JP5217578B2 - Building material manufacturing method and building material - Google Patents

Description

  The present invention relates to a building material manufacturing method for manufacturing a high-quality building material using an embossed plate prepared from arbitrary image data.

  Conventionally, building materials such as wallpaper are manufactured using an embossed plate. This embossed version is created as follows. Silicon is poured into a manuscript such as plaster to make a silicon plate, and a silicon plate is coated with graphite and copper-plated to create a copper mold, and then a copper mold is iron-plated to create an iron plate. After quenching the iron plate, the iron plate is turned into a roll, the shape is reproduced by multi-stage corrosion, and the embossed shape is rolled. A die is formed by embossing with a roll, and a mill is created by reversing the die after correcting the joint. After embossing the mill, turning it into a roll, using nitric acid to corrode the iron roll to create an embossing roll, going through sandblasting and plating processes, manufacturing the mill electroformed embossing plate, etc. Productivity was bad. In addition, the manufacturing time and cost were high.

  In order to reduce the manufacturing time and cost of the embossed plate and make the quality uniform, digitally input the surface irregularity shape, create a repeat image of the basic image, correct and synthesize, then engraved data from the repeat image There is a method in which an uneven pattern is engraved on the stamping material by an engraving machine based on the engraving data. (For example, see Patent Document 1)

Japanese Patent Laid-Open No. 2004-358862

  However, although the above method is suitable for engraving on a relatively small area, it takes too much time to input a three-dimensional uneven shape, and large area data required for building materials such as wallpaper can be obtained. I can't. In addition, a building material such as wallpaper does not have to reproduce the same surface shape as the original document, and has a feature that a shape optimized for the intended use and required texture is sufficient. Furthermore, after printing a pattern on the original paper coated with a non-foamed resin layer containing a foaming agent on the backing paper, it is necessary to cool the cylinder quickly when foaming by heating and embossing with a cylinder to obtain the wallpaper. Yes, a metal plate having higher conductivity than a resin plate is preferable.

  The present invention has been made in view of such problems, and its object is to provide a building material manufacturing method and the like for manufacturing high-quality wallpaper and the like using an embossed plate prepared from arbitrary image data. To do.

  In order to achieve the above-described object, the first invention provides a step (a) of acquiring first image data with a scanner, and a step of editing the first image data and generating second image data ( b), a step (c) of converting the second image data into engraving data, a step (d) of engraving a resin plate with an engraving machine using the engraving data, and the resin plate A step (e) of producing a silicon resin mold using the step, a step (f) of producing a copper plated plate using the silicon resin die, and an iron plated plate using the copper plated plate Using the step (g), the step (h) of producing an iron roll using the iron-plated plate, the step (i) of producing a die roll using the iron roll, and the die roll, Step (j) for producing a mill roll, and embossing using the mill roll A step (k) for producing a roll, a step (l) for producing a wallpaper original fabric, a step (m) for printing on the wallpaper original fabric, and heating and foaming the wallpaper original fabric subjected to the printing, And a step (n) of producing a building material by embossing using an embossing roll.

In the step (b), at least one of endless processing, noise removal, shading removal, and gloss unevenness removal is performed. Improve the quality level of building materials by performing luster unevenness simulation, etc., making the pattern while checking the quality of the image, and removing the uneven luster.
The building material is wallpaper.

  The second invention is a building material manufactured by the building material manufacturing method of the first invention.

  ADVANTAGE OF THE INVENTION According to this invention, the building material manufacturing method etc. which manufacture high quality wallpaper etc. can be provided using the embossed plate produced from arbitrary image data.

  Hereinafter, with reference to the attached drawings, wallpaper is taken up as a building material, and a preferred embodiment of a building material manufacturing method according to the present invention will be described in detail.

First, an embossed plate manufacturing system 1 for manufacturing an embossed plate for manufacturing wallpaper according to the present embodiment will be described with reference to FIG.
FIG. 1 is a diagram showing an outline of an embossed plate manufacturing system 1.

The embossed plate manufacturing system 1 includes a computer 3 to which a three-dimensional scanner 5 and an engraving machine 7 are connected.
The computer 3 is a computer such as a personal computer or a desktop computer.
The three-dimensional scanner 5 scans a fabric, a stone plate, a painted plate, or the like, which is an embossed shape, and captures image data in a gray scale bitmap format.

