general, wall materials having an uneven surface, exterior building materials, interior building materials, metal building materials, etc. (hereinafter referred to as "base materials") manufactured in connection with the ceramic industry or metal sizing (cold pressing). Is collectively applied with a coating device such as a roll coater, a screen printing machine, or a spray coating machine. Of these coating equipment, spray coating machines are suitable for applying a uniform coating over the entire surface of the substrate, but are not suitable for applying a decorative coating on a part of the substrate surface. is there. Also, the screen printing machine
Although it is suitable for applying a decorative coating to a part of the surface of the substrate, it is not suitable for applying a uniform coating over the entire surface of the substrate.

[0003] On the other hand, a roll coater can apply a uniform coating over the entire surface of a base material in the same manner as a spray coating machine if the circumferential surface of the transfer roll is formed smoothly. If a concavo-convex shape for imparting a design property is formed on the circumferential surface of the roll, a decorative coating film is applied to the base material surface in the same manner as a screen printing machine by the convex portion of the circumferential surface of the transfer roll. Therefore, it can be flexibly applied to both full-surface coating and decorative coating, and is widely used for coating a substrate having an uneven surface as described above.

[0004] A conventional coating method for a substrate having an uneven surface will be described below. FIG. 5 is a perspective view of a coated base material B having an appearance similar to a stack of bricks.
As shown in FIG. 5, on the base material B, a brick portion 26 in which a convex portion of a base material 25 having an uneven surface is coated with a paint having a brick-like appearance, and a concave portion of each brick portion 26 is provided. A joint 27 having a seam-like appearance is formed. Further, on the surface of the brick portion 26, there is formed a design portion 28 (design portion, pattern portion) to which a paint having a design property for expressing a realistic appearance as a brick is applied.

[0005] The base material B shown in Fig. 5 is generally coated by a procedure as shown in Fig. 6, for example. That is, as shown in FIG. 6, in this coating, first, a base material 25 is prepared (step S1), and the base material 25 is prepared.
, The color corresponding to the joint 27 (for example, gray)
The first color paint is sprayed on the entire surface of the base material 25 using a spray coater or the like to form the first coating film 30 (step S2). Next, the first coating film 30 is dried using a continuous drying furnace or the like (Step S3).

Subsequently, using a roll coater provided with a transfer roll having a smooth circumferential surface (cylindrical surface), a color (for example, brown) corresponding to the brick portion 26 is formed on the surface of the convex portion of the base material 25. Is applied again to form a second coating film 31 (step S4). Next, the second coating film 3
1 is dried using a continuous drying furnace or the like, as in the case of drying the first coating film 30 (step S5). Thus, the brick portion 26 and the joint portion 27 are formed on the surface of the base material 25.

Further, in order to enhance the design of the substrate B,
A third color paint corresponding to the design portion 28, which expresses an aggregate and a mixture having different hues, is provided with a convex portion (brick portion 26).
Is applied to a predetermined portion of the substrate to form a third coating film 32 (step S6). The third coating film 32 is applied by applying a coating material on the surface of the brick portion 26 using a roll coater provided with a transfer roll having irregularities of a predetermined shape on the circumferential surface. Thereafter, the third coating film 32 is dried using a continuous drying furnace or the like (Step S7). Thus,
A substrate B as shown in FIG. 5 is obtained. In this way, continuous application of a coating film having a desired design can be performed by selectively using the coating apparatus and repeatedly applying the coating material.

[0008]

However, in the conventional coating of such a base material, in a coating step of forming a coating film having a design using a roll coater, the irregular shape of the circumferential surface of the transfer roll is reduced. It is very difficult to form a high definition, so if you try to transfer a delicate design with high designability to a base material or a base material, the outline of the design will collapse, and the transferred design will be unclear. There was a problem that there was. Further, there is a problem that the durability or weather resistance of the coating film is inferior.

Therefore, a method has been proposed in which the transfer roll is formed of foamed rubber or low-hardness rubber or the like, and a high-definition uneven shape is formed on the circumferential surface of the transfer roll by a treatment using ultraviolet rays or a laser beam. I have. However, in the case of forming the high-definition unevenness on the circumferential surface of the transfer roll, the following problem occurs.

That is, in general, in coating using a roll coater, a considerably large amount of paint must be applied to the circumferential surface of the transfer roll as compared with printing. In general, the paint has a high viscosity. However, if a large amount of the paint having a high viscosity is adhered to (inlaid on) the surface of the transfer roll, the paint accumulates in the concave portion of the circumferential surface of the transfer roll. For this reason, there arises a problem that the paint is transferred to a portion other than the design portion on the base material. In addition, since it is difficult to clean the paint that has entered the micropores on the circumferential surface of the transfer roll, if the roll coater is stopped for a certain period of time, the paint that has not been cleaned solidifies, and therefore the transfer roll circles. When the hardness of the peripheral surface is increased or the concave portion of the peripheral surface is clogged, when the roll coater is used thereafter, the coating of the paint on the peripheral surface or the transfer of the paint is performed. There is a problem that it becomes difficult to form a high-definition design due to a decrease in the property.

SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned conventional problems. In a roll coater, cleaning of a concave portion or the like on the circumferential surface of a transfer roll can be effectively performed. An object or object to be solved is to provide an inexpensive and simple means for forming a high-definition coating film on a substrate.

[0012]

Means for Solving the Problems A first aspect of the present invention, which has been made to solve the above-mentioned problems, is to provide a roll coater for applying a coating film having a design property to a substrate. A mesh roll in which a plurality of grooves are formed in a mesh shape, and the paint supplied from the paint supply source is held by the grooves at a predetermined thickness on the circumferential surface; and (b) irregularities of a predetermined shape on the circumferential surface. Is formed, the paint held on the peripheral surface of the mesh roll in contact with the mesh roll is received on the circumferential surface, and the paint is transferred to the substrate as a coating film having a design property corresponding to the shape of the unevenness. A transfer roll, and (c) disposed so that an outer peripheral surface thereof is pressed against a circumferential surface of the transfer roll,
And a cleaning roll for collecting the paint remaining on the circumferential surface (mainly the convex portion) of the transfer roll after passing the transfer position and cleaning the circumferential surface. .

This roll coater is further provided with (d) a cleaning roll that contacts the circumferential surface of the transfer roll and cleans the paint adhering to the concave portion of the circumferential surface of the transfer roll. Is preferred. As the cleaning roll, for example, a roll provided with a cylindrical body and a brush attached to the outer peripheral surface of the cylindrical body and in contact with the circumferential surface of the transfer roll can be used. Further, a roll provided with a foam roll made of foam and in contact with the circumferential surface of the transfer roll and a pressure roll made of metal or plastic and pressed against the foam roll can also be used.

In this roll coater, since the cleaning roll is provided, excess paint adhering to the circumferential surface (mainly the convex portion) of the transfer roll can be effectively collected. Furthermore, if a doctor blade is arranged on this cleaning roll, excess paint transferred from the transfer roll to the cleaning roll can be scraped off from the outer peripheral surface of the cleaning roll efficiently, and the paint collection efficiency can be increased. . In addition, if a paint removing roll is mounted in place of the doctor blade, excess paint is effectively captured in a paint container (pan) containing a cleaning solvent.

In the case where a cleaning roll is provided in the roll coater, the paint adhered to the concave portion on the circumferential surface of the transfer roll is removed by the cleaning roll, so that the coating on the base material is removed. There is no problem that the paint is transferred to a part other than the design part. In addition, there is no problem that the coating material is solidified on the circumferential surface of the transfer roll to increase the hardness of the circumferential surface, or that the concave portion of the circumferential surface is clogged. For this reason, a high-definition coating film having high designability can be easily and inexpensively applied to the base material.

In the above-mentioned roll coater, the transfer roll comprises a substantially cylindrical (hard) shaft, and a substantially cylindrical plate having the above-mentioned irregularities formed on the outer surface of the shaft mounted on the outer peripheral surface of the shaft. It is preferably composed of a body. Here, as the plate structure, specifically, for example, a rubber layer having the irregularities formed on its outer surface, a rubber layer having the irregularities formed on its outer surface, and an elastic layer arranged inside the rubber layer And a sponge layer having the above-mentioned irregularities formed on the outer surface thereof.

In the above-mentioned roll coater, the irregularities formed on the rubber layer or the sponge layer of the transfer roll are
It is more preferable that the concave portion is formed to have a depth of 0.01 mm or more by a treatment using at least one of an ultraviolet ray and a laser beam. If you do this,
Even if the transfer roll is not replaced, the type of design to be coated on the base material can be freely switched simply by replacing the rubber layer, and the coating operation can be streamlined.

In the roll coater, it is preferable that a cylindrical sleeve made of metal (eg, nickel), glass reinforced plastic, or the like is interposed between the shaft body and the plate constituting body. More specifically, for example, it is preferable that a sleeve that can be fitted to the shaft is provided, and the plate component is mounted on the outer peripheral surface of the sleeve. This makes it very easy to attach or detach the plate structure to or from the shaft, and to exchange the plate structure in a short time.

Further, in the above roll coater,
It is preferable that the cleaning roll can be arbitrarily pressed and separated from the transfer roll. With this configuration, when the paint adheres to the concave portion on the circumferential surface of the transfer roll,
That is, since cleaning can be appropriately performed when cleaning is necessary, unnecessary cleaning is not performed.

