JP5776989B2 - Decorative plate manufacturing method and manufacturing apparatus - Google Patents

Description

  The present invention relates to a decorative board manufacturing method and a manufacturing apparatus for manufacturing a decorative board by laminating a decorative sheet on a substrate having a flat surface.

  Conventionally, a decorative board manufactured by laminating a decorative sheet and a base material is used in a housing member, furniture, a door, or the like. As such a decorative board, a decorative board having a mirror surface on the surface is preferred from the viewpoint of design.

  Generally, a decorative board is manufactured by applying an adhesive to the back surface of a decorative sheet, laminating the decorative sheet on a base material, and then sandwiching the laminated base material and the decorative sheet with a pair of pressure-bonding rolls. Here, if the temperature of the adhesive when sandwiched between a pair of pressure-bonding rolls is low, the fluidity of the adhesive is reduced, and therefore the thickness of the adhesive when sandwiched is not uniform. It is known that unevenness occurs on the surface of the decorative sheet of the manufactured decorative board. When such unevenness is generated on the surface of the decorative sheet of the decorative plate, the mirror surface property of the decorative plate is impaired, which is not preferable from the viewpoint of design.

  In order to solve such a problem, for example, in Patent Document 1 or 2, the laminated base material and the decorative sheet are pinched while being heated by a pair of pressure-bonding rolls, whereby the flow of the adhesive when pinched A method for securing the sex has been proposed.

Japanese Patent Laid-Open No. 2002-248689 Japanese Patent Laid-Open No. 3-118150

  By the way, the pressure-bonding roll is generally made of rubber or metal, and rubber or metal generally has a property of expanding as the temperature rises. For this reason, when there is variation in the temperature distribution of the pressure-bonding roll in the axial direction of the pressure-bonding roll, the amount of heat given to the laminated decorative plates to be bonded varies, and the degree of thermal expansion of the pressure-bonding roll is its axis. It is conceivable that the diameter of the crimping roll changes in the axial direction as a result. In this case, irregularities are formed in the axial direction on the surface of the pressure-bonding roll, and this may cause irregularities on the surface of the decorative sheet of the manufactured decorative board.

  Therefore, in order to manufacture a decorative plate having a mirror surface, it is important to heat the pressure-bonding roll so that the temperature in the axial direction is uniform. However, in the conventional decorative plate manufacturing method and manufacturing apparatus, no consideration is given to making the temperature in the axial direction of the pressure-bonding roll uniform.

  The present invention has been made in consideration of such points, and an object of the present invention is to provide a decorative board manufacturing method and manufacturing apparatus for manufacturing a decorative board having a mirror surface.

  The present invention provides, as a first solution, a method of manufacturing a decorative sheet laminated with a decorative sheet, a step of preparing a base having a flat surface, and an adhesive application mechanism to apply an adhesive to the back surface of the decorative sheet. A step of applying, a step of laminating a decorative sheet coated with an adhesive on the back surface, a step of sandwiching the laminated base material and the decorative sheet while heating with at least a pair of pressure-bonding rolls, and heating And the step of cooling the sandwiched base material and the decorative sheet with at least a pair of cooling rolls, and along the axial direction of the pressure-bonding roll in the vicinity of the pressure-bonding roll on the decorative sheet side of the pair of pressure-bonding rolls. A heating unit having a plurality of heating units arranged in a row, and each heating unit of the heating unit is entirely or at least partially rotated in the rotation direction and axial direction of the crimping roll. To provide a method for manufacturing a decorative laminate, characterized in that it is arranged so as to extend obliquely with respect.

  In the first solving means, the decorative plate manufacturing method includes a plurality of detection units arranged so as to be opposed to the pressure-bonding roll along the axial direction of the pressure-bonding roll on the decorative sheet side. While detecting the temperature or diameter of the location in the axial direction of the crimping roll and the detection result by each detection unit, while controlling the degree of heating to the crimping roll in each heating unit by the control unit for each heating unit And a step of heating the pressure-bonding roll by each heating unit.

