JPH06122124A - Production of grain pattern molding roll - Google Patents

Abstract

PURPOSE:To easily produce a molding roll having reverse grain patterns on the outer surface thereof and to make the reverse grain patterns continuous so as not to develop discontinuous joints. CONSTITUTION:Silicon rubber is cast on the periphery of the trunk of a tree to form a flexible film and a slit 4 is formed to a part of the flexible film to peel the film from the trunk 1 of the tree. This flexible film 3 is turned inside out to be wound around a columnar member and an epoxy resin is cast on the periphery of the flexible film 3 to form a cylindrical matrix and the flexible film 3 and the columnar member are removed from the inner surface of the cylindrical matrix. Electroforming is applied to the inner surface of the cylindrical matrix to form an electroforming roll shell. A roll core is arranged at the center position of the electroforming roll shell and the gap between the electroforming roll shell and the roll core is filled with an epoxy resin to form a bonding layer.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a roll used to form an uneven pattern on a synthetic resin sheet, and more particularly to a method for producing a roll capable of forming an unprecedented grain-like uneven pattern. It is related to.

[0002]

2. Description of the Related Art As a building material for an outer wall or an inner wall of a building,
By using the tree trunk as it is, or by using the skin surface portion peeled from the tree trunk, a rich natural feeling of the wood surface is given to the building. However, there is a problem that it is difficult to obtain a large amount of these building materials and they are expensive. One way to solve this problem is
It is conceivable to replace the conventional building material with a synthetic resin sheet having a tree-like textured pattern (hereinafter, simply referred to as a tree pattern), but heretofore, there has not been found a molding apparatus capable of molding such a synthetic resin sheet.

[0003]

Therefore, prior to reaching the present invention, the inventor of the present invention used a flat-plate electroformed mold in which a reverse skin texture pattern was transferred from the skin texture pattern using the skin texture part peeled from the tree trunk as a model. A method of manufacturing and forming a wood pattern on a synthetic resin sheet with this electroformed mold was considered, but there was a problem that a large synthetic resin sheet could not be formed. Next, using the same skin texture as a model, an electroformed roll in which an inverse wood texture pattern was transferred from the wood texture pattern was produced, and a method of shaping the wood texture pattern on a long synthetic resin sheet with this electroforming roll was considered. However, since a discontinuous seam always appears somewhere in the reverse wood surface pattern of the electroforming roll, there has been a problem that the seam is also periodically formed on the synthetic resin sheet.

An object of the present invention is to easily produce a molding roll having a reverse wood texture pattern on its outer surface, which is not available in the past, and to make the reverse wood texture pattern continuous without showing discontinuous seams. It is an object of the present invention to provide a novel method for producing a roll for molding a wood texture pattern.

[0005]

In order to achieve the above object, in the method for producing a roll for forming a wood texture pattern according to the present invention, a rubber material or an elastomer material is cast around a tree trunk. A step of forming a flexible membrane with a core, making a cut in a part of the flexible membrane and peeling the flexible membrane from the trunk of the tree, and a step of reversing the flexible membrane so that the inner surface is the outer surface and winding the flexible film around the cylinder A step of casting a synthetic resin material around the flexible membrane to form a cylindrical mother die, and removing the flexible membrane and the cylindrical body from the inner surface of the cylindrical mother die; and an inner surface of the cylindrical mother die. And a step of forming an electroformed roll shell by electroforming.

As the "tree trunk", various trunks such as birch, cedar, pine, Japanese cypress, etc., which have the desired wood texture, can be appropriately selected. This trunk can be used even when it grows on the ground, and can also be used by cutting it to a predetermined length. Examples of the rubber material of the “flexible film” include silicone rubber, urethane rubber, thiocol rubber and the like. Elastomer materials include polyolefin, styrene / ethylene /
Butylene copolymer etc. can be illustrated. Epoxy resin is preferable as the "cylindrical matrix" synthetic resin material. Examples of the electroformed material of the “electroformed roll shell” include nickel, copper, nickel-cobalt alloy, copper-cobalt alloy and the like.

Further, in the method for producing a roll for forming a wood surface pattern of the present invention according to claim 2, in the above-mentioned production method, a roll core is arranged at a central position of the electroformed roll shell, and the electroformed roll shell and the roll are provided. A step of filling a bonding material between the core and the core to form a bonding layer was added. Here, examples of the material of the "roll core" include metal, synthetic resin, wood and the like. Epoxy resin is preferable as the bonding material of the "bonding layer".

