KR101621961B1 - Apparatus for manufacturing paper sheet for surface material and mehod for manufacturing the same - Google Patents

Abstract

One embodiment of the present invention includes a heating roller including a first housing roller and a heat source mounted inside the first housing roller; An emboss roller including a core roller and a covering layer made of silicone rubber formed on a surface of the core roller; And a cooling roller including a second housing roller and a cooling water moving tube mounted inside the second housing roller, wherein a three-dimensional pattern is formed on the surface of the covering layer, the three-dimensional pattern including a relief portion and a negative- And a paper sheet, which is a surface sheet of paper.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention [0001] The present invention relates to an apparatus and a method for manufacturing a sheet material,

The present invention relates to an apparatus and a method for manufacturing a surface paper sheet, and more particularly, to a manufacturing apparatus and method for continuously producing a surface sheet of paper on which an emboss pattern is formed.

 A technique of forming an emboss on a surface material sheet wrapping the surface of a product is used as a method of implementing an aesthetic design on the surface of the product. Emboss is a concave-convex part formed on the surface. In the case of paper material, it is used for damping or cushioning material which requires attraction force and cushioning feeling. In the case of metal material, it is applied for decoration or slip prevention. In particular, the embossed surface material paper sheet can be variously applied as an interior sheet or a decor sheet. Examples of applications include household appliances, furniture, wood, iron plates, gypsum boards, metal plates, flooring materials, have.

On the other hand, in recent years, materials having irregular emboss patterns, such as crushed, wrinkled, crinkled, pleated, fluted, etc., . The following methods have been proposed to give such an emboss pattern.

(A) a wet laminating process of a thermoplastic plastic (eg, polypropylene, polystyrene, or polyvinyl chloride) using an adhesive on a paper substrate, a heating process, and a cooling process are sequentially performed, and then the laminated A method of imparting an emboss pattern to a paper substrate;

(B) a method of applying an emboss pattern while passing a wet polyurethane coating layer through an emboss roller heated by electric or thermal oil (SHTF (Synthetic Heat Transfer Fluid), for example, Therminol Series, Barrel Series, etc.);

(C) a method in which two or more embossing rollers having embossed and engraved patterns engage with each other and rotate while passing through paper, aluminum, or steel sheet, while embossing patterns are applied;

(D) a method of imparting an emboss pattern while passing toilet paper, paper, fiber or the like between a steel roller and a compression roller composed of a rubber or a compressed paper roller;

(E) a method of forming an emboss pattern on a smooth metal plate and attaching it to a compressor to give an emboss pattern to synthetic leather or the like; or

(E) coating a release layer made of a resin on a release paper on which an emboss pattern is formed, drying and solidifying the release layer, and removing the release paper to impart an emboss pattern to the release layer.

However, the above-described methods are disadvantageous in terms of discontinuous processing technology in which each step such as preheating, coating, embossing, baking, and cooling is performed separately, which raises the problem of increasing production facility installation cost.

SUMMARY OF THE INVENTION The present invention has been made to solve the above-mentioned problems in the prior art, and it is an object of the present invention to provide a manufacturing apparatus and a manufacturing method thereof that can continuously produce a paper sheet of a surface material on which an emboss pattern is formed.

In order to achieve the above object, one aspect of the present invention is a heating apparatus comprising: a heating roller including a first housing roller and a heat source mounted inside the first housing roller; An emboss roller including a core roller and a covering layer made of silicone rubber formed on a surface of the core roller; And a cooling roller including a second housing roller and a cooling water moving tube mounted inside the second housing roller, wherein a three-dimensional pattern is formed on the surface of the covering layer, the three-dimensional pattern including a relief portion and an engraved portion , And a surface material paper sheet.

In one embodiment, the surface of the heating roller may be coated with a ceramic.

In one embodiment, the heat source may be an infrared heat source.

In one embodiment, the core roller is a steel pipe, and the thickness of the steel pipe is 10 mm to 20 mm.

In one embodiment, the thickness of the coating layer may be between 2 mm and 10 mm.

In order to achieve the above object, another aspect of the present invention is a method for manufacturing a polyurethane film, comprising: coating a polyurethane coating on a surface of a paper substrate and drying to form a coating layer; Plasticizing the coating layer using a heating roller; Forming a three-dimensional pattern on the surface of the coating layer using an emboss roller; And a step of curing the coating layer using a cooling roller.

