JP2009026696A - Corona discharge treating device, method, and decorative material for floor manufactured using method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a corona discharge treating device, a corona discharge treating method, and a decorative material for a floor manufactured using this method, capable of carrying out corona discharge treatment surely to the decorative material for the floor having a wooden base board. <P>SOLUTION: The corona discharge treatment device is a device to carry out the corona discharge treatment to the decorative material for the floor having the wooden base board and a decorative layer, arranged with a prescribed spacing along the conveyance direction of the decorative material for the floor, and equipped with a plurality of roll bodies having a pair of rolls to press and convey the decorative material for the floor from the base board side and the decorative layer side, and at least one corona discharge unit having a corona discharge electrode and the counter electrode that are arranged between neighboring roll bodies, and opposedly arranged to pinch the decorative material for the floor from the base board side and the decorative layer side. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a corona discharge treatment in which a wooden substrate and a decorative layer are laminated in this order, and a corona discharge treatment is performed on a floor decorative material having a recess formed so that at least the backer layer is exposed from the decorative layer side. The present invention relates to an apparatus, a corona discharge treatment method, and a floor decorative material manufactured using the method.

  In recent years, decorative sheets made of sheet materials have been used for various applications such as wall materials. Such a decorative sheet is manufactured by applying a paint to the surface of a substrate made of a resin film. A method of applying a corona discharge treatment to the surface of the substrate prior to application of the paint is adopted. As a result, the adhesion of the paint was improved (for example, Patent Document 1).

By the way, in recent years, the decorative sheet as described above is often applied to a flooring material, and the above-mentioned decorative sheet is attached as a decorative layer to a wooden substrate, and a decorative material for flooring is used. . In such a decorative material for flooring, a concave portion such as a groove or a chamfered portion is often formed after applying the decorative layer, so that the design is improved by applying a paint to this portion. Is being considered. Therefore, similarly to the production of the decorative sheet, it is conceivable to perform a corona discharge treatment prior to the application of the paint to the recess.
JP 2007-9162 A

  However, while the decorative sheet is continuously drawn out from the roll, the floor decorative material is generally conveyed by a single sheet, and a wooden substrate is used for the floor decorative material. For this reason, it is difficult to simply apply the corona discharge treatment to the decorative sheet to the decorative material for flooring, and it is considered that a problem occurs.

  Accordingly, the present invention has been made to solve the above problem, and a corona discharge treatment apparatus and a corona discharge treatment method capable of reliably performing corona discharge treatment on a flooring decorative material having a wooden substrate. And a floor decorative material produced by using this method.

  The present invention has been made to solve the above problem, and is formed such that a wooden substrate, a backer layer, and a decorative layer are laminated in this order, and at least the backer layer is exposed from the decorative layer side. An apparatus for performing corona discharge treatment on a floor decorative material having a concave portion, the floor decorative material being arranged at a predetermined interval along a conveying direction of the floor decorative material, the floor decorative material being disposed on a substrate side and a decorative layer side Corona discharge disposed between a plurality of roll bodies having a pair of rolls to be conveyed while being pressed from between the adjacent roll bodies, and opposed to sandwich the flooring decorative material from the substrate side and the decorative layer side And at least one corona discharge unit having an electrode and a counter electrode.

  The floor decorative material targeted by the present invention is manufactured as a single sheet and uses a wood-based base material, and thus warpage may occur during the manufacturing process. Therefore, in the present invention, a plurality of roll bodies are arranged along the transport direction, and the floor decorative material is transported while being pressed by each roll body. Therefore, it is possible to convey the floor decorative material while correcting the warp. This prevents contact with the corona discharge unit due to warping of the decorative flooring. In addition, since the floor decorative material is pressed by the roll body on the upstream side and the downstream side in the transport direction, the floor decorative material is in a flat state between the roll bodies. And since the corona discharge unit is arrange | positioned between adjacent roll bodies and is facing the flat decorative material for floors, it can perform a corona discharge process reliably with respect to the decorative material for floors.

