JPH0729383B2 - Method for manufacturing synthetic resin pattern material - Google Patents

Description

TECHNICAL FIELD The present invention relates to a method for producing a relatively large-sized synthetic resin pattern material having a frame pattern, which is mainly used for large-sized tablecloths for home use and the like. .

(Prior Art) Conventionally, when manufacturing this kind of synthetic resin pattern cloth,
Using a mold such as a synthetic molding plate or metal cylinder, form a concave pattern part corresponding to the original design of the pattern material to be manufactured on the outer surface of this mold, and fill the pattern part with thermoplastic synthetic resin Then, it is manufactured by peeling after molding, or by forming a predetermined pattern on the synthetic resin sheet by a silk screen printing means in a build-up shape to manufacture.

(Problems to be Solved by the Invention) By the way, in the case of manufacturing a relatively large-sized synthetic resin pattern material having a frame pattern, the former method using a mold requires a metal material larger than the pattern material to be manufactured. A mold is required, for example, in the case of manufacturing a table cloth of about 153 × 280 cm used for parties and the like, when using a metal cylinder as the mold, a cylinder having a diameter of 89 cm and a length of about 170 cm is used. In addition, it is necessary to form a recessed pattern portion having a size corresponding to the original design of the frame pattern provided on the table cloth on the cylinder, and the formation of the recessed pattern portion and handling of the cylinder are required. It will be very difficult.

Moreover, even if the same design is used, if the table cloths have different sizes, it is necessary to prepare various cylinders corresponding to these sizes, which results in a large number of cylinders and complicated storage management. And a large storage space is required.

Further, in the latter manufacturing method using the silk screen printing means, there is a limit in the thickness of the obtained pattern, etc., and there are restrictions in design, so there is a problem that the customer's request cannot be sufficiently met.

The present invention has been made in view of the above various problems,
The purpose is to use a single mold that is smaller than the synthetic resin pattern material to be manufactured, and to easily form a concave pattern portion on the mold and handle the mold easily. Although it is possible, it is possible to manufacture various synthetic resin pattern fabrics of different sizes, and moreover, storage management becomes complicated,
It is an object of the present invention to provide a method for producing a synthetic resin pattern material that can obtain various patterns that can meet customer demands without requiring a large storage space.

(Means for Solving the Problems) In order to solve the above problems, in the present invention, a method for producing a synthetic resin pattern material, in which a concave pattern portion of a mold (1) is filled with a thermoplastic synthetic resin and molded. In, the concave pattern portion of the mold (1) is formed by a concave portion (1a) engraved by compressing the original design in the transfer direction, and the concave portion (1a) is filled with a heat-degradable synthetic resin and compressed. A forming step of forming an intermediate product (B) having a pattern, and contacting the intermediate product (B) separated from the mold (1) at a predetermined length from the center in the width direction to the outside in the width direction. (B) is provided with a width dimension holding means (6) for applying a tensile force outward in the width direction to prevent contraction inward in the width direction and holding the width dimension.
It is characterized by comprising a heating and stretching step of causing the width dimension holding means (6) to heat and stretch while holding the width dimension to reveal the original design.

In the heating and stretching step, a feed intermediate speed is different and a continuous intermediate product (B) is introduced, and the introduction side pinch rolls (4) and (4) for extending the intermediate product (B) and the stretching side pinch roll ( 5) and (5), and a width dimension 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). ,
It is preferable that the pinch rolls (4) and (5) are driven to heat and stretch while maintaining the width interval of the intermediate product (B).

In addition, it is preferable that the stretching side pinch roll (5) can adjust the rate of heating and stretching by changing the speed thereof.

(Operation) During the step of molding the synthetic resin pattern material, the mold (1) is formed with the concave portion (1a) formed by compressing the original design of the synthetic resin pattern material in the transfer direction. Therefore, by filling the concave portion (1a) with a thermoplastic synthetic resin, an intermediate product (B) having a compression pattern of the original design is molded, and the intermediate product (B) is formed by the mold (1). After being peeled from the sheet, in the heating and stretching step, the width dimension holding means (6) is contacted with a predetermined length from the center in the width direction to the outer side in the width direction, and a tensile force outward in the width dimension is applied to the width dimension holding means (6), While being prevented from shrinking inward in the direction, the width dimension is maintained and the material is heated and stretched, so that a synthetic resin pattern material having a size corresponding to the original design is manufactured.

