JP2003033716A - Painting roller and method for manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an inexpensive painting roller where a pile fiber is not frayed from a cut section when a strip is cut off from a roller cloth, and a method for manufacturing the painting roller. SOLUTION: The roller cloth 3 wound around a reel 9 is introduced between circular first transfer belts 10, 11 which are first transfer means through guide roller g. A hunting sensor 14 is provided on the upstream side of the first transfer belts 10, 11 to detect the side position of the cloth 3 just before it is introduced into the belts 10, 11. The cloth 3 is introduced between second transfer belts 15, 16 which are second transfer means from the first transfer means. A cutter 19 which cuts the cloth 3 to form a strip 2 and a heater 20 which heats the section of the strip 2 are provided between the belts 10, 11 and the belts 15, 16 to cut the cloth 3 with the cutter 19.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a coating roller in which pile yarn is prevented from fraying, and a method for manufacturing the coating roller.

[0002]

2. Description of the Related Art FIGS. 6 to 9 show a conventional method for forming a coating roller. That is, as shown in FIG. 6, a strip 1 for a roller is spirally wound around a pipe 1 to form a roll. The roller strip 2 is
As shown in FIG. 7, a wide roller cloth 3 is cut by a cutter 4 in parallel with the length direction to form a plurality of narrow strips 2. The roll cloth 3 is formed by weaving a pile yarn into a base cloth. FIG. 8 shows a base material 7 of the roller cloth 3, wherein the base material 7 has warp threads 5 and weft threads 6 alternately woven in plain weave.

FIG. 9 shows a state in which the pile fabric 8 serving as the tips of the rollers is woven into the base fabric 7. By thus weaving the pile yarn 8 into the base fabric 7, the pile yarn 8 is prevented from coming off from the base fabric 7. The warp threads 5 of the base fabric 7
The weft thread 6 and the weft thread 6 are made of thermoplastic resin.

A strip 2 formed by cutting the roller cloth 3 as described above is spirally wound around a pipe 1. When this is wound, the strip 2 and the strip 2 are bonded together with an adhesive or the like. After the strips 2 and 2 are bonded together, the entire surface of the wound strip 2 is brushed in order to make the bonded boundaries inconspicuous. Further, by performing the brushing as described above, the pile yarn 8 can be uniformly arranged on the entire roller surface. After brushing as described above, a handle (not shown) is inserted into the pipe 1 around which the strip 2 is wound, and this is used as a coating roller.

[0005]

When the roll cloth 3 is cut into strips 2 in the above-mentioned coating roller, the pile yarn 8 is frayed from the cut surface. The reason will be described below. That is, when the roller fabric of FIG. 9 is cut along the line AA to form the strip 2, the warp yarns 5 supporting the pile yarn 8 are lost, so that the pile yarn 8 is free in the left direction of the drawing. It will be in a state. When the pile yarn 8 becomes free in this way, it is frayed from the left side of the drawing.

When the pile yarn 8 is frayed as described above, the density of the pile yarn 8 between the strips 2 becomes small when the strip 2 is spirally wound. When the density of the pile yarn 8 is reduced in this way, there is a problem that the coating becomes uneven. Furthermore, when the density of the pile yarn 8 is reduced, the joint between the strips 2 becomes conspicuous. If the joints are conspicuous in this way, there is also a problem that the commercial value is reduced.

Further, after the strip 2 is spirally wound and then brushed, the pile yarn 8 on the cut surface of the strip 2 is also frayed during the brushing. This is because the brushing exerts a strong pulling direction force on the pile yarn 8. Therefore, there is a pile yarn 8 that is frayed by this brushing even if it is not frayed before brushing.

Further, if all the pile threads 8 on the cut surface, which may be frayed, are removed during brushing, there is no problem, but the pile threads 8 that were not removed during the brushing are frayed during coating. Sometimes. If it frays during painting, it becomes a bigger problem than if it frays during brushing. Because
This is because the frayed pile thread 8 adheres to the painted surface.