  In the first solving means, when heating the pressure-bonding roll on the decorative sheet side by each heating unit, the temperatures or diameters of a plurality of locations along the axial direction of the pressure-bonding roll detected by each detection unit are detected. You may control the degree of the heating with respect to the said press roll in each heating part by a control part for every heating part so that it may become substantially uniform.

  In the first solving means, each detection unit is provided so as to correspond to each heating unit, and based on the detection result by each detection unit, the control sheet is provided on the decorative sheet in the heating unit corresponding to the detection unit. You may control the degree of the heating with respect to the side press roll.

  As a second solution, the present invention provides a method for producing a decorative sheet laminated with a decorative sheet, a step of preparing a base material having a flat surface, and an adhesive application mechanism that applies an adhesive to the back surface of the decorative sheet. A step of applying, a step of laminating a decorative sheet coated with an adhesive on the back surface, a step of sandwiching the laminated base material and the decorative sheet while heating with at least a pair of pressure-bonding rolls, and heating And the step of cooling the sandwiched base material and the decorative sheet with at least a pair of cooling rolls, and the pressure-bonding roll on the decorative sheet side of the pair of pressure-bonding rolls has a water passage through which a heat medium passes. It consists of a metal crimping roll, and at the end of the crimping roll, a supply-side rotary joint that supplies a heat medium to the water pipe of the crimping roll, and a discharge side robot that discharges the heat medium from the water pipe To provide a method for manufacturing a decorative laminate, characterized in that a and tally joint.

  In the first and second solving means, the adhesive application mechanism includes a backup roll around which the decorative sheet is wound, and an adhesive applicator for applying an adhesive to the back surface of the decorative sheet wound around the backup roll. You may have. In this case, in the step of applying the adhesive, the adhesive is applied to the back surface of the decorative sheet wound around the backup roll by the adhesive applicator. Also, a backup roll heating unit having a plurality of backup roll heating units arranged in the axial direction of the backup roll is provided in the vicinity of the backup roll, and each backup roll heating unit of the backup roll heating unit is The whole or at least a part of the backup roll may be arranged to extend obliquely with respect to the rotation direction and the axial direction of the backup roll.

  The present invention provides, as a third solution, an adhesive application mechanism that applies an adhesive to the back surface of a decorative sheet in an apparatus for manufacturing a decorative sheet by laminating a decorative sheet on a substrate having a flat surface; Provided on the downstream side of the adhesive coating mechanism, provided on the downstream side of the pair of pressure-bonding rolls, and at least a pair of pressure-bonding rolls that sandwich the decorative sheet and the base material coated with adhesive on the back surface while heating. A plurality of heating elements arranged in the axial direction of the pressure-bonding roll in the vicinity of the pressure-bonding roll on the decorative sheet side of the pair of pressure-bonding rolls. Each heating part of the heating unit is arranged such that the whole or at least a part thereof extends obliquely with respect to the rotation direction and the axial direction of the pressure-bonding roll. Is the providing apparatus for manufacturing a decorative laminate, characterized in that.

  In the third solving means, the decorative plate manufacturing apparatus is a detection unit having a plurality of detection units provided to face the pressure-bonding roll along the axial direction of the pressure-bonding roll on the decorative sheet side, The detection unit detects the temperature or the diameter of the location in the axial direction of the crimping roll facing each detection unit, respectively, and based on the detection result by each detection unit, heating the crimping roll in each heating unit And a control unit that controls the degree of each heating unit.

  In the third solving means, the control unit detects the temperature at each of the plurality of locations in the axial direction of the pressure-bonding roll on the decorative sheet side detected by each detection unit so that the temperature or diameter of each of the heating units is substantially uniform. You may control the degree of the heating with respect to a press roll for every heating part.

  In the third solving means, each detection unit is provided corresponding to each heating unit, and the control unit, based on the detection result by each detection unit, the decorative sheet in the heating unit corresponding to the detection unit You may control the degree of the heating with respect to the side press roll.

