JPH04156329A - Manufacture of pattern texture made of synthetic resin - Google Patents

Abstract

PURPOSE:To manufacture various kinds of pattern textures made of a synthetic resin and having different sizes, using a smaller-sized mold than the size of a product, by engraving the mold with the original design of a pattern texture made of a synthetic resin, which is reduced in the transfer direction of the pattern texture, filling a synthetic resin in an engraved recess, and orienting under heating an intermediate article released from the mold while retaining the width of said article. CONSTITUTION:A recessed part 1a wherein the original design of a pattern ground made of a synthetic resin is reduced in the transfer direction of the pattern ground is engraved on the outer circumferential surface of a mold 1 consisting of a metal cylinder. For example, a thermoplastic synthetic resin extruded from an extruder 2 is filled into this recessed part, and the resin is released by a release roll 3 to mold an intermediate article. Vertically paired introduction side pinch rolls 4 are arranged outside the release roll 3 in the direction in which the pattern texture is transferred. Furthermore, a pair of orientation side pinch rolls 5 which rotate at a higher speed than the rotational speed of said pinch rolls 4 is arranged at a predetermined distance away from the pinch rolls 4. A width retaining means 6 for an intermediate article and a heating means 7 for the same are arranged at an intermediate portion between the pinch rolls 4 and the pinch rolls 5, and the intermediate article is heated while its width being retained and is oriented by the pinch rolls 4, 5. After the intermediate article is enlarged up to the size of the original design or up to a desired size, a strain- removing operation is carried out by a heating roll 8.

Description

DETAILED DESCRIPTION OF THE INVENTION (Field of Industrial Application) The present invention relates to a method for manufacturing a comparatively large synthetic resin patterned fabric having a frame pattern, which is mainly used for large household tablecloths, etc. .

(Prior art) Conventionally, when manufacturing this type of synthetic resin patterned fabric,
Using a mold such as a metal forming plate or a metal cylinder, an intaglio pattern corresponding to the original design of the pattern to be produced is formed on the outer surface of the mold, and the pattern is filled with thermoplastic synthetic resin. It has been manufactured by molding and then peeling it off, or by forming a predetermined pattern in a built-up shape on a synthetic resin sheet using silk screen printing means.

(Problem to be Solved by the Invention) However, when manufacturing a comparatively large patterned area made of synthetic resin with a frame pattern, the former method using a mold requires a pattern area larger than the patterned area to be manufactured. Approximately 153 x 280, which requires a mold and is used for parties, etc.
In the case of manufacturing a cm-sized tablecloth and using a metal cylinder as the mold, a cylinder with a diameter of 89 cm and a length of about 170 cm is required, and this cylinder also has a frame to be attached to the table cloth. It is necessary to form an intaglio pattern portion of a size corresponding to the original design of the pattern, making it extremely difficult to form the intaglio pattern portion and to handle the cylinder. Even if they have the same design, if the tablecloths have different sizes, it is necessary to prepare various cylinders corresponding to these sizes, which increases the number of types of cylinders and complicates storage management. There are problems such as the storage space becomes large and requires a large storage space. Furthermore, in the latter manufacturing method that uses silk screen printing means, there is a limit to the thickness of the pattern that can be obtained and is subject to design constraints, so there is a problem that it cannot fully meet customer requests.

The present invention was made in view of the various problems mentioned above.
The purpose of this is to use a single mold that is smaller than the synthetic resin pattern to be manufactured, and to easily form the intaglio pattern on the mold and handle the mold. However, it is possible to manufacture a variety of synthetic resin patterned fabrics with different sizes, but it also makes storage management complicated.
To provide a method for manufacturing a synthetic resin patterned fabric capable of obtaining various patterns that can meet customer requests without requiring a large storage space.

(Means for Solving the Problems) In order to solve the problems described in -, the present invention provides a mold (1).
In the method for manufacturing a synthetic resin patterned area in which the intaglio pattern part of the mold (1) is filled with thermoplastic synthetic resin and molded, the intaglio pattern part of the mold (1) is engraved by compressing the original design in the transfer direction. (Ia) and filling the recess (1a) with a thermoplastic synthetic resin to form an intermediate product (B) having a compressed pattern; and the intermediate product peeled from the mold (1). (B) is heated and stretched while maintaining the width of the intermediate product (B), thereby changing the original design.

