JP4195331B2

JP4195331B2 - Decorative plate manufacturing method and decorative plate manufacturing apparatus

Info

Publication number: JP4195331B2
Application number: JP2003135364A
Authority: JP
Inventors: 徳昭加隈; 幸治田熊; 基裕友森; 雅則谷上; 琢司中村
Original assignee: Toyo Kohan Co Ltd
Current assignee: Toyo Kohan Co Ltd
Priority date: 2003-05-14
Filing date: 2003-05-14
Publication date: 2008-12-10
Anticipated expiration: 2023-05-14
Also published as: JP2004338151A

Description

【０００１】
【発明の属する技術分野】
本発明は、ストライプ状の模様を有する化粧フィルム、その化粧フィルムを金属板に積層してなる化粧板に関し、特に長尺帯状の金属板に長尺帯状のストライプ状の模様を有する化粧フィルムを積層してなる化粧フィルム積層金属板を切断して得られる化粧板、およびその製造方法、製造装置に関する。
【０００２】
【従来の技術】
ユニットバスなどの建築内装材として、色や模様を塗装および／または印刷してなる化粧フィルムや、樹脂フィルム表面にエンボス模様等の凹凸模様を成形加工してなる化粧フィルムを金属板に積層してなる化粧板が用いられている。これらの化粧板を例えば図１に示すような壁材１として用いる場合、同一高さの壁部材１ａと壁部材１ｂを直角に突き合わせて壁角部が形成されるが、見栄えの観点から壁部材１ａの模様２ａと壁部材１ｂの模様２ｂも高さ方向にずれることなく同一高さで突き合わせるようにしなくてはならない。
【０００３】
このような、模様を塗装および／または印刷してなる化粧板、特にストライプ状の模様を有する化粧板としては、平行なストライプ状の模様が樹脂フィルムの長手方向に一定間隔で繰り返して塗装および／または印刷された長尺帯状の樹脂フィルムを長尺帯状の金属板に積層して作成し、繰り返される模様毎に一定間隔で切断して角形の板材とした図２に示すようなものが用いられる。すなわち、塗装および／または印刷してなる平行なストライプ状の模様１１ａおよび１１ｂが樹脂フィルムの長手方向に一定間隔１４で繰り返して塗装および／または印刷され、模様部分の両側に透明もしくは模様のない部分１２を有する長尺帯状の樹脂フィルム３０を金属板２０に積層し、切断線１３において、繰り返される模様毎に一定間隔１４で切断して角形の板材としたものが用いられる。なお、ストライプ状の模様としては、図３に示すように幾何学図形○４や幾何学図形◇５が横および縦に並んだ状態のものも含まれる。
【０００４】
しかし、長尺帯状の樹脂フィルムを金属板に連続して積層する場合、模様の繰り返し部がそれぞれ常時一定の長さとなるように金属板に積層する必要があるが、樹脂フィルムには搬送のために張力が負荷されたり、金属板に積層する際に接着を付勢するために加熱されることにより、長手方向に伸張したり伸縮したりするため、常に模様の繰り返し部を一定間隔で積層することは極めて困難である。そのため、切断した角形の板材の模様の繰り返し部の長さを１枚毎にチェックし、一定の許容誤差範囲にあるもののみを壁材として用いているが、チェックに手間がかかりコストアップの原因となり、また模様の繰り返し部の長さが許容誤差範囲を外れた不良品の発生は避けられず、歩留まりを向上させることができない。
【０００５】
金属板に樹脂フィルムを積層してなる化粧板として、例えば印刷樹脂フィルムを積層した化粧板や目地デザイン樹脂フィルム被覆金属板が開示されている（例えば特許文献１〜２参照）。
【０００６】
特許文献１に記載の化粧板は、透明な二軸延伸ポリエステル樹脂フィルムを最表層とし、その下層に印刷層、エンボス加工を施した機材樹脂層、接着樹脂層を順次積層して印刷樹脂フィルムとし、この印刷樹脂フィルムを金属板に積層してなる化粧板である。
【０００７】
特許文献２に記載の目地デザイン樹脂フィルム被覆金属板は、複層の樹脂フィルムに目地模様を印刷した層を設けるか、または複層の樹脂フィルムの最表層に目地模様の凹部を設け、選択的に凹部を塗装してなる複層樹脂フィルムを金属板に積層してなる目地デザイン樹脂フィルム被覆金属板である。
【０００８】
本出願に関する先行技術文献情報として次のものがある。
【特許文献１】
特開２００２−２１９７８８号公報
【特許文献２】
特開２００２−３６１７８６号公報
【０００９】
【発明が解決しようとする課題】
しかし、これらの公報においては、模様の繰り返し部分の長さを一定にして積層する方法や手段に関しての記載が無く、これらの公報に記載された技術では、模様の繰り返し部分の長さのチェックに要するコスト増、および歩留まり低下を解決することができない。
本発明は、長尺帯状の金属板に、長手方向に平行なストライプ状の模様を一定間隔で繰り返して有する長尺帯状の樹脂フィルムを連続的に積層してなる化粧板を１枚毎に切断する際に、切断板において繰り返すストライプ状の模様が一定の誤差範囲内に位置するように切断可能とする、化粧板の製造方法、化粧板の製造装置、化粧フィルム、およびその化粧フィルムを用いて製造してなる化粧板、ならびにその化粧板を用いたパネルを提供することを目的とする。
【００１０】
【課題を解決するための手段】
本発明の化粧板は、長尺帯状の金属板に長尺帯状の樹脂フィルムを連続的に積層する化粧板の製造方法において、長手方向に一定間隔でマーカーを付した樹脂フィルムを、金属板に積層した後のマーカー間の間隔の誤差が１０００ｍｍ当たり±１．５ｍｍ以内となるように、樹脂フィルムの張力を制御しながら積層することを特徴とする化粧板の製造方法（請求項１）、または
金属板の供給手段から供給される長尺帯状の金属板に、樹脂フィルムの供給手段から供給される長尺帯状の樹脂フィルムを１対のラミネートロールを用いて連続的に圧接して積層する化粧板の製造方法において、長手方向に一定間隔で樹脂フィルムに付したマーカーを、マーカーの検出手段を用いて検出するとともに、金属板の通板長さの測定手段を用いて金属板の通板長さを測定し、測定結果からマーカー間の距離を演算手段を用いて演算し、演算結果であるマーカー間の距離を表示手段に表示し、表示結果に基づいて、樹脂フィルムの供給手段とラミネートロールの間に設けた樹脂フィルムの張力制御手段を用いて、樹脂フィルムの張力を金属板に積層した後のマーカー間の間隔の誤差が１０００ｍｍ当たり±１．５ｍｍ以内となるように制御しながら積層することを特徴とする化粧板の製造方法（請求項２）、さらにまたは
金属板の供給手段から供給される長尺帯状の金属板に、樹脂フィルムの供給手段から供給される長尺帯状の樹脂フィルムを１対のラミネートロールを用いて連続的に圧接して積層する化粧板の製造方法において、長手方向に一定間隔で樹脂フィルムに付したマーカーを、マーカーの検出手段を用いて検出するとともに、金属板の通板長さの測定手段を用いて金属板の通板長さを測定し、測定結果からマーカー間の距離を演算手段を用いて演算し、演算結果を演算結果出力手段を用いて樹脂フィルムの供給手段とラミネートロールの間に設けた樹脂フィルムの張力制御手段に出力し、樹脂フィルムの張力を金属板に積層した後のマーカー間の間隔の誤差が１０００ｍｍ当たり±１．５ｍｍ以内となるように制御しながら積層することを特徴とする化粧板の製造方法（請求項３）、さらにまたは
長尺帯状の金属板に長尺帯状の樹脂フィルムを１対のラミネートロールを用いて連続的に積層した後、エンボスロールを用いて樹脂フィルム表面に、凹凸模様が長手方向に平行でストライプ状に一定間隔で繰り返されるようにエンボス加工を施す化粧板の製造方法において、エンボスロール表面の長手方向の片脇部または両脇部の周上の少なくとも１箇所に凹凸部を設けたエンボスロールを用い、エンボス加工時に樹脂フィルム表面の幅方向の片脇部または両脇部にエンボスロールの凹凸部を転写して凹凸マークを形成させ、エンボスロールの回転毎に樹脂フィルム表面に周期的に凹凸マークを形成させ、凹凸マークの間隔の誤差が１０００ｍｍ当たり±１．５ｍｍ以内となるようにエンボスロール表面の温度を制御しながらエンボス加工を施すことを特徴とする化粧板の製造方法（請求項４）、さらにまたは
金属板の供給手段から供給される長尺帯状の金属板に、樹脂フィルムの供給手段から供給される長尺帯状の樹脂フィルムを１対のラミネートロールを用いて連続的に圧接して積層した後、エンボスロールを用いて樹脂フィルム表面に、凹凸模様が長手方向に平行でストライプ状に一定間隔で繰り返されるようにエンボス加工を施す化粧板の製造方法において、エンボスロール表面の長手方向の片脇部または両脇部の周上の少なくとも１箇所に凹凸部を設けたエンボスロールを用い、エンボス加工時に樹脂フィルム表面の幅方向の片脇部または両脇部にエンボスロールの凹凸部を転写して凹凸マークを形成させ、エンボスロールの回転毎に樹脂フィルム表面に周期的に形成させた凹凸マーク凸部、凹凸マークの検出手段を用いて検出するとともに、金属板の通板長さの測定手段を用いて金属板の通板長さを測定し、測定結果から凹凸マーク間の距離を演算手段を用いて演算し、演算結果である凹凸マーク間の距離を表示手段に表示し、表示結果に基づいて、エンボスロール表面の温度の制御手段を用いて凹凸マーク間の間隔の誤差が１０００ｍｍ当たり±１．５ｍｍ以内となるようにエンボスロール表面の温度を制御しながら積層することを特徴とする化粧板の製造方法（請求項５）、さらにまたは
金属板の供給手段から供給される長尺帯状の金属板に、樹脂フィルムの供給手段から供給される長尺帯状の樹脂フィルムを１対のラミネートロールを用いて連続的に圧接して積層した後、エンボスロールを用いて樹脂フィルム表面に、凹凸模様が長手方向に平行でストライプ状に一定間隔で繰り返されるようにエンボス加工を施す化粧板の製造方法において、エンボスロール表面の長手方向の片脇部または両脇部の周上の少なくとも１箇所に凹凸部を設けたエンボスロールを用い、エンボス加工時に樹脂フィルム表面の幅方向の片脇部または両脇部にエンボスロールの凹凸部を転写して凹凸マークを形成させ、エンボスロールの回転毎に樹脂フィルム表面に周期的に形成させた凹凸マークを、凹凸マークの検出手段を用いて検出するとともに、金属板の通板長さの測定手段を用いて金属板の通板長さを測定し、測定結果から凹凸マーク間の距離を演算手段を用いて演算し、演算結果を演算結果出力手段を用いてエンボスロール表面の温度の制御手段に出力し、凹凸マーク間の間隔の誤差が１０００ｍｍ当たり±１．５ｍｍ以内となるようにエンボスロール表面の温度を制御しながら積層することを特徴とする化粧板の製造方法（請求項６）、であり
上記（請求項４〜６）のいずれかの化粧板の製造方法において、エンボスロール表面温度を基準温度±３０℃に制御することを特徴とする（請求項７）。
【００１１】
また本発明の化粧板の製造装置は、金属板の供給手段と、樹脂フィルムの供給手段と、樹脂フィルムの張力制御手段と、１対のラミネートロールと、樹脂フィルムに付したマーカーの検出手段と、金属板の通板長さの測定手段と、マーカー間の間隔を演算する演算手段と、演算結果の表示手段とからなる、化粧板の製造装置（請求項８）、または
金属板の供給手段と、樹脂フィルムの供給手段と、樹脂フィルムの張力制御手段と、１対のラミネートロールと、樹脂フィルムに付したマーカーの検出手段と、金属板の通板長さの測定手段と、マーカー間の間隔を演算する演算手段と、演算結果を樹脂フィルムの張力制御手段に出力する演算結果出力手段とからなる、化粧板の製造装置（請求項９）、さらにまたは
金属板の供給手段と、樹脂フィルムの供給手段と、１対のラミネートロールと、少なくとも樹脂フィルムと接するロール表面の周上の少なくとも１箇所に凹凸部を設けた一方のロールと他方のロールからなる１対のエンボスロールと、エンボスロール表面の温度の制御手段と、エンボスロールの凹凸部を設けたロールにより樹脂フィルム表面に転写された凹凸マーカーの検出手段と、金属板の通板長さの測定手段と、凹凸マーカー間の間隔を演算する演算手段と、演算結果の表示手段とからなる、化粧板の製造装置（請求項１０）、さらにまたは
金属板の供給手段と、樹脂フィルムの供給手段と、１対のラミネートロールと、少なくとも樹脂フィルムと接するロール表面の周上の少なくとも１箇所に凹凸部を設けた一方のロールと他方のロールからなる１対のエンボスロールと、エンボスロール表面の温度の制御手段と、エンボスロールの凹凸部を設けたロールにより樹脂フィルム表面に転写された凹凸マーカーの検出手段と、金属板の通板長さの測定手段と、凹凸マーカー間の間隔を演算する演算手段と、演算結果をエンボスロール表面の温度の制御手段に出力する演算結果出力手段とからなる、化粧板の製造装置（請求項１１）である。
【００１２】
また本発明の化粧フィルムは、長尺帯状の樹脂フィルムにおいて、幅方向の片脇部または両脇部を除いて、長手方向に平行なストライプ状の模様が一定間隔で繰り返して塗装および／または印刷され、幅方向の片脇部または両脇部にストライプ状の模様の繰り返しの間隔と同一間隔でマーカーが印刷されてなる、長尺帯状の金属板に連続的に積層するために用いる化粧フィルム（請求項１２）、または
色彩および／または模様の異なるストライプ状の模様が長手方向に平行に並んで塗装および／または印刷されてなる樹脂フィルムにおいて、隣接するストライプ状の模様の色彩および／または模様の相違を緩和させるために、ストライプ状の模様の境目にぼかし部を塗装および／または印刷してなる化粧フィルム（請求項１３）、さらにまたは
上記（請求項１２）の化粧フィルムにおいて、色彩および／または模様が異なるストライプ状の模様が並んで塗装および／または印刷され、かつ隣接するストライプの色および／または模様の相違を緩和させるために、ストライプの境目にぼかし部を塗装および／または印刷してなる化粧フィルム（請求項１４）である。
【００１３】
また本発明の化粧板は、上記（請求項１３）の化粧フィルムを金属板に積層してなる化粧板、または
上記（請求項１２または１４）の化粧フィルムを、上記（請求項１〜３）のいずれかの化粧板の製造方法を用いて金属板に積層した後、マーカー位置を基準として１枚毎に切断してなる化粧板、または
上記（請求項４〜８）のいずれかの化粧板の製造方法を用いて製造した化粧板を、凹凸マーカー位置を基準として１枚毎に切断してなる化粧板である。
【００１４】
また本発明の化粧パネルは、上記（請求項１６または１７）の化粧板を、片脇部または両脇部に設けられたマーカー部または凹凸マーカー部が隠れるように折り込んでなる化粧パネルである。
【００１５】
【発明の実施の形態】
以下、本発明を詳細に説明する。
先に述べたように、従来の化粧板の製造方法においては、繰り返し模様、特にストライプ状の模様を有する長尺帯状の樹脂フィルムを金属板に連続して積層する際に、樹脂フィルムには搬送のための張力が負荷されたり、金属板に積層する際に接着を付勢するために加熱されることにより長手方向に伸張したり伸縮したりするため、常に模様の繰り返し部を厳密に一定間隔で積層することは極めて困難であり、積層後に繰り返し単位で単板に切断して壁部材等に用いる際に、切断した単板を不良品を生ずることなく、模様、特にストライプ状の模様の位置をずらすことなく見栄えよく一致させて壁部を構成することが困難であり、模様がずれるものを不良品とせざるを得ず、製品としての歩留まりが悪かった。本発明においては、以下に示すように、樹脂フィルムを金属板に積層する際の樹脂フィルムの張力を加減したり、樹脂フィルムにエンボス加工を施す際のエンボスロール表面の温度を加減して、樹脂フィルムの伸びや縮みを一定となるように制御することにより、樹脂フィルムの模様の繰り返し部を常に一定間隔で積層することを可能とし、不良品の発生を抑制するものである。以下、図面を参照しながら本発明を説明する。
【００１６】
図４に本発明の化粧板の一例の概略を示す。すなわち、本発明の化粧フィルム３０は、先に図１に示した、同一高さの壁部材１ａと壁部材１ｂを直角に突き合わせて壁角部が形成した際に、壁部材１ａの模様２ａと壁部材１ｂの模様２ｂも高さ方向にずれることによる見栄え不良を極力回避するために、図４に示すように塗装および／または印刷してなる平行なストライプ状の模様１１ａおよび１１ｂと、ストライプ状の模様１１ａおよび１１ｂの間にぼかし部１１ｃを設け、金属板２０に積層して所定の寸法に切断して壁材とした際に、隣りあう壁材の模様のずれを目立たなくなるようにしている。
【００１７】
また、繰り返し模様を有する長尺帯状の樹脂フィルムである本発明の化粧フィルム３０を長尺帯状の金属板２０に連続的に積層する際に、模様の繰り返し部分の長さ、すなわちストライプ状の模様１１ａ、１１ｂ、１１ｃの長手方向のそれぞれの長さを足した長さが何処においても許容誤差範囲内で積層されるように、繰り返し部分であるストライプ状の模様１１ａ、１１ｂ、１１ｃの部分の片脇部または両脇部の透明または模様のない部分１２に塗装および／または印刷によりマーカー１５を長手方向に一定間隔で設ける。そして、連続的に進行する長尺帯状の金属板２０に連続的に長尺帯状の本発明の化粧フィルム３０を供給して当設して重ね合わせて１対のラミネートロールを用いて圧接して積層して化粧板１０とする際に、マーカーの検出手段を用いてマーカー１５を検出するとともに、金属板の通板長さの測定手段を用いて金属板２０の通板長さを測定する。そしてマーカー１５の検出毎の通板長さの測定結果から、各マーカー１５間の距離を演算手段を用いて演算し、演算結果を演算結果の表示手段に表示して、オペレータが表示結果に基づいて樹脂フィルムの供給手段と樹脂フィルム（化粧フィルム３０）の供給手段の間に設けた樹脂フィルムの張力制御手段を作動させて樹脂フィルムの張力を手動制御するか、または演算結果を演算結果出力手段を用いて樹脂フィルムの張力制御手段に出力して樹脂フィルムの張力制御手段を自動的に作動させて樹脂フィルムの張力を自動的に制御することにより、各マーカー間の間隔の誤差が一定範囲内、好ましくは１０００ｍｍ当たり±１．５ｍｍ以内となるように化粧フィルム３０を金属板２０に積層する。
【００１８】
化粧フィルム３０のストライプ状の模様１１ａ、１１ｂ、１１ｃの部分の少なくとも片脇部の透明または模様のない部分１２にマーカー１５を設ける必要があるが、化粧フィルム３０がわずかに蛇行して供給され、金属板２０に対して斜めに積層される場合もあるので、両脇部の透明または模様のない部分１２にマーカー１５を設けることが好ましい。
【００１９】