When the roll coater according to the present invention is used, the base material (one having an uneven surface and having a smooth surface) can be used without unnecessarily applying paint to portions other than the design portion of the base material. ), As a decorative part such as a fine decorative pattern, a single coat of a highly designed coating film having a sharp outline, a dry film thickness of 10 μm or more, and a concealment ratio of 90% or more. can do. For this reason, the object coated using the roll coater according to the present invention,
It becomes a high value-added base material. Thus, according to the second aspect of the present invention, a coating method characterized by applying a design coating having a dry film thickness of 10 μm or more to a substrate using any one of the roll coaters described above. Is provided. Further, according to a third aspect of the present invention, there is provided an object having a dry film thickness of 10 μm or more, in which a coating film is applied to a substrate using any one of the roll coaters described above.

The surface (rubber layer) of the transfer roll used in the present invention may be a polymer of a polymerizable monomer or chloroprene rubber, ethylene-chloroprene rubber, butyl rubber, silicone rubber, fluorine rubber, acrylic rubber, polysulfide rubber, natural rubber. , Butadiene rubber, isoprene rubber, foams of these rubbers, or reactants of these rubber components with photopolymerizable monomers.

When a polymer of a polymerizable monomer or a rubber, or a foam of a rubber or a reaction product of a rubber component and a polymerizable monomer is used as a material for a rubber layer of a transfer roll, the surface of the transfer roll can be designed and designed. Is easily formed by ultraviolet rays or a laser beam, and its durability is also improved. In particular, a composition comprising a rubber component and a photopolymerizable monomer is suitable for providing a rubber layer with a concavo-convex shape that imparts a design property by photopolymerization by ultraviolet irradiation.

Then, the rubber layer having the uneven shape imparting the design property is wound around a transfer roll, for example, prior to painting. Further, even when the circumference of the transfer roll is long, the rubber layer can be easily attached or attached to the transfer roll. Therefore, a polymer or rubber of such a polymerizable monomer, or a reaction product of a rubber foam or a rubber component and a polymerizable monomer is very suitable for use as a material of a rubber layer of a transfer roll.

The substrate on which the coating film having a design is applied (transferred) by the roll coater according to the present invention may be any material as long as the paint can be transferred by the roll coater. . As such a base material, for example, wall materials related to ceramics or metal sizing, those belonging to building materials, etc., gypsum board, fiber cement board, magnesium carbonate board, calcium silicate board, inorganic board such as asbestos board, or plywood, A wood board such as a particle board or a hard board can be used. Further, a metal plate such as an aluminum plate and an iron plate, a plastic plate such as polypropylene and polyvinyl chloride, and further, a tile, a wallpaper, and the like can be given.
These substrates may have a smooth surface or an uneven surface.

The surface portion of the rubber layer of the transfer roll used in the present invention has a surface hardness of JIS ASKER C (SR
IS0101) 30 °-A (JISK6301) 80 °
It is preferable to be formed of rubber. When a transfer roll having a rubber layer having such a surface hardness is used, the paint remaining on the transfer roll can be sufficiently squeezed out by pressing and arranging a cleaning roll on the transfer roll. It can be collected well on a cleaning roll. As described above, the remaining paint is efficiently collected, and as a result, the transfer roll receives the supply of the paint in a constant amount from the mesh roll, and transfers a coating film having a desired thickness with stable design. be able to.

The surface of the rubber layer of the transfer roll used in the present invention can be provided with an uneven shape having a recess depth of 0.01 to 1 mm, depending on the type of design to be transferred. By forming such a concave or convex shape having a depth or thickness, compared to the case where a conventional transfer roll is used,
The thickness of the transferred coating film can be made more uniform, and a coating film with high definition design can be obtained.

It is preferable that the concavo-convex shape for imparting a design formed on the rubber layer of the transfer roll used in the present invention is formed so that the depth of the concavity becomes 0.01 mm or more by an ultraviolet ray or a laser beam. On the surface of the rubber layer of the transfer roll, a concave and convex shape for imparting a design with ultraviolet light or a laser beam is uniformly and accurately formed with a concave depth of 0.01.
mm or more, it is possible to hold the necessary amount of paint on the surface of the transfer roll, and as a result, it is possible to transfer a paint film having a design to a substrate with high precision. it can.

For example, as shown in FIG. 4 (a), the transfer roll 2 used in the present invention has a cylindrical metal shaft 10 which can be rotated about a shaft 9 as a rotation axis. And a rubber layer 11 wound around the shaft body 10. A plurality of convex portions 12 are formed on the outer surface of the rubber layer 11, and a minute concave portion 13 is formed in each convex portion 12.
Are formed. Here, the rubber layer 11 of the transfer roll 2
The hardness of the rubber layer 11 can be arbitrarily set according to the object to be coated, but is preferably in the range of JIS C 30 ° to A80 °. Or two or more layers.

