JP5566943B2 - Manufacturing method for long materials - Google Patents

Description

  The present invention relates to a method for producing a long material.

  Conventionally, there is a demand for improving the appearance of a building by using natural wood as a long material such as a flooring used in a building. However, using natural wood may increase the cost. Therefore, a plurality of long materials are made into an extrusion-molded product obtained by extruding an extruded material containing wood powder and resin, and a technique such as that described in Patent Document 1 is applied to make a plurality of long materials natural. Giving the surface characteristics of a texture close to wood.

JP 2001-327913 A

  By the way, since the long material formed using the technology of Patent Document 1 has a grain pattern on the surface, it can express a texture close to natural wood when viewed from close, but when viewed from a distance. I can't see the grain pattern on the surface. For this reason, it can be seen as if the resin molded products of the same color are simply arranged. For example, unlike the case where natural woods are arranged, a monotonous impression may be given.

  Therefore, it is desired to produce a long material having gradation so as not to give a monotonous impression.

  An object of this invention is to manufacture the elongate material which has a gradation.

In order to solve at least one of the above problems, the invention according to claim 1 is, for example, as shown in FIGS.
In the covering material 27 obtained by extruding the extruded material 10 containing the wood powder and the resin to form the molded product body 13, and mixing the surface layer material 25 containing the wood powder and the resin and the pigments 20, 23, A molding step of covering the molded product body 13 and molding a long material 55 having the same cross section;
The mixing ratio of the surface material 25 and the pigments 20 and 23 is changed during the molding step.

  According to the first aspect of the present invention, since the color density can be changed by changing the mixing ratio of the surface layer material 25 and the pigments 20 and 23 during the molding step, there are various longitudinal directions. A long material having gradation can be manufactured. In addition, the covering material 27 obtained by mixing the surface material 25 containing the wood powder and the resin and the pigments 20 and 23 can be mixed with the wood powder by covering the molded product body 13, so that It is possible to produce a long material having a gradation of shade close to that of the material.

The invention according to claim 2 is, for example, as shown in FIG.
In the manufacturing method of the elongate material of Claim 1,
The pigment is a single color pigment 20 or a plurality of color pigments 20, 23, and the mixing ratio of the surface layer material 25 and the pigment is changed every predetermined time.

  According to the invention described in claim 2, the pigment is a single color pigment 20 or a plurality of color pigments 20, 23, and a mixing ratio of the surface layer material 25 and the pigments 20, 23 is changed every predetermined time. Thus, since the color shade of each color can be changed, a long material having various gradations in the longitudinal direction can be produced.

The invention of claim 3 is, for example, as shown in FIG.
In the manufacturing method of the elongate material of Claim 1 or 2,
Extruded material 10 containing wood powder and resin is extruded to form a molded product body 13, and the molded product body 13 is covered with the same pigment obtained by mixing a plurality of pigments 20 and 23. A molding process for molding a long material having a cross-section,
The mixing ratio of the pigments 20 and 23 of the plurality of colors is changed during the molding process.

  According to the invention described in claim 3, since the stage of changing colors can be expressed by changing the mixing ratio of the pigments of the plurality of colors during the molding step, the long material having various gradations in the longitudinal direction. Can be manufactured.

The invention according to claim 4 is, for example, as shown in FIG.
It further includes a cutting step of cutting the long material 55 by a predetermined length.

  According to the invention described in claim 4, by cutting the long material 55 into a predetermined length, a plurality of long materials having different gradations in the longitudinal direction as shown in FIG. 1 (c) are manufactured. it can.

The invention according to claim 5 is, for example, as shown in FIG.
It is the elongate material manufactured by the manufacturing method of the elongate material of Claim 4.

  According to the fifth aspect of the present invention, by providing the long material 55 manufactured by the long material manufacturing method according to the fourth aspect, for example, a plurality of long materials 55 can be arranged from a distance. Even when viewed, it is possible to give an impression closer to the case of arranging natural wood than the case of arranging monochromatic long materials.

  According to the present invention, a long material having gradation can be manufactured.

