JP4461318B2 - Laminating apparatus and floor material manufacturing method - Google Patents

Description

  The present invention relates to a laminating apparatus for laminating a decorative sheet on a base material made of wood, and a method for producing a flooring.

  Conventionally, a decorative sheet is often pasted on an indoor wall surface or the like for decoration. Such a decorative sheet is laminated on a base material via an adhesive, and then attached to a wall surface as a wall material (for example, Patent Document 1).

Conventionally, the decorative sheet as described above has been generally used as a wall material or a surface material of furniture, but recently, it has been proposed to use the decorative sheet as a flooring material. When a decorative sheet is used as a flooring material, the decorative sheet reinforced with a hard plastic sheet is used for the flooring material because strength is required compared with that used for a wall material. Thus, since the decorative sheet for flooring is thicker and harder than that for wall material, it is often prepared by making it a sheet instead of a roll. And this flooring is formed by laminating this decorative sheet on the base material to which the adhesive was applied.
Japanese Patent Publication No. 6-61902

  By the way, when laminating a decorative sheet on a substrate, it is necessary to prevent so-called air biting, in which air enters the laminated surface. Here, when the decorative sheet is prepared as a roll, the decorative sheet is fed out while applying tension to prevent the decorative sheet from forming wrinkles, thereby preventing the occurrence of air biting during lamination. Was. However, in the case of the above flooring, since the decorative sheet is prepared as a single sheet, it is difficult to apply tension to the decorative sheet. Therefore, there has been a demand for a method for preventing air biting even when laminating a sheet of decorative sheets.

  The present invention has been made in order to solve the above-described problems. When laminating a sheet of decorative sheet on a base material, a laminating apparatus capable of reliably preventing the occurrence of air biting, and a flooring material are provided. An object is to provide a manufacturing method.

  The present invention is a laminating apparatus for laminating a single sheet of decorative sheet on a base material coated with an adhesive, and is made to solve the above-mentioned problem, and is formed of an elastic material and holds the decorative sheet. A holding member having a holding surface to be moved, and a moving means for moving the holding member to the substrate side with the holding surface facing the substrate. It is formed in a cross-sectional arc shape inclined toward the end.

  When the laminating apparatus configured as described above is used, the decorative sheet is laminated on the base material as follows. That is, when the holding member is moved toward the base material in a state where the decorative sheet is held on the holding surface having an arcuate cross section, the protruding portion of the central portion first comes into contact with the base material. When the holding member is further moved from this state, the central portion thereof is pressed and elastically deformed, so that both ends of the holding member abut against the substrate following the central portion. Thus, if the movement of the holding member is continued, the decorative sheet is laminated on the base material in order from the central portion toward both ends with the elastic deformation of the holding member. As a result, it is possible to prevent the occurrence of air biting between the decorative sheet and the base material.

  In order to hold the decorative sheet on the holding surface, various modes can be adopted. For example, by forming a plurality of air holes on the holding surface and sucking air from the air holes to form a negative pressure. The decorative sheet can be configured to be held on the holding surface. At this time, if the air can be discharged from the air hole, the following effects can be obtained. That is, by discharging air during lamination, the decorative sheet can be pushed out to the substrate side, so that the decorative sheet can be smoothly transferred from the holding surface to the substrate.

  The floor material manufacturing method according to the present invention is a floor material manufacturing method for laminating a sheet of decorative sheets on a base material coated with an adhesive, with a central portion protruding and one end portion and the other end portion. A holding surface formed in a cross-sectional arc shape inclined toward the surface, and a holding member formed of an elastic material, and the holding member in a state where the decorative sheet is held on the holding surface And after the center part of the decorative sheet comes into contact with the base material, the holding member is further moved toward the base material to elastically deform the holding member. A step of laminating to the base material in order from the center to both ends, and a step of separating the decorative sheet from the holding surface after separating the holding member from the base material after the entire surface of the decorative sheet is laminated to the base material It is equipped with.

  According to this method, as the holding member is elastically deformed, the decorative sheet is laminated to the base material in order from the central portion toward the both end portions. It can be surely prevented from occurring.

  Further, the length X from one end portion to the other end portion of the decorative sheet held on the holding surface, and the height Z from the one end portion or the other end portion to the top of the decorative sheet central portion are X / Z ≧ 40. It is preferable to satisfy the relationship. This is because if X / Z is smaller than 40, both ends of the decorative sheet cannot be brought into contact with the substrate unless the elastic deformation of the holding member is increased. That is, it is because an excessive load is required for the holding member and the decorative sheet. By setting X / Z ≧ 40, the decorative sheet can be laminated on the base material without large elastic deformation of the holding member.