In one embodiment, the application amount of the polyurethane coating material may be 200 g / m ² to 270 g / m ² .

In one embodiment, the viscosity of the polyurethane coating may be from 8,000 cps (20 ° C) to 11,000 cps (20 ° C).

In one embodiment, the temperature of the heating roller may be adjusted from 90 ° C to 120 ° C.

In one embodiment, the temperature of the chill rollers can be adjusted from 15 [deg.] C to 25 [deg.] C.

An apparatus for producing a surface sheet of paper according to an aspect of the present invention and a method of manufacturing the same provide a method of manufacturing a surface sheet of paper by simplifying the manufacturing process of a surface sheet of paper using a device including a heating roller, an emboss roller, And the manufacturing cost can be reduced.

It should be understood that the effects of the present invention are not limited to the above effects and include all effects that can be deduced from the detailed description of the present invention or the configuration of the invention described in the claims.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a schematic diagram of an apparatus for manufacturing a sheet material sheet according to an embodiment of the present invention; FIG.
Fig. 2 is an enlarged view of the emboss roller of Fig. 1. Fig.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, the present invention will be described with reference to the accompanying drawings. The present invention may, however, be embodied in many different forms and should not be construed as limited to the embodiments set forth herein. In order to clearly illustrate the present invention, parts not related to the description are omitted, and similar parts are denoted by like reference characters throughout the specification.

Throughout the specification, when a part is referred to as being "connected" to another part, it includes not only "directly connected" but also "indirectly connected" . Also, when an element is referred to as "comprising ", it means that it can include other elements, not excluding other elements unless specifically stated otherwise.

Hereinafter, embodiments of the present invention will be described in detail with reference to the accompanying drawings.

Surface material  Paper sheet manufacturing apparatus

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a schematic diagram of an apparatus for manufacturing a sheet material sheet according to an embodiment of the present invention; FIG.

1, an apparatus for producing a surface sheet of paper according to an aspect of the present invention includes a heating roller 110 including a first housing roller and a heat source mounted inside the first housing roller, a core roller 121, And a covering layer 122 made of silicone rubber formed on the surface of the core roller 121 and a cooling water moving pipe 131 mounted inside the second housing roller and the second housing roller, (Not shown).

As used herein, the term " embossed " refers to a layer formed by embossing processing method that enables realistic depiction of the surface texture of a printed pattern in a material that imparts decorative qualities to printing.

The embossing method uses an emboss roller having concave and convex portions formed on its surface including embossed and engraved portions, and the embossed portion of the emboss roller 120 is formed into an engraved portion of the surface material paper sheet, The engraved portion of the surface material paper 120 is formed into the embossed portion of the sheet of paper.

As used herein, the term "sequential" means that the process is sequentially performed according to the process order, and refers to the order from left to right on the basis of the production apparatus of the surface material paper sheet of Fig.

The heating roller 110 according to one embodiment may be coated with a ceramic on its surface. The ceramic coating has a purpose of preventing the surface of the conductor, specifically, the heating roller, from being oxidized or abraded at a high temperature. Examples of the method of coating the ceramic include spraying, chemical vapor deposition (CVD) Physical vapor deposition (PVD) and the like can be used.

The ceramic coating layer formed on the surface of the heating roller can improve weatherability, antifouling property, heat resistance, antifouling property, rust prevention property, and the like of the steel material heating roller. Further, since the ceramic coating layer has a nonflammable and flame-retardant (heat-resistant temperature of 500 DEG C), such properties can be imparted to the heating roller.

In addition, the infrared ray heat source 111 may be mounted inside the heating roller 110 according to one embodiment. As used herein, the term " Infrared Ray (IR) " can be understood to include near-infrared, infrared, and far-infrared rays having a wavelength range of 0.75 to 1 mm.

Conventional industrial heat transfer equipment borrows most of the hot air convection type, but the hot air convection type has a drawback in that the heat transfer efficiency is low and the facility scale and energy consumption are large, the productivity is low, and uniform heating is difficult.

On the other hand, infrared rays are electromagnetic waves, and have characteristics such as linearity, reflectivity, permeability, and absorbability. Unlike a heat transfer method such as conduction or convection, infrared rays can be copied and absorbed into an object without intermediate medium and converted into heat. Therefore, when the infrared ray is used as the heating source, it is possible to uniformly heat the object to be heated in comparison with the heat transfer method of high energy efficiency and conduction, convection, and heating.