Further, as shown in FIG. 4B, a transfer roll 2 ′ having a foam layer 14 interposed between a cylindrical metal shaft 10 and a rubber layer 11 may be used. in this way,
By providing the foam layer 14, the elasticity of the foam layer 14 makes it possible to efficiently transfer a coating film having a design to a substrate such as a non-smooth wall material. The material of the foam layer 14 is not limited as long as it has high resilience and elasticity with little residual stress.
Although a polyurethane of 00 kg / m ³ can be mentioned, a material having a skin surface is preferable from the viewpoint of adhesiveness. The thickness of the foam layer 14 can be set to a desired value in consideration of circumstances such as whether the base material is a smooth surface or an uneven surface, but is usually 1 to 30 mm, and is preferably 1 to 30 mm. 5 to 25 mm. In addition, between each layer constituting the transfer roll 2 ′, an adhesive layer for preventing a shift between the layers and a rubber layer 11 having excellent mechanical strength, thermal stability, dimensional stability, etc. A plastic support layer that supports the foam layer 14 may be provided.

As shown in FIG. 4C, a transfer roll 2 "in which a sponge roll 15 is fitted around the outer periphery of a cylindrical metal shaft 10 may be used.

The cleaning roll used in the present invention is basically formed by removing the paint accumulated in the concave portion of the circumferential surface of the transfer roll.
Any material that can be removed by sucking or scraping can be used. For example, a plastic brush using nylon or the like or an animal brush using pig hair or the like attached to the roll surface can be used. In addition, foams such as CR, NBR and urethane, sponge rolls having a water-absorbing or oil-absorbing property such as a PVA foam and the like can also be used, and have a hardness of JIS C 10 ° to 80 ° and a thickness of 1 to 30 mm.
It is also possible to use a combination of a brush roll and a foam roll, or to arrange a plurality of these rolls.

Further, the cleaning roll may be appropriately brought into pressure contact with the surface of the transfer roll as required. Further, in order to enhance the collection efficiency of the paint, it is possible to provide a pan (dish) containing water, an organic solvent or the like, which is a lipophilic solvent of the paint, and this pan may be a closed type or an open type. Further, by using a roll of a metal or a plastic that can be pressed together with the cleaning roll, it is possible to increase the paint collection efficiency.

As the paint, an aqueous resin, a water-dispersed resin, and a solvent-based polymer such as an acrylic resin, a melamine resin, an alkyd resin, a cellulose derivative, a polyvinyl alcohol, a styrene-butadiene resin, a styrene-acrylic resin, and an epoxy resin are used as a vehicle. Colored paints containing additives such as coloring pigments, dyes, and, if necessary, extenders, thickeners, defoamers, dispersants, and surface conditioners can be used.
As the solvent, water or an organic solvent or a combination of both can be used.Water, lower alcohols such as methyl alcohol, ethyl alcohol, and isopropyl alcohol, ether alcohols such as diethylene glycol monomethyl ether, and ethers such as dioxane Kind,
Esters such as cellosolve acetate; ketones such as methyl ethyl ketone; and mixtures of two or more thereof.

[0034]

DESCRIPTION OF THE PREFERRED EMBODIMENTS Preferred embodiments of the present invention will be specifically described below with reference to the accompanying drawings. In addition,
In this embodiment, the base material on which the first coating film and the second coating film are applied is coated with a coating film having a design property on the second coating film. The present invention is not limited to such a form, but includes other forms, for example, a form in which a paint film having a design property is applied on the first paint film. FIG. 1 is an elevational cross-sectional view schematically showing a roll coater C according to the present invention for applying a decorative coating film 32 (third coating film) to a substrate B having an uneven surface. In addition, the base material B shown in FIG. 1 is, for example, a wall material or the like, which is a ceramic-related construction material having an uneven surface, which is coated with a brick-like appearance as shown in FIG. It is. The first coating film 30 for forming the joint portion 27 and the first coating film 30 for forming the brick portion 26 are formed on the base material B through, for example, steps S1 to S5 of a coating process as shown in FIG. The two coatings 31 have already been painted.

As shown in FIG. 1, the substrate B is transported in the direction of arrow Y by a transport mechanism (not shown). Then, the roll coater C, rotating a mesh roll 1 rotates in the arrow X ₁ direction, and the transfer roller 2 which rotates in the direction of arrow X _2, the cleaning roller 3 rotates in the arrow X ₃ direction, the arrow X ₄ direction Cleaning roll 4 is provided. Incidentally, the cleaning roll 4 is moved to the double arrow Z ₁ Z ₂ direction, so that it can make contact with or pressed against the transfer roller 2, or away from it.