  According to the present invention, air lamination can be reliably prevented when laminating a sheet of decorative sheet on a substrate.

  Hereinafter, an embodiment of a method for producing a flooring according to the present invention will be described with reference to the drawings. FIG. 1 is a cross-sectional view showing a schematic configuration of a flooring, and FIG. 2 is a flooring production line used in this embodiment.

First, an example of the flooring manufactured in the present embodiment will be described. As shown in FIG. 1, this flooring is obtained by laminating a decorative sheet A and a base material B with an adhesive C interposed therebetween. The decorative sheet A is obtained by laminating a conventionally used cover sheet A ₁ and a reinforcing sheet A ₂ with an adhesive. The cover sheet A ₁ has a thickness of about 150 μm and is formed as follows. That is, a printing layer (pattern) is formed on a polyethylene film colored with a basic color through a solid printing section, and an EB curable resin sheet is formed on the printing layer through a primer, an adhesive, and a polypropylene film. Has been. The surface of the EB curable resin sheet is embossed. The reinforcing sheet A ₂ has a thickness of about 400 μm and is made of polyester. Since the decorative sheet A configured in this way is thick and hard due to the reinforcing sheet A ₂ , it is prepared not as a roll but as a single sheet. Moreover, the base material B on which the decorative sheet A is affixed is made of wood, and is made of, for example, a wood fiber board or a plywood board.

  Next, the flooring production line according to the present embodiment will be described with reference to FIG. This production line is for laminating the decorative sheet A on the base material B made of wood via the adhesive C. As shown in FIG. 2, this production line includes a surface treatment device 1, an adhesive application device 3, a laminating device 5, and a pressing device 7 that are arranged from upstream to downstream (from the right side to the left side in the drawing). ing. The surface treatment apparatus 1 performs surface treatment of a base material, and first and second conveyors 91 and 92 for transporting the base material B are disposed on the upstream side and the downstream side thereof.

  FIG. 3 is a side view of the surface treatment apparatus. As shown in the figure, the apparatus is provided with a pressing portion 11 that presses the base material, and first and second roller portions 12 that transport the base material B to the upstream side and the downstream side of the pressing portion 11, 13 are arranged respectively. The pressing unit 11 includes a pair of pressing plates 111 and 112 and a press machine 113 that sandwich the base material B from above and below, and the upper pressing plate 111 is pressed by the pressing machine 113. Both pressing plates 111 and 112 are arranged at a predetermined interval in the vertical direction, and the gap serves as a passage through which the base material B enters. The distance between the pressing plates 111 and 112 is set slightly smaller than the thickness of the base material B. Moreover, both the press plates 111 and 112 are configured as follows in order to allow the base material B to smoothly enter the gap therebetween. That is, while the end portion of the upper pressing plate 111 is inclined upward, the end portion of the lower pressing plate 112 is inclined downward, so that the upstream gap between the pressing plates 111 and 112 is widened. . The upper pressing plate 111 is provided with a heating device (not shown) so that the base material B passing between the pressing plates can be heated. In addition, each press plate 111,112 is formed with the metal plate by which chrome plating was made | formed, for example, and the surface facing the base material B is formed smoothly.

  Each roller part 12 and 13 is comprised by the driving rollers 12a and 13a which sandwich the base material B from the up-down direction, and the driven rollers 12b and 13b. Press machines 12c and 13c are attached to the bearings of the driving rollers 12a and 13a arranged on the upper side, and the driving rollers 12a and 13a rotate while applying pressure to the base material B. Thereby, the base material B can be advanced with a strong force and can enter the gap between the pressing plates 111 and 112.

  Returning to FIG. 2, the description of the production line will be continued. As described above, the adhesive application device 3 is disposed downstream of the surface treatment device 1. The adhesive applicator 3 is provided with a known roller (not shown) for applying an adhesive to the base material B. That is, the adhesive applied to the surface of the roller rotates on the upper surface (one surface) of the base material B so that the adhesive on the roller surface is transferred to the upper surface of the base material B. The adhesive used here is a hot melt adhesive, but it is preferable to use a PUR (Poly Urethane Reactive) type hot melt. This is because the initial tack force is stronger than other water-based adhesives. The adhesive used here has a low viscosity from the viewpoint of reducing the manufacturing cost. For example, an adhesive having a viscosity of 8000 mPas or less is preferably used, and an adhesive having 6500 mPas or less is used. More preferred is 5000 mPas or less. A third conveyor 93 is disposed on the downstream side of the adhesive application device 3, and the base material B coated with the adhesive is conveyed to the laminating device 5 by the conveyor 93.