In the heating stretching step, feeding speeds are different, a continuous intermediate product (B) is introduced, and pinch rolls (4) (4) on the introduction side and a pinch roll (4) on the stretching side are used to stretch the intermediate product (B). 5) In addition to comprising (5), a width holding means (6) for holding the width of the intermediate product (B) introduced between the pinch rolls (4) and (5) and a heating device (7), The intermediate product (B) is produced by driving the pinch rolls (4) and (5).
It is preferable to carry out the heating and stretching while maintaining a width interval of .

Further, it is preferable that the speed of the stretching side pinch roll (5) is variable so that the rate of heating stretching can be adjusted.

(Function) During the molding process of synthetic resin patterned material, the mold (1
) has the recess (1a) formed by compressing the original design of the synthetic resin pattern to be produced in the transport direction, so by filling the recess (1a) with thermoplastic synthetic resin, An intermediate product (B) having a compressed pattern of the original design is molded, and this intermediate product (B) is molded into the mold (1).
After being peeled off from the intermediate product (B), the intermediate product (B) is heated and stretched in the transfer direction while maintaining its width in a heating stretching process, thereby producing a patterned synthetic resin fabric having a size corresponding to the original design. Furthermore, the mold (1) used in the above molding process is sized to correspond to the intermediate product (B), that is, it is smaller than the original design of the synthetic resin patterned material to be manufactured. Therefore, the recess (1a) can be easily formed in the mold (1), and the mold (1) can also be easily handled. Moreover, in order to form the synthetic resin pattern by heating and stretching the intermediate product (B), by changing the stretching ratio of the intermediate product (B), using one mold (1),
It is now possible to manufacture various types of synthetic resin patterned fabrics with different sizes, which makes storage management more complicated.
Various patterns that can meet customer requests can be obtained without requiring a large storage space.

In the stretching and heating step, feed speeds are different, introducing the continuous intermediate product (B) and stretching the intermediate product (B) by introducing side pinch rolls (4) (4) and stretching side pinch rolls (5). ) and (5), and also comprises a width holding means (6) for holding the width of the intermediate product (B) to be introduced between the pinch rolls (4) and (5), and a heating device (7), and the heating device (7). The intermediate product (B) is produced by driving each pinch roll (4) and (5).
When heating and stretching is performed while maintaining a width interval of Synthetic resin patterned fabrics can be easily and continuously produced.

Further, when the speed of the stretching side pinch roll (5) is made variable to make it possible to adjust the ratio of heating stretching, by changing the speed of the pinch roll (6) relative to the introduction side pinch roll (4), The size of the intermediate product (B) in the transport direction can be changed freely, easily, and accurately, and various synthetic resin patterns with different sizes can be obtained.

(Example) The method for manufacturing a patterned synthetic resin fabric according to the present invention will be described below with reference to Examples shown in the drawings. FIG. 1 shows an example of manufacturing equipment used in the same manufacturing method. In the figure, (1) is a mold made of a metal cylinder, and an extruder ( A peeling roll (3) is brought into contact with the outer circumference of the mold (1) on the side opposite to the extruder (2), while facing the extrusion opening at the tip end of the mold (2).

The outer peripheral surface of the mold (1) is engraved with a recess (1a) in which the original design of the synthetic resin pattern to be manufactured is compressed in the pattern transport direction, and the extruder is inserted into this recess (1a). (2) filling the thermoplastic synthetic resin extruded from the mold, curing the thermoplastic synthetic resin in the recess (1a) as the mold (1) rotates, and peeling it off with the peeling roll (3); As a result, an intermediate product having a compressed pattern compressed in the transport direction with respect to the original design is molded. In other words, when manufacturing a rectangular synthetic resin patterned area (A) having a frame pattern (a) as shown in FIG.
) is compressed in the direction of transport, and a concave part (1a) is engraved on the mold (1), so that the frame pattern (b) and the overall appearance are compressed in the direction of transport, as shown in Figure 3. The intermediate product (B) is then molded.

Then, a pair of upper and lower introduction-side pinch rolls (4) (4) for introducing the intermediate product CB) are disposed oppositely to each other at an outer position of the peeling roll (3) in the pattern transfer direction, and each A pair of stretch-side pinch rolls (5) (5) that are rotated at a higher speed than each of the pinch rolls (4) are disposed in an opposing manner at an outward position a predetermined distance away from the pinch rolls (4),
The intermediate product (B) is stretched by the rotational speed difference between the introduction and stretching side pinch rolls (4) and (5), and the introduction and stretching side pinch rolls (4) and (5)
A width holding means (6) and a heating device (7) for the intermediate product (B) are respectively disposed in the intermediate part of the intermediate product (B), and these holding means (
6) and a heating device (7) to heat the intermediate product (B) while maintaining its width, thereby stretching the intermediate product (B) in the transfer direction with each of the pinch rolls (4) and (5). Do it like this.