As described above, the pile yarn 8 is unraveled during coating in many cases especially in summer when the temperature becomes high. That is, as the temperature rises, the coating material is likely to volatilize, and the drying rate of the coating material increases with this volatilization. The faster it dries,
The paint that has penetrated into the roller becomes hard during painting,
Its tackiness increases. When the roller is rolled in such a state that the adhesiveness of the paint is high, the pile yarn 8 is pulled by the paint and the pile yarn 8 is frayed. Then, the frayed pile thread 8 adheres to the painted surface.

In order to prevent the pile yarn 8 from fraying, it is conceivable to cut the roll cloth 3 while heating it. By cutting while heating, the resin base material 7 is melted by heat. That is, the base material 7 on the cut surface of the strip 2 is melted by heat, and the melting can prevent fraying. As a specific means of cutting by this heating, for example, cutting by laser cutting or cutting by an ultrasonic cutter or a hot blade can be considered. However, the above laser cutting and ultrasonic cutting are very expensive.
If such a high cost method is used, there is a problem that the cost of the entire roller increases.

Further, the above-mentioned laser cutting and cutting with a hot blade are often used for cutting relatively thin cloth such as curtains and ribbons. However, the roller cloth 3 is thicker than the curtain or ribbon. Therefore, when trying to cut the roller cloth 3, the laser irradiation time must be lengthened in the case of laser cutting, and the temperature of the hot blade must be raised in the case of cutting with a hot blade.

If the irradiation time of the laser cut is lengthened, there is a problem that the cut surface of the strip 2 is burnt. Further, when the hot blade is heated to a high temperature, the hot blade cannot withstand the high temperature. In any case, the above laser cutting, ultrasonic wave, or cutting with a hot blade was not a method that can be practically adopted.

An object of the present invention is to provide a coating roller which does not fray pile threads from the cut surface when the strip is cut from the roll cloth and which is low in cost, and a method for manufacturing the coating roller. That is.

[0014]

A first aspect of the present invention comprises a pipe and a strip wound around the pipe, the strip being formed by cutting a roll cloth.
This strip is a coating roller having a structure in which a pile yarn is knitted into a base fabric in which warp and weft yarns are plain-woven, and the base fabric on the cut surface of the strip is melted by heat to prevent the pile yarn from fraying. It is characterized in that a fray prevention portion is formed.

According to a second aspect of the invention, there is provided a first conveying means for conveying the roller cloth material, a second conveying means, a cutter provided between the first conveying means and the second conveying means, and a downstream of the cutter. And a heater provided, which conveys the roller cloth material from the first conveying means to the second conveying means, and cuts the roller cloth material conveyed from the first conveying means with a cutter to form a strip. The cut surface of the strip is heated by a heater to form a fray-preventing portion on the cut surface of the strip, and the strip is wound around a pipe.

According to a third aspect of the invention, the heater is provided with a base portion and a convex portion, and a pointed portion is formed at the tip of the convex portion, and
The bottom portion of the strip is heated by the base portion, and the cut surface of the strip is heated by the convex portion. According to a fourth aspect of the present invention, the first conveyor and the second conveyor are each composed of a pair of conveyor belts, and the surface of the conveyor belt is formed with irregularities so that a roller cloth is provided between the conveyor belts of each pair. It is characterized in that it is sandwiched.

[0017]

1 to 5 show one embodiment of the present invention. In the description of this embodiment,
The same components as those in the conventional example are denoted by the same reference numerals as those in the conventional example. FIG. 1 is a side view of a coating roller manufacturing apparatus D for cutting the roller cloth 3 into strips 2 and melting the cut surface of the strips 2 with heat. FIG. 2 is a schematic perspective view of the coating roller manufacturing apparatus D shown in FIG.