  In the third solving means, each detection unit detects a temperature at a location in the axial direction of the crimping roll on the decorative sheet side facing each detection unit, or an axis of the crimping roll facing each detection unit. It may be a displacement sensor that detects the diameter of the location in the direction.

  The present invention provides, as a fourth solving means, an apparatus for manufacturing a decorative board by laminating a decorative sheet on a substrate having a flat surface, and an adhesive application mechanism for applying an adhesive to the back surface of the decorative sheet; Provided on the downstream side of the adhesive coating mechanism, provided on the downstream side of the pair of pressure-bonding rolls, and at least a pair of pressure-bonding rolls that sandwich the decorative sheet and the base material coated with adhesive on the back surface while heating. And at least a pair of cooling rolls that sandwich and cool the decorative sheet, and the pressure-bonding roll on the decorative sheet side of the pair of pressure-bonding rolls comprises a metal pressure-bonding roll having a water pipe through which a heat medium passes. The supply-side rotary joint that supplies the heat medium to the water pipe of the pressure-bonding roll and the discharge-side rotary joint that discharges the heat medium from the water-flow pipe are provided at the end of the pressure roller. Providing an apparatus for manufacturing decorative laminates, characterized in that.

  In the third and fourth solutions, the adhesive application mechanism includes a backup roll around which the decorative sheet is wound, and an adhesive applicator for applying an adhesive to the back surface of the decorative sheet wound around the backup roll. You may have. Also, a backup roll heating unit having a plurality of backup roll heating units arranged in the axial direction of the backup roll is provided in the vicinity of the backup roll, and each backup roll heating unit of the backup roll heating unit is The whole or at least a part of the backup roll may be arranged to extend obliquely with respect to the rotation direction and the axial direction of the backup roll.

  According to the decorative plate manufacturing method and manufacturing apparatus according to the first and third solving means of the present invention, the decorative sheet side of the pair of press rolls is arranged in the vicinity of the press roll on the decorative sheet side along the axial direction of the press roll. A heating unit having a plurality of heating units is provided. For this reason, the degree of heating with respect to the crimping roll in each heating unit can be adjusted for each heating unit, and thereby, in the axial direction of the crimping roll, for example, heat in the central region and the end region of the crimping roll. The crimping roll can be heated so that the degree of expansion is equal. Moreover, each heating part of the heating unit is arranged so that the whole or at least a part thereof extends obliquely with respect to the rotation direction and the axial direction of the crimping roll. For this reason, compared with the case where each heating part is arranged so as to extend parallel to the rotation direction of the roll, the area heated by one heating part can be increased in the axial direction of the crimping roll. Thereby, the said crimping | compression-bonding roll can be heated without a clearance gap along the axial direction of the said crimping | compression-bonding roll by each heating part. Therefore, the crimping roll can be heated so that the degree of thermal expansion of the crimping roll is uniform along the axial direction of the crimping roll, thereby making the diameter of the crimping roll uniform in the axial direction. be able to. As a result, the laminated base material and the decorative sheet can be uniformly clamped over the entire surface, and as a result, a decorative board having a mirror surface can be produced.

  According to the method and apparatus for manufacturing a decorative board according to the second and fourth solving means of the present invention, the pressure-bonding roll on the decorative sheet side of the pair of pressure-bonding rolls has a water pipe through which a heat medium passes. The pressure-bonding roll is provided with a supply-side rotary joint that supplies a heat medium to the water pipe of the pressure-bonding roll and a discharge-side rotary joint that discharges the heat medium from the water-flow pipe. Yes. For this reason, the crimping roll can be heated so that the degree of thermal expansion of the crimping roll is uniform along the axial direction of the crimping roll, thereby making the diameter of the crimping roll uniform in the axial direction. can do. As a result, the laminated base material and the decorative sheet can be uniformly clamped over the entire surface, and as a result, a decorative board having a mirror surface can be produced.