As the width holding means, for example, a plurality of expanders C1-/l/(
60) is used. This expander roll (60) is
As shown in FIG. 5, there is a support shaft (62) to which a cam (61) having inclined grooves (81a) at both ends is fixed, and a cylindrical body (63) rotatably supported by the support shaft (62). ), and a large number of slide bars (64) supported on the outer circumferential surface of both ends of the cylindrical body (63) so as to be slidable in the axial direction, and one end of the slide bar (64) includes: A plunging rod (65) is provided that protrudes into the inclined groove (61a), and when the cylindrical body (63) rotates due to the frictional resistance accompanying the transfer of the intermediate product (B), the slide bar (64) The fixed plunging rod (65) is guided by the inclined groove (81a) and moves in the axial direction of the support shaft (62), thereby causing the slide bar (64) to slide into the intermediate product as shown by the arrow in FIG. (
As it goes from the winding start position to the separation position in B), it slides outward in the axial direction along the outer peripheral surface of the cylindrical body (θ3), and applies tensile force to both sides in the width direction to the intermediate product (13). do,
This intermediate product (B) is prevented from shrinking in the width direction.
The width of B) is maintained.

Further, as shown in FIG. 6, as the width holding means (6), a pair of two-lower rolls (66) and (68) which are always in contact with each other with a tension spring or the like is used, and each of these rolls (66 )
By arranging a plurality of sets of the intermediate product (B) in an inclined manner on both sides of the intermediate product (B) in the width direction, and transporting the intermediate product (B) while being held between the rolls (66), the intermediate product ( A tensile force may be applied to B) on both sides in the width direction to prevent the intermediate product (B) from shrinking in the width direction and maintain its width.

Further, a heating roll (8) for annealing the synthetic wood + i = patterned fabric (A) taken out from the pinch roll (5) is arranged near the stretching side pinch roll (5). , by transferring the synthetic resin pattern fabric (A) transferred from the pinch roll (5) via the intermediate roll (9) while being heated by the heating roll (8);
This is to remove the distortion of the synthetic resin patterned area (A).

Further, a plurality of cooling rolls (10) are placed in contact with a part of the outer periphery of the heating roll (8), so that each of the cooling rolls (10)
) takes over and cools the synthetic resin patterned fabric (A) that has been annealed with the heating roll (8), and winds up the cooled synthetic resin patterned fabric (A) with a winding device (11). So do it.

The various rolls used in the above manufacturing equipment are 1 (7) -
The mold (1) and the introduction-side pinch roll (4) are rotated at the output side of the motor (12) at the same circumferential speed. The motor (1
A continuously variable transmission (13) and a differential gear (14) are connected to the output side of the pinch roll (4) in 2), and the stretching side pinch roll (5) is connected to the output side of the differential gear (14). A heating roll (8) and a cooling roll (10) are interlocked and connected so that their circumferential speeds are the same, and the mold (1) is driven by the motor (12).
) and the introducing side pinch roll (4), the continuously variable transmission (13) rotates the drawing side pinch roll (
5) and by rotating the heating roll (8) and cooling roll (10) at high speed, the intermediate product (B) molded on the mold (1) side is expanded to the size of the original design. , the synthetic resin patterned area (A) is manufactured.

In the embodiment shown in FIG. 1, an intermediate wool (15) is used to supply a backing film (F) to a part of the outer periphery of the mold (1).
and supplying the film (F) from the roll (15) to the intermediate product (B) to be molded with the mold (1),
The film (F) is attached and integrated with the synthetic resin patterned area (A) to be manufactured.

Next, a method for manufacturing the synthetic resin patterned area (A) using the manufacturing apparatus having the following configuration will be described.

First, when manufacturing a synthetic resin patterned area (A) having a rectangular shape of length and width W and having a frame pattern (a) as shown in FIG. A plate-making design is formed by compressing the original design by a predetermined size in the pattern transfer direction, and based on this plate-making design, an intermediate product (B
) A mold (1) consisting of a metal cylinder having an outer surface of a size corresponding to the size of the mold (1) is manufactured. That is, when the dimensions of the patterned area (A) are length L x width W, the size of the mold (1) to be used is calculated from these dimensions, that is, the mold (1) is circular in diameter. When the circumferential length is πD, this mold (1) is manufactured by reducing the size to a constant ratio πD/L. In addition, when using an existing mold (1), the plate-making design is calculated by calculating the circumferential length (πD) of the mold (1) with respect to the length (L) of the original design, and It is formed by compressing the length (L) of the original design by the ratio (πD/L) of the circumferential length (πD).

