JP2005271226A - Decorative sheet manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a novel technique causing no air bubbles between the inner surface of a recessed groove and a decorative sheet when a decorative sheet is bonded to a base material having the recessed groove to manufacture the decorative sheet having no blister or wrinkles caused by adhesion failure and good in appearance. <P>SOLUTION: An adhesive is applied to the almost enire surface containing the inner surface of the recessed groove on the side having the recessed groove 2 of the base material 1 and/or the almost entire surface on the back side of the decorative sheet 3 and the decorative sheet is placed on the surface on the side of the recessed groove of the base material. A press roll 6 having a needle-like member 8 having a protruded length larger than the thickness of the decorative sheet provided to its pressing surface is fitted in the recessed groove to press the decorative sheet to the inner surface of the recessed groove by the pressing surface of the press roll not only to bond the decorative sheet to the inner surface of the recessed groove through the adhesive under pressure but also to form a through-hole (10) to the decorative sheet by the needle-like member of the press roll. When the press roll is separated from the recessed groove, residual air between the recessed groove and the decorative sheet can be allowed to escape to the surface side of the decorative sheet through the through-hole of the decorative sheet. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  The present invention relates to a method for manufacturing a decorative board.

  As shown in FIG. 10, when a decorative sheet 3 is to be manufactured by sticking a decorative sheet 3 to a base material 1 in which concave grooves 2 such as a V-shaped cross section are continuously formed along the longitudinal direction, The sheet 3 must be attached to the inner surface of the groove 2 in a state of being folded along the shape of the groove 2, but it is difficult for air to escape when the decorative sheet 3 is folded. Bubbles 4 remain in between. For this reason, there was a problem that poor adhesion occurred, blisters and wrinkles appeared, and the appearance was deteriorated.

In order to eliminate the problem of such adhesion failure, it is possible to stick a decorative sheet with a number of pressing rolls sequentially from the center or end of the base material so that no bubbles remain in the groove. The following patent documents 1 and 2 are proposed.
JP 55-77570 A Japanese Patent Laid-Open No. 10-146939

  However, even with the above prior art, bubbles still remain in the groove of the base material when the decorative sheet is pasted, and the problem of deterioration in appearance caused by blisters and wrinkles of the decorative sheet due to poor adhesion has been completely solved. Not in.

  Therefore, an object of the present invention is to provide a novel method for preventing bubbles from being generated between the inner surface of the groove and the decorative sheet when the decorative sheet is attached to a substrate having a groove, This is to make it possible to produce a decorative board having a good appearance without blisters and wrinkles.

  In order to achieve the above object, the present invention according to claim 1 is characterized in that a decorative sheet is attached to the surface of the base material on which the concave grooves are continuously formed along the longitudinal direction. In the method for producing a decorative board, an adhesive is applied to substantially the entire surface including the inner surface of the groove on the side having the groove and / or substantially the entire back surface of the decorative sheet, and the groove side of the substrate A decorative sheet is placed on the surface, and a pressing roll provided with a needle-like object having a protruding length equal to or larger than the thickness of the decorative sheet is inserted into the groove, and the pressing surface of the pressing roll When the decorative sheet is pressed against the inner surface of the concave groove by pressing the decorative sheet on the inner surface of the concave groove with an adhesive, and a through-hole is formed in the decorative sheet by the needle-like material of the pressing roll, and the pressing roll is separated from the concave groove The residual air between the groove and the decorative sheet in the through hole of the decorative sheet It is characterized in that escape to the decorative sheet surface side through.

  Claim 2 is a method for manufacturing a decorative board according to claim 1, wherein a pressing roll having a pressing surface corresponding to the shape of the concave groove of the substrate is used, and the pressing roll is fitted into the concave groove once. It is characterized by performing decorative sheet pressing and through-hole formation.

  According to a third aspect of the present invention, in the method for manufacturing a decorative board according to the first aspect, a plurality of pressing rolls each having a pressing surface corresponding to a part of the shape of the concave groove of the base material are used, and these pressing rolls are sequentially arranged. It is characterized by being fitted into a concave groove.

  According to a fourth aspect of the present invention, in the method for manufacturing a decorative board according to any one of the first to third aspects, the needle-like object protrudes along the insertion direction of the pressing roll.

  As the base material, a woody base material such as solid wood, plywood, fiberboard, laminated wood, or single board laminated material is used. On at least the surface of the base material, concave grooves having a predetermined cross-sectional shape are continuously formed along the longitudinal direction. The cross-sectional shape of the groove is arbitrary, and can be a V-groove, U-groove, square groove, R-groove, or the like.

  As the decorative sheet, a decorative paper, a decorative synthetic resin sheet, or the like on which an arbitrary pattern is printed can be used, and the thickness thereof is about 0.1 to 0.3 mm. You may use what the coating was given to the surface, and the surface protection layer was formed. Alternatively, an optional coating may be applied after the decorative sheet is attached, or a surface protective layer may be formed.

