JPH0838967A - Roll coating apparatus - Google Patents

Abstract

PURPOSE:To produce the pattern, whose rugged pattern is ununiform like a skin of a natural ragstone or wood and whose step of the ruggedness is large, easily and in high quality. CONSTITUTION:This device consists of a shaft 1 composing a rotary shaft and an elastic cylindrical member provided on the outer periphery in the axial direction of the shaft 1, and the elastic member has at least two layers being different from hardness toward the radial direction and also the member has higher hardness in a layer 3 (outer layer) at the outer periphery side than hardness of a layer 2 (inner layer) at the shaft side.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a coating apparatus, and more particularly to a pattern roller for forming an uneven pattern, and more particularly, for forming a pattern having an uneven uneven pattern and a large uneven step like natural rubble stone and wood skin. The present invention relates to a roll coating device particularly suitable for

[0002]

2. Description of the Related Art Conventionally, as a method of forming an uneven pattern by coating on the surface of a flat board, a method of pouring a coating material into a mold having an uneven pattern to solidify it, a board A method of pressing a mold while the coating layer formed thereon is soft, and a method of partially scraping off the board surface are used.

In addition to this, after applying a mastic material (a paint used for outdoor concrete surfaces, brick surfaces, etc., which can be thickly applied like plaster), as is done in some construction sites. A method of rolling the pattern roller to form an uneven pattern on the surface of the substrate before the surface becomes hard is used. However, in the method of rolling with this pattern roller, there is an unavoidable variation in the thickness of the board itself, which is the object to be coated, or the mastic material used, so a regular pattern roller always applies a uniform and constant transfer pressure. However, there is a limit to this, and the present situation is that the conventional method is limited to the case where a uniform pattern is formed with relatively few uneven steps. In particular, in the conventional pattern roller, when the uneven pattern is made into a non-uniform pattern to give a natural texture, the ratio of the unevenness on the right and left sides of the roller is different, which results in the mastic material protruding from one end. However, there is a problem in that the patterns and designs to be formed are greatly limited.

[0004]

DISCLOSURE OF THE INVENTION The present invention is directed to solving the above-mentioned problems of the prior art, and the uneven pattern is uneven and uneven like the skin of natural rubble stone and wood. An object of the present invention is to provide a roll coating device capable of easily forming a pattern having a large step with high quality.

In order to achieve the above object, a roll coating apparatus according to the present invention comprises a shaft constituting a rotary shaft and a cylindrical elastic member provided on the outer circumference of the shaft in the axial direction. However, a member having at least two layers having different hardness in the radial direction and having a hardness of the outer peripheral surface side layer (outer layer) higher than that of the axial side layer (inner layer). It is a feature.

As described above, in the roll coating apparatus according to the present invention, since the elastic member is composed of at least two layers having different hardness, and the hardness of the outer layer is relatively higher than the hardness of the inner layer, it is conventionally formed. It is possible to easily form high quality with a non-uniform pattern or uneven pattern with large steps, which was difficult to achieve, as a sharp pattern that is close to natural, and the loss of coating material can be minimized. .

According to the knowledge of the inventor of the present invention, as a result of various studies on a method of forming a concavo-convex pattern such as a natural rubble pattern by rolling compaction by a roll coating device, the elastic characteristics of a cylindrical elastic member of the roll coating device , Especially found that it is necessary to adjust the rubber hardness to an optimum value, but newly found that it is difficult to stably form a sharp pattern such as a rubble pattern only by adjusting the rubber hardness. It was

That is, in order to absorb the variation in the thickness of the object to be coated and make the transfer pressure of the roller constant, it is effective to make the surface of the roller have an appropriate hardness. At this time, the uneven pattern is formed depending on the balance between the hardness of the uneven pattern roller and the hardness (viscosity, viscosity) of the mastic material. However, if the surface hardness of the pattern roller is too hard, the convex portion determines the transfer pressure. Therefore, in the case of a pattern having a large step, the phenomenon that the concave portion is not sufficiently filled with the mastic material is likely to occur, and when the pattern has a left-right difference, the amount of the mastic material protruding increases. On the other hand, if the surface hardness of the pattern roller is too soft, the transfer pressure is adjusted well, and the exposure of the mastic material to the left and right can be prevented, but the uneven pattern loses sharpness, so that a sharp pattern like a natural rubble pattern or It is difficult to stably form a delicate pattern such as a bark of wood.