[0008]

According to the present invention as set forth in claim 1, since a flexible film is formed by casting a rubber material or an elastomer material around the trunk of the tree, the inner surface of the flexible film is covered with the skin of the tree trunk. The reverse wood skin pattern is faithfully transferred and formed. Further, since the flexible film is cut in a part thereof and peeled off from the trunk of the tree, the reverse wood texture patterns on both sides of the cut are naturally continuous when these are combined.
Then, since this flexible film is inverted and wound around the cylindrical body so that the inner surface thereof becomes the outer surface, the reverse wood texture pattern on both sides of the cut is continuous if only the cut is carefully aligned. Therefore, on the inner surface of the cylindrical mother die formed based on this flexible film, a wood texture pattern is transferred from the reverse wood texture pattern of the flexible membrane, and the electroformed roll shell formed on the basis of this cylindrical mother die. On the outer surface, a reverse skin texture pattern is transferred and formed from a cylindrical mother die pattern. This reverse wood surface pattern is continuous and does not show discontinuous seams.

Further, according to the invention of claim 2,
Since the roll core is arranged at the center position of the electroformed roll shell and the binding material is filled between the electroformed roll shell and the roll core to form the binding layer, the electroforming roll shell and the roll core are coupled layers. And the inner surface side of the electroformed roll shell is backed up by the joining layer and the roll core.

[0010]

EXAMPLE A method for manufacturing a roll for forming a wood texture pattern according to an embodiment of the present invention will be described below in the order of steps with reference to FIGS. First, as shown in FIG. 1, a tree trunk 1 having a desired pattern of skin is selected. In this embodiment,
The trunk 1 is used as it is on the ground.

As shown in FIG. 2, the outer diameter of the trunk 1 is about 20
The outer cylinder 2 is constructed by fitting two split cylinders 2a having an inner diameter larger than mm coaxially with the outer circumference of the trunk 1, and fixing the flange portions 2b of both split cylinders 2a together with screws 12 or the like. Therefore, between the trunk 1 and the outer cylinder 2 is about 1 over the entire circumference.
A substantially uniform gap of 0 mm is formed. The flexible film 3 is formed by casting silicone rubber in this gap and curing it.

As shown in FIG. 3, after the outer cylinder 2 is removed, a longitudinally extending cut 4 is formed in a part of the flexible membrane 3 and the flexible membrane 3 is peeled from the trunk 1 so as to be developed from the cut 4. On the inner surface of the flexible film 3, an inverted wood texture pattern is transferred from the wood texture of the trunk 1, and the inverse wood texture patterns on both sides of the cut line 4 are naturally continuous when combined.

Next, as shown in FIG. 4, the flexible film 3 is turned upside down so that the inner surface with the reverse wood texture pattern is the outer surface, and the flexible film 3 is wound around the columnar body 5 and attached by an adhesive. At this time, in particular, the cuts 4 are carefully aligned so that the reverse skin texture patterns on both sides of the cuts 4 are continuous. The columnar body 5 is assembled so as to be disassembled by four divided columns 5a and the end members 5b at the upper and lower end central portions, and the inside is hollow.

Next, as shown in FIG. 5, two split cylinders 6a having an inner diameter larger than the outer diameter of the flexible membrane 3 by about 20 mm.
Is fitted on the outer periphery of the flexible membrane 3 coaxially, and the flange portions 6b of the two divided cylinders 6a are aligned and fixed by screws 12 or the like to form the outer cylinder 6. Therefore, a substantially uniform gap of about 10 mm is formed between the flexible membrane 3 and the outer cylinder 6 over the entire circumference. A cylindrical mother die 7 is formed by casting epoxy resin in this gap and curing it.

Then, the cylindrical body 5 is disassembled and removed, and the flexible film 3 is peeled from the inner surface of the cylindrical mother die 7 to expose the inner surface as shown in FIG. On the inner surface of the cylindrical mother die 7, a reverse skin texture pattern is transferred and formed on the flexible film 3, and the skin texture pattern is completely continuous over the entire circumference.