  The laminating apparatus 5 is an apparatus that laminates the base material B and the decorative sheet A. As shown in FIG. 4, the laminating apparatus 5 is provided with a standby unit 51 arranged in parallel with the production line, and a sheet of decorative sheet A is disposed in the standby unit 51. A side portion of the standby unit 51 is provided with a placement unit 53 (see FIG. 2) on which a decorative sheet A is laminated, and the decorative sheets A on the placement unit 53 are moved to the standby unit 51 one by one. The At this time, the movement of the decorative sheet A from the placement unit 53 to the standby unit 51 may be automatically performed by a transport device such as a robot arm, or may be performed manually.

  FIG. 5 is a plan view of the standby unit 51. As shown in the figure, the upper surface of the standby section 51, that is, the standby plane 51a on which the decorative sheet A is arranged is formed in a mesh shape, and air is sucked from the opening of the mesh. Thereby, a negative pressure is formed in the opening of the mesh and the decorative sheet A is sucked into the standby plane 51a. Further, the decorative sheet A on the standby unit 51 is moved onto the production line by the moving device (moving means) 52. As shown in FIG. 4, the moving device 52 includes a rail 521 that extends perpendicularly to the line above the production line, and the holding member 522 that holds the decorative sheet A moves along the rail 521. ing.

  FIG. 6 is a cross-sectional view of the holding member. The holding member 522 is made of, for example, an elastic material such as neoprene rubber, and is movable in the vertical direction by the cylinder 523 while moving along the rail 521. The lower surface of the holding member 522 is a holding surface 522a on which the decorative sheet A is held. The holding surface 522a is formed in a cross-sectional arc shape that protrudes from the central portion and is inclined toward the front end portion and the rear end portion. That is, the holding surface 522a forms a curved surface that protrudes downward from the front end portion and the rear end portion toward the center portion with respect to the traveling direction of the production line. Here, the shape of the holding surface 522a and the decorative sheet A include the horizontal distance X between the front end portion and the rear end portion of the decorative sheet A to be held, and the central top portion that is convex from the front end portion or the rear end portion. It is preferable that the distance Z to satisfy the relationship of X / Z ≧ 40. If it does in this way, the decorative sheet A can be laminated to the base material B, without the large elastic deformation of the holding member 522 so that it may mention later.

  Furthermore, a plurality of air holes (not shown) for sucking and discharging air are formed in the holding surface 522a, and negative pressure can be formed by sucking air from the air holes. Thereby, the decorative sheet A that contacts the holding surface 522a can be sucked and held. Then, the floor material formed by the laminating apparatus 5 is conveyed to the pressing apparatus 7 by the fourth conveyor 524 on the laminating apparatus 5.

  FIG. 7 is a side view of the pressing device. As shown in the figure, the pressing device 7 is composed of a pair of rollers 71 and 72 arranged in the vertical direction. The roller 72 arranged on the lower side is connected to a motor 74 via a belt 73 wound around a bearing, and constitutes a driving roller. On the other hand, the roller 71 disposed on the upper side constitutes a driven roller. The bearing of the driven roller 71 is provided with a press machine 75, and the driven roller 71 is pressed against the drive roller 72 by the press machine 75. Then, the floor material S passes between the rollers 71 and 72 thus configured.

  Next, the manufacturing process of the flooring by the manufacturing line comprised as mentioned above is demonstrated. In that, the lamination process of a decorative sheet and a base material is demonstrated with reference to FIG. First, the base material B is conveyed to the surface treatment apparatus 1 one by one by the first conveyor 91. The conveyed base material B advances while being sandwiched by the first roller portion 12 and enters the gap of the pressing portion 11. At this time, since pressure is applied to the upper pressing plate 111 by the press machine 113, the base material B advances while the surface is pressed. As a result, the surface of the base material B is leveled and smoothed while being rubbed. The portion of the base material B that has passed through the pressing portion 11 is pulled downstream by the rotation while being sandwiched by the second roller portion 13. Thus, since the base material B is advanced with a strong force by the rotation of the first and second roller portions 12 and 13, it can be advanced downstream against the pressure by the pressing plates 111 and 112. It has become.