The mesh roll 1 is for supplying a coating material having a predetermined thickness to the transfer roll 2, and is brought into contact with the transfer roll 2 at a desired pressure. And
Paint is supplied to the mesh roll 1 from a paint supply source (not shown) such as a paint tank. A doctor blade 7 is arranged at a predetermined distance from the peripheral surface of the mesh roll 1. This doctor blade 7
Is designed to hold the paint on the mesh roll 1 and supply the paint onto the mesh roll 1 with a film thickness (for example, about 250 μm) corresponding to the distance between the mesh roll 1 and the doctor blade 7. An open paint container 8 (pan) that receives and stores paint falling from the mesh roll 1 is disposed below the mesh roll 1.

As shown in FIG. 3, a cylindrical mesh roll 1 is coaxially mounted on a rotating shaft 5 and has a plurality of mesh-shaped grooves 6 (for example, having a depth of 30) on its peripheral surface.
Lattice-shaped grooves of about 400 μm). The mesh-shaped groove 6 ensures that the paint is held at an appropriate thickness on the peripheral surface, and prevents the paint from being biased by the centrifugal force caused by the rotation of the mesh roll 1 and the paint from dripping. Has a function.

The transfer roll 2 is arranged so as to contact the surface of the substrate B. As shown in FIG. 4A, the transfer roll 2 has a cylindrical shape made of metal such as aluminum so that the mesh roll 1 can contact the transfer roll 2 at a desired pressure. Shaft 1
0 has a structure in which a rubber layer 11 is wound around the outer periphery, or a structure in which the rubber layer 11 is attached to a shaft 10. The transfer roll 2 is coaxially mounted on the shaft 9. A plurality of convex portions 12 are formed on the outer surface of the rubber layer 11, and minute concave portions 13 are formed in each convex portion 12.

As described above, the surface of the rubber layer 11 of the transfer roll 2 has irregularities (patterns representing aggregates, lumps of a mixture of different hues, moss, etc.) imparting a desired design property. Using a laser beam, it is formed to a thickness or depth of, for example, 0.01 mm or more, more preferably 0.05 to 2 mm. If you use ultraviolet light or laser light,
The rubber layer 11 can be formed with a uniform thickness or depth to provide a concavo-convex shape imparting a design property with a clear contour. Examples of the material of the rubber layer 11 suitable for processing by such an ultraviolet ray or a laser beam include a partially cross-linked copolymer composed of butadiene / methacrylic acid / divinylbenzene / methyl methacrylate, and styrene / isoprene /
Rubber molded product composed of styrene copolymer, maleic acid monoester-modified isoprene polymer, N, N-diethylaminopropylmethacrylamide, lauryl methacrylate and 2-ethyleneanthraquinone (for example, trade name “Flexid D-123”, hardness after curing) JIS A40 °, 3.
1 mm: Nippon Paint Co., Ltd.), styrene / isoprene /
Rubber molded products containing a styrene copolymer as a main component (for example, trade name “Sirel TDR”, “Sirel DPS Flexoplate”: manufactured by Du Pont) and the like can be mentioned.

A silver salt film obtained by applying a pattern (gradation), shape, or combination thereof (dots, lines, solid netting, AM screening, etc.) capable of imparting a design property to these rubber molded articles is vacuum adhered. After irradiation with ultraviolet light or direct writing with a laser and photopolymerization, the non-exposed part is developed and dried using water, perchlorethylene, etc. Is obtained (rubber layer 11). In order to obtain a rubber molded body (rubber layer 11) having a concavo-convex shape imparting designability by ultraviolet light or laser, a design pattern, shape,
It is also effective to convert these combinations into electrical signals corresponding to them and form a concavo-convex shape on the rubber layer 11. In addition, a rubber molded article for acrylic liquid casting (trade name "APR": manufactured by Asahi Kasei Corporation) can also be used.

Note that, as shown in FIG.
A transfer roll 2 ′ having a foam layer 14 (elastic layer, cushion layer) interposed between the transfer roll 2 ′ and the rubber layer 11 may be used.
4C, a transfer roll 2 ″ in which a sponge roll 15 is fitted around the outer periphery of the shaft 10 may be used. In this case, a design portion is provided on the outer periphery of the sponge roll 15. Are formed to form a convex portion 16 and a minute concave portion 17.

Incidentally, the transfer rolls 2, 2 ', 2 "
In the case where the contents of the design painting are changed, the rubber layer 11, the rubber layer 11 with the foam layer 14 (elastic layer, cushion layer), or the sponge roll 15 (hereinafter referred to as a After removing the “plate component” from the shaft 10, another plate component must be attached to the shaft 10. Therefore, it is preferable that the transfer rolls 2, 2 ′, and 2 ″ have a structure that allows the plate structure to be easily attached to the shaft body 10 and easily removed.