The mold (1) used in the above molding process
Has a size corresponding to the intermediate product (B), that is, smaller than the original design of the synthetic resin pattern material to be manufactured. The recess (1a) can be easily formed, and the mold (1) can be easily handled.

Moreover, one mold (1) is used by changing the stretching ratio of the intermediate product (B) to heat and stretch the intermediate product (B) to form the synthetic resin pattern material. It is possible to manufacture various synthetic resin pattern fabrics of different sizes, and therefore, without complicating storage management and requiring a large storage space,
It is possible to obtain various patterns that can meet customers' requests.

In the drawing and heating process, the introduction side pinch rolls (4) and (4) and the drawing side pinch rolls (5) for introducing the continuous intermediate product (B) having different feeding speeds and extending the intermediate product (B). ) (5), a width dimension 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),
When heating and stretching are performed while driving the pinch rolls (4) and (5) while maintaining the width interval of the intermediate product (B),
By using the pinch rolls (4) and (5), the intermediate product (B) can be enlarged in the transfer direction to the size of the original design to easily and continuously produce a long synthetic resin pattern material. it can.

Further, when the speed of the drawing side pinch roll (5) is variable and the rate of heating drawing can be adjusted, by changing the speed of the pinch roll (5) with respect to the introduction side pinch roll (4), The size of the intermediate product (B) in the transfer direction can be freely, easily and accurately changed, and various kinds of synthetic resin patterned fabrics having different sizes can be obtained.

(Examples) Hereinafter, a method for manufacturing a synthetic resin pattern material according to the present invention will be described with reference to Examples of the drawings.

FIG. 1 shows an example of a manufacturing apparatus used in the manufacturing method. In the figure, (1) is a metal mold made of a metal cylinder, and an extruder ( The tip end extrusion port of 2) is faced, and the peeling roll (3) is brought into contact with the outer peripheral portion of the mold (1) on the side opposite to the extruder (2).

On the outer peripheral surface of the mold (1), a concave portion (1a) obtained by compressing an original design pattern made of synthetic resin to be produced in the pattern transfer direction is engraved, and the concave portion (1a) is provided with the extruder. Filling with a thermoplastic synthetic resin extruded from (2), curing the thermoplastic synthetic resin in the recess (1a) as the mold (1) rotates, and peeling it with the peeling roll (3). Thus, an intermediate product having a compressed pattern compressed in the transfer direction with respect to the original design is molded.

That is, when a rectangular synthetic resin pattern material (A) having a frame pattern (a) as shown in FIG. 2 is manufactured, the original design of the pattern material (A) is transferred in the transfer direction. The compressed recess (1a) is engraved in the mold (1) to form a frame pattern (b) and an intermediate product (B) whose overall appearance is compressed in the transfer direction as shown in FIG. Do as you do.

Then, a pair of upper and lower introduction side pinch rolls (4) and (4) for introducing the intermediate product (B) are arranged in contact with each other at a position outside the peeling roll (3) in the transfer direction and the like, and A pair of stretching side pinch rolls (5) (5), which are rotated at a higher speed than the respective pinch rolls (4), are arranged in an abutting manner at an outer position apart from each pinch roll (4) by a predetermined distance. The intermediate product (B) is stretched by the difference in rotational speed between the introduction and stretching side pinch rolls (4) and (5), and the introduction and stretching side pinch rolls (4) are also stretched.
The width dimension holding means (6) and the heating device (7) for the intermediate product (B) are respectively arranged in the middle portion of (5), and the width dimension holding means (6) and the heating device (7) are arranged. By heating while maintaining the width of the intermediate product (B), the intermediate product (B) is stretched in the transfer direction by the pinch rolls (4) and (5).

As the width dimension holding means (6), for example, a plurality of expander rolls (60) used at the time of manufacturing a synthetic resin sheet are used.

As shown in FIG. 5, this expander roll (60) rotates on a support shaft (62) having a cam (61) having inclined grooves (61a) at both ends fixed thereto, and the support shaft (62). The cylinder (63) is freely supported, and a large number of slide bars (64) are slidably supported on the outer peripheral surfaces of both ends of the cylinder (63) in the axial direction.