  At least the surface (pressing surface) of the pressing roll is formed of an elastic material such as synthetic rubber or synthetic resin, and the cross-sectional shape of the pressing surface is formed to correspond to the cross-sectional shape of the concave groove of the base material. A plurality of needle-like objects protrudes and is fixed to the pressing surface of the pressing roll. Here, the needle-like object means having a sharp tip, and the shape of the other parts is not particularly limited. Needle-like objects are installed at intervals of about 10 to 50 mm in the circumferential direction of the presser roll.

  The needle-shaped object needs to have a protruding length enough to penetrate the decorative sheet when the decorative sheet is pressed against the concave groove of the base material with a pressing roll, and therefore is substantially the same as or slightly larger than the thickness of the decorative sheet. It has a long protruding length. For example, the protruding length of the needle-shaped object from the surface of the pressing roll is about 0.2 to 0.5 mm.

  The needle-shaped object penetrates the decorative sheet when the decorative sheet is pressed into the groove of the base material with a pressing roll, and then is pulled out of the decorative sheet to form a through-hole corresponding to the diameter of the needle-shaped object. However, air is allowed to escape from the concave groove through the through hole, and in order to sufficiently perform this function, the diameter of the needle-like object is preferably 0.2 mm or more. On the other hand, if the diameter of the needle-like material is too large, the through-hole formed in the decorative sheet also becomes large, and there is a risk that the appearance will be noticeably impaired, so that the upper limit is preferably about 0.8 mm. Therefore, the preferable diameter range of the needle-like object is 0.2 to 0.8 mm.

  Moreover, in order to fully perform the above-mentioned air escape function, it is preferable that the needle-like objects are installed at intervals of about 10 to 50 mm in the circumferential direction of the pressing roll. For example, if needles are placed on a press roll having a circumference of 150 mm at intervals of 10 mm, needles will be provided at 15 locations along the circumference of the press roll. Needle-like objects will be provided at five locations along the circumference, and if the installation interval is 50 mm, the needle-like objects will be provided at three locations along the circumference of the pressing roll.

  According to the decorative plate manufacturing method of the present invention, in the concave groove portion of the base material, a pressing roll in which needle-like objects protrude from the pressing surface corresponding to the concave groove shape is used. Since the decorative sheet is inserted into the groove and pressed against the inner surface of the concave groove with an adhesive, the needle-like material penetrates the decorative sheet and forms a through hole. Therefore, when the pressing roll is separated from the groove, the remaining air between the groove and the decorative sheet can be released to the surface side of the decorative sheet through the through hole of the decorative sheet, Therefore, a good appearance can be maintained without causing swelling or wrinkles of the decorative sheet.

  FIG. 1 shows an example of a decorative board 5 manufactured by the method of the present invention, in which a decorative sheet 3 is adhered to the surface of the substrate 1 having concave grooves 2 and 2 continuous along the longitudinal direction. It becomes. The concave grooves 2 and 2 in this embodiment are V-grooves.

  2 and 3 show an example 6 of a pressing roll used in the method of the present invention for manufacturing the decorative board 5 of FIG. 1, which has a pair of pressing surfaces 7a, 7b corresponding to the shapes of the concave grooves 2, 2, Needle-like objects 8, 8.. . . Is fixed. Needle-like objects 8, 8. . . Has a substantially conical shape, and its center line X is orthogonal to the rotation axis 9 of the presser roll 6. Needles 8,8. . . Is set to a dimension that is substantially the same as or slightly larger than the thickness of the decorative sheet 3.

  After applying the adhesive to substantially the entire surface including the inner surfaces of the concave grooves 2 and 2 on the concave groove forming side of the base material 1 and placing the decorative sheet 3 on the adhesive application surface, the base on which the decorative sheet 3 is placed Using a plurality of pressing rolls rotating at a speed synchronized with the conveying speed of the material 1, the decorative sheet 3 is sequentially pressed from the center or one end of the base material 1 to the adhesive-coated surface of the base material 1. .

  At this time, the decorative sheet 3 is pressure-bonded by a normally used pressing roll (not shown) on the flat surface portion of the substrate 1 excluding the concave grooves 2 and 2, but each concave groove 2 is shown in FIG. As shown in FIG. 2 and FIG. 3, the pressing roll 6 having the shape and configuration as shown in FIG. 2 and FIG. 3 is used, and this is inserted into the concave groove 2, and the decorative sheet 3 is pressed against the inner surface of the concave groove 2 coated with the adhesive. Thus, the decorative sheet 3 is pressure-bonded to the inner surface of the groove.