Next, as shown in FIG. 7, a conductive film (not shown) is formed on the inner surface of the cylindrical mother die 7 by applying conductive paint, silver mirror reaction, etc., and the conductive film is electroformed to a thickness of 2 mm. ~ 7m
The m electroformed roll shell 8 is formed. On the outer surface of the electroformed roll shell 8, a reverse wood surface pattern is transferred and formed from the cylindrical mother die 7, and the reverse wood surface pattern is completely continuous over the entire circumference.

Next, as shown in FIG. 8, an electroformed roll shell 8 is formed.
A roll core 9 with a support shaft 10 is disposed at the center position of, and an epoxy resin as a bonding material is filled between the electroformed roll shell 8 and the roll core 9 to form a bonding layer 11. And
The outer cylinder 6 is removed, and the cylindrical mother die 7 is eluted with a solvent to remove it, whereby the wood pattern pattern forming roll 13 as shown in FIG. 9 is completed.

A heated thermoplastic synthetic resin sheet (not shown) is provided on the wood pattern forming roll 13 manufactured in this embodiment.
By pressing, it is possible to transfer and form the wood texture pattern from the reverse wood texture pattern on the outer surface of the roll to the synthetic resin sheet, and the wood texture pattern can be made continuous without a seam. Shaped synthetic resin sheets include building materials for exterior or interior walls of buildings, automobile interior materials,
It can be used for furniture materials.

The present invention is not limited to the configuration of the above-described embodiment, but may be modified and embodied without departing from the spirit of the invention, for example, as follows. (1) Fine vent holes may be formed in the electroformed roll shell 8. In this case, for example, by adopting the method disclosed in Japanese Patent Publication No. 2-14434, it is possible to form the vent holes at the same time as forming the electroformed roll shell. (2) When the vent hole is formed in the electroformed roll shell 8, the bonding layer 11 is made air-permeable, a decompression chamber is provided in the roll core 9, and a decompression device is connected to the decompression chamber to form a composite during shaping. The transferability can be enhanced by sucking the resin sheet into the electroformed roll shell 8.

[0020]

As has been described in detail above, according to the present invention as set forth in claim 1, it is possible to easily manufacture a molding roll having a reverse grain surface pattern which has not existed on the outside, and the reverse grain surface pattern is produced. Can be continuous with no discontinuous seams. Further, according to the present invention as set forth in claim 2, a molding roll having high strength can be easily manufactured.

[Brief description of drawings]

FIG. 1 is a perspective view of a tree trunk used in an embodiment of the present invention.

FIG. 2 is a partially cutaway perspective view showing a step of forming a flexible film around a tree trunk.

FIG. 3 is a perspective view of a process of peeling a flexible film from a tree trunk.

FIG. 4 is a perspective view showing a partially broken step of winding a flexible film around a cylinder.

FIG. 5 is a partially cutaway perspective view showing a step of forming a cylindrical matrix around a flexible film.

FIG. 6 is a partially cutaway perspective view showing a state where a flexible film and a cylindrical body are removed from the inner surface of a cylindrical mother die.

FIG. 7 is a partially cutaway perspective view showing a step of forming an electroformed roll shell on the inner surface of a cylindrical mother die.

FIG. 8 is a partially cutaway perspective view showing a step of forming a bonding layer between an electroformed roll shell and a roll core.

FIG. 9 is a perspective view of the manufactured roll for forming a wood surface pattern.

[Explanation of symbols]

1 Tree Trunk 3 Flexible Membrane 4 Cut 5 Cylindrical 7 Cylindrical Master 8 Electroformed Roll Shell 9 Roll Core 11 Bonding Layer

Claims (2)

[Claims] 1. A step of casting a rubber material or an elastomer material around a trunk of a tree to form a flexible membrane, and notching the flexible membrane by cutting a part of the flexible membrane from the trunk of the tree, and the flexible membrane. Inversion so that the inner surface is the outer surface and winding around the cylinder, and a synthetic resin material is cast around the flexible membrane to form a cylindrical master, and the inner surface of the cylindrical master is And a step of removing the flexible film and the columnar body from the above, and a step of performing electroforming on the inner surface of the cylindrical mother die to form an electroformed roll shell. 2. The method according to claim 1, further comprising the step of disposing a roll core at a central position of the electroformed roll shell and filling a binding material between the electroformed roll shell and the roll core to form a binding layer. For manufacturing a roll for forming a wood grain pattern.