At one end of the slide bar (64), the inclined groove (61
a) a thrusting rod (65) is provided, which is fixed to the slide bar (64) when the cylindrical body (63) is rotated by frictional resistance associated with the transfer of the intermediate product (B). (65)
Is guided by the inclined groove (61a) and moves in the axial direction of the support shaft (62), whereby the slide bar (64) is
As shown by the arrow in FIG. 5, the intermediate product (B) slides axially outward along the outer peripheral surface of the cylindrical body (63) as it goes from the winding start position to the separated position, and the intermediate product (B) From the center in the width direction to the outside in the width direction, the intermediate product (B) is contacted with a predetermined length and a tensile force outward in the width direction is applied to the intermediate product (B) to prevent contraction inward in the width direction. The width dimension of B) is maintained.

Further, as the width dimension holding means (6), as shown in FIG. 6, a pair of upper and lower rolls (66) (66) which are always in contact with each other by a tension spring or the like is used. A plurality of sets of the intermediate product (B) are arranged on both sides in the width direction in an inclined manner, and the intermediate product (B) is transferred while being sandwiched between the rolls (66). From the center of the width direction of (B) to the outer side in the width direction, the intermediate product (B) is contacted with a predetermined length to apply a tensile force outward in the width direction to prevent contraction inward in the width direction. The width may be retained.

Further, a heating roll (8) for annealing the synthetic resin pattern material (A) taken out from the pinch roll (5) is arranged near the stretching side pinch roll (5), The synthetic resin pattern material (A) delivered from the pinch roll (5) through the intermediate roller (9) is transferred while being heated by the heating roller (8), whereby the synthetic resin pattern material (A) is transferred. ) To remove the distortion.

Further, a part of the outer periphery of the heating roll (8) is contacted with a plurality of cooling rolls (10), and the synthetic resin annealed by the heating rolls (8) by each cooling roll (10). The patterned material (A) is taken up and cooled, and the cooled synthetic resin material (A) is wound up by the winding device (11).

The various rolls used in the above manufacturing apparatus are driven to rotate by one motor (12), that is, the mold (1) and the introduction side pinch roll (4) are provided on the output side of this motor (12). ) And are linked together so that the peripheral speeds are the same, and a continuously variable transmission (13) and a differential gear (14) are connected to the output side of the pinch roll (4) in the motor (12). The extension side pinch roll (5), the heating roll (8) and the cooling roll (10) are interlockingly connected to the output side of the differential gear (14) so that the peripheral velocities are the same. The drawing side pinch roll (5), the heating roll (8), and the cooling roll by the continuously variable transmission (13) against the rotation of the mold (1) and the introduction side pinch roll (4) by 12). (10) rotation With fast, intermediate product to be molded in the mold (1) side (B) by expanding to a size of the original design, it is to manufacture the synthetic resin pattern areas (A).

Further, in the embodiment of FIG. 1, an intermediate roll (15) for supplying a backing film (F) is provided on a part of the outer periphery of the mold (1), and the mold (1) is fed from the roll (15). The film (F) is supplied to the intermediate product (B) molded in (1), and the film (F) is attached to and integrated with the synthetic resin pattern material (A) to be manufactured.

Next, a method for manufacturing the synthetic resin pattern material (A) by the manufacturing apparatus configured as described above will be described.

First, when manufacturing a synthetic resin pattern material (A) having a rectangular shape with a length L and a width W having a frame-shaped pattern (a) as shown in FIG. From a metal cylinder having an outer surface of a size corresponding to the intermediate product (B) shown in FIG. 3, which is based on this plate-making design, is formed by compressing the original design by a predetermined size in the pattern transfer direction. The mold (1) is manufactured.

That is, when the size of the pattern material (A) is length L × width W, the size of the mold (1) to be used is calculated from this size, that is, the mold (1) has a diameter D. When the circumference length is πD, this mold (1) is manufactured by reducing it to a constant ratio πD / L.

When the existing die (1) is used, the plate making design is calculated by calculating the circumferential length (πD) of the die (1) with respect to the length (L) of the original design line. Ratio of original design length (L) to the circumference length (πD) (πD / L)
It is compressed and formed.

In any case, the circumferential length (πD) of the mold (1)
However, the length of the intermediate product (B) is smaller, and the size of the intermediate product (B) is smaller than the original design of the synthetic resin pattern material (A) to be manufactured. Thus, the recess (1a) is formed in the mold (1) based on the plate-making design which is reduced from the original design.