As shown in FIGS. 1 and 2, the roller cloth 3 wound around the reel 9 is guided to the first by way of the guide roller g.
It is guided between the annular first conveyor belts 10 and 11 which are the conveyor means. The first conveyor belt 10 includes a guide roller 12
The guide roller 12 is supported by a and 12b.
The outer sides of a and 12b are rotated. Similarly,
The first conveyor belt 11 is supported by guide rollers 13a and 13b, and the guide roller 13b is rotated by a motor (not shown). Therefore, the first conveyor belt 11 rotates in the arrow X direction.

A meandering sensor 14 is provided on the upstream side of the first conveyor belts 10 and 11. The meandering sensor 14 detects the position of the side surface of the roller cloth 3 immediately before being guided to the first conveyor belts 10 and 11. Therefore, if the side surface of the roller cloth 3 is displaced, it is determined that the roller cloth 3 is meandering. When the meandering sensor 14 detects the meandering of the roller cloth 3, the first conveyor belts 10 and 11 move in the width direction of the roller cloth 3 to correct the meandering of the roller cloth 3. .

The roller cloth 3 having the meandering corrected as described above is guided between the first conveyor means and the second conveyor belts 15 and 16 which are the second conveyor means. The second conveyor belt 1
5 is supported by guide rollers 17a and 17b,
The second conveyor belt 16 includes guide rollers 18a and 18b.
To be supported by. Further, the guide roller 18b is rotated by a motor (not shown). Therefore, the second conveyor belt 16 rotates in the arrow Y direction.

As described above, the roller cloth 3 wound on the reel 9 is passed between the first conveyor belts 10 and 11.
The second conveyor belts 15 and 16 are guided. When guided in this way, the first conveyor belt 10 is moved downward in the figure, and the roller cloth 3 is sandwiched between the first conveyor belt 10 and the first conveyor belt 11. I am trying to do it. Similarly, the second conveyor belt 15 is moved toward the second conveyor belt 16 so as to sandwich the roller cloth 3.

When the roller cloth 3 is supported so as to be sandwiched between the first conveyor belts 10 and 11 and the second conveyor belts 15 and 16 as described above, the first conveyor belt 11 and the second conveyor belt 16 are rotated. The roller cloth 3 moves to the right in the figure. Further, the first conveyor belt 10 and the second conveyor belt 15 sandwiching the roller cloth 3 rotate with the movement of the roller cloth 3. Further, the first and second conveyor belts 10, 11, 15, 16 are provided with irregularities on their surfaces so that the roller cloth 3 sandwiched between them does not slip. As described above, since the roller cloth 3 is supported by the first conveyor belts 10 and 11 and the second conveyor belts 15 and 16 so as not to slip, the roller cloth 3 is taut.

Further, between the first conveyor belts 10 and 11 and the second conveyor belts 15 and 16, a cutter 19 for cutting the roller cloth 3 to form a strip 2 and a cutting of the cut strip 2 are provided. And a heater 20 for heating the surface. And the cloth for the roller 3 which is stretched tightly
Is cut by the cutter 19.

A spare cutter 21 is provided below the cutter 19 shown in FIG. Then, depending on the type of the roll cloth 3, the lower spare cutter 21 is pushed upward so that the cutter can be replaced. This is because the roller cloth 3 has different thicknesses, widths, and the like depending on its type, and the width of the strip 2 to be cut also differs. Therefore, depending on the type of the roller cloth 3 and the width of the strip 2, This is because the cutter has to be replaced. By thus providing the spare cutter 7 below the cutter 19, the cutter can be easily replaced.

Further, the heater 20 is also movable up and down. That is, when the heater 20 is not used, it is lowered to the position indicated by the solid line in FIG. 1, but when it is used, it is raised to the position indicated by the alternate long and short dash line. Because the heater 2
This is because 0 is a very high temperature, and if it is raised even when it is not in use, the heat shortens the life of the roller and the cutter 19.