Examples of the infrared heat source that can be used include, but are not limited to, a halogen lamp, a sheath heater coated with an infrared radiation material, a ceramic sintering tube, and a ceramic sintered radiator into which a resistance heating wire is inserted .

Fig. 2 is a cross-sectional view of one surface of the emboss roller of Fig. 1 enlarged. 2, the emboss roller 120 according to an embodiment of the present invention may include a core roller 121 and a coating layer 122 on the surface of the core roller 121, A concave-convex pattern composed of the relief portions 123 and the relief portions 124 may be formed on the surface of the concave portion 122.

The core roller 121 may be a steel pipe, and the wall thickness of the steel pipe may be 10 mm to 20 mm. Since the emboss roller 120 not only forms a three-dimensional pattern on the surface of the surface material paper sheet but also is positioned adjacent to the downstream side of the heating roller 110, the surface material paper sheet heated by the heating roller is pre- pre-cooling. The core roller 121 may be a hollow steel pipe whose interior is empty so that the heat transfer efficiency is improved during the pre-cooling so that heat can be smoothly discharged from the surface material paper sheet.

If the pipe wall of the steel pipe is less than 10 mm, the durability of the emboss roller 120 may be reduced to shorten the life of the manufacturing apparatus, and if it exceeds 20 mm, the pre-cooling effect may be weak.

In addition, the thickness of the coating layer 122 according to one embodiment may be 2 mm to 10 mm. The cover layer 122 of the emboss roller 120 may be made of silicone rubber and the silicone rubber is excellent in heat resistance and cold resistance so that the emboss roller 120 located between the heating roller 110 and the cooling roller 130 120 can be improved. When the thickness of the coating layer 122 is less than 2 mm, it is difficult to control the depth of the emboss pattern, and when the thickness exceeds 10 mm, the heat transfer efficiency of the core roller can be reduced.

Alternatively, the apparatus for producing the surface material paper sheet may further include a cooling drum and a rewinder on the downstream side of the cooling roller 130, each of which is known in the art And is not particularly limited.

Surface material  Manufacturing method of paper sheet

Hereinafter, a method of producing a surface material paper sheet using the above-described surface material paper sheet production apparatus will be described in detail.

According to another aspect of the present invention, there is provided a method of producing a surface sheet of paper, comprising the steps of: applying a polyurethane coating to a surface of a paper substrate and drying the same to form a coating layer; heating the coating layer using a heating roller Forming a three-dimensional pattern on the surface of the coating layer using the emboss roller 120, and curing the coating layer using a cooling roller 130 .

The paper base material should have such a strength that it can withstand the pressure applied during the manufacturing process of the surface material paper sheet, and the emboss pattern should be easily formed.

The kind of the paper substrate is not particularly limited, but it is preferable to use a non-coated paper such as a Kraft paper, a top quality paper, a white paper roll, a glassine paper, a cup paper, . In the case of producing synthetic leather or processing a melamine faced sheet, a neutral paper having excellent durability and heat resistance as compared with an acidic paper can be used.

As shown in FIG. 1, the polyurethane paint can be applied on the driven roller 140. The types of coating apparatus that can be used to apply the polyurethane coating include gravure coater, flexo coater, roll coater, bar coater, But is not limited thereto.

Preferably, a roll coater including an upper roll and a lower roll (the driven rollers 140) may be used in consideration of the kind and shape of the coated paint and the conductor to be coated, and more preferably, It is possible to use a comma coater which can easily adjust the coating width and the coating amount even when coating a coating material having a high viscosity of 1000 cps or more. The blade is positioned adjacent to the upstream of the upper roll to prevent the spread of the paint or adhesive and to concentrate the paint or adhesive on the coated area.

With such a comma coater 150, the polyurethane paint can be coated on the paper substrate and cured or dried, and the curing or drying conditions are not particularly limited as long as they are well known in the art.

According to one embodiment, the application amount of the polyurethane coating material may be 200 g / m ² to 270 g / m ² . During the poly when the application amount of the urethane paint 200g / m ² is less than the surface material of paper can be difficult with a depth adjustment of the concave-convex pattern formed on a sheet, 270 g / m when the ^second exceed the strength of the surface member sheet of paper degradation process Cracks can occur.