The engraving machine 7 is a machine that performs mechanical engraving or laser engraving of an embossed plate from image data.
When the engraving data sent from the computer 3 is grayscale image data, the engraving machine 7 indicates that the grayscale image data is expressed in 256 gray scales, the grayscale 0% portion is convex, and the grayscale 100% portion is Carving as a concave.
The depth of engraving can be arbitrarily set. For example, when the depth of engraving is set to 500 μm, the gray scale 0% portion is 0 μm deep, the gray scale 50% portion is 250 μm deep, and the gray scale 100 % Portion has a depth of 500 μm.

Next, the computer 3 will be described with reference to FIGS.
FIG. 2 is a diagram illustrating a hardware configuration of the computer 3, and FIG. 3 is a diagram illustrating details of the storage device 12 of the computer 3.

  The computer 3 includes a control unit 11, a storage device 12, a media input / output unit 13, an input unit 14, a printing unit 15, a display unit 16, a communication unit 17, and the like interconnected by a bus 18.

  The control unit 11 includes a CPU (Central Processing Unit) that executes a program, an OS (Operating System), a ROM (Read Only Memory) for storing program instructions or data, and a RAM (Random Access Memory). Composed. The control unit 11 controls the operation of the entire computer 3.

The storage device 12 is a storage medium for storing fixed data such as a control program of the computer 3, various programs, data, and the like.
The media input / output unit 13 is a medium drive such as a CD-ROM (Compact Disc Read Only Memory) or CD-RW (CD-ReWriteable) flexible disk, MO (Magneto Optical Disc), etc. Write data to the media.
The input unit 14 is an input device such as a keyboard and a mouse.
The printing unit 15 prints necessary information according to a request from the user.
The display unit 16 is a display device such as a CRT or LCD.
The communication unit 17 is a communication control device, a communication port, or the like.

As shown in FIG. 3, the storage device 12 holds an OS 21, an embossed plate manufacturing program 22, scan data 23, engraving data 24, and the like.
The OS 21 is a program that controls the entire computer 3.
The embossed plate manufacturing program 22 converts and edits the scan data 23 to create engraving data 24, sends the engraving data 24 to the engraving machine 7, and engraves the embossed plate.

The scan data 23 is image data of an arbitrary object such as a woven fabric, a stone plate, a painted plate, a plastered wall, and the like captured by the three-dimensional scanner 5. The computer 3 converts and edits the scan data 23 to generate engraving data 24.
The engraving data 24 is data used for engraving the embossed plate by the engraving machine 7 and is gray scale image data in a bitmap format.

Next, the embossed plate manufacturing system 1 was used with reference to FIGS. 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20. The operation of the wallpaper manufacturing embodiment will be described.
FIG. 4 is a flowchart showing the flow of processing for wallpaper production, FIG. 5 is a diagram showing an example of a fabric 31 that is an original document having an embossed shape, and FIG. 6 is an example of a scanned image 33 captured from the original document having an embossed shape. FIG. 7 is a diagram showing an example of the scanned image 33 with feed, FIG. 8 is a diagram showing an example of the final image 35, FIG. 9 is a diagram showing an example of silicon resin mold fabrication, FIG. Is a diagram showing an example of copper-plated plate production, FIG. 11 is a diagram showing an example of iron-plated plate production, FIG. 12 is a diagram showing an example of iron-plated plate, and FIG. 13 is an example of iron roll production. FIG. 14 is a diagram showing an example of iron roll production, FIG. 15 is a diagram showing an example of iron roll production, FIG. 16 is a diagram showing an example of iron roll production, and FIG. 17 is an iron roll (die roll). FIG. 18 is a diagram showing an example of production, and FIG. 18 shows an iron roll (die roll). FIG, 19 illustrates an example of the figures, FIG. 20 shows an example of an iron roll (mill roll) is a diagram showing an example of an embossing roll.

  As shown in FIG. 4, in order to manufacture an embossing roll (embossing plate) in the embossing plate manufacturing system 1, the computer 3 scans the original document from the three-dimensional scanner 5 and takes in the scan data 23 (step S10). The engraving data 24 is created by performing data processing such as processing, removal of wrinkles and gloss unevenness (step S20), the engraving data 24 is sent to the engraving machine 7 and engraved on the resin plate (step S30). Silicon resin mold production (step S41), copper plating plate production (step S42), iron plating plate production (step S43), iron roll 1 production (step S44), iron roll 2 production (step S45), iron roll 3 production ( An embossing roll is manufactured by step S46), embossing roll production (step S47), and embossing roll surface treatment (step S48) (step S40).

  In a separate process, a wallpaper original fabric in which a backing paper is coated with a non-foamed resin layer containing a foaming agent is manufactured (step S50), a pattern is printed (step S60), and then heated and foamed in a foaming furnace. The embossing roll manufactured in step S40 is embossed on the wallpaper material to obtain a product wallpaper (step S70).