When forming the concave portion (1a) in the mold (1), if the original design of the pattern material (A) is stored as data in a computer or the like in advance, the data is calculated and An original plate of the plate-making design corresponding to the intermediate product (B) shown in FIG. 3 is produced, and when the original design is a handwriting or a photograph, the plate-making is performed by photographing with a camera using a cylindrical lens or the like. An original plate of the design is produced, or it is taken in as computer data by using a scanner or the like and arithmetically processed to produce the original plate.

Then, a positive film or the like is made from the original plate, and the recess (1a) is reduced to the mold (1) by a chemical corrosion method.
Is formed, or is directly input from a computer data to a laser plate making system or an electronic engraving system to form the concave portion (1a).

Then, using the mold (1) manufactured as described above, the recess (1a) of the mold (1) is filled with the thermoplastic resin from the extruder (2), and the intermediate roll is also used. (15)
By supplying the backing film (F) from
With the rotation of the mold (1), the resin in the recess (1a) is cured to line the film (F), and
A third pattern (b) corresponding to the recess (1a) is formed.
Intermediate product (B) as shown in the figure, that is, width W x length πD /
The intermediate product (B) of L is continuously manufactured.

In this case, the depth of the recess (1a) and the thickness of the film (F) in the case of backing are made deeper or thicker in advance according to the compression ratio of the original design, in other words, the stretching ratio, and then stretched. At times, the thickness is the frame pattern pattern of the original design, and the film thickness is suitable for lining.

The intermediate product (B) is peeled off by the peeling roll (3) and supplied between the introduction side pinch rolls (4) and the stretching side pinch rolls (5) to maintain the width dimension. When the synthetic resin pattern material (A) having the same size as the original design is obtained by being heated by the heating device (7) while being kept at the predetermined width W by the means (6), each pinch roll (4) ) (5) The rotational speed ratio between (5) and (5) is adjusted to (L / πD), and as shown in FIG. 4, a synthetic resin pattern material (A ′) of a desired size (L ′) different from the original design is used. ), The speed ratio is set to (L '
/ ΠD).

Then, after being stretched by the pinch rolls (4) and (5) to the size of the original design or a desired size, annealing is performed by the heating roll (8) to remove strain, and It is cooled by each cooling roll (10) and wound on the winding device (11), and the wound product of the winding device (11) is cut, for example, the length L × width W The synthetic resin pattern material (A) 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 pattern material (A), the pinch rolls (4) are By changing the speed ratio of (5), that is, the stretching ratio, it is possible to manufacture various synthetic resin pattern fabrics (A) of different sizes using one mold (1), and to meet the customer's request. Various patterns that can be dealt with can be obtained.

The stretching ratio of the intermediate product (B) by each of the pinch rolls (4) and (5) is preferably 50% or less, particularly 35% or less, and the size of the intermediate product (B) is the synthetic resin. It is desirable to set it to about 20% with respect to the pattern-making ground (A), especially about 10% depending on the pattern design, and by doing so, a good product can be surely obtained without the pattern collapse.

Next, a method for producing the synthetic resin pattern material (A) will be described with reference to specific examples.

First of all, the original design of length 264 x width 150 cm was taken in as data into a computer using a scanner, and arithmetic processing was performed at a compression ratio of 0.769 in order to indent into a mold (1) made of a metal cylinder with a diameter of 650 mm. An original plate was produced, a positive film was produced from the original plate, the mold (1) was subjected to chemical corrosion treatment, and then plated to form a recess (1a) in the mold (1).

Then, a vinyl chloride resin mixed with a plasticizer as a thermoplastic resin is extruded from the extruder (2) and filled in the recess (1a) of the mold (1), and as the backing film (F). A 0.1 mm vinyl chloride film was adhered, the intermediate product (B) was molded by the mold (1), and then the intermediate product (B) was peeled off by the peeling roll (3).

In addition, the introduction side and the drawing side pinch rolls (4) (5)
Were adjusted to 4 m / min and 5.55 m / min, respectively, to obtain a synthetic resin pattern material (A) having a length of 280 × a width of 150 cm.

In the above examples, the backing film (F) was attached to the intermediate product (B) to produce the synthetic resin pattern material (A) having the film (F). It is not always necessary to provide (F). Further, although the case where the metal cylinder is used as the mold (1) has been described in the above embodiment, the present invention is not limited to the metal cylinder, and a flat metal forming plate can be used.