  As described above, the pressing surfaces 7a and 7b corresponding to the shape of the concave groove 2 of the pressing roll 6 have needle-like objects 8 and 8 having a protruding length equal to or greater than the thickness of the decorative sheet 3. . . Are fitted into the groove 2 and the decorative sheet 3 is pressure-bonded to the inner surface of the groove, and at the same time the needles 8, 8. . . Penetrates the decorative sheet 3 to form a through hole. Therefore, when the pressing roll 6 is separated from the groove 2, the residual air between the groove 2 and the decorative sheet 3 is removed from the decorative sheet 3 through the through hole 10 of the decorative sheet 3 as shown in FIG. 5. Since it can escape to the surface side and does not leave the bubbles 4 (FIG. 10) as in the prior art, it does not cause blisters and wrinkles of the decorative sheet 3 and can maintain a good appearance.

  After the decorative sheet 3 is pressure-bonded to the entire surface of the substrate 1 including the inner surface of the concave groove 2 as described above, the decorative sheet 5 shown in FIG.

  FIG. 6 shows another example 6 'of a pressing roll used in the method of the present invention for producing the decorative board 5 of FIG. This pressing roll 6 'has substantially the same shape and configuration as the pressing roll 6 shown in FIGS. 2 and 3, but the needle-like objects 8', 8 '. . . Is different in that it is configured as a small-diameter pin protruding in the radial direction (that is, the direction orthogonal to the rotation axis 9 of the pressing roll 6) with a protruding length substantially the same as or slightly larger than the thickness of the decorative sheet 3. Yes. Except this difference, it is the same as the pressing roll 6 shown in FIG. 2 and FIG. Further, the action when the pressing sheet 6 'is used to press the decorative sheet 3 in the concave groove 2 and the air escape by the through hole 9 is the same as described above with reference to FIGS. The description is omitted.

  2 and FIG. 3 and the pressing roll 6 ′ shown in FIG. 6 are both needle-like objects 8, 8. . . , 8, 8 '. . . However, when such presser rolls 6 and 6 ′ are rotated around the rotary shaft 9, a needle-like object provided near the tip and a needle-like object provided near the rotary shaft 9 Then the peripheral speed is different. For this reason, when the needle-like objects are arranged on the pressing surfaces 7a and 7b in the thickness direction of the pressing rolls 6 and 6 '(radially aligned from the center of the rotary shaft 9), the pressing rolls 6 and 6' Deviation occurs during rotation, and when these needles penetrate the decorative sheet 3, the decorative sheet 3 is forcibly pulled and damaged. Therefore, when the pressing rolls 6 and 6 ′ having such a configuration are used, it is necessary to arrange the needle-like objects on the pressing surfaces 7a and 7b so that they are not radially aligned in the thickness direction of the pressing rolls 6 and 6 ′. is there. The arrangement state of the needle-like object 8 ′ taking the above into consideration is shown in FIG. 7 for the pressing roll 6 ′ of FIG. 6, and the needle-like objects 8 ′, 8 ′. . . Are alternately arranged on the outer side (side closer to the tip) and the inner side (side closer to the rotating shaft 9) with a predetermined angular interval. Needless to say, the presser roll 6 shown in FIGS. 2 and 3 can be arranged in the same state as shown in FIG.

  FIG. 8 shows still another example 6 ″ of a pressing roll used in the method of the present invention for producing the decorative board 5 of FIG. The pressing roll 6 ″ has a pressing surface 7c substantially parallel to the rotating shaft 9, and the pressing surface 7c has a pin-like needle-like object 8 ″, 8 similar to that in the pressing roll 6 ′ of FIG. ''. . . Are fixed in the radial direction (that is, in a direction perpendicular to the rotation axis 9 of the pressing roll 6 ″) so as to protrude with a protruding length substantially the same as or slightly larger than the thickness of the decorative sheet 3. Each needle-like object 8 '' may have a conical shape as shown in FIGS.

  In order to manufacture the decorative board 5 of FIG. 1 using this pressing roll 6 ″, the adhesive is applied almost over the entire surface including the inner surfaces of the concave grooves 2 and 2 on the concave groove forming side of the substrate 1 in the same manner as described above. , And the decorative sheet 3 is placed on the adhesive-coated surface, and then the base material is rotated using a plurality of pressing rolls that rotate at a speed synchronized with the conveying speed of the base material 1 on which the decorative sheet 3 is placed. The decorative sheet 3 is sequentially pressed against the adhesive-coated surface of the substrate 1 from the center or one end of the substrate 1. At this time, the decorative sheet 3 is pressure-bonded by a normally used pressing roll (not shown) on the flat surface portion of the substrate 1 excluding the concave grooves 2 and 2, but each concave groove 2 is shown in FIG. 9. As shown in FIG. 8, the pressing surface 7 c of the pressing roll 6 ″ having the shape and configuration shown in FIG. 8 is fitted in the groove 2 so as to be parallel to one inner surface of the groove 2, and the decorative sheet 3 is coated with the adhesive. At the same time as pressing against the inner surface of the concave groove 2, the needles 8 ", 8". . . A through-hole (9) is formed in the decorative sheet 3, and then, although not shown in the figure, the pressing surface 7c of the pressing roll 6 '' is made parallel to the other inner surface of the concave groove 2 in the same manner as shown in FIG. It fits into the groove 2 and presses and presses the decorative sheet 3 against the other inner surface of the concave groove 2 to which the adhesive is applied. . . By forming the through-hole (9) by the decorative sheet 3, the decorative sheet can be pressed onto the inner surface of the concave groove 2 and the through-hole can be formed.