  In the said apparatus, a roll body can be comprised as follows. That is, in the roll body, the rotation axis of the roll arranged on the corona discharge electrode side can be fixed, and the rotation axis of the roll arranged on the counter electrode side can be elastically moved up and down. According to this structure, since the rotating shaft of the roll arrange | positioned at the corona discharge electrode side is being fixed, the curvature to the corona discharge electrode side of the decorative material for floors can be prevented reliably. Therefore, the floor decorative material being conveyed can be reliably prevented from coming into contact with the corona discharge electrode.

  In addition, since the flooring decorative material uses a wooden substrate, there is a risk of twisting in the width direction in addition to warping in the thickness direction. The material may meander. Therefore, it is preferable to further provide a guide member that sandwiches the floor decorative material from the width direction and guides the progress in the conveyance direction. By doing so, the floor decorative material being conveyed is prevented from meandering in the width direction, and corona discharge treatment can be performed stably.

  The corona discharge unit can have various configurations, but a known structure such as a wire electrode or a ball electrode can be used. For example, when each corona discharge electrode is constituted by a wire electrode, it is preferable to use at least one wire electrode and arrange it so as to extend in the width direction of the floor decorative material. Thereby, a corona discharge process can be efficiently performed with respect to a wide area.

  In addition, the present invention has been made to solve the above-described problem, and the wooden substrate, the backer layer, and the decorative layer are laminated in this order, and at least the backer layer is exposed from the decorative layer side. A method of performing corona discharge treatment on a floor decorative material having a formed recess, wherein a plurality of roll bodies having a pair of upper and lower rolls are arranged at predetermined intervals, and the floor cosmetic material is pressed by these roll bodies And a step of performing corona discharge treatment on the decorative layer side of the floor decorative material between the adjacent roll bodies.

  Further, the floor decorative material according to the present invention is made to solve the above-mentioned problems, and is manufactured by applying a paint to the decorative layer side after the corona discharge treatment method described above. is there.

  ADVANTAGE OF THE INVENTION According to this invention, a corona discharge process can be reliably performed to the decorative material for floors which has a wood type board | substrate.

  Hereinafter, an embodiment of a corona discharge treatment apparatus according to the present invention will be described with reference to the drawings. FIG. 1 is a side sectional view of a corona discharge treatment apparatus according to the present embodiment, and FIG. 2 is a sectional view taken along line AA in FIG.

  As shown in FIG. 1, this corona discharge treatment apparatus is an apparatus for carrying a corona discharge treatment in the middle of conveying a flooring decorative material from the right side to the left side of the drawing. Eight sets of roll bodies having a pair of upper and lower rolls are arranged from the upstream to the downstream in the conveyance route of the floor decorative material, and the floor decorative material Y passes downstream between the rolls of each roll body. It is conveyed to the side. Hereinafter, these roll bodies will be referred to as first to eighth roll bodies 11 to 18 from the upstream side. Moreover, between the 3rd-7th roll bodies 13-17, four corona discharge units which perform the corona discharge process to the flooring decorative material Y, ie, the 1st-4th corona discharge units 21-24 from the upstream, are. Has been placed.

  First, the roll body will be described. The surfaces of all rolls constituting the roll bodies 11 to 18, that is, the upper rolls 111 to 181 and the lower rolls 112 to 182 are formed of a metal such as stainless steel. The 1st roll body 11 arrange | positioned in the uppermost stream has a larger diameter than another roll, and, thereby, can also provide pressing force with respect to the flooring decorative material with a curvature originally. The other second to eighth roll bodies 12 to 18 have the same diameter. For example, the roll diameter of the first roll body 11 can be 200 to 400 mm, and the roll diameters of the other roll bodies 12 to 18 can be 80 to 200 mm. Moreover, in each roll body 11-18, the 1st belt 3 is wound around the bearing of the upper side rolls 111-181 via several pulleys, The 1st motor arrange | positioned at the upper part of this apparatus housing | casing This belt 3 is moved by 4. Therefore, when the first motor 4 is driven, the belt 3 is moved, whereby all the upper rolls 111 to 181 are rotated simultaneously. Similarly, the second belt 5 is wound around the bearings of the lower rolls 112 to 182 via a plurality of pulleys, and the second belt 5 is moved by the second motor 6 disposed at the lower part of the apparatus. Then, all the lower rolls 112 to 182 are rotated at the same time. In other words, all the rolls are driven to rotate and come into contact with the floor decorative material Y to be conveyed downstream.