FIG. 1 is a front view showing a decorative board manufacturing apparatus according to a first embodiment of the present invention. FIGS. 2A and 2B are a plan view and a side view showing the heating unit in the first embodiment of the present invention. FIG. 3 is a diagram showing a detection device according to the first embodiment of the present invention. FIG. 4 is a cross-sectional view showing a decorative board according to the first embodiment of the present invention. FIGS. 5A and 5B are a plan view and a side view showing a case where the heating unit of the heating unit is provided orthogonal to the axial direction of the press roll as a first comparative example. FIG. 6 is a plan view showing a heating unit in a second comparative example. FIG. 7 is a plan view showing a heating unit in a third comparative example. FIG. 8 is a plan view showing a heating unit in a modification of the first embodiment of the present invention. FIG. 9 is a plan view showing a heating unit in another modification of the first embodiment of the present invention. FIG. 10 is a diagram showing a positional relationship when the die head and the backup roll are viewed from the left-right direction in the second embodiment of the present invention. FIG. 11 is a view showing a heating unit for a backup roll in the second embodiment of the present invention. FIG. 12 is a diagram showing a backup roll detection unit according to the second embodiment of the present invention. FIG. 13: is a front view which shows the manufacturing apparatus of the decorative board in the 3rd Embodiment of this invention. FIG. 14 is a perspective view showing a pressure-bonding roll on the decorative sheet side in the third embodiment of the present invention. FIG. 15 is a view showing a rotary joint provided in a pressure-bonding roll on the decorative sheet side in the third embodiment of the present invention.

First Embodiment Hereinafter, a first embodiment of the present invention will be described with reference to FIGS. First, referring to FIG. 1, an entire decorative board manufacturing apparatus 1 that manufactures a decorative board 30 by laminating a decorative sheet 33 on a base 31 having a flat surface will be described.

Decorative plate manufacturing apparatus As shown in FIG. 1, the decorative plate 30 manufacturing device 1 is bonded to a decorative sheet supply roll 8 for supplying a decorative sheet 33 and a back surface 33 b of the decorative sheet 33 supplied from the decorative sheet supply roll 8. An adhesive application mechanism 46 for applying the adhesive 32a, a pair of pressure-bonding rolls 2a and 2b for sandwiching the base sheet 31 while heating the decorative sheet 33 with the adhesive 32a applied to the back surface 33b, and the base 31 and the cosmetic A pair of first cooling rolls 3a and 3b and a pair of second cooling rolls 4a and 4b that sandwich and cool the sheet 33 are provided. Among these, the adhesive application mechanism 46 is, as shown in FIG. 1, a backup roll 50 around which the decorative sheet 33 from the decorative sheet supply roll 8 is wound, and a back surface 33 b of the decorative sheet 33 wound around the backup roll 50. And an adhesive applicator 47 for applying the adhesive 32a. The pair of crimping rolls 2a and 2b are provided on the downstream side of the backup roll 50 and the adhesive applicator 47, and the pair of first cooling rolls 3a and 3b and the pair of second cooling rolls 4a and 4b are a pair of It is provided downstream of the pressure-bonding rolls 2a and 2b.

  Here, as shown in FIG. 1, the decorative sheet 33 is first supplied from the decorative sheet supply roll 8 toward the backup roll 50. Next, the adhesive 32a is applied to the back surface 33b of the decorative sheet 33 by the adhesive applicator 47, and then the decorative sheet 33 is sent by the backup roll 50 toward the pair of pressure-bonding rolls 2a and 2b. Moreover, the base material 31 is conveyed by the some conveyance roll 6 toward a pair of crimping | compression-bonding rolls 2a and 2b from an upstream. Then, the decorative sheet 33 and the base material 31 are nipped while being heated in the pair of pressure-bonding rolls 2a and 2b, and then the decorative sheet 33 and the base material 31 are paired with the pair of first cooling rolls 3a and 3b and the pair of first rolls. The two cooling rolls 4a and 4b are cooled, whereby the decorative board 30 is manufactured.