The viscosity of the polyurethane paint may be 8,000 cps (20 ° C) to 11,000 cps (20 ° C). When the viscosity of the polyurethane paint is less than 8,000 cps (20 캜), the processability may be deteriorated. When the viscosity is more than 11,000 cps (20 캜), it is difficult to control the amount of application of the polyurethane paint, The appearance quality of the surface material may be deteriorated.

Therefore, the viscosity of the coating material can be controlled within a certain range by adding a solvent to the polyurethane coating material. The solvent may be at least one selected from the group consisting of esters, alcohols, ketones, aliphatic hydrocarbons, and aromatic hydrocarbons.

Examples of the ester-based solvent include methyl acetate, ethyl acetate, n-butyl acetate, cellosolve acetate, propylene glycol monomethyl acetate, 3-methoxybutyl acetate, methyl butyrate, ethyl butyrate and propyl propionate have.

Examples of the alcohol-based solvent include methanol, ethanol, propanol, isopropanol, n-butanol, amyl alcohol, octyl alcohol and decanol.

Examples of the ketone-based solvent include acetone, cyclohexanone, methyl amyl ketone, diisobutyl ketone, methyl ethyl ketone, and methyl isobutyl ketone, and methyl ethyl ketone is preferably used.

Examples of the aliphatic hydrocarbon-based solvent include chain-like hydrocarbons such as pentane, hexane, heptane, octane, nonane, decane, dodecane, tetradecane, hexadecane and the like, and alicyclic hydrocarbons such as cyclohexane, methylcyclohexane, ethylcyclohexane, Cyclic hydrocarbons and the like can be used.

Examples of the aromatic hydrocarbon-based solvent include benzene, ethylbenzene, chlorobenzene, toluene, and xylene.

Preferably, from the viewpoint of environmental problems, a mixture of cyclohexane-based aliphatic solvent and ester-based or ketone-based solvent can be used.

The heating roller 110 and the emboss roller 120 are rotated in opposite directions with the surface material paper sheet coated with the polyurethane coating on the paper base so that the surface paper sheet is heated and pressed, An emboss pattern can be formed on the polyurethane coating layer.

According to one embodiment, the temperature of the heating roller 110 may be adjusted from 90 ° C to 120 ° C. By heating the polyurethane coating layer using the heating roller 110 and imparting flexibility to the coating layer, it is possible to form the emboss pattern more clearly. When the temperature of the heating roller 110 is less than 90 ° C, a temperature sufficiently higher than the glass transition temperature (Tg) of the polyurethane paint is not maintained and it is difficult to form a deep emboss pattern. In this case, unnecessary energy consumption and quality deterioration may degrade process efficiency.

Since the infrared ray heat source can be mounted on the heating roller 110, infrared rays are irradiated from the infrared heat source to the heating roller 110 to be heated, so that the heating roller 110 can be uniformly heated in a non- have. That is, the heating roller 110, which is an object to be heated in a large area, can be quickly and uniformly heated in a non-contact manner.

Further, it may further include a temperature control device for selectively controlling the temperature of the heating roller 110.

The paper base material can be preheated by the heating roller 110 and can be pressed by the emboss roller 120. 3, the emboss roller 120 having embossed patterns including embossed portions and engraved portions is used in the embossing process, and the embossed portion 123 and the embossed portion 124 of the emboss roller are used, Can be formed into the engraved portion and the embossed portion, respectively, in the polyurethane coating layer.

On the other hand, after forming an emboss pattern on the polyurethane coating layer, a high gloss layer can be further formed. The hygroscopic layer can prevent surface contamination and scratching of the surface material sheet, can achieve gloss, and can add various characteristics such as antimicrobial and heat resistance depending on the case.

The hygroscopic layer may be formed by curing an ultraviolet ray curable resin. Specifically, the hygroscopic layer may be formed of a polyester resin, a urethane acrylate resin, an epoxy acrylate resin, a polyester acrylate resin A polyethylene terephthalate resin (PET), a polyethylene terephthalate resin (PET), a polylactic acid resin (PLA), or a mixture thereof, It can be formed by curing treatment.

According to one embodiment, the temperature of the cooling roller 130 may be adjusted to 15 [deg.] C to 25 [deg.] C. As shown in FIG. 1, the cooling roller can mount the cooling water moving pipe 131 inside the roller, and the shape of the emboss pattern formed on the polyurethane coating layer through the cooling process using the cooling roller 130 It can be kept sharp.