Therefore, the present inventor can solve the above problems all at once by providing a difference in hardness between the inside and the outer layer of the roller and making the hardness of the outer layer relatively higher than the hardness of the inner layer. The inventors have found out what can be done and completed the present invention.

[0010]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be specifically described below based on embodiments shown in the drawings.

FIG. 1 shows a coating material (mastic material) on the surface of an object to be coated by using a roll coating apparatus according to an embodiment of the present invention.
FIG. 6 is a cross-sectional view showing how to form an uneven pattern according to FIG. That is, in the roll coating apparatus according to the present invention, two elastic member layers, that is, the inner layer 2 and the outer layer 3 are provided on the outer circumference of the shaft 1 that constitutes the rotating shaft.

Here, a hardness difference is provided between the inner layer 2 and the outer layer 3, and the hardness of the outer layer 3 is relatively higher than the hardness of the inner layer 2. When the relative relationship of hardness is opposite, the effect of the present invention described above cannot be obtained.

An uneven pattern is formed on the surface of the outer layer 3 as shown in the figure, and the outer layer 3 is rolled by rolling on the coating material layer 5 applied and formed on the board 4 which is the member to be coated. The uneven pattern on the surface is transferred.

In the present invention, the elastic member layer is preferably made of rubber, and the rubber hardness of the inner layer 2 is usually JIS-K.
1 as measured by the C-type rubber hardness meter specified in -6301
0 to 55 degrees, and the rubber hardness of the outer layer 3 is 40 to 9
It is preferably in the range of 0 degree.

In the present invention, the hardness difference between the inner layer and the outer layer is 10 to 70 degrees, preferably 20 to 60, as measured by a C type rubber hardness meter specified in JIS-K-6301.
The range of the degree is preferable for achieving a superior effect.

Since an uneven pattern is formed on the outer layer,
When the rolling force is applied to the coating surface of the coating material, the rolling force of the convex portion is large and the rolling force of the concave portion is small, so that a pressure difference is inevitably generated between the concave portion and the convex portion. For this reason, the coating material tends to protrude outward in the convex portion, but by interposing an inner layer having a hardness smaller than that of the outer layer inside the outer layer, the pressure difference caused by the inner layer to the outer layer is skillfully manipulated. It is considered that the coating material absorbs and that the coating material acts to suppress the tendency of the coating material to protrude. The range of the hardness difference as described above is effective in promoting such an action.

Further, in the present invention, it is preferable that the inner layer 2 is thicker than the outer layer 3. The thickness of the inner layer and the outer layer is appropriately set particularly according to the shape and size of the uneven pattern formed on the outer layer surface (the height difference between the concave portion and the convex portion), and is not particularly limited. No, but usually, for example, 5 to 50 mm for the inner layer and 1 to 2 for the outer layer
It is preferably set to about 0 mm, particularly about 2 to 12 mm.

In the example of FIG. 1, there is an interface between the inner layer and the outer layer, but in the present invention, in addition to this aspect, the rubber hardness continuously changes in the cross-sectional direction (radial direction). Or a mode in which the hardness gradient is inclined. Further, the present invention also includes a case where the elastic member is composed of three or more layers as long as the above conditions are satisfied.

Hereinafter, the present invention will be described more specifically based on actual manufacturing examples and coating examples. Example 1 A polyurethane foam rubber sheet having a thickness of 15 mm (rubber hardness of 30 degrees) was wrapped around a 400 mmφ iron core, and a polyurethane sheet obtained by taking a mold from a quarry stone plate of natural sandstone (maximum thickness 11 mm, minimum thickness). 2mm, rubber hardness 60 degrees)
Was wound around to form a coating device of the present invention (hereinafter, also referred to as a compaction roller).