図５は目地模様を有する化粧フィルム３０を金属板２０に積層して化粧板１０とする場合を示す。目地模様は目地をはっきりと際立たせる図柄の性格上、柄模様部１１ａと目地部１１ｄの間にぼかし部を設けることが困難であり、また柄模様部１１ａの幅に対して目地部１１ｄの幅が０〜８ｍｍ程度と狭いために、模様の繰り返し部分の長さ、すなわちストライプ状の模様１１ａと目地部１１ｄの長手方向のそれぞれの長さを足した長さが何処においても許容誤差範囲内で積層する場合の誤差範囲が図４に示した図柄の模様の場合よりも厳しく、マーカー１５をできるだけ小さい間隔で、例えば図５のようにストライプ状の模様１１ａが等間隔である場合は１個のストライプ状の模様１１ａ毎にマーカー１５を設けて、きめ細かく張力制御することが好ましい。このようにして目地模様の化粧フィルムを積層する場合、各マーカー部の間隔は５００ｍｍあたり±１ｍｍ以内、好ましくは５００ｍｍあたり±０．５ｍｍ以内となるように化粧フィルム３０を金属板２０に積層することが好ましい。
【００２０】
また、化粧板としては、上記のように模様を塗装および／または印刷を施したした化粧フィルムを金属板に積層する以外に、樹脂フィルムの表面にエンボス加工を施したり、または塗装および／または印刷を施したした樹脂フィルムの表面にエンボス加工を施して意匠性をさらに向上させた化粧フィルムを金属板に積層する場合もある。このように、長尺帯状の樹脂フィルムの表面にエンボス加工を施して長尺帯状の金属板に積層する場合、図７および図９に示すようにして積層する。すなわち、図９に示すように、樹脂フィルム（化粧フィルム３０）を金属板２０に１対のラミネートロール２２を用いて圧接して積層した後、樹脂フィルムと接する側のロールとして図７に示すようにロールの表面にエンボス模様１６ａを刻設したエンボスロール１８ａ、他の側のロールとして圧接用のロール１８ｂを用い、エンボス模様を樹脂フィルム表面に転写する。そしてこのエンボスロールによるエンボス加工に際して、エンボスロール１８ａの表面のエンボス模様１６ａを刻設していない長さ方向の片脇部または両脇部の周上の少なくとも１箇所に凹凸部１７ａを刻設しておき、樹脂フィルム表面にエンボス加工を施すと同時に、フィルムの片脇部または両脇部に周期的に凹凸部１７ａにより凹凸マーカー１７を転写して形成させる。凹凸部１７ａは、細線状の凹凸マーカー１７が得られるように刻設しておくと、高精度で凹凸マーカー１７を検出することができて好ましい。
【００２１】
そして、連続的に進行する長尺帯状の金属板２０に連続的に長尺帯状の樹脂フィルム（化粧フィルム３０）を供給して当設して重ね合わせ、１対のラミネートロール２２を用いて圧接して積層した後、１対のエンボスロール１８を用いて樹脂フィルム表面にエンボス模様１６および凹凸マーカー１７を形成させて化粧板１０とする際に、凹凸マーカーの検出手段を用いて凹凸マーカー１７を検出するとともに、金属板の通板長さの測定手段を用いて金属板２０の通板長さを測定する。そして凹凸マーカー１７の検出毎の通板長さの測定結果から、各凹凸マーカー１７間の距離を演算手段２５を用いて演算し、演算結果を演算結果の表示手段２６に表示して、オペレータ２８が表示結果に基づいてエンボスロール表面の温度の制御手段２９を作動させて、エンボスロール表面の温度を制御するか、または演算結果を演算結果出力手段２７を用いてエンボスロール表面の温度を出力してエンボスロール表面の温度の制御手段２９を自動的に制御することにより、ロールの径を一定以内に制御して、各凹凸マーカー間の間隔の誤差が一定範囲内、好ましくは１０００ｍｍ当たり±１．５ｍｍ以内となるように化粧フィルム３０を金属板２０に積層する。
【００２２】
次に、本発明の化粧板の製造装置および製造方法について説明する。図８に本発明の化粧板の製造装置の一例の概略を示す。図８は樹脂フィルムの脇部に一定間隔でマーカーを設け、マーカーを検出して樹脂フィルムの張力を制御して模様の繰り返し部の長さを一定範囲内の誤差に収める製造装置の例である。図８に示す本発明の化粧板の製造装置において、図示しないアンコイラー等の金属板２０の供給手段と、図示しないアンコイラー等の樹脂フィルム（化粧フィルム）３０の供給手段とから、それぞれ金属板２０、および図４および図５に示す繰り返し模様、すなわちストライプ模様１１ａ、１１ｂ、１１ｃや目地模様１１ｄと、それらの脇部に設けたマーカー１５を有する樹脂フィルム３０を、本図上において左から右に向かって供給する。次いで金属板２０に樹脂フィルム３０を当接し、１対のラミネートロール２２を用いて両者を挟み付けて圧接し積層する。このとき、後記するように、樹脂フィルム３０は樹脂フィルムのアンコイラーとラミネートロール２２の間に設けられたロール２１ａ、２１ｂおよびロールの回転速度が可変の制御手段からなる張力制御装置とラミネートロール２２との間で張力を制御されながら、ラミネートロール２２に供給される。以上のようにして金属板２０の表面に樹脂フィルム（化粧フィルム）３０が積層され、繰り返し模様とその脇部に一定間隔で設けられたマーカー１５を有する化粧板１０が製造され、本図上を右に進行していく。
【００２３】
このようにして化粧板１０を製造する際に、樹脂フィルムの繰り返し模様部分が常時一定の長さで金属板に積層されるようにするため、各マーカー１５の間隔を常時測定し、各マーカー１５の間隔の誤差が一定範囲内、好ましくは１０００ｍｍ当たり±１．５ｍｍ以内、繰り返し模様が目地模様である場合は５００ｍｍ当たり±１５ｍｍ以内、より好ましくは５００ｍｍ当たり±０．５ｍｍ以内となるように、アンコイラーからラミネートロール２２に向けて樹脂フィルム３０を供給する際に、張力を制御しながら供給して積層することにより、上記の誤差範囲を実現する。すなわち、レーザーセンサーやＣＣＤカメラ等のマーカーの検出手段２３を用いてマーカー１５が通過した際に信号を出力し、その時の、金属板２０すなわち化粧板１０の通板長さを金属板の通板長さの測定手段２４を用いて測定するようにして、各マーク１５が通過する毎に、その前に通過したマーク１５の通板長さとの差から、各マーカー１５間の間隔を演算手段２５を用いてオンラインで演算し、演算結果をディスプレイなどの演算結果の表示手段２６に表示して、オペレータ２８が表示結果に基づいて樹脂フィルムの供給手段と樹脂フィルム（化粧フィルム）３０のアンコイラーとの間に設けた樹脂フィルムの張力制御手段２１を手動で作動させ、すなわちラミネートロール２２の回転速度に対する張力制御手段２１のロール２１ａ、２１ｂの回転速度を手動で調整して樹脂フィルムの張力を制御するか、または演算結果を演算結果出力手段２７を用いて樹脂フィルムの張力制御手段２２に出力してラミネートロール２２の回転速度に対する張力制御手段２１のロール２１ａ、２１ｂの回転速度を自動的に調整することにより樹脂フィルムの張力を制御、すなわち、間隔が所定の間隔よりも小さい場合は張力を増加し、大きい場合は張力を減少して、各マーカー１５間の間隔の誤差が一定範囲内、好ましくは１０００ｍｍ当たり±１．５ｍｍ以内となるように化粧フィルム３０を金属板２０に積層する。
【００２４】
また、本発明の化粧板は、以下の図９に示すように樹脂フィルム表面にエンボス加工を施して、繰り返し模様としてエンボス模様を設ける際に、樹脂フィルムのエンボス模様を形成させない片脇部または両脇部にエンボス加工による凹凸マーカーを一定間隔で形成させ、凹凸マーカーを検出してエンボスロールの表面温度を制御してロール径が一定範囲内の誤差に収まるようにして模様の繰り返し部の長さを一定範囲内の誤差に収める製造装置を用いて製造することもできる。図９に示す本発明の化粧板の製造装置において、図示しないアンコイラー等の金属板２０の供給手段と、図示しないアンコイラー等の樹脂フィルム（化粧フィルム）３０の供給手段とから、それぞれ金属板２０、および樹脂フィルム３０を、本図上において左から右に向かって供給する。次いで金属板２０に樹脂フィルム３０を当接し、１対のラミネートロール２２を用いて両者を挟み付けて圧接し積層する。次いで樹脂フィルムと接する側のロールとしてロールの表面にエンボス模様１６ａを刻設したエンボスロール１８ａ、他の側のロールとして圧接用のロール１８ｂを用いて樹脂フィルム表面にエンボス模様を転写する。そしてこのエンボスロールによるエンボス加工に際して、エンボスロール１８ａの表面のエンボス模様１６ａを刻設していない長さ方向の片脇部または両脇部の周上の少なくとも１箇所に凹凸部１７ａを凹設しておき、樹脂フィルム表面にエンボス加工を施すと同時に、フィルムの片脇部または両脇部に周期的に凹凸部１７ａにより凹凸マーカー１７を転写して形成させる。このようにして、図６に示すように、化粧フィルム３０の表面に繰り返しのエンボス模様１６と、エンボス模様１６の片脇部または両脇部の模様のない部分１２に凹凸マーカー１７が一定間隔で周期的に形成された化粧板１０が得られる。このとき、後記するように、エンボスロール１８ａおよび圧接用のロール１８ｂは、表面温度を加減してロール径を一定に制御しながら、樹脂フィルムにエンボス模様１６およびその脇部に一定間隔で設けられた凹凸マーカー１７を有する化粧板１０が製造され、本図上を右に進行していく。
【００２５】
このようにして化粧板１０を製造する際に、樹脂フィルムの繰り返されるエンボス模様部分が常時一定の長さで金属板に積層されるようにするため、各凹凸マーカー１７の間隔を常時測定し、各凹凸マーカー１７の間隔の誤差が一定範囲内、好ましくは１０００ｍｍ当たり±１．５ｍｍ以内となるように、エンボスロール１８ａおよび圧接用のロール１８ｂの表面温度を加減してロール径を一定に制御しながらエンボス加工を施すことにより、上記の誤差範囲を実現する。すなわち、レーザーセンサーやＣＣＤカメラ等のマーカーの検出手段２３を用い凹凸マーカー１７が通過した際に信号を出力し、その時の、金属板２０すなわち化粧板１０の通板長さを金属板の通板長さの測定手段２４を用いて測定するようにして、各凹凸マーカー１７が通過する毎に、その前に通過した凹凸マーカー１７の通板長さとの差から、各凹凸マーカー１７間の間隔を演算手段２５を用いてオンラインで演算し、演算結果をディスプレイなどの演算結果の表示手段２６に表示して、オペレータ２８が表示結果に基づいてエンボスロール表面の温度の制御手段２９を手動で作動させる。すなわち、エンボスロール１８ａおよび圧接ロール１８ｂの内部を空洞にし、内部に水等の冷媒を循環可能としておき、これらのロール内部に制御弁を制御しながら冷媒を循環させるように構成したエンボスロール表面の温度の制御手段２９の制御弁を手動で作動させてエンボスロール表面の温度を加減するか、または演算結果を演算結果出力手段を用いてエンボスロール表面の温度の制御手段２９に出力してエンボスロール表面の温度の制御手段２９、すなわち上記の制御弁を自動的に作動させてエンボスロール表面の温度を基準温度±３０℃となるように冷媒の循環量を加減することにより、ロールの径を一定範囲の誤差以内に制御して、各凹凸マーカー１７間の間隔の誤差が一定範囲内、好ましくは１０００ｍｍ当たり±１．５ｍｍ以内となるように化粧フィルム３０を金属板２０に積層する。
【００２６】
このように図８または図９に示すようにして、繰り返し模様の長さを一定にして金属板２０に樹脂フィルム３０を積層した化粧板１０は本図上をさらに右の矢印方向に進行し、図示しないコイラー等の巻き取り手段に長尺帯状の化粧板１０として巻き取られる。本発明の化粧板は図８または図９に示す上記のような製造装置および製造方法を用いて製造される。その後長尺帯状の化粧板１０を、コイラーから巻き解きながら、マーカー１５または凹凸マーカー１７を基準とする一定位置で切断することにより、一定長さの単板の化粧板とする。このようにして切断された単板の化粧板においては、切断前の長尺帯状の状態の長手方向で、単板の同一箇所に同一模様が位置することになるので、これらの単板を並べても模様のずれは殆ど生じることがない。しかし、単板の化粧板においては切断前の長尺帯状の状態の幅方向の片脇部または両脇部にマーカー１５または凹凸マーカー１７が形成されているので、これらの部分が隠れるように単板の元の長手方向の片脇部または両脇部をマーカー部または凹凸マーカー部が隠れるように折り込んで化粧パネルとして利用することが好ましい。また、模様のずれが多少生じても問題のない用途には、繰り返されるストライプ状の模様の境目に、隣接するストライプ状の模様の色彩および／または模様の相違を緩和させるぼかし部を塗装および／または印刷してなる化粧フィルムを金属板に特に繰り返しの長さの誤差を一定範囲内の誤差に管理することなく、そのまま積層して化粧板とし、それを一定長さで切断してなる角板状の単板の化粧板を用いてもよい。
【００２７】
本発明の化粧板や化粧パネルは、上記のように繰り返し模様の長さが各単板で同一であるので、並べて置いた場合に模様のずれがなく、また繰り返し模様の境界部にぼかし部を設けているので模様がずれても目立つことがなく、見栄えに優れており、壁部材などの建築内装部材、冷蔵庫等の家電製品の外装部材、ユニットバスやシステムキッチン等の目地板として、好適に適用することができる。
【００２８】
【発明の効果】
本発明の化粧板に用いる化粧フィルムは、化粧板を壁部材等の用途において並べて用いた場合に、模様のずれによる見栄え不良を極力回避するために、繰り返し模様の境界部にぼかし部を設けているので模様がずれても目立つことがない。また、本発明の化粧板は、繰り返し模様を有する長尺帯状の本発明の化粧フィルムを長尺帯状の金属板に連続的に積層する際に、模様の繰り返し部分の長さが何処においても許容誤差範囲内で積層されるように、繰り返し部分の片脇部または両脇部に塗装および／または印刷によりマーカーを、またはエンボス加工により凹凸マーカーを長手方向に一定間隔で設け、検出手段を用いてマーカーまたは凹凸マーカーを検出するとともに、通板長さの測定手段を用いて金属板の通板長さを測定し、測定結果から各マーカー間または各凹凸マーカー間の距離を演算手段を用いて演算し、演算結果を演算結果の表示手段に表示して、オペレータが表示結果に基づいて樹脂フィルムの供給手段と化粧フィルムの供給手段の間に設けた樹脂フィルムの張力制御手段を手動で作動させて樹脂フィルムの張力を制御するか、または演算結果を演算結果出力手段を用いて樹脂フィルムの張力制御手段に出力して樹脂フィルムの張力制御手段を自動的に作動させて樹脂フィルムの張力を自動的に制御することにより、各マーカー間または各凹凸マーカー間の間隔の誤差が一定範囲内、好ましくは１０００ｍｍ当たり±１．５ｍｍ以内となるように化粧フィルムを金属板に積層してなる化粧板である。この長尺帯状の化粧板を一定長さで切断して角板状の単板の化粧板とした場合、単板の化粧板においては切断前の長尺帯状の状態の長手方向で、単板の同一箇所に同一模様が位置することになるので、これらの単板を並べても模様のずれは殆ど生じることがない。また、単板の化粧板の切断前の長手方向の脇部を折り曲げて化粧パネルに成形することにより、単板の脇部に形成されたマーカーまたは凹凸マーカーを隠して壁部材等の用途に用いることができる。
そのため、本発明の化粧板および化粧パネルは、見栄えに優れており、壁部材などの建築内装部材、冷蔵庫等の家電製品の外装部材、ユニットバスやシステムキッチン等の目地板として、好適に適用することができる。
【図面の簡単な説明】
【図１】従来の壁材の一例を示す概略図。
【図２】従来の化粧板の一例を示す概略図。
【図３】ストライプ状の模様の一例を示す概略図。
【図４】本発明の化粧板の一例を示す概略図。
【図５】本発明の化粧板の他の一例を示す概略図。
【図６】本発明の化粧板の他の一例を示す概略図。
【図７】本発明の化粧板の製造に用いるエンボスロールの概略図。
【図８】本発明の化粧板の製造装置の一例を示す概略図。
【図９】本発明の化粧板の製造装置の他の一例を示す概略図。
【符号の説明】
１：壁材
１ａ：壁部材
１ｂ：壁部材
２ａ：模様
２ｂ：模様
１０：化粧板
１１ａ：ストライプ状の模様
１１ｂ：ストライプ状の模様
１１ｃ：ぼかし部
１１ｄ：目地部
１２：透明または模様のない部分
１３：切断線
１４：一定間隔のピッチ
１５：マーカー
１６：エンボス模様
１６ａ：エンボス模様
１７：凹凸マーカー
１７ａ：凹凸部
１８：エンボスロール
１８ａ：エンボスロール
１８ｂ：圧接ロール
２０：金属板
２１：樹脂フィルムの張力制御手段
２１ａ：ロール
２１ｂ：ロール
２２：一対のラミネートロール
２２ａ：ラミネートロール
２２ｂ：ラミネートロール
２３：マーカーまたは凹凸マーカーの検出手段
２４：金属板の通板長さの測定手段
２５：演算手段
２６：演算結果の表示手段
２７：演算結果出力手段
２８：オペレータ
２９：ロール表面温度の制御手段
３０；化粧板[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a decorative film having a striped pattern, and a decorative board obtained by laminating the decorative film on a metal plate, and in particular, laminating a decorative film having a long striped striped pattern on a long strip-shaped metal plate. It is related with the decorative board obtained by cut | disconnecting the decorative film laminated metal plate formed, its manufacturing method, and a manufacturing apparatus.
[0002]
[Prior art]
As a building interior material such as a unit bath, a decorative film formed by painting and / or printing a color or pattern, or a decorative film formed by forming an uneven pattern such as an embossed pattern on the surface of a resin film is laminated on a metal plate. A decorative board is used. When these decorative plates are used as, for example, the wall material 1 as shown in FIG. 1, the wall member 1a and the wall member 1b having the same height are abutted at right angles to form a wall corner portion. The pattern 2a of 1a and the pattern 2b of the wall member 1b must also be matched at the same height without shifting in the height direction.