(Effects of the Invention) As described above, in the method for manufacturing a synthetic resin pattern material according to the present invention, the concave pattern portion provided on the mold (1) is engraved by compressing the original design in the transfer direction ( 1a), and the recess (1a) is filled with a thermoplastic synthetic resin,
A molding step of molding an intermediate product (B) having a compression pattern,
From the center in the width direction of the intermediate product (B) separated from the mold (1) to the outside in the width direction, the intermediate product (B) is contacted with a predetermined length to apply a tensile force outward in the width direction to the intermediate product (B). A width dimension holding means (6) for holding the width dimension by preventing contraction inward in the direction is provided, and the width dimension of the intermediate product (B) is held by the width dimension holding means (6). However, since it has a heating and drawing step of heating and drawing to bring out the original design, one mold (1) smaller than the synthetic resin pattern material (A) to be manufactured is produced. It is possible to manufacture various kinds of synthetic resin patterned fabrics (A) having different sizes while easily and easily forming the concave portion (1a) in the mold (1) and handling thereof. ,
Moreover, it is possible to obtain various patterns that can meet the demands of customers without complicating storage management and requiring a large storage space.

Further, in the stretching heating step, the feeding speed is different,
Introducing the continuous intermediate product (B), the intermediate product (B)
A pair of introduction side pinch rolls (4) and a stretching side pinch roll (5) for stretching the film are provided, and the width of the intermediate product (B) introduced between the pinch rolls (4) and (5) is held. A width dimension holding means (6) and a heating device (7) are provided, and heating and stretching are performed while driving the pinch rolls (4) and (5) while maintaining the width interval of the intermediate product (B). By doing so, each of the pinch rolls (4) and (5) can expand the intermediate product (B) in the transfer direction to the size of the original design or a required size, and thus the long synthetic product. The resin pattern material (A) can be easily continuously manufactured.

Furthermore, by making the speed of the stretching side pinch roll (5) variable and adjusting the rate of heat stretching, the size of the intermediate product (B) in the transfer direction can be freely and accurately changed, It is possible to easily and accurately obtain various synthetic resin pattern materials (A) having different sizes.

[Brief description of drawings]

FIG. 1 is a partially cutaway side view showing an example of a manufacturing apparatus used in a method for manufacturing a synthetic resin pattern material according to the present invention, FIG. 2 is a front view showing a synthetic resin pattern material to be manufactured, and FIG. FIG. 4 is a front view of an intermediate product, FIG. 4 is a front view corresponding to FIG. 2 showing another embodiment to be manufactured, and FIG. 5 is an explanatory view when an expander roll is used as a width dimension holding means. The figure is a plan view showing another example of the width dimension holding means. (1) …… Mold (1a) …… Concave (4) …… Introduction side pinch roll (5) …… Stretching side pinch roll (6) …… Width dimension holding means (7) …… Heating device (B) …… Intermediate product

Claims (3)

[Claims] 1. A method for producing a synthetic resin pattern material, comprising molding a thermoplastic resin into the concave pattern portion of the mold (1), wherein the concave pattern portion of the mold (1) is formed. , The original design is compressed in the transfer direction and formed by the engraved recess (1a),
A molding step of filling the recessed portion (1a) with a heat-dissipative synthetic resin to form an intermediate product (B) having a compression pattern, and a center in the width direction of the intermediate product (B) separated from the mold (1). To the outside in the width direction, contacting the intermediate product (B) in the width direction by a predetermined length, and applying a pulling force outward in the width direction to prevent contraction inward in the width direction and hold the width dimension. A synthetic resin comprising a means (6), wherein the intermediate product (B) is heated and stretched by the width dimension holding means (6) while holding the width dimension thereof to reveal the original design. A method for manufacturing a patterned fabric. 2. A continuous intermediate product (B) having different feed speeds.
And a drawing side pinch roll (4) and a drawing side pinch roll (4) for drawing the intermediate product (B).
(5) and each of the pinch rolls (4)
A width dimension holding means (6) for holding the width of the intermediate product (B) introduced between (5) and a heating device (7) are provided, and the intermediate product is driven by driving the pinch rolls (4) and (5). The method for producing a synthetic resin pattern fabric according to claim 1, wherein the stretched pattern is heated and stretched while maintaining the width interval (B). 3. The method for producing a synthetic resin pattern material according to claim 2, wherein the rate of heating and stretching is adjusted by changing the speed of the stretching side pinch roll (5).