A heat shield plate 23 is provided between the cutter 19 and the heater 20. The heat shield plate 23 moves up and down in accordance with the vertical movement of the heater 20. That is, when the heater 20 is raised, the blocking plate 18 is lowered, and when the heater 20 is lowered, the blocking plate 18 is raised to protect the cutter 19 from the heat of the heater 20.

In the above-described structure, the roller cloth 3 is stretched and conveyed from the first conveyor belts 10 and 11 to the second conveyor belts 15 and 16 to raise the cutter 19 upward. When the cutter 19 is lifted up in this way, the cutter 19 cuts the roller cloth 3,
Let's call it strip 2. Then, the cut surface of the strip 2 is heated by the heater 20, and the strip 2 is discharged from the second conveyor belts 15 and 16.

Here, the strip 2 is cut,
The state until heating will be described in detail. FIG. 3 is an enlarged perspective view of the cutter 19 and the heater 20. In FIG. 3, the cutter 19 cuts the roller cloth 3, and the cut surface is heated by the heater 20. FIG. 4 is an enlarged cross-sectional view of the heater 20.

As shown, the heater 20 includes a base 2
4 and the convex portion 25, and the pointed portion 26 is formed at the tip of the convex portion 25. In addition, the side surface 25a of the convex portion 25
Are substantially perpendicular to the base 24.
Further, the height of the side surface 25a of the convex portion 25 is substantially the same as the thickness of the base cloth 7 of the roller cloth 3.

As shown in FIG. 4, the convex portion 25 of the heater 20 is provided on the extension line of the blade of the cutter 19. Then, the cutter cloth 19 is used to cut the roller cloth 3 into strips 2 and
The cut surface of the strip 2 is heated by the heater 20.
That is, when the roller cloth 3 is cut by the cutter 19 into the strip 2, the strip 2 moves along the side surface 25 a of the convex portion 25.

Thus, when the cut surface moves along the side surface 25a, the cut surface is melted by the heat of the heater 20. At this time, the heater 24 has a base portion 24 and a convex portion 25.
Is provided, the strip 2 is melted into an L-shape. That is, in the strip 2, the cut surface that contacts the side surface 25a and the bottom surface 2a that contacts the base portion 24 are melted.

As described above, by heating the cut surface, the warp yarn and the weft yarn at the left end of FIG. 5 are melted, and the fray prevention portion 22 is formed. By forming the anti-raveling portion 22 in this way, the pile yarn 8 at the left end does not fray. Moreover, since the fray prevention portion 22 is formed by melting the base material 7, the fray prevention portion 22 is integrated with the base material 7. Therefore, the fray prevention portion 22 does not easily come off the base material 7. Since the fray-preventing portion 22 does not easily come off, even if the pile yarn 8 is strongly pulled during brushing or painting, it does not fray.

By heating a part of the bottom surface 2a of the strip 2 by the base portion 24, the warp threads 5 and the weft threads 6 on the bottom surface 2a are also melted. When the warp yarns 5 and the weft yarns 6 on the bottom surface 2a are thus melted, the melted yarns are exactly welded to the woven portion of the pile yarn 8. Therefore, the pile yarn 8 can be held more firmly.

Furthermore, since the convex portion 25 is perpendicular to the base portion 24, the cut surface of the strip 2 melted by the convex portion 25 can also be vertical. In this way, by making the cut surfaces vertical, when the strip 2 is spirally wound and adhered, the cut surfaces come into close contact with each other, so that stronger adhesion can be achieved. Moreover, since the cut surfaces are in close contact with each other as described above, the joints are not noticeable.
Therefore, it is possible to prevent the joint value from conspicuously lowering the commercial value.

When the cutter 19 is worn,
The cut surface of the strip 2 becomes rough.
If the cut surfaces are rattled in this manner, it becomes difficult to bond the cut surfaces to each other, and moreover, the joints are conspicuous. Therefore, when the cutter 19 is worn as described above, the effect of finishing the cut surface at a right angle by melting is particularly exerted. Further, by melting the cut surface and the bottom surface 2a of the strip 2 into an L-shape, the side surface and the lower surface are even more perpendicular to each other, so that the finish can be cleaned.