(A) is a figure which shows an example of the manufacturing apparatus used for the manufacturing method of the elongate material which concerns on this invention, (b) is an image figure at the time of manufacturing and cutting a elongate material to predetermined length, (C) is II sectional drawing. It is a flowchart which shows an example of the manufacturing method of the elongate material which concerns on this invention. (A) is a figure which shows an example of the mixing ratio of the pigment based on this invention, (b) is a figure which shows Sb gradation, (c) is a figure which shows Br gradation. 1 is a side sectional view of an extrusion mold according to the present invention. It is the sectional view on the AA line in FIG. It is an enlarged view of the X circle part in FIG.

  Embodiments of the present invention will be described below with reference to the drawings.

<Embodiment>
(Long material manufacturing equipment)
In FIG. 1, a long material manufacturing apparatus 100 includes an extrusion molding machine 30, a hopper 31 into which an extruded material 10 containing wood powder and resin is charged, a charging unit 42 into which a base pigment 20 is charged, and a mixing device. A feeding portion 43 into which pigment is charged, a hopper 41 into which the surface layer material 25 containing wood powder and resin is charged, an extrusion machine 40 that mixes and extrudes wood powder, resin, and a plurality of pigments, and extrusion molding The molded product main body 13 is formed from the extruded material 10 extruded from the machine 30, and the mold 32 is configured to cover the molded product main body 13 with the coating material 27 extruded from the extrusion molding machine 40, and the automatic feeder 50. The long material manufacturing apparatus 100 is an apparatus that manufactures a long material 55 having a two-layer structure (see FIG. 1C) composed of a molded product body 13 and a covering material 27 that covers the molded product body 13.

  Here, the automatic feeder 50 is a control device that controls the amount and time of the mixing pigment 23 and changes the color of the coating material 27. The automatic feeder 50 opens and closes a valve (not shown) provided at the lower portion of the charging unit 43 to adjust the charging amount of the mixing pigment and to control the timing of opening and closing to control the charging time. . Moreover, since an extrusion molding machine is known as shown in, for example, JP-A-2002-225111, description thereof is omitted.

  Next, with reference to FIGS. 4-6, the metal mold | die 32 for manufacturing the elongate material which has a 2 layer structure is demonstrated below.

  Inside the mold 32, a main material resin flow path 33 is formed so as to penetrate the mold 32 from side to side in FIG. Connected to the left end portion of the mold 32 is an extrusion molding machine 30 for extruding and supplying the main material resin (extrusion material 10) to the main material resin flow path 33. A mandrel 34 is inserted into the main material resin flow path 33, and the mandrel 34 is disposed at a predetermined interval between the inner peripheral surface of the main material resin flow path 33. As shown in FIG. 5, four mandrels 34 are arranged, and the four mandrels 34 form the same cavity as the cross section of the mandrel 34 inside the extruded product.

  The mold 32 is divided into a first mold 35 and a second mold 36, and a covering material 27 is formed between the first mold 35 and the second mold 36. A multi-layer molding die 32A is provided. The first mold 35 is connected to the extrusion molding machine 30, and the second mold 36 is connected to the front end surface of the first mold 35 with the multilayer mold 32 </ b> A interposed therebetween.

  The multilayer mold 32A is formed in a rectangular plate shape. A through hole 37 that penetrates the multilayer molding die 32A in the thickness direction is formed in the substantially central portion, and the through hole 37 is disposed so as to be continuous with the main material resin flow path 33. ing. That is, a main material resin flow path 33a is formed in the first mold 35, and a main material resin flow path 33b is formed in the second mold 36. The through hole 37 is arranged so as to connect 33b. Further, the inner peripheral surface of the through-hole 37 protrudes inward from the inner peripheral surface of the main material resin flow path 33, and as shown in FIG. 6, the inclination is inclined inward toward the flow direction of the main material resin. It is comprised from the surface 37a and the parallel surface 37b parallel to the flow direction of main material resin from the front-end | tip part of this inclined surface 37a.