The gap between the upper rolls 111 to 181 and the lower rolls 112 to 182 is slightly smaller than the thickness of the floor decorative material Y to be conveyed. For example, when the thickness of the floor decorative material Y is 12 mm, the gap between both rolls can be 11.8 mm. Further, the bearings of the upper rolls 111 to 181 are fixed, while the bearings of the lower rolls 112 to 182 are provided with suspensions. Therefore, the lower rolls 112 to 182 can move up and down, and the floor decorative material Y can be pressed and unevenness can be absorbed. At this time, the pressure which acts on the floor decorative material Y from the lower rolls 112 to 182 can be set to 1 N to 50 N / cm ² , for example.

  As shown in FIG. 2, guide members 7 are arranged at both ends in the width direction in the conveyance path of the floor decorative material Y. The guide member 7 includes a pair of guide pieces 71 extending in a bar shape along the transport direction X. The distance T between the guide pieces 71 is slightly wider than the width of the floor decorative material Y. For example, if the width of the floor decorative material Y is 303 mm, the width T between the guide pieces 71 is 330 to 300 mm. It can be 340 mm. This guides the progress of the floor decorative material Y in the conveying direction and prevents meandering.

Next, the corona discharge units 21 to 24 will be described. FIG. 3 is a perspective view of the corona discharge unit. Although the figure shows the first corona discharge unit 21, the other units have the same configuration. Each corona discharge unit 21-24 is arrange | positioned along the conveyance direction X between the 3rd-7th roll bodies 13-17, respectively, and is arrange | positioned on both sides of the flooring decorative material Y. It is comprised by the corona discharge electrodes 211-241 and the counter electrodes 212-242 arrange | positioned below. The corona discharge electrodes 211 to 241 include two wire electrodes W ₁ and W ₂ arranged in parallel, and each of the wire electrodes W ₁ and W ₂ is formed in a convex U-shape, and the floor decorative material Y It is arrange | positioned so that it may extend in the width direction. On the other hand, the counter electrodes 212 to 242 are formed in a rectangular shape, and are arranged immediately below the wire electrodes W ₁ and W ₂ . All the electrodes are arranged away from the floor decorative material Y by a predetermined distance. Moreover, the roll body arrange | positioned on both sides of the corona discharge units 21-24 needs to be arrange | positioned at predetermined distance. This is because the surface of the roll is made of metal, so that the discharge does not go to the flooring decorative material Y but goes to the roll. For example, when the roll diameter is 100 mm, the distance D between the centers of adjacent rolls is preferably 300 mm (see FIG. 2). In addition, since ozone generate | occur | produces from the corona discharge units 21-24, although a illustration is abbreviate | omitted, it is preferable to also provide the unit which collect | recovers ozone.

  Next, an example of a floor decorative material targeted in the present embodiment will be described. FIG. 4 is a cross-sectional view of the floor decorative material, and FIG. 5 is a cross-sectional view of the main part of FIG. As shown in FIG. 4, this floor decorative material Y is obtained by laminating a decorative sheet (decorative layer) A, a backer layer (synthetic resin layer) B, and a wooden substrate C in this order. As the decorative sheet A, known ones can be used, for example, those described in JP-A-2006-283345 and JP-A-2004-17590 can be used. As a specific example, the decorative sheet A has a thickness of about 100 to 200 μm and a printed layer (pattern) is formed on a polyolefin film colored with a basic color through a solid printed portion. Further, a protective layer made of an EB curable resin is formed on the printed layer via a polyolefin film and an adhesive. The surface of the protective layer is embossed. The backer layer B has a thickness of about 100 to 400 μm and is made of polypropylene resin. Thus, since the backer layer B is thick and hard, it improves the impact resistance as a flooring. Moreover, this wood type board | substrate C is being fixed to the backer layer B via the adhesive agent, for example, is comprised with the wood fiber board, the plywood, etc. whose thickness is 3-15 mm. The floor decorative material thus formed is not prepared by a roll, but is carried into the above-described apparatus in a single sheet.