Next, the ALC having the surface which has been subjected to the base treatment is smooth.
A mastic material (made by Asahi Kasei Kogyo Co., Ltd., whose surface is filled with a sealing material and made smooth) with an extender pigment such as calcium carbonate dispersed in an acrylic emulsion resin and has a B-type viscosity. (A total of 350-450 poise) is applied with a coating roll so that the wet film thickness is 2 mm, and immediately put a rail between the guide roller and the above-mentioned compaction roller where the gap is adjusted and the uneven surface is applied on the coated surface. Formed. The surface of this roller was preliminarily moistened with kerosene so that the mastic material would not adhere to it.

In this production example, a sharp pattern made of a mastic material could be formed on the ALC board, even though the uneven pattern was a split stone pattern. Although the variation in the thickness of the board was 1.5 mm at the maximum, there was no change in the amount of protrusion of the mastic material, and no shortage of the rolling roller was observed. Comparative Example 1 A rolling roller was constructed by winding a polyurethane sheet (maximum thickness: 11 mm, minimum thickness: 2 mm, rubber hardness: 60 degrees), which was modeled from a quarry stone plate of natural sandstone, around an iron core of 400 mmφ.

Then, a pattern made of a mastic material was formed on the ALC board by the same method as in Example 1 by using this pressure roller.

In this rolling roller, it was recognized that the thickness of the board was easily affected, and when the board thickness was large, the amount of the mastic material protruding increased, so that the pattern of the convex portion was broken. On the other hand, when the plate thickness was thin, the amount of protrusion was reduced, and the shortage of contact with the pressure roller became conspicuous, and it was not possible to stably form a satisfactory pattern. Comparative Example 2 A rolling roller was constructed by winding a polyurethane sheet (maximum thickness 20 mm, minimum thickness 9 mm, rubber hardness 30 degrees), which was modeled from a quarry stone plate of natural sandstone, around an iron core of 400 mmφ.

Then, a pattern made of a mastic material was formed on the ALC board by the same method as in Example 1 by using this pressure roller.

This pressure roller is susceptible to variations in board thickness, and if the board thickness is large, there is a problem in that the uneven pattern is significantly broken and a sharp pattern is not formed. Further, it was difficult to adjust the gap between the guide roller and the compaction roller, and it was not possible to increase the coating amount of the mastic material to stably form the pattern. Comparative Example 3 A polyurethane foam rubber sheet having a thickness of 15 mm (rubber hardness of 60 degrees) was wrapped around a 400 mmφ iron core, and a polyurethane sheet obtained by taking a mold from a quarry stone plate of natural sandstone (maximum thickness 11 mm, minimum thickness). 2mm, rubber hardness 30 degrees)
Was wound around to form a compaction roller of the present invention.

Then, a pattern made of a mastic material was formed on the ALC board in the same manner as in Example 1 by using this pressure roller.

Since the rubber hardness of the outer layer and that of the inner layer are reversed in this way, it is easily affected by variations in the plate thickness of the board, and the uneven pattern disappears in the part where the plate thickness is partially thick, resulting in a smooth surface. It's finished. Reference Example 1 A polyurethane foam rubber sheet of 15 mm thickness (rubber hardness of 20 degrees) is wound around a 400 mmφ iron core, and a rubber sheet obtained by taking a mold from a quarry stone plate of natural sandstone (maximum thickness 10 mm, minimum thickness 2 mm, rubber hardness 30 degrees) was wound to form the rolling roller of the present invention.

Then, a pattern made of a mastic material was formed on the ALC board by the same method as in Example 1 by using this pressure roller.