In either case, the circumferential length (πD) of the mold (1) is the length of the intermediate product (B), and the size of the intermediate product (B) is determined by the size of the intermediate product (B). The size is smaller than the original design of the synthetic resin patterned area (A), and a recess (1a) is formed in the mold (1) based on the plate-making design that is reduced from the original design. It is.

Furthermore, when forming the concave portion (1a) in the mold (1), if the original design of the patterned area (A) is stored in advance as data in a computer or the like, this data may be processed by calculation. An original plate of the plate-making design corresponding to the intermediate product (B) shown in Figure 3 is produced, and if the original design is handwritten or photographed, it is photographed with a camera using a cylindrical lens, etc. Either an original version of the design is produced, or the original version is produced by importing the data into a computer using a scanner or the like and performing arithmetic processing. Then, a positive film or the like is made from the original plate, and the reduced recess (1a) is formed in the mold (1) using a chemical etching method, or the computer data is directly applied to a laser engraving system or an electronic engraving system. The recessed portion (1a) is formed by inputting the information.

Using the mold (1) manufactured as described above, the recess (1a) of the mold (1) is filled with thermoplastic resin from the extruder (2), and the intermediate roll (15
), the resin in the recess (1a) is cured as the mold (1) rotates, and the film (P) is lined with the recess. An intermediate product (B) as shown in FIG. 3 in which a pattern (b) corresponding to (1a) is formed, that is, an intermediate product (B) having a width W×length πD/L is continuously manufactured. In this case, the depth of the recess (1a) and the thickness of the film (F) in the case of lining are made deep or thick in advance according to the compression ratio of the original design, in other words, the stretching ratio. Sometimes, the thickness of the frame pattern is the same as the original design, and the thickness of the film is suitable for backing.

Further, the intermediate product (B) is peeled off by the peeling roll (3), and is supplied between each of the introduction side pinch rolls (4) and each stretching side pinch roll (5), and is When heating the synthetic resin pattern (A) with the same size as the original design by heating it with the heating device (7) while maintaining the predetermined width W in step (6), each of the pinch rolls (4) (5) The rotational speed ratio between the two is adjusted to (L/πD), and as shown in FIG.
When trying to obtain the speed ratio, (L'/πD)
It is adjusted to And the pinch roll (4) (
After being stretched to the original design size or desired size by step 5), annealing is performed to remove distortion by the heating rolls (8), and the cooling rolls (10) The winding device (11
), and by cutting the amount taken up by the winding device (11), the synthetic resin patterned fabric (A) having, for example, length L x width W is manufactured. As described above, when the intermediate product (B) is heated and stretched by the pinch rolls (4) and (5) to form the synthetic resin patterned area (A), the pinch rolls (4) (5
) by changing the speed ratio, that is, the stretching rate, 1
Using one mold (1), it is possible to manufacture various patterns made of synthetic resin (A) of different sizes, and various patterns that can meet the needs of customers can be obtained.

The intermediate product CB by the pinch rolls (4) and (5)
) is desirably 50% or less, especially 35% or less, and the dimensions of the intermediate product (B) are about 20% of the synthetic resin patterned material (A), especially for the pattern design. However, it is desirable to set it to about 10%, and by doing so, a good product can be reliably obtained without the pattern being distorted.

Next, a method for manufacturing the synthetic resin patterned area (A) will be explained using a specific example. First, length 264 x width 150 c-
The original design was imported as data into a computer using a scanner, and in order to be intaglio-engraved into a mold (1) consisting of a metal cylinder with a diameter of 650 IIm, the original design was processed using a compression rate of 0.769 to produce an original plate. A positive film was made from the original plate, and the mold (1) was subjected to chemical corrosion treatment, and then plating was performed to form a recess (1a) in the mold (1). Then, in the recess (1a) of the mold (1),
A vinyl chloride resin mixed with a plasticizer is extruded and filled from the extruder (2) as a thermoplastic resin, and a vinyl chloride film of Ool M11 is attached as the backing film (1). ) and the intermediate product (B
), and this hindlimb intermediate product (B) was passed through the peeling roll (
3). In addition, the respective speeds of the introducing side and stretching side pinch rolls (4) and (5) were set to 4 m/min, respectively.
Adjust to 5.55m/min, length 280 x width 150
A cWl synthetic resin patterned area (A) was obtained.