  As shown in FIG. 1, the adhesive applicator 47 includes a die head 47a for applying the adhesive 32a to the back surface 33b of the decorative sheet 33 wound around the backup roll 50, and an adhesive for supplying the adhesive 32a to the die head 47a. And a supply unit 47b. The die head 47 a is provided to face the backup roll 50 so as to extend along the axial direction of the backup roll 50. In this case, the adhesive 32a is applied to the back surface 33b of the decorative sheet 33 by the die head 47a while being heated to the softening temperature or higher.

  As shown in FIG. 1, a backup roll heating unit 40 for heating the surface of the backup roll 50 and a backup roll detection unit 45 for detecting the temperature of the backup roll 50 are provided in the vicinity of the backup roll 50. Yes.

Press roll now to FIG. 1, will be described a pair of crimping rolls 2a, for 2b. As shown in FIG. 1, the pair of crimping rolls 2 a and 2 b includes a crimping roll 2 a on the decorative sheet 33 side and a crimping roll 2 b on the base material 31 side.

Although the material which comprises the surface of a pair of press roll 2a, 2b is not specifically limited, Preferably, the surface of a pair of press roll 2a, 2b is each covered with elastic bodies, such as rubber | gum. Thus, when the decorative sheet 33 and the base material 31 are clamped by the pair of press rolls 2a and 2b, the surface of each press roll 2a and 2b can be compressed and deformed by pressing from the decorative sheet 33 or the base material 31. it can. For this reason, the distance (nip length L ₁ shown in FIG. ₁ ) that the decorative sheet 33 and the base material 31 move while being sandwiched between the pair of pressure-bonding rolls 2a and 2b is such that the surface of the roll is made of a hard substance such as metal. It becomes longer than the case. Thus a pair of crimping rolls 2a, the surface of the 2b by covering an elastic material such as rubber, it is possible to increase the nip length L _1. Thereby, the base material 31 and the decorative sheet 33 can be pinched more uniformly over time, and as a result, the specularity of the manufactured decorative board 30 can be improved.

  The material of the elastic body that constitutes the surface of the pair of pressure-bonding rolls 2a and 2b is not particularly limited, and is appropriately selected according to a desired clamping pressure, nip length, and the like. Examples of the elastic body include urethane rubber, EPDM, EPM, fluororesin, fluororubber, nitrile rubber, butadiene rubber, silicone resin, silicone rubber, butyl rubber, styrene butadiene rubber, natural rubber, and mixtures thereof. it can. Moreover, you may laminate | stack these elastic bodies and may comprise the surface of a pair of press roll 2a, 2b.

  By the way, an elastic body such as rubber and a metal are greatly different in specific heat, thermal conductivity, and linear expansion coefficient. For this reason, when the surface of the pressure-bonding roll 2a is heated as will be described later, variations in temperature distribution on the surface of the pressure-bonding roll 2a are more likely to occur than when the surface is made of metal. Therefore, in order to manufacture the decorative plate 30 having a mirror surface, it is important to provide means for appropriately heating the pressure-bonding roll 2a along the axial direction of the pressure-bonding roll 2a. The crimping roll 2a has a thermal expansion characteristic such that the diameter changes by 2% when the temperature changes from 20 degrees to 120 degrees, for example.

Heating unit As shown in FIG. 1, the heating unit 10 for heating the surface of the pressure-bonding roll 2a and the temperature of the surface of the pressure-bonding roll 2a are arranged in the vicinity of the pressure-bonding roll 2a on the decorative sheet side of the pair of pressure-bonding rolls 2a and 2b A detection unit 20 for detection is provided. First, the heating unit 10 will be described with reference to FIGS. 1 and 2A and 2B.

  Fig.2 (a) is a top view which shows the case where the heating unit 10 is seen from upper direction (arrow A), and FIG.2 (b) shows the case where the heating unit 10 is seen from the side (arrow B). It is a side view. As shown to Fig.2 (a), the heating unit 10 has the some heater (heating part) 10a-10i arranged along the axial direction of the crimping | compression-bonding roll 2a. Here, each of the heaters 10a to 10i is provided so as to face the pressure-bonding roll 2a, and each of the heaters 10a to 10i heats a portion (region) of the pressure-bonding roll 2a facing the heaters 10a to 10i. Is done. Each heater 10a-10i is comprised from infrared heaters, such as a short wavelength infrared heater and a medium wavelength infrared heater (carbon heater), for example. In addition, you may use heaters other than an infrared heater as each heater 10a-10i.