[0003]
As such a decorative board obtained by painting and / or printing a pattern, in particular, a decorative board having a stripe-like pattern, the parallel stripe-like pattern is repeatedly applied and / or repeated at regular intervals in the longitudinal direction of the resin film. Alternatively, a long strip-shaped resin film that is printed is laminated on a long strip-shaped metal plate, and is cut at regular intervals for each repeated pattern to form a rectangular plate as shown in FIG. . That is, the parallel striped patterns 11a and 11b formed by painting and / or printing are repeatedly painted and / or printed at regular intervals 14 in the longitudinal direction of the resin film, and transparent or non-patterned portions on both sides of the pattern portion. A long strip-shaped resin film 30 having 12 is laminated on the metal plate 20, and the cutting line 13 is cut at regular intervals 14 for each repeated pattern to form a rectangular plate material. The striped pattern includes a pattern in which the geometric figure 4 and the geometric figure ◇ 5 are arranged horizontally and vertically as shown in FIG.
[0004]
However, when laminating a long strip of resin film continuously on a metal plate, it is necessary to laminate the metal film so that the repeated portions of the pattern are always at a constant length. When it is applied with tension or when it is laminated to a metal plate, it is heated to energize the adhesion, so that it stretches or stretches in the longitudinal direction. It is extremely difficult. For this reason, the length of the cut part of the cut rectangular plate material is checked for each sheet, and only those that are within a certain tolerance range are used as the wall material. In addition, the occurrence of defective products in which the length of the repeated portion of the pattern is outside the allowable error range cannot be avoided, and the yield cannot be improved.
[0005]
As a decorative plate formed by laminating a resin film on a metal plate, for example, a decorative plate in which a printed resin film is laminated or a joint design resin film-coated metal plate is disclosed (for example, see Patent Documents 1 and 2).
[0006]
The decorative board described in Patent Document 1 has a transparent biaxially stretched polyester resin film as the outermost layer, and a printed layer, an embossed equipment resin layer, and an adhesive resin layer are sequentially laminated to form a printed resin film. The decorative resin plate is formed by laminating the printing resin film on a metal plate.
[0007]
The joint design resin film-covered metal plate described in Patent Document 2 is provided with a layer of a joint pattern printed on a multilayer resin film, or a joint pattern recess is provided on the outermost layer of the multilayer resin film. A joint design resin film-covered metal plate obtained by laminating a multilayer resin film formed by coating a recess on a metal plate.
[0008]
Prior art document information relating to the present application includes the following.
[Patent Document 1]
JP 2002-219788 A
[Patent Document 2]
JP 2002-361786 A
[0009]
[Problems to be solved by the invention]
However, in these publications, there is no description about the method and means for laminating with the length of the repeated portion of the pattern being constant, and in the techniques described in these publications, the length of the repeated portion of the pattern is checked. The increase in cost required and the decrease in yield cannot be solved.
The present invention cuts a decorative sheet formed by continuously laminating a long strip-shaped resin film having a strip-shaped pattern parallel to the longitudinal direction on a long strip-shaped metal plate at regular intervals. Using a decorative plate manufacturing method, a decorative plate manufacturing apparatus, a decorative film, and the decorative film, which enables cutting so that a striped pattern repeated on the cutting plate is positioned within a certain error range. An object of the present invention is to provide a decorative board manufactured and a panel using the decorative board.
[0010]
[Means for Solving the Problems]
The decorative board of the present invention is a method for manufacturing a decorative board in which a long band-shaped resin film is continuously laminated on a long band-shaped metal sheet. A method for producing a decorative board, characterized in that lamination is performed while controlling the tension of a resin film so that an error in an interval between markers after lamination is within ± 1.5 mm per 1000 mm, or
A makeup in which a long band-shaped resin film supplied from a resin film supply unit is continuously pressed and laminated on a long band-shaped metal plate supplied from a metal plate supply unit using a pair of laminating rolls. In the plate manufacturing method, the marker attached to the resin film at regular intervals in the longitudinal direction is detected using the marker detection means, and the length of the metal plate is measured using the length measurement means of the metal plate. The distance between the markers is calculated from the measurement result using the calculation means, the distance between the markers as the calculation result is displayed on the display means, and based on the display result, the resin film supply means and the laminate roll Using the resin film tension control means provided between the markers, the error between the markers after laminating the resin film tension on the metal plate is within ± 1.5 mm per 1000 mm. Method for manufacturing a decorative laminate, which comprises stacked while controlling (Claim 2), further or
A makeup in which a long band-shaped resin film supplied from a resin film supply unit is continuously pressed and laminated on a long band-shaped metal plate supplied from a metal plate supply unit using a pair of laminating rolls. In the plate manufacturing method, the marker attached to the resin film at regular intervals in the longitudinal direction is detected using the marker detection means, and the length of the metal plate is measured using the length measurement means of the metal plate. The distance between the markers is calculated using the calculation means from the measurement result, and the calculation result is calculated between the resin film supply means and the laminate roll using the calculation result output means. It is characterized by laminating while controlling the tension of the resin film to be within ± 1.5 mm per 1000 mm after the tension of the resin film is laminated on the metal plate. Method for manufacturing a decorative plate (claim 3), further or
After continuously laminating a long band-shaped resin film on a long band-shaped metal plate using a pair of laminate rolls, the embossing roll is used to form a concavo-convex pattern in stripes parallel to the longitudinal direction. In the manufacturing method of the decorative plate for embossing so as to be repeated at regular intervals, using an embossing roll provided with an uneven portion at least one side on the circumference of one side or both sides in the longitudinal direction of the embossing roll surface, When embossing, embossing rolls are transferred to one or both sides of the resin film surface in the width direction to form uneven marks, and the embossing rolls are formed periodically on each resin film surface. Embossing while controlling the temperature of the embossing roll surface so that the error of the uneven mark spacing is within ± 1.5 mm per 1000 mm. Method for manufacturing a decorative laminate, characterized in Succoth (Claim 4), further or