  Further, a coating resin flow path 38 is formed inside the multilayer mold 32A. The coating resin flow path 38 includes two vertical flow paths 38a and 38a extending in the vertical direction, and an annular flow path 38b connected to the lower ends of the vertical flow paths 38a and 38a. The annular flow path 38b is provided so as to surround the main material resin flow path 33 in a cross section intersecting with the flow direction of the main material resin, that is, to surround the through hole 37. The number of the longitudinal flow paths 38a may be one or three or more.

  The annular flow path 38 b is formed in a groove shape on the surface of the multilayer molding die 32 A, and a gap 39 is formed between the annular flow path 38 b and the through hole 37. That is, the surface around the through-hole 37 of the multilayer molding die 32A is slightly recessed from the surface of the multilayer molding die 32A, and the retracted surface and the surface of the second mold 36 The gap 39 is formed between them.

  Then, the covering material 27 flowing through the annular flow path 38 b enters the main material resin flow path 33 through the gap 39 and rides on the surface of the molded product body 13 flowing through the main material resin flow path 33 and flows together with the molded product body 13. It is like that. The thickness of the covering material 27 is adjusted by the protruding length that the inner peripheral surface of the through hole 37 protrudes inward from the inner peripheral surface of the main material resin flow path 33 and the width of the gap 39.

  A connection adapter 60 is attached to the upper surface of the multilayer molding die 32A. The connection adapter 60 is for connecting an extrusion molding machine 40 (not shown) that extrudes and fills the coating material 27 to the coating resin flow path 38, and a vertical flow path 60a and a lower end of the vertical flow path 60a. Branch flow paths 60b, 60b branched from the section, and connection flow paths 60c, 60c for connecting the branch flow paths 60b, 60b to the longitudinal flow paths 38a, 38a of the coating resin flow path 38. The longitudinal flow path 60a is opened in the upper surface of the connection adapter 60, and the resin extruder is connected to this opening part.

  As shown in FIGS. 4 to 6, the multilayer mold 32 </ b> A is disposed between the first mold 35 and the second mold 36 that constitute the mold 32. The multilayer molding die 32A is sandwiched between the first mold 35 and the second mold 36 and is firmly fixed. And it arrange | positions so that the through-hole 37 and the main material resin flow path 33 of the metal mold | die 32 may become coaxial. As a result, the inner peripheral surface of the through hole 37 protrudes inward from the inner peripheral surface of the main material resin flow path 33, and the upstream edge of the inclined surface 37 a of the through hole 37 is the main edge of the first mold 35. It matches the opening edge of the material resin flow path 33a, and the through hole 37 and the main material resin flow path 33a are smoothly connected.

  When the main material resin (extrusion material 10) is extruded from the extruder 30 and supplied to the main material resin flow path 33, the main material resin moves the main material resin flow path 33 downstream (right side in FIG. 4). The flow is narrowed slightly inward by the inclined surface 37a of the multilayer molding die 32A, and further flows parallel to the main material resin flow path 33 by the parallel surface 37b. Since the parallel surface 37 b protrudes inward from the inner peripheral surface of the main material resin flow path 33, the portion between the parallel surface 37 b is between the molded product main body 13 and the inner peripheral surface of the main material resin flow path 33. Since a gap is formed in the gap, the coating material 27 is extruded and supplied into the gap.

  That is, when the coating material 27 is extruded and supplied from the extrusion machine 40 connected to the connection adapter 60 to the coating resin flow path 38, the coating material 27 is supplied to the longitudinal flow path 60a, the branch flow paths 60b and 60b, and the connection flow. Flows through the channels 60c, 60c, is supplied to the coating resin flow path 38 of the multilayer molding die 32A, and further flows through the longitudinal flow paths 38a, 38a of the coating resin flow path 38 to enter the annular flow path 38b. It flows through this annular flow path 38b. The covering material 27 flowing through the annular flow path 38b passes through the gap 39, reaches the gap between the molded product main body 13 and the inner peripheral surface of the main material resin flow path 33, and flows through the main material resin flow path 33 at this portion. It rides on the surface of the molded product body 13 and flows together with the molded product body 13.

  Thus, by extruding, a multi-layered long material 55 as shown in FIG. 3C can be obtained.

  As described above, according to the present embodiment, it is possible to manufacture the multi-layered long material 55 using the multi-layer forming die 32A.