Therefore, as shown in FIGS. 7 (a) to 7 (c), in order to facilitate attachment or detachment of the plate structure to or from the shaft 10, a metal or glass reinforced plastic or the like is provided between the two. A sleeve 40 may be provided. In this case, first, the plate structure is attached to the outer peripheral surface of the sleeve 40, and then the sleeve 40 with the plate structure is extrapolated to the shaft 10 or the shaft 10 is inserted into the sleeve 40. The sleeve 40 may be mounted on the shaft 10 first, and then the plate component may be mounted on the outer peripheral surface of the sleeve 40.

The sleeve 40 that can be used here
Examples thereof include a cylindrical metal sleeve made of a metal material such as nickel and a cylindrical glass reinforced plastic sleeve. The shaft 1 of the sleeve 40
To make it easier to attach or remove from
The inner peripheral surface of the sleeve 40 may be formed in a tapered shape, while the outer peripheral surface of the shaft body 10 may be formed in a tapered shape corresponding to the inner peripheral surface of the sleeve. Further, the sleeve 40 may be subjected to a conductive treatment for preventing static electricity.

As a method of attaching the plate structure to the sleeve 40, as in the case of directly attaching the plate structure to the shaft 10, an uneven shape for imparting a desired design property is formed on the outer peripheral surface of the sleeve 40. A method of bonding or attaching the rubber layer 11 provided on the surface can be used. Further, first, the foam layer 14 is formed on the outer peripheral surface of the sleeve 40.
(A rubber layer or a soft plastic layer may be adhered or attached), and thereafter, a rubber layer 11 having an uneven shape imparting a desired design on the outer surface of the foam layer 14 is adhered or attached. Such a method can be used. Alternatively, a method of adhering or attaching a sponge roll 15 having a concavo-convex shape on the outer peripheral surface of the sleeve 40 to impart a desired design property to the surface can be used.

When the sleeve 40 is used as described above, compressed air is blown out from an air outlet formed on the outer peripheral surface of the shaft 10 in order to further facilitate the attachment or detachment of the sleeve 40 to or from the shaft 10. It is preferable to provide an air blowing mechanism. In this case, the sleeve 4
When attaching or detaching the shaft 0 to or from the shaft body 10, compressed air is supplied to the gap between the outer peripheral surface of the shaft body and the inner peripheral surface of the sleeve via the air outlet, and the sleeve 40 is slightly expanded by the air pressure of the compressed air. Thereby, the friction between the sleeve 40 and the shaft body 10 is reduced, and the attachment or detachment of the sleeve 40 to or from the shaft body 10 becomes easy. When the supply of the compressed air is stopped, the sleeve 40 and the shaft body 10 come into close contact.

When the sleeve 40 is used as described above, it is preferable that the shaft body 10 is cantilevered by the roll coater body. With this configuration, when performing the mounting operation or the removing operation of the sleeve 40, the mounting operation of the sleeve 40 or the mounting operation of the sleeve 40 is performed by attaching or removing the sleeve 40 from the side opposite to the side where the shaft body 10 is cantilevered. The removal operation becomes very easy, and the sleeve 40 can be replaced in a short time.

As shown in FIG. 1 again, the cleaning roll 3 collects the paint adhered to the surface of the transfer roll 2 that has passed the paint transfer position, and cleans the surface of the transfer roll 2. This cleaning roll 3 includes
Preferably, a doctor blade 18 for scraping paint on the cleaning roll 3 and an open paint receiver 19
(Bread) are attached, but these may be omitted.

[0049] As apparent from FIG. 1, the cleaning roller 3 is seen in the transfer roller rotational direction (direction of arrow X _2), the trailing side of the transfer position where the rubber transfer roll 2 is in contact with the base material B of (rear) It is arranged at a predetermined position.
The cleaning roll 3 is pressed against the surface of the rubber transfer roll 2 in order to collect the paint adhering to the surface of the rubber transfer roll 2 that has passed the transfer position. In the cleaning roll 3, the paint transferred from the transfer roll 2 to the cleaning roll 3 is scraped off by the doctor blade 18 and stored in the paint receiver 19. Here, the paint accumulated in the paint receiver 19 is appropriately
It is returned to a paint tank or the like (not shown). In addition, if a cleaning roll is mounted in place of the doctor blade 18 and a cleaning solvent is put in the paint receiver 19, the paint adhered to the cleaning roll 3 is washed by the cleaning solvent and is transferred to the paint receiver 19. Be captured.

As described above, the coating film 3 having a design property is applied to the base material B.
Since the paint remaining on the transfer roll 2 after the coating of the rubber transfer roll 2 is collected by the cleaning roll 3, the surface of the rubber transfer roll 2 can be kept in a state where no excess paint remains, and the mesh roll 1 Can be maintained at an appropriate film thickness with respect to the base material B. So basically,
A certain or fairly stable coating can be achieved.