After laminating a long band-shaped resin film supplied from a resin film supply unit on a long band metal plate supplied from a metal plate supply unit using a pair of laminating rolls. In the manufacturing method of a decorative board, embossing is performed on the surface of the resin film using an embossing roll so that the concavo-convex pattern is repeated in a striped manner in parallel with the longitudinal direction. Or, using an embossing roll with at least one uneven part on the circumference of both side parts, the uneven part of the embossing roll is transferred to one side part or both side parts in the width direction of the resin film surface during embossing. The mark is formed and detected by using the convex / concave mark detecting means periodically formed on the surface of the resin film every time the embossing roll is rotated. Measure the length of the metal plate using the length measurement means of the metal plate, calculate the distance between the concave and convex marks using the calculation means from the measurement result, The distance is displayed on the display means, and the embossing roll surface temperature is adjusted based on the display result so that the error in the spacing between the concave and convex marks is within ± 1.5 mm per 1000 mm using the embossing roll surface temperature control means. A method for producing a decorative board, wherein the laminate is performed while being controlled (Claim 5), or
After laminating a long band-shaped resin film supplied from a resin film supply unit on a long band metal plate supplied from a metal plate supply unit using a pair of laminating rolls. In the manufacturing method of a decorative board, embossing is performed on the surface of the resin film using an embossing roll so that the concavo-convex pattern is repeated in a striped manner in parallel with the longitudinal direction. Or, using an embossing roll with at least one uneven part on the circumference of both side parts, the uneven part of the embossing roll is transferred to one side part or both side parts in the width direction of the resin film surface during embossing. While detecting the concavo-convex mark formed on the surface of the resin film every time the embossing roll is rotated using the concavo-convex mark detection means Measure the length of the metal plate using the length measurement means of the metal plate, calculate the distance between the concave and convex marks from the measurement result using the calculation means, and use the calculation result output means And the laminate is controlled while controlling the temperature of the embossing roll surface so that the error in the spacing between the concave and convex marks is within ± 1.5 mm per 1000 mm. The manufacturing method of claim (Claim 6)
In the decorative plate manufacturing method according to any one of the above (claims 4 to 6), the embossing roll surface temperature is controlled to a reference temperature ± 30 ° C (claim 7).
[0011]
The decorative board manufacturing apparatus of the present invention includes a metal plate supply means, a resin film supply means, a resin film tension control means, a pair of laminate rolls, and a marker detection means attached to the resin film. A decorative plate manufacturing apparatus (claim 8), comprising: a plate length measuring means for a metal plate; a calculation means for calculating an interval between markers; and a calculation result display means.
Metal plate supply means, resin film supply means, resin film tension control means, a pair of laminating rolls, marker detection means attached to the resin film, and metal plate length measurement means And a decorative plate manufacturing apparatus (Claim 9), further comprising: a calculation means for calculating an interval between the markers; and a calculation result output means for outputting a calculation result to the tension control means of the resin film.
A metal plate supply means, a resin film supply means, a pair of laminate rolls, and at least one place on the circumference of the roll surface in contact with the resin film, one roll and the other roll. A pair of embossing rolls, a means for controlling the temperature of the embossing roll surface, a means for detecting the concavo-convex marker transferred to the resin film surface by the roll provided with the concavo-convex part of the embossing roll, and a measurement of the length of the metal plate A decorative plate manufacturing apparatus (claim 10), further comprising: means; computing means for computing an interval between the uneven markers; and a computation result display means.
A metal plate supply means, a resin film supply means, a pair of laminate rolls, and at least one place on the circumference of the roll surface in contact with the resin film, one roll and the other roll. A pair of embossing rolls, a means for controlling the temperature of the embossing roll surface, a means for detecting the concavo-convex marker transferred to the resin film surface by the roll provided with the concavo-convex part of the embossing roll, and a measurement of the length of the metal plate An apparatus for manufacturing a decorative board, comprising: a means; a computing means for computing a distance between the concave and convex markers; and a computation result output means for outputting the computation result to a temperature controlling means on the surface of the embossing roll.
[0012]
Further, the decorative film of the present invention is a long strip-shaped resin film, except that one side or both sides in the width direction are repeated and a striped pattern parallel to the longitudinal direction is repeatedly painted and / or printed. A decorative film used for continuously laminating a long strip-shaped metal plate in which markers are printed at the same intervals as the repeated intervals of the stripe pattern on one side or both sides in the width direction ( Claim 12), or
In order to alleviate the difference in color and / or pattern of adjacent stripe patterns in a resin film in which stripe patterns having different colors and / or patterns are painted and / or printed in parallel in the longitudinal direction A decorative film obtained by painting and / or printing a blurred portion at the border of a stripe pattern (claim 13), or
In the decorative film of the above (Claim 12), in order to alleviate the difference in color and / or pattern of adjacent stripes, stripe-shaped patterns having different colors and / or patterns are painted and / or printed side by side. A decorative film obtained by painting and / or printing a blurred portion at a boundary between stripes.
[0013]
The decorative board of the present invention is a decorative board obtained by laminating the decorative film of the above (Claim 13) on a metal plate, or
After laminating the decorative film of the above (Claim 12 or 14) on a metal plate using any one of the manufacturing methods of the decorative board of the above (Claims 1 to 3), the cut film is cut one by one with reference to the marker position. Decorative veneer or
A decorative board produced by cutting the decorative board manufactured using the decorative board manufacturing method according to any one of the above (claims 4 to 8) on a sheet-by-sheet basis with respect to the position of the uneven marker.
[0014]
The decorative panel of the present invention is a decorative panel formed by folding the decorative plate of the above (Claim 16 or 17) so that the marker portion or the uneven marker portion provided on one side or both sides is hidden.
[0015]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, the present invention will be described in detail.
As described above, in the conventional method of manufacturing a decorative board, when a continuous belt-like resin film having a repetitive pattern, particularly a striped pattern, is continuously laminated on a metal plate, it is conveyed to the resin film. Because it is stretched or stretched in the longitudinal direction by being heated to energize the adhesive when it is laminated to a metal plate or heated, it always stretches the pattern repeatedly at regular intervals It is extremely difficult to laminate with a pattern, especially when it is used as a wall member etc. after being cut into a single unit in a repeating unit after lamination, the position of the pattern, particularly the striped pattern, without producing a defective product. It was difficult to configure the wall portion with good appearance without shifting, and a product with a misaligned pattern had to be regarded as a defective product, resulting in poor product yield. In the present invention, as shown below, the tension of the resin film when laminating the resin film on the metal plate is adjusted, or the temperature of the embossing roll surface when embossing is applied to the resin film, By controlling the elongation and shrinkage of the film to be constant, it becomes possible to always laminate the repeated portions of the pattern of the resin film at a constant interval, and suppress the occurrence of defective products. The present invention will be described below with reference to the drawings.