In this pressure roller, variations in the board thickness of the board are absorbed by the rubber sheet on the inner layer side to form a good uneven pattern, but since the rubber hardness of the outer layer is relatively small, the board thickness is large and In the portion where the coating amount of the mastic coating material was small, the uneven pattern tended to be slightly lacking in sharpness. Reference example 2 A 400 mmφ iron core is wrapped with a polyurethane foam rubber sheet with a thickness of 15 mm and a rubber hardness of 30 degrees, and on the surface of the rubber sheet, a rubber sheet made from a quarry stone plate of natural sandstone (maximum thickness 10 mm, minimum thickness 2 mm, rubber hardness 95 degrees) was wound to form the rolling roller of the present invention.

Then, a pattern made of a mastic material was formed on the ALC board in the same manner as in Example 1 by using this pressure roller.

In the case of this pressure roller, no particular problem occurs in the formation of the uneven pattern, but since the rubber hardness of the outer layer is relatively high, the outer layer sheet is difficult to deform, and therefore the function of the inner layer sheet is not always fully utilized. , The mastic coating material tends to stick out on the outside of the board. Reference Example 3 A rubber sheet having a thickness of 10 mm and a rubber hardness of 5 degrees is wound around a 400 mmφ iron core, and a rubber sheet obtained by taking a mold from a quarry stone plate of natural sandstone (maximum thickness 11 mm, minimum thickness 2 mm, A rubber roller having a rubber hardness of 50 degrees) was wound to form a rolling roller of the present invention.

Then, a pattern made of a mastic material was formed on the ALC board by the same method as in Example 1 by using this pressure roller.

In the case of this roller, it is considered that the rubber hardness of the inner layer is too small, and the convex portions of the outer layer act so as to crush the inner layer. Reference Example 4 A rubber sheet having a thickness of 10 mm and a rubber hardness of 70 degrees is wound around a 400 mmφ iron core, and a rubber sheet obtained by taking a mold from a quarry stone plate of natural sandstone (maximum thickness 10 mm, minimum thickness 2 mm, A rubber roller having a hardness of 80 degrees) was wound around the roller to form the rolling roller of the present invention.

Then, a pattern made of a mastic material was formed on the ALC board by the same method as in Example 1 using this pressure roller.

In the case of this pressure roller, no particular problem occurs in forming the uneven pattern, but since the rubber hardness of the inner layer is relatively high and is close to that of the outer layer, variations in the roller compaction of the outer layer are dispersed by the inner layer. It can be seen that the mastic material tends to stick out to the outside of the board, which makes it difficult to set the coating amount of the mastic material.

[Brief description of drawings]

FIG. 1 is a cross-sectional view showing how a concavo-convex pattern is formed on a surface of an object to be coated by using a roll coating apparatus according to an embodiment of the present invention.

[Explanation of symbols]

 1 axis 2 inner layer 3 outer layer 4 board 5 coating material layer

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Takashi Yokoya 1-1-1 Uchisaiwaicho, Chiyoda-ku, Tokyo Inside Asahi Kasei Housing Co., Ltd.

Claims (6)

[Claims] 1. A shaft comprising a rotating shaft, and a cylindrical elastic member provided on the outer periphery of the shaft in the axial direction, wherein the elastic member has at least two layers having different hardness in the radial direction. And a hardness of a layer (outer layer) on the outer peripheral surface side is higher than a hardness of a layer (inner layer) on the shaft side, the roll coating apparatus. 2. The elastic member is made of rubber, the rubber hardness of the inner layer is 10 to 55 degrees as measured by a C-type rubber hardness meter specified in JIS-K-6301, and the rubber hardness of the outer layer. Is 40 to 90 degrees, The roll coating apparatus according to claim 1. 3. The hardness difference between the inner layer and the outer layer is JIS-K-
10 measured by the C-type rubber hardness tester specified in 6301.
The roll coating apparatus according to claim 1, which is in the range of ˜70 degrees, preferably 20 to 60 degrees. 4. The roll coating apparatus according to claim 1, wherein an uneven pattern is formed on the outer surface of the elastic member. 5. The roll coating apparatus according to claim 1, which is used for coating a mastic material. 6. The roll coating apparatus according to claim 1, wherein the inner layer is thicker than the outer layer.