  In the above description, the decorative sheet 3 is pressure-bonded to the V groove 2 of the base material 1 and the through-hole 9 for discharging the remaining air is formed in the decorative sheet 3. When the groove 2 has a complicated shape, a plurality of types of pressing rolls having a pressing surface corresponding to a part of the inner surface of the concave groove are prepared, and these are sequentially inserted into the concave groove for a plurality of times. By performing the decorative sheet pressure bonding and through-hole formation, a decorative plate can be manufactured by applying the method of the present invention to a substrate having a concave groove having a complicated shape.

  The present invention is not limited to the above-described embodiment, and various modifications can be made within the scope of the invention described in the claims. For example, it was described that the decorative sheet 3 is placed on the adhesive application surface after the adhesive is applied to substantially the entire surface including the inner surfaces of the concave grooves 2 and 2 on the concave groove forming side of the substrate 1. Alternatively, or together with this, the adhesive-coated back surface may be placed on the surface of the substrate 1 where the concave groove 2 is formed after the adhesive is applied to substantially the entire back surface side of the decorative sheet 3.

It is a perspective view which shows an example of the decorative board manufactured by this invention method. It is sectional drawing which shows an example of the pressing roll used for the method of this invention which manufactures the decorative board of FIG. It is a partial expanded sectional view of this pressing roll. It is sectional drawing which shows the state which inserted this pressing roll in the ditch | groove of the base material. When the pressing roll is separated from the concave groove of the base material through the state of FIG. 4, the decorative sheet is pressure-bonded to the inner surface of the concave groove of the base material and a through hole is formed in the decorative sheet by the needle-shaped object of the pressing roll. FIG. It is sectional drawing which shows the other example of the pressing roll used for the method of this invention which manufactures the decorative board of FIG. It is a perspective view of this pressing roll. It is sectional drawing which shows another example of the pressing roll used for the method of this invention which manufactures the decorative board of FIG. It is sectional drawing which shows the state which inserted this pressing roll in the ditch | groove of the base material. It is sectional drawing which shows the state which the bubble remains between the ditch | groove inner surface of a base material, and a decorative sheet in the manufacturing method of the decorative board by a prior art, and has produced the adhesion defect.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Base material 2 Concave groove 3 Decorative sheet 4 Air bubble 5 Decorative plate 6, 6 ', 6''Press roll 7a, 7b, 7c Press surface 8, 8', 8 '' Needle 9 Rotating shaft 10 of press roll hole

Claims (4)

In a method of manufacturing a decorative board by attaching a decorative sheet to a surface of a substrate having grooves formed continuously along the longitudinal direction, the side of the substrate having the grooves An adhesive is applied to substantially the entire surface including the inner surface of the groove and / or substantially the entire back surface of the decorative sheet, the decorative sheet is placed on the surface of the substrate on the groove side, and the thickness of the decorative sheet is applied to the pressing surface. A presser roll provided with a needle-like object having a projection length of more than a certain length is inserted into the groove, and the decorative sheet is pressed against the inner surface of the groove with the pressing surface of the presser roll so that the decorative sheet is interposed through an adhesive. And press-fit to the inner surface of the groove, and form a through-hole in the decorative sheet with needles of the pressing roll, and when the pressing roll leaves the groove, the remaining air between the groove and the decorative sheet penetrates the decorative sheet. Makeup characterized by escaping to the decorative sheet surface side through a hole The method of production. The use of a pressing roll having a pressing surface corresponding to the shape of the concave groove of the substrate, and performing the decorative sheet pressing and through-hole formation in a single step of inserting the pressing roll into the concave groove. A method for producing a decorative board according to 1. The makeup according to claim 1, wherein a plurality of pressing rolls each having a pressing surface corresponding to a shape of a part of the groove of the base material are used, and these pressing rolls are sequentially inserted into the groove. A manufacturing method of a board. The method for manufacturing a decorative board according to any one of claims 1 to 3, wherein the needle-like object protrudes along the insertion direction of the pressing roll.

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