In addition, unlike the conventional cooling process, immediately after the embossed pattern is formed, the surface material paper sheet is cooled to suppress the blooming phenomenon of the polyurethane paint, and the surface of the paper sheet is prevented from oxidation, The adhesion of the paper sheet can be improved.

The temperature of the cooling roller 130 is preferably kept lower than the glass transition temperature of the coating layer. When the temperature of the cooling roller 130 is less than 15 ° C, equipment required for cooling the refrigerant is added, If the temperature is higher than 25 DEG C, it is difficult to maintain the shape of the emboss pattern clearly.

The surface material paper sheet manufacturing process can control the processing speed from 100 m / min to 1,100 m / min. If the processing speed is less than 100 m / min, the productivity may deteriorate. If the processing speed is more than 1,100 m / min, the frequency of cutting the surface material paper substrate may increase, or the transition of the polyurethane paint may become unstable.

Meanwhile, each step of the method of manufacturing a sheet material of a surface material according to an embodiment of the present invention may be performed successively. In the case of a discontinuous process such as a conventional sheet method, a paper sheet is obtained by arranging a paper substrate in a coating process line using a conveyor system, coating and drying at each process step, I could.

However, the discontinuous process has a problem in that the productivity is decreased in proportion to the interval between the respective sheets, and the surface material paper sheet produced by the discontinuous process has a problem that the storage efficiency at the time of product storage and the transportation efficiency at the time of product shipment are inferior.

On the other hand, in the case of a continuous process, a paper substrate of a continuous successive type is passed through each process step of the continuous line, and the finished product is wound and held in a roll form, not a sheet form. In the continuous process, the productivity is superior to the conventional discontinuous process, and the storage efficiency and transportation efficiency of the surface material paper sheet can be greatly improved.

It will be understood by those skilled in the art that the foregoing description of the present invention is for illustrative purposes only and that those of ordinary skill in the art can readily understand that various changes and modifications may be made without departing from the spirit or essential characteristics of the present invention. will be. It is therefore to be understood that the above-described embodiments are illustrative in all aspects and not restrictive. For example, each component described as a single entity may be distributed and implemented, and components described as being distributed may also be implemented in a combined form.

The scope of the present invention is defined by the appended claims, and all changes or modifications derived from the meaning and scope of the claims and their equivalents should be construed as being included within the scope of the present invention.

110: heating roller
111: built-in heat source
120: Emboss roller
121: Core roller
122:
123: convex portion
124: recessed concave portion
130: cooling roller
131: cooling water moving pipe
140: Roller roller
150: Comma coater printing device

Claims (10)

A heating roller including a first housing roller and a heat source mounted inside the first housing roller;
An emboss roller including a core roller and a covering layer made of silicone rubber formed on a surface of the core roller; And
And a cooling roller including a second housing roller and a cooling water moving tube mounted inside the second housing roller,
Wherein the core roller is an empty steel pipe,
Wherein a three-dimensional pattern is formed on the surface of the covering layer, the three-dimensional pattern including a relief portion and a negative portion.
The apparatus according to claim 1, wherein the surface of the heating roller is coated with ceramic.
The apparatus of claim 1, wherein the heat source is an infrared heat source.
The apparatus according to claim 1, wherein the steel pipe has a wall thickness of 10 mm to 20 mm.
The apparatus according to claim 1, wherein the thickness of the coating layer is 2 mm to 10 mm.
Applying a polyurethane paint to the surface of the paper substrate and then drying to form a coat layer;
Plasticizing the coating layer using a heating roller;
Forming a three-dimensional pattern on the surface of the coating layer using an emboss roller; And
And curing the coating layer using a cooling roller,
Wherein the emboss roller comprises a core roller and a coating layer made of silicone rubber formed on a surface of the core roller,
Wherein the core roller is an empty steel pipe.
The method according to claim 6, wherein the coating amount of the polyurethane coating is 200 g / m ² to 270 g / m ² .
The method according to claim 6, wherein the polyurethane coating has a viscosity of 8,000 cps (20 캜) to 11,000 cps (20 캜).
7. The method according to claim 6, wherein the temperature of the heating roller is adjusted to 90 to 120 占 폚.
7. The method according to claim 6, wherein the temperature of the cooling roller is adjusted to 15 to 25 占 폚.

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