[0016]
FIG. 4 shows an outline of an example of the decorative board of the present invention. That is, the decorative film 30 of the present invention has the pattern 2a of the wall member 1a when the wall corner 1a is formed by abutting the wall member 1a and the wall member 1b having the same height at a right angle as shown in FIG. In order to avoid poor appearance due to the pattern 2b of the wall member 1b being shifted in the height direction as much as possible, parallel striped patterns 11a and 11b formed by painting and / or printing as shown in FIG. A blur portion 11c is provided between the patterns 11a and 11b, and when the wall material is formed by being laminated on the metal plate 20 and cut to a predetermined size, the shift of the pattern of the adjacent wall material is made inconspicuous. .
[0017]
Further, when the decorative film 30 of the present invention, which is a long strip-shaped resin film having a repeated pattern, is continuously laminated on the long strip-shaped metal plate 20, the length of the repeated portion of the pattern, that is, a striped pattern. A piece of a striped pattern 11a, 11b, 11c that is a repeated portion so that the length of each of the lengths of 11a, 11b, 11c plus the length in the longitudinal direction is laminated within an allowable error range everywhere. Markers 15 are provided at regular intervals in the longitudinal direction by painting and / or printing on the side portions or the transparent or non-patterned portions 12 on both side portions. Then, the continuous belt-like metal plate 20 is continuously supplied with the decorative film 30 of the present invention in the form of a long strip, and is put on top of each other and overlapped and pressed using a pair of laminate rolls. When the decorative plate 10 is laminated, the marker 15 is detected using the marker detection means, and the length of the metal plate 20 is measured using the length measurement means of the metal plate. Then, the distance between the markers 15 is calculated from the measurement result of the plate length for each detection of the marker 15 by using the calculation means, the calculation result is displayed on the calculation result display means, and the operator is based on the display result. The resin film tension control means provided between the resin film supply means and the resin film (decorative film 30) supply means is operated to manually control the resin film tension, or the calculation result is output to the calculation result output means. Is used to output the resin film tension control means and automatically activate the resin film tension control means to control the resin film tension automatically. The decorative film 30 is preferably laminated on the metal plate 20 so as to be within ± 1.5 mm per 1000 mm.
[0018]
It is necessary to provide the marker 15 on the transparent or non-patterned portion 12 of at least one side of the striped pattern 11a, 11b, 11c portion of the decorative film 30, but the decorative film 30 is supplied in a slightly meandering manner, In some cases, the marker 15 is laminated obliquely with respect to the metal plate 20, and therefore it is preferable to provide the marker 15 on the transparent or non-patterned portion 12 on both sides.
[0019]
FIG. 5 shows a case where the decorative film 30 having a joint pattern is laminated on the metal plate 20 to form the decorative plate 10. In the joint pattern, it is difficult to provide a blurred portion between the pattern portion 11a and the joint portion 11d due to the nature of the pattern that makes the joint stand out clearly, and the width of the joint portion 11d is larger than the width of the pattern portion 11a. Therefore, the length of the repeated portion of the pattern, that is, the length obtained by adding the lengths of the striped pattern 11a and the joint portion 11d in the longitudinal direction is within an allowable error range everywhere. The error range in the case of stacking is stricter than in the case of the pattern shown in FIG. 4, and the markers 15 are spaced as small as possible. For example, when the stripe-shaped patterns 11a are equally spaced as shown in FIG. It is preferable to provide a marker 15 for each stripe pattern 11a and finely control the tension. When laminating a decorative film with a joint pattern in this way, the decorative film 30 is laminated on the metal plate 20 so that the interval between the marker portions is within ± 1 mm per 500 mm, preferably within ± 0.5 mm per 500 mm. Is preferred.
[0020]
In addition to laminating a decorative film having a pattern painted and / or printed as described above on a metal plate, the decorative plate is embossed on the surface of the resin film, or painted and / or printed. In some cases, a decorative film that has been further improved in design by embossing the surface of the resin film that has been subjected to is laminated on a metal plate. Thus, when embossing is given to the surface of a long strip-shaped resin film and it laminates | stacks on a long strip-shaped metal plate, it laminates | stacks as shown in FIG. 7 and FIG. That is, as shown in FIG. 9, as shown in FIG. 7, the resin film (decorative film 30) is pressed and laminated on the metal plate 20 using a pair of laminating rolls 22 and then is in contact with the resin film. The embossing pattern 18a is engraved on the surface of the roll, and the pressing roll 18b is used as the roll on the other side, and the embossing pattern is transferred to the surface of the resin film. When embossing with the embossing roll, an uneven portion 17a is engraved in at least one place on one side of the length direction or the circumference of both sides where the embossed pattern 16a on the surface of the embossing roll 18a is not engraved. In addition, the embossing is performed on the surface of the resin film, and at the same time, the concavo-convex markers 17 are periodically transferred by the concavo-convex portions 17a on one or both sides of the film. It is preferable that the concavo-convex portion 17a is engraved so that the fine concavo-convex marker 17 can be obtained because the concavo-convex marker 17 can be detected with high accuracy.
[0021]
Then, a continuous belt-shaped resin film (decorative film 30) is continuously supplied to the continuous belt-shaped metal plate 20 which is continuously applied and overlapped, and pressed by using a pair of laminate rolls 22 When the embossed pattern 16 and the concavo-convex marker 17 are formed on the surface of the resin film by using a pair of embossing rolls 18 to form the decorative board 10, the concavo-convex marker 17 is formed using the concavo-convex marker detecting means. In addition to the detection, the length of the metal plate 20 is measured using a means for measuring the length of the metal plate. Then, the distance between the concave and convex markers 17 is calculated using the calculation means 25 from the measurement result of the plate length for each detection of the concave and convex markers 17, and the calculation result is displayed on the calculation result display means 26. The embossing roll surface temperature control means 29 is operated based on the display result to control the embossing roll surface temperature, or the calculation result is output to the embossing roll surface temperature using the calculation result output means 27. By automatically controlling the temperature control means 29 on the surface of the embossing roll, the diameter of the roll is controlled within a certain range, and the error in the spacing between the uneven markers is within a certain range, preferably ± 1. The decorative film 30 is laminated on the metal plate 20 so as to be within 5 mm.
[0022]