Moreover, as shown to Fig.2 (a), as for each heater 10a-10i, the whole is the rotation direction (up-down direction in Fig.2 (a)) and the axial direction (left-right direction in Fig.2 (a)) of the press roll 2a. ) To extend obliquely. That is, the angle θ between the extending direction of the heaters 10a to 10i and the axial direction of the press roll 2a (indicated by a two-dot chain line in FIG. 2A) is 0 ° <θ <90 ° or 0 °> θ. The size is> −90 °. In this case, the angle θ is preferably in the range of 30 ° ≦ θ ≦ 60 ° or −30 ° ≧ θ ≧ −60 °, for example, the angle θ is 60 °.
The extending directions of the heaters 10a to 10i are parallel to each other. As shown to Fig.2 (a), each heater 10a-10i is connected to the control part 22, respectively, and the degree of the heating with respect to the crimping | compression-bonding roll 2a in each heater 10a-10i is set for every heater 10a-10i by the control part 22. Are controlled independently of each other.

Next, with reference to FIG. 2 (a) (b), the distance between each heater 10a-10i and the surface of the press roll 2a is demonstrated. As shown in FIG. 2 (a), the heaters 10a~10i are respectively have the same length _{s 1.} In this case, as shown in FIG. 2 (b), the distance from the end of the heater 10a to the surface of the press roll 2a has a s _3.

The distance s ₃ from the end of the heater 10a to the surface of the pressure-bonding roll 2a in the present embodiment will be described in comparison with the first comparative example shown in FIGS. 5 (a) and 5 (b). 5 (a) and 5 (b), the heaters 14a to 14i are arranged so that the entirety thereof extends in parallel with the rotation direction of the pressure-bonding roll 2a (vertical direction in FIG. 5 (a)) (first). It is the top view and side view which show a comparative example. Note the length _{t 1} of each heater 14a~14i is made equal to the length _{s 1} of each heater 10a~10i in this embodiment.

As mentioned above, the heaters 14a~14i its entirety is disposed so as to extend parallel to the direction of rotation of the press roll 2a, Therefore, the distance t ₃ of the end portion of the heater 14a to the surface of the press roll 2a (See FIG. 5B) is larger than the distance s ₃ (see FIG. 2B) from the end of the heater 10a to the surface of the press roll 2a in the present embodiment. In other words, according to the present embodiment, the heaters 10a to 10i are arranged so that the entirety of the heaters 10a to 10i extends obliquely with respect to the rotation direction and the axial direction of the pressure-bonding roll 2a. Compared with the case where the heaters 10a to 10i are arranged so as to extend in parallel with the rotation direction (first comparative example), the distance between the end portions of the heaters 10a to 10i and the surface of the pressure-bonding roll 2a can be reduced. Thereby, the surface of the press roll 2a can be more efficiently heated by the heaters 10a to 10i.

Next, with reference to Fig.2 (a), the area | region heated by each heater 10a-10i in the press roll 2a is demonstrated. As described above, each of the heaters 10a to 10i heats a portion (region) facing the heaters 10a to 10i in the pressure-bonding roll 2a. In this case, as shown in FIG. 2 (a), in the present embodiment, the area to be heated by the heater 10h example of the surface of the press roll 2a has a region indicated by reference numeral s _4.

The region s ₄ which is heated by the heater 10h in the present embodiment will be described in comparison with the first comparative example shown in Figure 5 (a). As shown in FIG. 5 (a), in the first comparative example, the area to be heated by the heater 14h example of the surface of the press roll 2a has a region indicated by reference numeral t _4.