At this time, it is preferable that the pressure which presses the base material B by the press part 11 is 0.1-0.5 kg / cm < ² >. This is because when the pressure is less than 0.1 kg / cm ² , the surface of the base material is not sufficiently smoothed, whereas when the pressure is greater than 0.5 kg / cm ² , the friction force between the base material B and the pressing plate is too large. This is because the base material B becomes difficult to advance. Further, from the viewpoint of manufacturing efficiency, the speed at which the base material advances by the first and second roller portions 12 and 13 is preferably 1 m / min or more.

Thus, the base material B that has passed through the surface treatment device 1 is conveyed to the adhesive application device 3 by the second conveyor 92. In the adhesive application device 3, the adhesive is applied to the upper surface of the base material B by a roller. At this time, the surface of the base material B to which the adhesive is applied is smoothed and the unevenness is leveled. Therefore, it is possible to prevent the extra adhesive from being used due to the adhesive entering the recess. In addition, it is preferable that the adhesive agent apply | coated to the surface of the base material B is 15-100 g / cm < ² >. This is because if it is smaller than 15 g / cm ² , sufficient adhesive force cannot be obtained, and if it is larger than 100 g / cm ² , the manufacturing cost increases.

  Subsequently, the base material B to which the adhesive is applied is conveyed to the laminating apparatus 5 shown in FIG. 4 by the third conveyor 93 and is temporarily stopped. At this time, the decorative sheet A moved from the placement unit 53 is already arranged in the standby unit 51. In the standby plane 51a on which the decorative sheet A is arranged, air is sucked from the opening of the mesh to form a negative pressure, and the decorative sheet A is sucked onto the standby plane 51a by this negative pressure. Thereby, the wrinkles of the decorative sheet A are stretched by suction. Therefore, the decorative sheet A on the standby plane 51a waits in a flat state from which wrinkles are removed. In addition, although the suction pressure in the standby plane 51a varies depending on the type of the decorative sheet, for example, in the case of the decorative sheet A described with reference to FIG.

  Following this, the holding member 522 is moved onto the standby unit 51, and air is sucked from the air holes to hold the decorative sheet A on the holding surface 522a. At this time, as shown in FIG. 8A, the decorative sheet A is adsorbed in a state of being deformed into a cross-sectional arc along the holding surface 522a. And after raising the holding member 522 and separating the decorative sheet A from the standby plane 51a, the holding member 522 is moved to the production line side along the rail 521 and positioned above the substrate B that is stopped. . Subsequently, when the holding member 522 is lowered, first, the protruding central portion of the decorative sheet A comes into contact with the base material B as shown in FIG. When the holding member 522 is further lowered in this state, as shown in FIG. 8C, the central portion of the holding member 522 that is in contact is elastically deformed, and the front portion and the rear portion are formed of the base material following the central portion. Abut against B. Thus, when the holding member 522 continues to descend, the decorative sheet A is laminated on the base material B in order from the central portion toward the front end portion and the rear end portion with the elastic deformation of the holding member 522. Note that if the above-mentioned X / Z is smaller than 40 due to the relationship between the decorative sheet A and the holding surface 522a, both ends of the decorative sheet A abut against the base material B unless the elastic deformation of the holding member 522 is increased. X / Z ≧ 40 is preferable because the holding member 522 and the decorative sheet A may be excessively loaded.

  As shown in FIG. 8D, when the entire surface of the decorative sheet A is laminated on the upper surface of the base material B, the suction of air in the air holes is stopped and the decorative sheet A is separated from the holding member 522. Subsequently, when air is discharged from the air holes, the decorative sheet A is pushed out toward the base material B, and the decorative sheet A smoothly moves from the holding member 522 to the base material B. Thus, the decorative sheet A is laminated on the base material B to form a floor material, and is conveyed to the pressing device 7 by the fourth conveyor 524. Note that the suction pressure of the decorative sheet A on the holding surface 522a can be substantially the same as that of the standby plane 51a.

  Subsequently, when the floor material S enters between the rollers 71 and 72 in the pressing device 7 shown in FIG. 5, the floor material S advances by the rotation of the driving roller 72 and is pressed between the rollers 71 and 72. Pass while. As described above, when the surface of the flooring S is pressed, the adhesive penetrates the base material B, so that the decorative sheet A and the base material B can be firmly fixed. The flooring is completed through the above steps. In addition, it is preferable that the pressure which presses the flooring S with the rollers 71 and 72 is 20-80 kg / cm in linear pressure. This is because if it is less than 20 kg / cm, the adhesive force is insufficient, and if it is greater than 80 kg / cm, the substrate B may be destroyed.