  Further, since the annular molding flow path 38b of the covering resin flow path 38 is provided so as to surround the main material resin flow path 33 in the cross section intersecting with the flow direction of the main material resin in the multilayer molding die 32A. The surface of the main body 13 can be easily and reliably covered with the covering material 27.

  In addition, a connection adapter 60 for connecting a resin extruder for extruding and filling the coating material 27 to the coating resin flow path 38 is attached to the multi-layer molding die 32A. By connecting the extrusion molding machine 40, the resin can be extruded and filled into the coating resin flow path 38 of the multilayer molding die 32A. Further, when a plurality of types of multilayer molding molds 32A are prepared, the resin can be extruded and filled into the coating resin flow paths 38 of the respective multilayer molding molds 32A by attaching and changing the connection adapter 60 thereto.

(Mixing ratio of multiple pigments)
The Sb gradation shown in FIG. 3B shows that the base pigment Sb (Sunday brown) and the mixing pigment Br (brown) are No. 1 shown in FIG. The state in which the long materials 55 cut after being formed at the pigment mixing ratios indicated by 0 to 3 are arranged is shown. In addition, the Br gradation shown in FIG. 3C shows that the base pigment Br (brown) and the mixing pigment Gr (gray) No. 1 shown in FIG. The state in which the long materials 55 cut after being formed at the pigment mixing ratios indicated by 0 to 3 are arranged is shown. Usually, no. A long material is formed and cut for each pigment mixing ratio shown in 0 to 3. Therefore, even if a long material formed of pigments mixed at the same pigment mixing ratio is cut to produce a plurality of long materials, the same color is obtained. Therefore, for example, in order to express the Sb gradation shown in FIG. It was necessary to produce a long material for each pigment mixing ratio shown in 0-3.

(Long material manufacturing method)
Next, an example of manufacturing a long material in the present embodiment using the pigment mixing ratio of the Sb gradation shown in FIG. 3A will be described with reference to FIG.

  First, the extruded material 10 containing wood powder and resin charged into the hopper 31 is melted by the extrusion forming machine 30 and extruded into the mold 32, and extrusion molding is performed by the mold 32 to form the molded product body 13 ( Step S1). On the other hand, the pigments 20 and 23 of a plurality of colors are mixed at a predetermined mixing ratio (for example, No. 1 in the pigment mixing ratio of the Sb gradation) by the extrusion forming machine 30 and extruded into the mold 32, and the coating material is coated by the mold 32. 27, the molded product main body 13 is covered, and a long material 55 having the same cross section is formed (step S2). Then, the long material 55 is extruded from the mold 32, and after a predetermined time has elapsed, the mixing ratio of the pigments of the plurality of colors is changed to another mixing ratio (for example, No. 2), and the automatic charging machine 50 supplies the mixing ratio to the charging unit 43. The provided valve is opened and the mixing pigment Br is increased and changed (step S4). After a while after the change of the mixing ratio, the color of the covering material becomes a color obtained with another mixing ratio (for example, No. 2). In other words, no. 1 (sb 95%, Br 5%) and No. 1 2 (Sb 87.5%, Br 12.5%) depending on the mixing ratio, the color of the transition stage appears as the color of the coating material 27. Therefore, as shown in FIG. 1A and FIG. 1C, gradation appears in the length direction of the long material 55. And the said process is performed continuously until manufacture of a elongate material is complete | finished (step S5). The change of the mixing ratio is performed after the predetermined time has elapsed. 0-No. 3 may be repeated in that order. 0-No. You may perform so that any of 3 may be selected arbitrarily.

  According to the present embodiment, by changing the mixing ratio of the pigments of the plurality of colors during the molding step, the long material is manufactured, so that the long material having gradation can be manufactured.

  In addition, according to the present embodiment, by changing the mixing ratio of the pigments of the plurality of colors every predetermined time, it is possible to express a stage in which the color changes, so that a long material having various gradations in the longitudinal direction is manufactured. it can. Here, every predetermined time is, for example, each time every 10 seconds or every 20 seconds, or includes a combination of different times such as 10 seconds → 20 seconds → 15 seconds.