2 (a) and FIGS. 5 (a) As is apparent from, the area s ₄ which is heated by the heater 10h of the surface of the press roll 2a, the region t is heated by the heater 14h of the surface of the press roll 2a Greater than ₄ . In other words, according to the present embodiment, the heaters 10a to 10i are arranged so that the whole of the heaters 10a to 10i extends obliquely with respect to the rotation direction and the axial direction of the pressure-bonding roll 2a. Compared with the case where it is arranged so as to extend in parallel with the rotation direction, it is possible to enlarge the area heated by each of the heaters 10a to 10i on the surface of the pressure-bonding roll 2a. In this case, for example, as shown in FIG. 2 (a), the arrangement interval and θ for each heater 10a~10i to the region _{s 5} which is heated by the region _{s 4} and the heater 10i that is heated by the heater 10h is overdetermined By doing so, it becomes possible to heat the surface of the pressure-bonding roll 2a without any gap along the axial direction of the pressure-bonding roll 2a. Thereby, the temperature of the press roll 2a can be made more uniform along the axial direction of the press roll 2a, and thereby the diameter of the press roll 2a can be made more uniform in the axial direction.

Detection Unit Next, the detection unit 20 will be described with reference to FIGS. As shown in FIGS. 1 and 3, the detection unit 20 includes a plurality of temperature sensors 20 a to 20 c provided along the axial direction of the pressure-bonding roll 2 a (the left-right direction in FIG. 3). These temperature sensors 20a to 20c are provided so as to face the pressing roll 2a, respectively, and the temperature of the portion in the axial direction of the pressing roll 2a facing the temperature sensor 20a to 20c is determined by each temperature sensor 20a to 20c. Detected. As the temperature sensors 20a to 20c, either a contact type temperature sensor or a non-contact type temperature sensor may be used. 3 shows three temperature sensors 20a to 20c, the number of temperature sensors in the detection unit 20 is not limited to three. For example, each temperature sensor is paired with each heater 10a to 10i. A total of nine temperature sensors may be provided so as to correspond to each other.

As shown in FIG. 3, each temperature sensor 20 a to 20 c is connected to the control unit 22, and information on the temperature detected by each temperature sensor 20 a to 20 c is sent to the control unit 22.
The temperature sensors 20a to 20c are provided so as to correspond to the heaters 10a to 10i, respectively. More specifically, the temperature sensor 20a is provided to correspond to the three heaters 10a to 10c, the temperature sensor 20b is provided to correspond to the three heaters 10d to 10f, and the temperature sensor 20c is provided to the three heaters. It is provided so as to correspond to 10 g to 10 i.

  Based on the detection results of the temperature sensors 20a to 20c of the detection unit 20, the control unit 22 controls the degree of heating of the pressure roll 2a in the heaters 10a to 10i of the heating unit 10 for each of the heaters 10a to 10i. More specifically, the control unit 22 controls the heating unit 10 so that the temperatures at a plurality of locations (three locations) along the axial direction of the pressure-bonding roll 2a facing the temperature sensors 20a to 20c are substantially uniform. The degree of heating with respect to the pressure-bonding roll 2a in each heater 10a to 10i is controlled for each heater 10a to 10i. More specifically, since the temperature sensors 20a to 20c are provided so as to correspond to the heaters 10a to 10i, respectively, the control unit 22 detects that the temperature detected by the temperature sensor 20a is another temperature sensor 20b, When the temperature is lower than the temperature detected by 20c, control is performed to increase the outputs of the heaters 10a to 10c corresponding to the temperature sensor 20a.

Cooling roll then reference to FIG. 1, a pair of first cooling roll 3a, 3b and a pair of second cooling roller 4a, 4b will be described. As shown in FIG. 1, the pair of first cooling rolls 3 a and 3 b includes a first cooling roll 3 a on the decorative sheet 33 side and a first cooling roll 3 b on the base material 31 side, and a pair of second cooling rolls. 4a, 4b consists of the 2nd cooling roll 4a by the side of the decorative sheet 33, and the 2nd cooling roll 4b by the side of the base material 31.