However, with such a cleaning roll 3 alone, if the viscosity of the paint supplied to the circumferential surface (surface) of the transfer roll 2 is high, or if the paint adhered to the circumferential surface of the transfer roll 2 When is cured, the paint adhering to the transfer roll 2 may not be sufficiently removed. In such a case, if an attempt is made to transfer a fine decorative pattern or the like, the contour of the decorative pattern may be distorted due to the clogging of the concave portion 13 of the transfer roll 2 where the pattern is dug. Further, when it is desired to increase the thickness of the coating or to apply the coating to a substrate having considerable unevenness, it is necessary to considerably increase the transfer pressure of the transfer roll 2, but at that time, the transfer pressure is excessively increased. In such a case, the coating material accumulates in the concave portion 13 of the transfer roll 2, and the above-described problem becomes remarkable.

Therefore, the roll coater C is in contact with the circumferential surface of the transfer roll 2 (rubber layer 11), and is used for cleaning the paint adhered to the concave portion 13 of the circumferential surface of the transfer roll 2. A roll 4 is provided. The cleaning roll 4, as viewed in the transfer roll rotation direction (direction of arrow X _2), a trailing side of the cleaning roll 3 (rear), and a predetermined position of the leading side of the mesh roll 1 (front) Are located. Note that the cleaning roll 4 may be disposed on the leading side (front side) of the cleaning roll 3.

[0053] The cleaning roller 4, a cylindrical body 20 rotates in the arrow X ₄ direction, a brush 21 attached to the circumferential portion in contact or pressure contact with the circumferential surface of the transfer roll 2 of the circular column body 20 Is provided. Here, the brush 21
For example, a plastic brush using nylon or the like or an animal brush using pig hair or the like is used. Then, the brush 21 comes into contact with the circumferential surface of the transfer roll 2 and effectively removes paint that has accumulated or adhered to the concave portion 13 of the transfer roll. Further, the cleaning roll 4
Slightly below, an open-type pan 22 (dish) containing water, an organic solvent, and the like, which are lipophilic solvents for the paint, is provided. A part of the brush 21 is immersed in the lipophilic solvent in the pan 22, so that the brush 21 can effectively remove the paint in the concave portion 23 by the action of the lipophilic solvent. A solvent removing device for wiping off the parent solvent adhering to the circumferential surface of the transfer roll 2 may be provided on the trailing side (rear side) of the cleaning roll 4 when viewed in the rotation direction of the transfer roll 2. .

The cleaning roll 4 can be moved in the directions of double arrows Z _{1 and} Z ₂ . Therefore, the concave portion 13 on the circumferential surface of the transfer roll 2 can be appropriately cleaned as needed, and unnecessary cleaning can be avoided.

Further, a substantially cylindrical body 2 as shown in FIG.
Instead of a cleaning roll 4 composed of a brush 0 and a brush 21, a foam roll 23 (or a sponge roll) made of urethane foam, PVA foam, or the like, as shown in FIG. A cleaning roll 4 ′ may be provided to suck up the paint accumulated in the concave portion 13 on the circumferential surface of the transfer roll 2. In this case, in order to squeeze out the paint held by the foam roll 23 and drop it on the pan 22,
Metal or plastic pressure roller 24 pressed against
Is preferably installed.

Thus, in the roll coater C,
The paint adhered or deposited on the concave portion 13 of the rubber layer 11 of the transfer roll 2 is effectively removed (recovered) by the cleaning roll 4, so that the paint is transferred to a portion other than the design portion on the base material B. There is no problem such as that In addition, problems such as solidification of the paint on the circumferential surface of the transfer roll 2 to increase the hardness of the circumferential surface and clogging of the concave portion 13 of the circumferential surface do not occur. For this reason,
The high-definition coating film 32 having high designability can be applied to the base material B easily at low cost. That is, it is possible to form a high-definition design on the base material B, and it is not necessary to temporarily stop the process to wash the transfer roll 2, thereby improving the production efficiency.

[0057]

As described above, according to the present invention, the paint that has protruded into the concave portion during the coating can be removed by the roll coater having the cleaning roll and the cleaning roll, and the uneven shape imparting the design can always be accurately formed. Can be formed. Therefore, the roll coater having this washing roll can transfer a paint film having a design property with high accuracy. Further, if the washing roll according to the present invention is used, the transfer roll can be washed in the roll coater even after the coating is completed, so that no special washing device is required, and the roll coater is inexpensive. Become. Further, when changing the contents of the design portion, it is not necessary to remove the heavy transfer roll, so that the safety of the roll coater is enhanced.

[Brief description of the drawings]

FIG. 1 is a schematic view schematically showing an elevational cross-sectional structure of a roll coater according to the present invention.

FIG. 2 is a schematic diagram schematically showing an elevational cross-sectional structure of a modified example of the roll coater shown in FIG.