  Further, as shown in FIG. 5, a plurality of grooves are formed on the surface of the decorative material for floor Y in order to improve the design. In FIG. 5, only one is shown for explanation. The groove V is formed by cutting the decorative sheet A so as to have a V-shaped cross section. The deepest portion of the groove V reaches the wood substrate B, and the decorative sheet A, the backer layer B, and the wood substrate B are exposed from the wall surface of the groove V. Moreover, the depth is 0.5-1.0 mm, for example. As described below, the groove V of the floor decorative material Y formed in this way is colored with paint.

  Then, the coloring method to the flooring decorative material using the said corona discharge treatment apparatus is demonstrated, referring FIGS. 6-8. FIG. 6 is a flowchart showing steps up to coloring, FIG. 7 is a schematic configuration diagram of the coloring step, and FIG. 8 is a cross-sectional view of the floor decorative material in the coloring step.

  As shown in FIG. 6, before coloring the groove V, first, a floor decorative material as shown in FIGS. 4 and 5 is manufactured (S1). That is, a structure in which a plurality of grooves V are already formed is prepared. Subsequently, the wood chips adhering to the floor decorative material Y are removed. This is because, since the flooring decorative material Y uses the wood substrate B, wood dust may be generated, and if this wood dust adheres to the wire electrode W, the corona discharge treatment may vary. is there. Therefore, in the wood chip removing step, wood chips are removed on both the upper surface and the lower surface of the floor decorative material Y (S2). Wood chips are removed from the upper surface of the floor decorative material Y using a known roll cleaner, brush, and dust collector. On the other hand, it is preferable to use a known sanding machine and dust collector for the lower surface in addition to the apparatus used on the upper surface. This is because the wooden substrate B is exposed on the lower surface of the floor decorative material Y, and wood chips are easily generated. Note that not all of the above-described devices can be used, and some of them can be used in combination.

  The floor decorative material Y from which the wood chips are removed in this way is inserted into the corona discharge treatment apparatus so that the decorative sheet A side faces upward. The floor decorative material Y is carried downstream while a large pressure is applied by the first roll body 11. Then, the warp is corrected while being pressed from above and below by each of the roll bodies 12 to 18, and the corona discharge unit performs corona discharge treatment on the corrected and flat surface (S3). Thereby, the cross section of the decorative material Y for floors exposed from the groove | channel V formed in the decorative sheet A side is activated.

  Subsequently, the floor decorative material subjected to the corona discharge treatment is allowed to enter the coloring device to color the grooves (S4). As shown in FIG. 7, the apparatus includes an application unit 81 that applies paint and a scraping unit 82 that is disposed on the downstream side of the application unit and scrapes the applied paint. The coating unit 81 includes a pair of upper and lower rolls 811 and 812, and the coating roll 813 is in contact with the upper roll 811, and the coating is applied to the upper roll 811. The material of the roll surface can be formed of, for example, a sponge. Further, the roll rotates in the forward direction so that the floor decorative material Y can be conveyed to the scraping unit 82 side. On the other hand, the scraping unit 82 includes a pair of upper and lower rolls 821 and 822 whose surfaces are formed of rubber or the like, and a doctor blade 823 is in contact with the upper roll 821. Further, the rolls 821 and 822 rotate in the opposite direction to the rolls 811 and 812 of the coating unit 81 to make it easy to scrape the paint.

  Then, when a flooring decorative material as shown in FIG. 8A enters the coloring device, the flooring decorative material Y includes a groove V by the application unit 81 as shown in FIG. 8B. The paint P is applied to the entire decorative sheet. At this time, since the corona discharge treatment is performed on the backer layer B exposed from the groove V, the paint adheres even if the backer layer B is formed of an olefin resin. Next, the paint is scraped off by the scraping unit 82. That is, the paint applied to the surface of the decorative sheet A by the upper roll 821 is scraped off. That is, as shown in FIG. 8C, the paint on the surface of the decorative sheet A is scraped off except for the paint P that has entered the groove V, and the floor decorative material Y is colored only in the groove V. . Through the above steps, coloring of the groove V is completed.