Next, the manufacturing apparatus and manufacturing method of the decorative board of the present invention will be described. FIG. 8 shows an outline of an example of the decorative board manufacturing apparatus of the present invention. FIG. 8 shows an example of a manufacturing apparatus in which markers are provided at regular intervals on the side of the resin film, the marker is detected, the tension of the resin film is controlled, and the length of the repeated portion of the pattern falls within an error within a certain range. . In the decorative plate manufacturing apparatus of the present invention shown in FIG. 8, the metal plate 20, respectively, includes a supply means for a metal plate 20 such as an uncoiler (not shown) and a supply means for a resin film (decorative film) 30 such as an uncoiler (not shown). 4 and 5, the resin film 30 having the repeated patterns, that is, the stripe patterns 11a, 11b, 11c and the joint pattern 11d, and the markers 15 provided on the side portions thereof, is directed from left to right in the figure. And supply. Next, the resin film 30 is brought into contact with the metal plate 20, and a pair of laminating rolls 22 are used to sandwich and press the two to laminate them. At this time, as will be described later, the resin film 30 is composed of rolls 21a and 21b provided between an uncoiler of the resin film and the laminating roll 22, and a tension control device including laminating rolls 22 and control means having a variable rotation speed. While being controlled in tension, the laminate roll 22 is supplied. As described above, the resin film (decorative film) 30 is laminated on the surface of the metal plate 20, and the decorative plate 10 having the repetitive pattern and the markers 15 provided at regular intervals on the side portions thereof is manufactured. Proceed to the right.
[0023]
Thus, when the decorative board 10 is manufactured, the interval between the markers 15 is constantly measured so that the repeated pattern portion of the resin film is always laminated on the metal plate with a constant length. The decoiler is designed so that the error of the interval is within a certain range, preferably within ± 1.5 mm per 1000 mm, and within ± 15 mm per 500 mm when the repeated pattern is a joint pattern, more preferably within ± 0.5 mm per 500 mm. When the resin film 30 is supplied to the laminating roll 22 from above, the above error range is realized by supplying and laminating while controlling the tension. That is, a signal is output when the marker 15 passes using the marker detection means 23 such as a laser sensor or a CCD camera, and the length of the metal plate 20, that is, the decorative plate 10 at that time is set to the length of the metal plate. Each time the marks 15 pass as measured using the length measuring means 24, the interval between the markers 15 is calculated from the difference from the passing plate length of the mark 15 that passed before. And the calculation result is displayed on the calculation result display means 26 such as a display, and the operator 28 determines whether the resin film supply means and the uncoiler of the resin film (decorative film) 30 are based on the display result. The tension control means 21 for the resin film provided therebetween is manually operated, that is, the roll 21a of the tension control means 21 with respect to the rotational speed of the laminate roll 22. The rotational speed of 21b is manually adjusted to control the tension of the resin film, or the calculation result is output to the tension control means 22 of the resin film using the calculation result output means 27 and the tension with respect to the rotation speed of the laminate roll 22 is output. The tension of the resin film is controlled by automatically adjusting the rotation speed of the rolls 21a and 21b of the control means 21, that is, the tension is increased when the interval is smaller than the predetermined interval, and the tension is decreased when the interval is larger. Thus, the decorative film 30 is laminated on the metal plate 20 so that the error in the interval between the markers 15 is within a certain range, preferably within ± 1.5 mm per 1000 mm.
[0024]
Further, the decorative board of the present invention is provided with one side portion or both sides on which the embossed pattern of the resin film is not formed when embossing is performed on the surface of the resin film as shown in FIG. The length of the repeated part of the pattern is formed by forming embossed concave and convex markers on the side parts at regular intervals, detecting the concave and convex markers and controlling the surface temperature of the embossing roll so that the roll diameter falls within an error within a certain range Can also be manufactured using a manufacturing apparatus that fits within an error within a certain range. In the decorative plate manufacturing apparatus of the present invention shown in FIG. 9, the metal plate 20 includes a metal plate 20 such as an uncoiler (not shown) and a resin film (decorative film) 30 such as an uncoiler (not shown). The resin film 30 is supplied from the left to the right in the figure. Next, the resin film 30 is brought into contact with the metal plate 20, and a pair of laminating rolls 22 are used to sandwich and press the two to laminate them. Next, the embossed pattern is transferred onto the surface of the resin film by using an embossing roll 18a in which an embossed pattern 16a is engraved on the surface of the roll as a roll in contact with the resin film, and a pressure-contacting roll 18b as a roll on the other side. When embossing with this embossing roll, the concave and convex portion 17a is provided in at least one place on the circumference of one side or both sides in the length direction where the embossed pattern 16a on the surface of the embossing roll 18a is not engraved. In addition, the embossing is performed on the surface of the resin film, and at the same time, the concavo-convex markers 17 are periodically transferred by the concavo-convex portions 17a on one or both sides of the film. In this way, as shown in FIG. 6, the embossed pattern 16 is repeatedly formed on the surface of the decorative film 30, and the concave and convex markers 17 are arranged at regular intervals on one side of the embossed pattern 16 or on the part 12 without the pattern on both sides. The decorative board 10 formed periodically is obtained. At this time, as will be described later, the embossing roll 18a and the press-contacting roll 18b are provided on the resin film at regular intervals at the embossed pattern 16 and the side thereof while controlling the surface temperature to keep the roll diameter constant. The decorative board 10 having the uneven markers 17 is manufactured, and proceeds to the right in the figure.
[0025]
Thus, when the decorative board 10 is manufactured, the interval between the concave and convex markers 17 is constantly measured so that the repeated embossed pattern portion of the resin film is always laminated on the metal plate with a constant length, The roll diameter is controlled to be constant by adjusting the surface temperature of the embossing roll 18a and the pressure-applying roll 18b so that the error of the interval between the concave and convex markers 17 is within a certain range, preferably within ± 1.5 mm per 1000 mm. The above error range is realized by embossing. That is, a signal is output when the concave / convex marker 17 passes using a marker detection means 23 such as a laser sensor or a CCD camera, and the length of the metal plate 20, that is, the decorative plate 10 at that time is set to the length of the metal plate. Each time the concave / convex markers 17 pass as measured using the length measuring means 24, the interval between the concave / convex markers 17 is determined based on the difference from the plate length of the concave / convex markers 17 that have passed therethrough. The calculation means 25 is used for online calculation, the calculation result is displayed on the calculation result display means 26 such as a display, and the operator 28 manually operates the embossing roll surface temperature control means 29 based on the display result. . That is, the embossing roll 18a and the press-contacting roll 18b are made hollow so that a coolant such as water can be circulated therein, and the surface of the embossing roll configured to circulate the coolant while controlling the control valve inside these rolls. The control valve of the temperature control means 29 is manually operated to increase or decrease the temperature of the embossing roll surface, or the calculation result is output to the embossing roll surface temperature control means 29 using the calculation result output means. By controlling the surface temperature control means 29, that is, the above-mentioned control valve automatically, and adjusting the circulation amount of the refrigerant so that the surface temperature of the embossing roll becomes the reference temperature ± 30 ° C., the diameter of the roll is made constant. Control within the error of the range, the error of the spacing between the concave and convex markers 17 is within a certain range, preferably within ± 1.5 mm per 1000 mm The decorative film 30 is laminated on the metal plate 20 so that