FIG. 3 is an external perspective view of a mesh roll used in the roll coater shown in FIG. 1 or FIG.

4 (a) is an external perspective view in which a part of a transfer roll used in the roll coater shown in FIG. 1 or 2 is broken, and FIGS. 4 (b) and (c) each show a modified example of the transfer roll. It is the external appearance perspective view which the part shown was broken.

FIG. 5 is a perspective view of a ceramic-related construction material coated with a brick-like appearance.

FIG. 6 is a flow chart showing a coating process of a substrate for ceramics and metal sizing.

FIGS. 7A to 7C respectively show FIGS. 4A to 4C;
FIG. 6 is a cross-sectional view of the transfer roll shown in FIG.

[Explanation of symbols]

B base material, C roll coater, 1 mesh roll,
2 transfer roll, 2 'transfer roll (modification), 2 "transfer roll (modification), 3 cleaning roll, 4 cleaning roll, 4' cleaning roll (modification), 5 rotating shaft, 6 groove, 7 doctor Blade, 8 paint container (pan), 9 shaft, 10 shaft, 11 rubber layer,
12 convex portion, 13 concave portion, 14 foam layer, 15 sponge roll, 16 convex portion, 17 concave portion, 18 doctor blade, 19 paint pan (pan), 20 cylinder, 2
1 brush, 22 breads, 23 foam rolls, 24
Press roll, 25 Base material, 26 Brick part, 27
Joint part, 28 design part, 30 first coating film, 31 second coating film, 32 third coating film, 40 ... sleeve.

Claims (14)

[Claims] 1. A roll coater for coating a coating film having a design property on a substrate, wherein a plurality of grooves are formed in a mesh shape on a peripheral surface thereof, and paint supplied from a paint supply source is supplied to the peripheral surface by the grooves. A mesh roll that holds a predetermined thickness on the surface, and irregularities of a predetermined shape are formed on a circumferential surface of the mesh roll, and the paint held on the circumferential surface of the mesh roll in contact with the mesh roll is applied to the circumferential surface. And a transfer roll that transfers the paint to the substrate as a coating film having a design property corresponding to the shape of the irregularities, and is disposed such that the outer peripheral surface thereof is pressed against the circumferential surface of the transfer roll, and the transfer is performed. And a cleaning roll for collecting the paint remaining on the circumferential surface of the transfer roll after passing the position and cleaning the circumferential surface. 2. A cleaning roll for contacting a circumferential surface of the transfer roll and cleaning a paint adhering to a concave portion of the circumferential surface of the transfer roll is provided. Item 1. The roll coater according to Item 1. 3. The transfer roll according to claim 1, wherein the transfer roll has a substantially cylindrical shaft.
The roll coater according to claim 1, further comprising a substantially cylindrical plate component mounted on an outer peripheral surface of the shaft and having the irregularities formed on an outer surface thereof. 4. . 4. The roll coater according to claim 3, wherein the plate structure is a rubber layer having the irregularities formed on an outer surface thereof. 5. A printing plate comprising: a rubber layer having the irregularities formed on an outer surface thereof; and an elastic layer disposed inside the rubber layer. Item 4. The roll coater according to Item 3. 6. The roll coater according to claim 3, wherein the plate structure is a sponge layer having the irregularities formed on an outer surface thereof. 7. The concave and convex portions formed on the rubber layer or the sponge layer of the transfer roll have a concave portion depth of 0.01 by a treatment using at least one of an ultraviolet ray and a laser beam.
The roll coater according to any one of claims 4 to 6, wherein the roll coater is formed to have a thickness of not less than mm. 8. The roll coater according to claim 3, wherein a cylindrical sleeve is interposed between the shaft body and the plate constituting body. 9. The sleeve according to claim 3, wherein a sleeve capable of being fitted to the shaft is provided, and the plate structure is mounted on an outer peripheral surface of the sleeve. A roll coater as described in one. 10. The cleaning roll according to claim 1, further comprising a cylindrical body, and a brush attached to an outer peripheral surface of the cylindrical body and in contact with a peripheral surface of the transfer roll. 9. The roll coater according to any one of 9 above. 11. A foam roll, wherein the cleaning roll is made of a foam, and is in contact with a circumferential surface of the transfer roll.
The roll coater according to any one of claims 1 to 9, further comprising a pressure roll made of metal or plastic and pressed against the foam roll. 12. The roll coater according to claim 1, wherein the cleaning roll can be arbitrarily pressed against and separated from the transfer roll. . 13. A coating material having a dry film thickness of 10 μm or more and having a design property is applied to a substrate by using the roll coater according to claim 1. Method. 14. An object to be coated having a dry film thickness of 10 μm or more, wherein a coating film is applied on a substrate using the roll coater according to any one of claims 1 to 12.