Next, each step of the wallpaper manufacturing process will be described in detail.
In the input step of Step S10, a 350 × 280 mm fabric 31 shown in FIG. 5 is prepared as an original document having an embossed shape. The original document is not limited to a woven fabric, and an arbitrary object such as a stone plate, a painted plate, or a plastered wall may be used.
The size of the fabric 31 serving as the original document is not limited to 350 × 280 mm. When the size of the woven fabric 31 is larger than 350 × 280 mm, the unit of the scan data 23 to be obtained can be made larger, so the unit of the embossing roll image feed becomes larger, and a large pattern such as a stucco painted wall tone In the case of, the pattern habit is less noticeable.

The woven fabric 31 is stuck on the same size plastic plate with double-sided tape and divided into a size of 70 × 70 mm together with the plastic plate. When dividing, the portion of the fabric 31 is completely scratched with a cutter or the like, and an ultrasonic cutter or the like may be used for cutting the portion of the plastic plate on the back surface. In order to perform cutting with a cutter or the like, the thickness of the plastic plate is preferably about 3 to 5 mm.
The control unit 11 of the computer 3 uses the three-dimensional scanner 5 to scan each of the 20-divided 70 × 70 mm fabrics 31 and captures bitmap-format grayscale scan data 23. The input resolution is X, Y = 0.05 mm pitch.

In the data processing step in step S20, the control unit 11 of the computer 3 combines the scan data 23 of the 70 × 70 mm fabric 31 obtained by dividing the 20-division from the three-dimensional scanner 5 into one image.
The scan data 23 of the fabric 31 divided into 20 parts is connected as an original document. However, a slight deviation occurs in the pattern in the document setting at the time of input. The retouch function is used to correct the pattern boundary so that it cannot be identified (step S21).
Further, when the document is set, an uneven surface difference is generated in each image of the 20 divided fabrics 31 due to a thickness error of the double-sided tape. Therefore, noise due to the surface difference is removed by removing the low frequency component of the scan data 23. (Step S22).

As shown in FIG. 6, an image of 310 × 230 mm is cut out as a scan image 33 from an image of the scan data 23 of 350 × 280 mm.
As shown in FIG. 7, the cut-out scan image 33 is fed and the outline of the scan image 33 is corrected by a copy drag function of the image editing software, etc., so that the connection of the patterns is not obscure.
Further, gloss unevenness image simulation or the like is performed (step S23), the pattern is removed (step S24), and the gloss unevenness is removed (step S25), thereby increasing the quality level of the wallpaper that is the final product.
As shown in FIG. 8, a 400 × 300 mm image is cut out from the fed scan image 33 with the scan image 33 as the center to obtain a final image 35, and the control unit 11 of the computer 3 outputs the image to the engraving machine 7. Image format conversion is performed on the suitable engraving data 24 (step S26).

In the resin engraving process of step S30, the control unit 11 of the computer 3 outputs the engraving data 24 to the engraving machine 7 and engraves the resin plate. NBR (nitrile rubber) is used for the resin plate.
In general, since the surface unevenness height difference of the fabric-like resin-based wallpaper is 300 to 800 μm, the height difference of the unevenness to be engraved on the resin plate to be an embossed plate for embossing the unevenness of the wallpaper is 500 μm.

In the embossing roll manufacturing process in step S40, a negative silicon resin mold is produced by the silicon squeeze mold material 45 on the surface of the 400 × 300 mm resin plate uneven document engraved in step S30 (step S41). As shown in the figure, graphite for energization is applied to a silicon resin-type pattern surface 41, and then a 1.0 mm copper plating 43 is applied to make a positive plate. As shown in FIG. (Step S42).
As shown in FIG. 11, iron plating 47 is applied to the pattern surface of the copper plate 43. The iron material is about 5 mm.
As shown in FIG. 12, the copper plate 43 is peeled off to form an iron plate 49 (step S43). The iron plate 49 raises altitude by baking.

Next, the iron cylinder 51 which becomes an iron roll is produced by corroding the surface of the iron cylinder (step S44).
As shown in FIG. 13, an anticorrosion varnish 53 is applied to the surface of an iron cylinder 51 having a circumference of 450 mm and a surface width of 400 mm, and is rolled on the pattern surface 41 of the iron plate 49 produced in step 43. As shown in FIG. 14, the surface on which a part of the anticorrosion varnish 53 is written by the convex portion of the iron plate 49 is etched with nitric acid. The depth of corrosion is determined by the fineness of the pattern, but is 100 μm, for example.