[0026]
Thus, as shown in FIG. 8 or FIG. 9, the decorative board 10 in which the length of the repeated pattern is made constant and the resin film 30 is laminated on the metal plate 20 proceeds further in the direction of the arrow on the right side of the figure, It is wound up as a long belt-like decorative board 10 by a winding means such as a coiler (not shown). The decorative board of the present invention is manufactured using the above manufacturing apparatus and manufacturing method shown in FIG. 8 or FIG. Thereafter, the long strip-shaped decorative board 10 is unwound from the coiler and cut at a fixed position with the marker 15 or the concave / convex marker 17 as a reference, thereby obtaining a single-panel decorative board having a fixed length. In the veneer veneer cut in this way, the same pattern is located at the same location of the veneer in the longitudinal direction of the long strip state before cutting, so these veneers are arranged side by side. However, there is almost no pattern shift. However, in the veneer decorative plate, the marker 15 or the concave / convex marker 17 is formed on one side or both sides in the width direction in the state of a long strip before cutting. It is preferable to fold one side part or both side parts of the original longitudinal direction of the plate so that the marker part or the uneven marker part is hidden and use it as a decorative panel. For applications where there is no problem even if there is a slight shift in the pattern, paint and / or a blurring portion that relaxes the color and / or pattern difference between adjacent stripe patterns at the boundary between repeated stripe patterns. Or, the decorative film is printed on a metal plate, and the square plate is formed by laminating it as it is without changing the error of the repeat length to an error within a certain range, and cutting it to a certain length. A single veneer decorative plate may be used.
[0027]
Since the decorative board and decorative panel of the present invention have the same repeated pattern length for each single plate as described above, there is no pattern deviation when placed side by side, and there is a blurring part at the boundary of the repeated pattern. Because it is provided, it does not stand out even if the pattern is shifted, it is excellent in appearance, suitable as a building interior member such as a wall member, an exterior member of household appliances such as a refrigerator, and a joint plate such as a unit bath or a system kitchen Can be applied.
[0028]
【The invention's effect】
The decorative film used for the decorative board of the present invention is provided with a blurring part at the boundary part of the repeated pattern in order to avoid the appearance defect due to the shift of the pattern as much as possible when the decorative board is used side by side in applications such as wall members. Therefore, even if the pattern is shifted, it will not stand out. In addition, the decorative board of the present invention allows the length of the repeated portion of the pattern to be allowed anywhere when the long strip of the decorative film of the present invention having a repeated pattern is continuously laminated on the long metal plate. Using a detection means, markers are provided at regular intervals in the longitudinal direction by painting and / or printing on one side or both sides of the repeated part, or embossing so as to be laminated within the error range. In addition to detecting markers or uneven markers, measure the length of the metal plate using the means for measuring the length of the plate, and use the calculation means to calculate the distance between the markers or between the uneven markers from the measurement results. The calculation result is displayed on the calculation result display means, and the tension of the resin film provided between the resin film supply means and the decorative film supply means by the operator based on the display result. The control means is operated manually to control the resin film tension, or the calculation result is output to the resin film tension control means using the calculation result output means, and the resin film tension control means is automatically operated. By automatically controlling the tension of the resin film, the decorative film is placed on the metal plate so that the error in the interval between the markers or between the uneven markers is within a certain range, preferably within ± 1.5 mm per 1000 mm. This is a laminated decorative board. When this long strip-shaped decorative board is cut to a certain length to form a square-plate-shaped single decorative plate, the single-panel decorative plate is a single plate in the longitudinal direction of the long strip-like state before cutting. Since the same pattern is located at the same location of the two, even if these single plates are arranged, there is almost no deviation of the pattern. In addition, by bending the longitudinal side part before cutting of the veneer decorative board and forming the decorative panel, the marker or the uneven marker formed on the side part of the veneer is concealed and used for a wall member or the like. be able to.
Therefore, the decorative board and the decorative panel of the present invention are excellent in appearance, and are suitably applied as building interior members such as wall members, exterior members of household appliances such as refrigerators, and joint boards for unit baths and system kitchens. be able to.
[Brief description of the drawings]
FIG. 1 is a schematic view showing an example of a conventional wall material.
FIG. 2 is a schematic view showing an example of a conventional decorative board.
FIG. 3 is a schematic diagram showing an example of a stripe pattern.
FIG. 4 is a schematic view showing an example of a decorative board of the present invention.
FIG. 5 is a schematic view showing another example of the decorative board of the present invention.
FIG. 6 is a schematic view showing another example of the decorative board of the present invention.
FIG. 7 is a schematic view of an embossing roll used for producing the decorative board of the present invention.
FIG. 8 is a schematic view showing an example of a decorative board manufacturing apparatus according to the present invention.
FIG. 9 is a schematic view showing another example of the decorative board manufacturing apparatus of the present invention.
[Explanation of symbols]
1: Wall material
1a: Wall member
1b: Wall member
2a: Pattern
2b: Pattern
10: decorative board
11a: Striped pattern
11b: Striped pattern
11c: Blur part
11d: Joint part
12: Transparent or unpatterned part
13: Cutting line
14: Pitch at regular intervals
15: Marker
16: Embossed pattern
16a: Embossed pattern
17: Uneven marker
17a: uneven part
18: Embossing roll
18a: Embossing roll
18b: pressure contact roll
20: Metal plate
21: Resin film tension control means
21a: Roll
21b: Roll
22: A pair of laminate rolls
22a: Laminate roll
22b: Laminate roll
23: Marker or uneven marker detection means
24: Means for measuring the length of a metal plate
25: Calculation means
26: Means for displaying calculation results
27: Calculation result output means
28: Operator
29: Roll surface temperature control means
30; decorative board