Further, since the pointed portion 26 is formed on the convex portion 25, the pointed portion 26 can easily enter between the cut surfaces. In this way the point 2
By inserting 6 between the cut surfaces, the cut surface can be guided to the side surface 25 a of the convex portion 25. Therefore, the cut surface surely contacts the side surface 25a without shifting from the convex portion 25, and the side surface 25a
The anti-raveling portion 22 can be formed.

In addition, in this embodiment, since the roller cloth 3 is supported by the first conveyor belts 10 and 11 so as to sandwich the roller cloth 3, the roller cloth 3 is prevented from being displaced while being conveyed. . Moreover, since the unevenness is formed on the surfaces of the first conveying belts 10 and 11, the roller cloth 3 can be supported more firmly.

Similarly, since unevenness is also formed on the surfaces of the second conveyor belts 15 and 16 and the roll cloth 3 for cutting, that is, the strip 2 is supported so as to be sandwiched between these, it may be displaced. Absent. Moreover, the first conveyor belts 10 and 11 and the second conveyor belts 15 and 16
Thus, since the roller cloth 3 is supported while being taut, the cutting position of the cutter 19 does not shift.

Further, in this embodiment, the cutter 19
After the roller cloth 3 is cut by the cutter 19, the cut surface is melted. Therefore, it is not necessary to replace the cutter with a laser or a hot blade. That is, the conventional cutter can be used as it is. Therefore, the cost of replacing the cutter is not required. Moreover, the heater is much cheaper than the laser and the hot blade, and by adopting this heater, it is possible to realize the anti-fraying of the strip 2 at a low cost.

Further, in this embodiment, the heater 2
Since the heating is performed by using 0, the heat of the heater 20 can be easily changed according to the thickness of the roller cloth 3. That is, when the thickness is thin, the temperature can be set low to prevent the strip 2 from melting more than necessary. Further, when the thickness of the roll cloth 3 is high, the cut surface of the strip 2 can be surely melted by setting the temperature of the heater 20 high.

In the above embodiment, the pile yarn 8 is woven into the base fabric 7, and this is used as it is for the roll fabric 3.
Other than this, it is also possible to use a base material 7 in which a pile yarn 8 is knitted and then the back side of the base material 7 is impregnated with a resin. In this way, by impregnating the resin on the back side of the base cloth 7,
It is possible to prevent the pile yarn 8 of the entire strip 2. Further, the strength of the strip 2 can be maintained by impregnating the above resin. Strip 2 like this
By maintaining the strength of No. 1, it is easy to wind this when winding it around the pipe 1.

Further, the roll cloth 3 in which the back side of the base material 7 is impregnated with the resin as described above is cut by the manufacturing apparatus D for the coating roller used in this embodiment to form the strip 2, and By heating the cut surface with the heater 20, it is possible to further prevent the pile yarn 8 from fraying. The reason is as follows. That is, when the cloth for a roller having the back side impregnated with the resin is formed into a strip 2 and the strip 2 is heated by the heater 20 into an L shape, a fray prevention portion is formed on the cut surface. Moreover, in addition to the warp threads 5 and the weft threads 6, the impregnated resin is also welded to a part of the bottom surface 2a, so that the pile threads 8 can be firmly held. Therefore, it is possible to further prevent the pile yarn 8 from fraying.

[0043]

According to the first aspect of the invention, since both sides of the strip are melted by heat to form the fray-preventing portion, the pile yarn is not frayed. Since the pile thread does not fray, it will not adhere to the painted surface. In addition, since the fray prevention portion is formed by melting the base material, the fray prevention portion and the base material are integrated, and the fray prevention portion is not easily removed from the base material.