  The process of coating anticorrosion varnish 53 on the surface of the iron cylinder 51 in a state in which a part of the pattern is corroded, rolling on the pattern surface 41 of the iron plate 49, and etching the surface with nitric acid is repeated five times. The position of the pattern is matched and the depth of corrosion is about 100μ. As shown in FIG. 15, the first corroded portion is further corroded by the second and subsequent corrosions, and the anticorrosion varnish 53 is overwritten for the first time in the second time, resulting in a corroded overwritten portion 57. By repeating the corrosion process five times, the surface of the iron cylinder 51 is made a concavo-convex plate of 100 to 500 μm.

Masking for anticorrosion is performed so that the circumference of the pattern of the iron cylinder 51 is 310 mm, and the other portions are corroded. The plate depth of corrosion is about 530 μ so that it is several tens of μ deeper than the deepest part of the pattern. As shown in FIG. 16, the 310 mm line around the circumference of the pattern is not a straight line but a zigzag key.
The iron cylinder 51 is baked to increase the surface height and to be an iron roll.

Next, the iron cylinder 63 which becomes a die roll is produced using the iron cylinder 51 produced in step S44 (step S45).
An iron cylinder 63 having a circumference of 310 mm and a surface width of 400 mm that is not quenched is prepared, and a corrosion-resistant varnish 53 is applied to the surface. As shown in FIG. 17, the anticorrosion varnish 53 applied to the surface of the iron cylinder 63 is written down using the iron cylinder 51 produced in step S44, and the surface of the iron cylinder 63 is etched with acetic acid. The corrosion depth is about 100 μm.

The process of coating anticorrosion varnish 53 on the surface of the iron cylinder 63 in which a part of the pattern is corroded, writing down a part of the pattern on the iron cylinder 51, and etching the surface with acetic acid is repeated five times. The position of the pattern is matched and the depth of corrosion is about 100μ. By repeating the corrosion process five times, the surface of the iron cylinder 63 is made into a concavo-convex plate of 100 to 500 μm.
If the zigzag line at the joint is conspicuous after completion of the five corrosion processes, repair the pattern with a hardware tool.

As shown in FIG. 18, anticorrosion masking is applied to the portion of the iron cylinder 63 where the pattern in the surface width direction is 230 mm, and the 230 mm line is not a straight line but a zigzag key shape. The masking portions other than the anticorrosion masking at both ends of the iron cylinder 63 are etched so as to be several tens of microns deeper than the deepest portion of the pattern to about 530 microns.
The surface of the iron cylinder 63 is baked to increase the surface height, thereby forming a die roll.

Next, using the iron cylinder 63 produced in step S45, an iron cylinder 65 serving as a mill roll is produced (step S46).
An iron cylinder 65 having a circumference of 310 mm and a surface width of 550 mm that is not quenched is prepared, and an anticorrosion varnish 53 is applied to the surface. As shown in FIG. 19, the anticorrosion varnish 53 applied to the surface of the iron cylinder 65 is sent twice in the surface width direction using the pattern which is the surface irregularity of the iron cylinder 63 produced in step S45, and the pattern is written down. . The feed in the surface width direction is written with a shift of 155 mm in the circumferential direction. The surface of the iron cylinder 65 is etched with nitric acid. The corrosion depth is about 100 μm.

For the iron cylinder 65 in which a part of the pattern is corroded, the process of coating the surface with an anticorrosion varnish 53, writing down a part of the pattern with the iron cylinder 63, and etching the surface with nitric acid, align the position of the pattern Repeat four more times.
If the zigzag line at the joint is conspicuous after completion of the five corrosion processes, repair the pattern with a hardware tool.

Anti-corrosion masking is applied to the portion where the pattern in the surface width direction of the iron cylinder 65 is 460 mm, and the 460 mm line is not a straight line but a zigzag key type. The masking portions other than the anticorrosion masking at both ends of the iron cylinder 65 are etched so as to be several tens of microns deeper than the deepest portion of the pattern to about 530 microns.
The iron cylinder 65 is baked to increase the surface height and form a mill roll.

Next, using the iron cylinder 65, an iron cylinder 67 serving as an embossing roll is produced (step S47).
An iron cylinder 67 having a circumference of 620 mm and a surface width of 1500 mm that has not been quenched is prepared, and the anticorrosion varnish 53 is applied to the surface. As shown in FIG. 20, the anticorrosion varnish 53 applied to the surface of the iron cylinder 67 is fed twice in the circumferential direction using the handle that is the surface irregularity of the iron cylinder 65 produced in step S46, and the surface width direction Sent three times in parallel to write down the design. The surface of the iron cylinder 67 is etched with nitric acid. The corrosion depth is about 100 μm.