  Further, according to the present embodiment, by covering the molded product main body 13 with the coating material 27 obtained by mixing the surface layer material 25 containing wood powder and resin and the plurality of pigments 20 and 23. Since wood powder can be mixed, it is possible to produce a long material having a gradation of colors that are close to natural.

  Furthermore, this embodiment further includes a cutting step of cutting the long material 55 by a predetermined length during or after the production of the long material 55 described above. The long material is cut during or after the long material forming step.

  According to the present embodiment, a plurality of long materials can be manufactured by cutting the long material 55 at a predetermined length, and a plurality of gradations having different gradations in the longitudinal direction as shown in FIG. Long materials can be manufactured. Furthermore, even when a plurality of long materials are arranged and viewed from a distance, it is possible to give an impression close to that when natural woods are arranged, as compared with a case where monochromatic long materials are arranged.

(Modification)
In the above embodiment, the example in which the automatic charging device 50 controls the charging amount and time of the mixing pigment 23 by the charging device 43 has been described. However, the present invention is not limited to this, and the automatic charging machine inputs only a single color pigment of either the base pigment 20 or the mixing pigment 23, controls the amount and time of the single color pigment, and controls the surface layer material 25. The mixing ratio of the pigment may be increased / decreased every predetermined time during the process of forming the long material, and the shade of the color of the covering material 27 may be changed. Further, the automatic charging machine makes the mixing ratio of the base pigment 20 and the mixing pigment 23 constant, controls the charging amount and time of the mixed pigment, and sets the mixing ratio of the mixed pigment to the surface layer material every predetermined time. The color density of the covering material 27 may be changed during the long material forming process. Further, the automatic charging machine may control the charging amount and time of both the base pigment 20 and the mixing pigment 23 during the long material forming process to change the color of the covering material 27. In the above embodiment, the example in which the base pigment 20, the mixing pigment 23, and the surface layer material 25 are mixed has been described. However, the surface layer material 25 is not used, and the mixing ratio of the base pigment 20 and the mixing pigment 23 is changed. The main body 13 may be colored to give a gradation. Also, instead of the surface layer material 25, a different third color pigment, a base pigment 20, and a mixing pigment 23 are mixed, and the mixing ratio is changed every predetermined time to give gradation to the molded product body 13. Also good. In addition, the cutting in the cutting step is, for example, the long material after cutting has gradation in the longitudinal direction, such as the top long material in FIG. In this way, it is desirable to cut so that different materials can be produced in various lengths. According to the length of the long material after cutting, the mixing ratio of the pigment with respect to the surface layer material or the plurality of colors in order to obtain the long material of various variations by cutting the formed long material as it is It is desirable to determine a predetermined time for changing the pigment mixing ratio.

DESCRIPTION OF SYMBOLS 10 Extruded material 13 Molded article main body 20 Base pigment 23 Mixing pigment 25 Surface layer material 27 Coating material 30, 40 Extruder 31, 41 Hopper 32 Die 42, 43 Input part 55 Long material 50 Automatic feeder 100 Long material manufacturing device

Claims (5)

An extruded material containing wood powder and resin is extruded to form a molded product body, and the molded product body is covered with a coating material obtained by mixing a surface layer material containing wood powder and resin and a pigment. A molding process for molding a long material having the same cross section,
A method for producing a long material, wherein a mixing ratio of the surface layer material and the pigment is changed during the molding step. In the manufacturing method of the elongate material of Claim 1,
The method for producing a long material, wherein the pigment is a single color pigment or a plurality of color pigments, and the mixing ratio of the surface layer material and the pigment is changed every predetermined time. Extruded material containing wood powder and resin is formed by extrusion molding to form a molded product body, and a long material having the same cross section by covering the molded product body with a pigment obtained by mixing a plurality of color pigments With a molding process to mold
A method for producing a long material, wherein a mixing ratio of the plurality of color pigments is changed during the molding step. In the manufacturing method of the elongate material as described in any one of Claim 1 to 3,
A method for producing a long material, further comprising a cutting step of cutting the long material by a predetermined length.   The long material manufactured by the manufacturing method of the long material of Claim 4.