  As described above, according to the present embodiment, the decorative sheet A and the base material B are laminated using the holding member 522 having the holding surface 522a formed in an arc shape in cross section and made of an elastic material. Therefore, the following effects can be obtained. That is, as described above, since the decorative sheet A is deformed in an arc along the holding surface 522a, the decorative sheet A is smoothly moved from the central portion toward the both ends with the elastic deformation of the holding member 522. Can be laminated to the base material B. As a result, it is possible to reliably prevent so-called air biting, in which air enters between the decorative sheet A and the base material B, and to form a beautiful flooring without wrinkles.

  As mentioned above, although one Embodiment of this invention was described, this invention can be variously changed unless it deviates from the meaning. For example, in the above-described embodiment, the holding surface is formed in a cross-sectional arc shape that protrudes from the front end portion and the rear end portion toward the center portion, but both side ends of the holding surface (ends in the direction perpendicular to the traveling direction of the production line) It is also possible to form a convex cross-sectional arc shape from the (part) toward the central part.

  Moreover, in the said embodiment, although the air hole is formed in the holding surface 522a and the decorative sheet A is hold | maintained by attracting | sucking air from here, even if it is other than this, the curved holding surface 522a If it is the structure which can hold | maintain the decorative sheet A, it will not specifically limit.

  Furthermore, in the said embodiment, although the said apparatus is used with respect to the base material which consists of wood, this invention is applicable also to the base material formed with metals other than wood, for example.

It is sectional drawing of the flooring used for this invention. It is a schematic plan view of the flooring production line according to one embodiment of the present invention. It is a side view of the surface treatment apparatus of the base material in the manufacturing line of FIG. It is the II arrow directional view of FIG. FIG. 3 is a plan view of a standby unit in the production line of FIG. 2. It is sectional drawing of the holding member in the manufacturing line of FIG. It is a side view of the press apparatus in the manufacturing line of FIG. It is a figure explaining the lamination process of a decorative sheet and a base material.

Explanation of symbols

52 Moving device (moving means)
522 holding member 522a holding surface A decorative sheet B base material

Claims (5)

A laminating apparatus for laminating a sheet of decorative sheet on a substrate coated with an adhesive,
A plurality of air holes are formed, and a standby unit having a standby plane on which a single-sheet decorative sheet is placed by sucking air from the air holes to form a negative pressure;
A holding member formed of an elastic material and having a holding surface for holding a decorative sheet;
Moving means for moving the holding member to the base while moving the holding member to the standby to hold the decorative sheet on the standby, and with the holding surface facing the base; With
The holding surface is a laminating apparatus in which a central portion protrudes and is formed in a cross-sectional arc shape that is inclined toward one end and the other end. The laminating apparatus according to claim 1, wherein a plurality of air holes are formed in the holding surface, and a decorative sheet is held on the holding surface by sucking air from the air holes to form a negative pressure.   The laminating apparatus of Claim 2 comprised so that air can be discharged | emitted from the said air hole. A method for producing a flooring material in which a sheet of decorative sheets is laminated to a base material coated with an adhesive,
A step of preparing a holding member formed of an elastic material having a holding surface formed in a cross-sectional arc shape in which a central portion protrudes and is inclined toward one end and the other end;
Placing the single sheet decorative sheet on the standby plane formed with a plurality of air holes, and sucking the decorative sheet to the standby plane by suctioning air from the air holes to form a negative pressure; and
Holding the decorative sheet on the standby plane on the holding surface of the holding member;
A step of moving the holding member toward the substrate after separating the standby sheet from the standby plane while holding the decorative sheet on the holding surface ;
After the central portion of the decorative sheet comes into contact with the base material, the holding member is further moved toward the base material and elastically deformed, whereby the decorative sheet is sequentially transferred from the central portion toward the base material toward the base material. Laminating process;
And a step of separating the holding member from the holding surface and laminating the decorative sheet from the holding surface after the entire surface of the decorative sheet is laminated to the base material.   The length X from one end portion to the other end portion of the decorative sheet held on the holding surface and the height Z from the one end portion or the other end portion to the top of the central portion of the decorative sheet satisfy X / Z ≧ 40. The manufacturing method of the flooring material of Claim 4 which satisfy | fills a relationship.

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