  As described above, according to the present embodiment, the following effects can be obtained. In other words, the floor decorative material Y to be used here is manufactured as a single sheet and uses a wood-based base material, which may cause warpage during the manufacturing process. Therefore, in this embodiment, the plurality of roll bodies 11 to 18 are arranged along the transport direction, and the floor decorative material Y is transported while being pressed by the rotation of the roll bodies 11 to 18. Therefore, it is possible to convey the floor decorative material Y while correcting the warp. In addition, since the length of the target floor decorative material Y is larger than the distance D between the roll bodies 11 to 18, the floor cosmetic material Y is pressed down by the roll bodies 11 to 18 on the upstream side and the downstream side in the transport direction. Will be corrected. Thus, since the floor decorative material Y is in a flat state between the roll bodies 11 to 18, the corona discharge units 21 to 24 are arranged between the adjacent roll bodies 11 to 18 and are used for a floor in a flat state. Since it faces the decorative material, corona discharge treatment can be reliably performed on the decorative material for floor.

  As mentioned above, although one Embodiment of this invention was described, this invention is not limited to the said embodiment, A various change is possible unless it deviates from the meaning. For example, the numbers of roll bodies and corona discharge units are not limited to those described above, and may be determined as appropriate depending on the size of the target floor decorative material. Moreover, in the said embodiment, although a wire electrode is used in a corona discharge unit, a ball electrode can also be used and will not be specifically limited if the corona discharge process can be performed to the desired part of the flooring decorative material.

  In addition to the above-described floor decorative materials, for example, the backer layer can be made of a resin other than an olefin resin such as a PET resin, or a floor decorative material not provided with a backer layer. The above corona discharge treatment apparatus can also be applied. In this case, if the corona discharge treatment is performed, the adhesion can be improved when the paint is applied to the decorative sheet.

(Example)
Examples of the present invention will be described below. However, the present invention is not limited to the following examples.

Here, as an example, a floor decorative material was produced by the following procedure.
(1) An adhesive (BA-10 / BA-11B) manufactured by Chuo Rika Kogyo Co., Ltd. was applied to the surface of a wood substrate made of plywood (12 mm thick × 945 mm × 1840 mm) at about 9 g / scale angle.
(2) A floor sheet (0.4 mm thickness) was laminated on the plywood with a laminator machine. This floor sheet is a laminate of the above-described decorative sheet and a backer layer, and this backer layer is formed of a polypropylene resin.

An example of creating a decorative sheet here is as follows. That is, a urethane / nitrified cotton primer layer (solid content: 2 g / m ² ) is formed on one surface of a colored polypropylene film having a thickness of 60 μm subjected to double-sided corona discharge treatment by gravure printing, and the other surface is formed. A two-component curable urethane printing ink was used to form a solid pattern printing layer and a wood grain pattern printing layer on the solid pattern printing layer by a gravure printing method. After the gravure printing, an adhesive layer (2 g / m ² as a solid content) made of a two-component curable urethane resin was formed on the entire surface of the pattern printing layer. A polypropylene-based thermoplastic elastomer to which a benzotriazole-based ultraviolet absorber and a hindered amine-based radical scavenger are added is heated and melt-extruded with a T-die extruder to form a transparent resin layer having a thickness of 80 μm. Formed. Next, a two-part curable urethane resin in which an embossed plate with a wood grain conduit pattern is provided on the transparent resin layer surface, and an acrylic / urethane block copolymer is a main component and isocyanate is added as a curing agent on the entire transparent resin layer surface. Was applied to form a transparent primer layer (1 g / m ² as solid content). Further, a urethane acrylate ionizing radiation curable resin is applied to the entire surface of the transparent primer layer and irradiated with an electron beam [acceleration voltage: 175 KeV, irradiation amount: 5 Mrad] to form a transparent surface protective layer (solid content of 15 g / m ^2). A decorative sheet serving as a decorative layer was formed.
(3) The plate material prepared in (2) was pressed with a cold press machine at about 30 N / cm ² for 30 minutes, and then cured for 3 days to obtain a base material for a flooring decorative material.
(4) This floor decorative material is chopped into 313 mm width × 1840 mm length with a gang saw machine, and floor processing (sane processing, V-shaped groove processing and chamfering processing) is further performed with a tenor machine. The final size of the flooring decorative material was 303 mm × 1818 mm.
(5) The corona discharge treatment was performed on the floor decorative material thus produced by the corona discharge treatment apparatus shown in the above embodiment. The conditions are as follows.
・ Electrode method: Wire electrode ・ Distance between electrodes (horizontal distance of wire electrode of each corona discharge electrode): 5 mm
・ Power setting: 1800W
・ Voltage setting: 33kV
・ Feeding speed of flooring material: 60m / min
-Number of roll bodies: 8-Interval between roll bodies: 300 mm
・ Roll diameter: 100mm (uppermost roll diameter: 300mm)
-Roll pressure: 5 N / cm ²
(6) The coating material (W-SF) manufactured by Showa Ink Industry Co., Ltd. was colored with the coloring apparatus shown in the above embodiment on the floor decorative material subjected to the corona discharge treatment.