For the iron cylinder 67 in which some of the patterns are corroded, the process of coating the surface with anticorrosion varnish 53, writing down some of the patterns with the iron cylinder 65, and etching the surface with nitric acid, align the positions of the patterns Repeat four more times.
Anticorrosion masking is applied to the pattern portion of the iron cylinder 67, and the non-pattern portions at both ends of the iron cylinder 67 are corroded. The depth of corrosion is about 1 mm.
In the process of anti-corrosion masking, the key pattern for connection may be eliminated.

  The surface of the iron cylinder 67 is subjected to # 80 blast shot, and is further subjected to surface treatment by applying 20-30 .mu.g glossy cyclochrome plating to complete the embossing roll (step S48).

In a step separate from the embossing roll manufacturing step, a wallpaper original fabric in which a backing paper is coated with a non-foamed resin layer containing a foaming agent is manufactured (step S50), and a pattern is printed on the wallpaper original fabric (step S60).
The wallpaper fabric on which the pattern is printed is heated and foamed in a foaming furnace, the foam thickness including the backing paper is set to about 700 μm, and then embossed with an iron cylinder 67 produced in step S40. It is produced (step S70).

  As described above, according to the present embodiment, it is possible to provide a building material manufacturing method for manufacturing high-quality wallpaper or the like using an embossed plate prepared from arbitrary image data.

  The preferred embodiment of the wallpaper manufacturing method according to the present invention has been described above with reference to the accompanying drawings, but is not limited to the above-described embodiment. It is obvious for those skilled in the art that various modifications or modifications can be conceived within the scope of the technical idea described in the claims, and these are naturally within the technical scope of the present invention. It is understood that it belongs.

The figure which shows the outline | summary of the embossing plate manufacturing system 1 The figure which shows the hardware constitutions of the computer 3 The figure which shows the detail of the memory | storage device 12 of the computer 3 Flow chart showing the flow of processing for wallpaper production The figure which shows an example of the textile fabric 31 used as the original document of embossed shape The figure which shows an example of the scanned image 33 taken in from the original document of embossed shape The figure which shows an example of the scan image 33 which attached the feed The figure which shows an example of the final image 35 Diagram showing an example of silicon resin mold fabrication The figure which shows an example of copper plating board manufacture The figure which shows an example of iron plating board manufacture The figure which shows an example of an iron plating board Diagram showing an example of iron roll production Diagram showing an example of iron roll production Diagram showing an example of iron roll production Diagram showing an example of iron roll production Diagram showing an example of iron roll (die roll) production The figure which shows an example of an iron roll (die roll) The figure which shows an example of an iron roll (mill roll) Diagram showing an example of embossing roll

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ......... Embossed plate manufacturing system 3 ......... Computer 5 ......... 3D scanner 7 ......... Engraving machine 11 ......... Control unit 12 ......... Storage device 13 ......... Media input / output unit 14 ......... Input unit 15 ......... Printing unit 16 ......... Display unit 17 ......... Communication unit 18 ......... Bus 21 ......... OS
22 ......... Embossed plate manufacturing program 23 ......... Scanning data 24 ......... Engraving data 31 ......... Textile 33 ......... Scanned image 35 ......... Final image 41 ......... Pattern 43 ......... Copper plating 45 ......... Silicon dandruff material 47 ......... Iron plating 49 ......... Steel plates 51, 63, 65, 67 ......... Iron cylinder 53 ......... Anti-corrosion varnish 55 ......... First corrosion mark 57 ......... Writing part

Claims (4)

Acquiring the first image data with a scanner (a);
Editing the first image data and generating second image data (b);
A step (c) of converting the second image data into engraving data;
A step (d) of engraving a resin plate with an engraving machine using the engraving data;
A step (e) of producing a silicon resin mold using the resin plate;
Using the silicon resin mold to produce a copper plated plate (f);
A step (g) of producing an iron-plated plate using the copper-plated plate;
Step (h) of producing an iron roll using the iron plating plate,
Step (i) of producing a die roll using the iron roll;
A step (j) of producing a mill roll using the die roll;
Using the mill roll to produce an embossing roll (k);
A step (l) of producing a wallpaper material,
A step (m) of printing on the wallpaper material;
Step (n) of producing a building material by heating and foaming the wallpaper original fabric subjected to printing, embossing using the embossing roll,
The building material manufacturing method characterized by comprising.   The building material manufacturing method according to claim 1, wherein the step (b) performs at least one of endless processing, noise removal, shading removal, and gloss unevenness removal.   The building material manufacturing method according to claim 1, wherein the building material is wallpaper.   A building material manufactured by the building material manufacturing method according to claim 1.

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