In the second example, a backing film (F) is attached to the intermediate product (B) to produce a patterned synthetic resin fabric (A) having the film (F). However, it is not always necessary to provide the backing film (F).

Further, in the above embodiment, a case has been described in which a metal cylinder is used as the mold (1), but the present invention is not limited to a metal cylinder, and it is also possible to use a flat metal molded plate.

(Effects of the Invention) As explained above, in the method for manufacturing a synthetic resin patterned area according to the present invention, the intaglio pattern portion provided in the mold (1) is compressed in the transfer direction to form the recessed portion ( 1a) and filling the recess (!a) with a thermoplastic synthetic resin to form an intermediate product (B) with a compressed pattern; The intermediate product (B) is heat-stretched while maintaining the width of the intermediate product (B) to reveal the original design. Using one mold (1) smaller than the patterned area (A), the recess (1a) can be formed in the mold (1) and handled easily, It is possible to manufacture various synthetic resin patterned fabrics (A) of different sizes, and it is possible to meet customer requests without complicating storage management or requiring large storage space. Various patterns can be obtained.

Further, in the stretching and heating step, the feeding speed is different,
By introducing the continuous intermediate product (B), the intermediate product (B)
A pair of introduction-side pinch rolls (4) and stretching-side pinch rolls (5) are provided for stretching, and the width of the intermediate product (B) introduced between the respective pinch rolls (4) and (5) is maintained. A width maintaining means (6) and a heating device (7) are provided so that the intermediate product (B) is heated and stretched while maintaining the width interval by driving each of the pinch rolls (4) and (5). By doing this, the medium 17i1 item (B) can be expanded in the transfer direction to the original design size or a desired size using the pinch rolls (4) and 2l- (5). The synthetic resin patterned area (A) can be easily and continuously produced.

Furthermore, by making the speed of the stretching side pinch rolls (5) variable and adjusting the heating stretching ratio, the size of the intermediate product (B) in the transport direction can be freely and accurately changed, Various synthetic resin patterned fabrics of different sizes (
A) can be obtained easily and accurately.

[Brief explanation of the drawing]

FIG. 1 is a partially cutaway side view showing an example of a manufacturing apparatus used in the method for manufacturing a synthetic resin pattern according to the present invention, FIG. 2 is a front view showing a synthetic resin pattern to be manufactured, and FIG. A front view of the intermediate product, FIG. 4 is a front view corresponding to FIG. 2 showing another example of manufacturing, FIG. 5 is an explanatory diagram when an expander roll is used as the width holding means, and FIG. 6 FIG. 3 is a plan view showing another example of the width holding means. (1) ψ fist, 轡, mold (1a)...φ, recess (4) Φ, Φ...introduction side pinch roll (5)----stretching side pinch roll (6), fist... Width retaining means (7)... Heating device (B)... ΦΦ meeting intermediate product

Claims (1)

[Scope of Claims] 1) A method for manufacturing a patterned area made of synthetic resin by filling and molding a thermoplastic synthetic resin into the intaglio pattern portion of a mold (1), the method comprising: Molding in which the pattern part is formed by a concave part (1a) carved by compressing the original design in the transport direction, and this concave part (1a) is filled with thermoplastic synthetic resin to form an intermediate product (B) with a compressed pattern. and a heating stretching step of heating and stretching the intermediate product (B) peeled from the mold (1) while maintaining the width of the intermediate product (B) to reveal the original design. Method of manufacturing patterned fabric. 2) Pinch rolls (4) (4) on the introduction side and stretching side pinch rolls (5) (5) that have different feeding speeds and introduce continuous intermediate products (B) and stretch the intermediate products (B). and a heating device (7) and a width holding means (6) for holding the width of the intermediate product (B) introduced between the pinch rolls (4) and (5), and a heating device (7). 4)(5
2. The method for manufacturing a patterned synthetic resin fabric according to claim 1, wherein the intermediate product (B) is heated and stretched while maintaining the width interval by driving the intermediate product (B). 3) The method for producing a synthetic resin patterned fabric according to claim 2, wherein the speed of the stretching side pinch rolls (5) is made variable to adjust the rate of heating and stretching.