According to the second aspect of the invention, since the heater for melting the cut surface of the strip is provided downstream of the cutter, the end portion of the strip does not fray. Moreover, it is not necessary to replace the cutter with an expensive one to prevent the fray. Therefore, it is possible to prevent the strip from fraying at low cost simply by providing the heater.

According to the third aspect of the invention, the heater is provided with the base portion and the convex portion, and the pointed portion is formed at the tip of the convex portion. Therefore, the cut surface of the strip is protruded by the pointed portion. Can be guided to the department. Furthermore, by the base,
The bottom surface of the strip can be welded. Therefore, it is possible to further prevent the strip cut surface from being frayed.

According to a fourth aspect of the present invention, the first conveyor means and the second conveyor means are provided with a pair of conveyor belts, respectively, and the surface of the conveyor belt is formed with irregularities, and the cloth for rollers is provided between the conveyor belts. Since the roller cloth is sandwiched, the roller cloth can be firmly held, and the roller cloth can be prevented from being displaced.

[Brief description of drawings]

FIG. 1 is a side view of an apparatus D for producing a coating roller for melting a cut surface of a strip by heat.

FIG. 2 is a schematic perspective view of a coating roller manufacturing apparatus D shown in FIG.

FIG. 3 is an enlarged perspective view of a cutter and a heater.

FIG. 4 is an enlarged sectional view of a heater.

FIG. 5 is an enlarged cross-sectional view of the strip after it has been melted by heat.

FIG. 6 is a perspective view when forming a conventional coating roller.

FIG. 7 is a perspective view when a conventional cloth for rollers is cut into strips.

FIG. 8 is an enlarged view of the base fabric of the strip.

FIG. 9 is an enlarged view when a pile yarn is woven into the base fabric.

[Explanation of symbols]

1 pipe 2 strips 2a bottom 3 Roller cloth 4 cutter 5 Warp 6 weft 7 base fabric 8 pile yarn 10 First conveyor belt 11 First conveyor belt 15 Second conveyor belt 16 Second conveyor belt 19 cutter 20 heater 22 Fray prevention section 23 base 24 convex 25 pointed part D Painting roller manufacturing equipment

Continued front page    F term (reference) 3B154 AA06 AB20 AB24 BA31 BA32                       BA47 BA49 BB12 BB54 BB62                       BB76 BC31 DA22                 3J103 AA02 AA24 AA32 AA41 EA09                       EA11 FA09 GA02 GA73 HA03                       HA19                 4F042 FA05 FA14 FA47

Claims (4)

[Claims] 1. A structure comprising a pipe and a strip wound around the pipe, wherein the strip is formed by cutting a cloth for a roller, and the strip is formed by weaving a pile yarn into a base fabric in which a warp yarn and a weft yarn are plain-woven. The coating roller characterized in that the base material of the cut surface of the strip is melted by heat to form a fray prevention portion for preventing fray of the pile yarn. 2. A first transporting means for transporting the roller cloth material, a second transporting means, a cutter provided between the first transporting means and the second transporting means, and a heater provided downstream of the cutter. A roll cloth is conveyed from the first conveying means to the second conveying means, and the roll cloth conveyed from the first conveying means is cut by a cutter to form a strip, and a cut surface of the strip Is heated with a heater to form a fray-prevention portion on the cut surface of the strip,
A method for producing a coating roller, which comprises winding the strip around a pipe. 3. The heater comprises a base portion and a convex portion, a pointed portion is formed at the tip of the convex portion, the bottom surface of the strip is heated by the base portion, and the cut surface of the strip is heated by the convex portion. The method of manufacturing a coating roller according to claim 2, wherein 4. The first conveying means and the second conveying means are each composed of a pair of conveyor belts, and unevenness is formed on the surface of the conveyor belts, and a roller cloth is sandwiched between each pair of conveyor belts. The method for manufacturing a coating roller according to claim 2 or 3, which is configured.