  On the other hand, a floor decorative material produced without performing only corona discharge treatment in the above process was used as a comparative example.

  A paint peeling experiment was performed on the floor decorative materials according to Examples and Comparative Examples thus produced. Here, Nichiban cello tape (registered trademark) was applied to the groove and the chamfered C surface, and the adhesion of the paint when it was suddenly peeled upward was evaluated. As a result, in the examples, there was no peeling of the paint, but in the comparative example, there was peeling of the paint on the entire sheet surface.

  In addition, the corona treatment of the decorative sheet for flooring with a maximum arrow height of about 20 mm was performed, but the degree of warpage was corrected to be small, and corona discharge treatment was possible without contact with the electrodes.

It is a side view which shows one Embodiment of the corona discharge processing apparatus which concerns on this invention. It is the sectional view on the AA line of FIG. It is a perspective view of a corona discharge unit. It is sectional drawing of the decorative material for floors. It is principal part sectional drawing of the decorative material for floors. It is a flowchart which shows the manufacturing process of the decorative material for floors. It is a side view which shows the outline of a coloring device. It is sectional drawing which shows the mode of coloring to the decorative material for floors.

Explanation of symbols

11-18 Roll body 21-24 Corona discharge unit 211-241 Corona discharge electrode 221-242 Counter electrode 7 Guide member Y Floor decorative material

Claims (6)

An apparatus for performing corona discharge treatment on a flooring decorative material having a wooden substrate and a decorative layer,
A plurality of roll bodies having a pair of rolls arranged at predetermined intervals along the conveying direction of the floor decorative material and conveying the floor decorative material while pressing the floor decorative material from the substrate side and the decorative layer side;
At least one corona discharge unit having a corona discharge electrode and a counter electrode disposed between the roll bodies adjacent to each other so as to sandwich the floor decorative material from the substrate side and the decorative layer side;
A corona discharge treatment apparatus.   In the roll body, the roll arranged on the corona discharge electrode side has a rotation axis fixed, while the roll arranged on the counter electrode side is configured such that the rotation axis can move up and down elastically. The corona discharge treatment apparatus according to claim 1.   The corona discharge treatment apparatus according to claim 1, further comprising a guide member that sandwiches the floor decorative material from the width direction and guides the progress in the conveyance direction. Each corona discharge electrode is composed of at least one wire electrode,
The corona discharge treatment apparatus according to claim 1, wherein the wire electrode extends in a width direction of the floor decorative material. An apparatus for performing corona discharge treatment on a flooring decorative material having a wooden substrate and a decorative layer,
A plurality of roll bodies having a pair of upper and lower rolls are arranged at a predetermined interval, and the floor body is conveyed while pressing the floor decorative material by these roll bodies;
Applying a corona discharge treatment to the decorative layer side of the floor decorative material between the adjacent roll bodies.   A flooring decorative material produced by applying a paint to the decorative layer side following the corona discharge treatment method according to claim 5.

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