Claims

In a method for manufacturing a decorative board in which a long belt-like resin film is continuously laminated on a long belt-like metal plate, a resin film with markers at regular intervals in the longitudinal direction is placed between the markers after being laminated on the metal plate. A method for producing a decorative board, comprising: laminating while controlling the tension of a resin film so that an error in spacing is within ± 1.5 mm per 1000 mm.

A makeup in which a long band-shaped resin film supplied from a resin film supply unit is continuously pressed and laminated on a long band-shaped metal plate supplied from a metal plate supply unit using a pair of laminating rolls. In the plate manufacturing method, the marker attached to the resin film at regular intervals in the longitudinal direction is detected using the marker detection means, and the length of the metal plate is measured using the length measurement means of the metal plate. The distance between the markers is calculated from the measurement result using the calculation means, the distance between the markers as the calculation result is displayed on the display means, and based on the display result, the resin film supply means and the laminate roll Using the resin film tension control means provided between the markers, the error between the markers after laminating the resin film tension on the metal plate is within ± 1.5 mm per 1000 mm. Method for manufacturing a decorative laminate, which comprises stacked while controlling.

A makeup in which a long band-shaped resin film supplied from a resin film supply unit is continuously pressed and laminated on a long band-shaped metal plate supplied from a metal plate supply unit using a pair of laminating rolls. In the plate manufacturing method, the marker attached to the resin film at regular intervals in the longitudinal direction is detected using the marker detection means, and the length of the metal plate is measured using the length measurement means of the metal plate. The distance between the markers is calculated using the calculation means from the measurement result, and the calculation result is calculated between the resin film supply means and the laminate roll using the calculation result output means. It is characterized by laminating while controlling the tension of the resin film to be within ± 1.5 mm per 1000 mm after the tension of the resin film is laminated on the metal plate. Method of manufacturing a decorative plate.

After continuously laminating a long band-shaped resin film on a long band-shaped metal plate using a pair of laminate rolls, the embossing roll is used to form a concavo-convex pattern in a stripe shape parallel to the longitudinal direction. In the manufacturing method of the decorative plate for embossing so as to be repeated at regular intervals, using an embossing roll provided with a concavo-convex portion in at least one place on one side of the longitudinal direction of the embossing roll surface or both sides, During embossing, the concave and convex portions of the embossing roll are transferred to one or both sides of the resin film surface in the width direction to form concave and convex marks, and the concave and convex marks are periodically formed on the surface of the resin film every time the embossing roll rotates. Embossing while controlling the temperature of the embossing roll surface so that the error of the uneven mark spacing is within ± 1.5 mm per 1000 mm. Method for manufacturing a decorative laminate, characterized in Succoth.

After laminating a long band-shaped resin film supplied from a resin film supply unit on a long band metal plate supplied from a metal plate supply unit using a pair of laminating rolls. In the manufacturing method of a decorative board, embossing is performed on the surface of the resin film using an embossing roll so that the concavo-convex pattern is repeated in a striped manner in parallel with the longitudinal direction. Or, using an embossing roll with at least one uneven part on the circumference of both side parts, the uneven part of the embossing roll is transferred to one side part or both side parts in the width direction of the resin film surface during embossing. While detecting the concavo-convex mark formed on the surface of the resin film every time the embossing roll is rotated using the concavo-convex mark detection means Measure the length of the metal plate using the means for measuring the length of the metal plate, calculate the distance between the concave and convex marks using the calculation means from the measurement results, and calculate the distance between the concave and convex marks. Is displayed on the display means, and the embossing roll surface temperature is controlled based on the display result so that the error in the spacing between the concave and convex marks is within ± 1.5 mm per 1000 mm using the embossing roll surface temperature control means. A method for producing a decorative board, wherein the laminate is laminated.

After laminating a long band-shaped resin film supplied from a resin film supply unit on a long band metal plate supplied from a metal plate supply unit using a pair of laminating rolls. In the method for manufacturing a decorative board, embossing is performed on the surface of the resin film using an embossing roll so that the concavo-convex pattern is repeated in a striped manner in parallel with the longitudinal direction. Alternatively, an embossing roll provided with at least one uneven part on the periphery of both side parts is used to transfer the uneven part of the embossing roll to one side part or both side parts in the width direction of the resin film surface during embossing. While detecting the concavo-convex mark formed on the surface of the resin film every time the embossing roll is rotated using the concavo-convex mark detection means Measure the length of the metal plate using the length measurement means of the metal plate, calculate the distance between the concave and convex marks from the measurement result using the calculation means, and use the calculation result output means And the laminate is controlled while controlling the temperature of the embossing roll surface so that the error in the spacing between the concave and convex marks is within ± 1.5 mm per 1000 mm. Manufacturing method.

The method for producing a decorative board according to any one of claims 4 to 6, wherein the embossing roll surface temperature is controlled to a reference temperature ± 30 ° C.

Metal plate supply means, resin film supply means, resin film tension control means, a pair of laminating rolls, marker detection means attached to the resin film, and metal plate length measurement means And a decorative plate manufacturing apparatus comprising a calculation means for calculating an interval between markers, and a calculation result display means.

Metal plate supply means, resin film supply means, resin film tension control means, a pair of laminating rolls, marker detection means attached to the resin film, and metal plate length measurement means And an arithmetic result output means for outputting the calculation result to the tension control means for the resin film.

A metal plate supply means, a resin film supply means, a pair of laminate rolls, and at least one place on the circumference of the roll surface in contact with the resin film, one roll and the other roll. A pair of embossing rolls, a means for controlling the temperature of the embossing roll surface, a means for detecting the concave and convex marks transferred to the resin film surface by the roll provided with the concave and convex portions of the embossing roll, and measuring the length of the metal plate An apparatus for manufacturing a decorative board, comprising: a means; a computing means for computing an interval between the concave and convex marks; and a computation result display means.

A metal plate supply means, a resin film supply means, a pair of laminate rolls, and at least one place on the circumference of the roll surface in contact with the resin film, one roll and the other roll. A pair of embossing rolls, a means for controlling the temperature of the embossing roll surface, a means for detecting the concavo-convex marker transferred to the resin film surface by the roll provided with the concavo-convex part of the embossing roll, and a measurement of the length of the metal plate An apparatus for manufacturing a decorative board, comprising: means; computing means for computing an interval between the concave and convex markers; and computation result output means for outputting a computation result to a temperature controlling means on the surface of the embossing roll.