  Of these, the first cooling roll 3a and the second cooling roll 4a on the decorative sheet 33 side are made of metal, while the first cooling roll 3b and the second cooling roll 4b on the base material 31 side are elastic bodies such as rubber. Formed from. Moreover, the 1st cooling roll 3a and the 2nd cooling roll 4a by the side of the decorative sheet 33 each have the water flow pipe (not shown) which lets a refrigerant pass inside. Moreover, the supply side rotary joint which supplies a refrigerant | coolant to the said water flow pipe, and the discharge | emission side rotary joint which discharges the refrigerant | coolant from a water flow pipe are respectively in the edge part of the 1st cooling roll 3a by the side of the decorative sheet 33, and the 2nd cooling roll 4a. Rotary joints 3c and 4c are provided. Thus, the surface of the 1st cooling roll 3a and the 2nd cooling roll 4a can be cooled by letting a refrigerant pass inside the 1st cooling roll 3a and the 2nd cooling roll 4a, respectively. Accordingly, the base 31 and the decorative sheet 33 can be sandwiched and cooled by the pair of first cooling rolls 3a and 3b and the pair of second cooling rolls 4a and 4b.

Veneer now to FIG. 4, it will be described in detail decorative plate 30. FIG. 4 is a view showing a cross section of the decorative board 30. As shown in FIG. 4, the decorative board 30 is formed by laminating a decorative sheet 33 and a substrate 31 via an adhesive layer 32 made of an adhesive 32 a such as a reactive hot melt adhesive (for example, a PUR adhesive). It is formed by.

(Base material)
First, the base material 31 will be described. The material of the base material 31 is not particularly limited, and various plate-like materials can be used. For example, a wood board such as a high density wood fiber board, a low density wood fiber board, a particle board, a wood powder plastic particle board and a wood powder plastic board, a plastic board (resin board), a paper laminated board, etc. may be used. it can.
The thickness of the base material 31 is not particularly limited, but is preferably 1 to 50 mm, more preferably 4 to 30 mm, and even more preferably 4 to 20 mm from the viewpoints of manufacturing limitations and weight.

The high density wood fiberboard refers to a wood fiberboard having a density of 0.80 g / cm ³ or more among fiberboards defined in JIS A5905-2003. The medium density fiberboard refers to a wood fiberboard having a density of less than 0.80 g / cm ³ and a density of 0.35 g / cm ³ or more among the fiber boards defined in JIS. The wood fiberboard specified by the above JIS is a board formed mainly from wood and other plant fibers. Generally, the surface hardness is high, and if an appropriate density is selected, a dent when an object collides with it is selected. It is a strong and useful material. In addition, the cost of the material can be obtained at a lower cost than plastic.
As such a wood fiberboard, MDF (medium density fiberboard), a hard board, etc. are mentioned preferably.
The low density wood fiberboard refers to a wood fiberboard having a density of less than 0.35 g / cm ³ among fiberboards defined in JIS A5905-2003. Examples of such a low density wood fiberboard include an insulation board, a tatami board, and a sizing board.

(Adhesive layer)
Next, the adhesive layer 32 will be described. As the adhesive 32a that forms the adhesive layer 32, a reactive hot melt adhesive is preferably used. Of this reactive hot melt adhesive, a PUR adhesive is particularly preferred.

Examples of the polyol component that can be used in the PUR adhesive include polyester polyols such as polyester diol, polyether polyols such as polyether diol, and mixtures or copolymers thereof. Furthermore, an acrylic polyol, a polycarbonate polyol, a polyolefin polyol, a castor oil polyol, a polyhydric alcohol, etc., or a mixture or copolymer thereof can be used.
Further, the polyisocyanate component is not particularly limited, but for example, aromatics such as phenylene diisocyanate, tolylene diisocyanate (TDI), 4,4′-diphenylmethane diisocyanate, 2,4-diphenylmethane diisocyanate, naphthalene diisocyanate, etc. Examples thereof include aliphatic or alicyclic diisocyanates such as diisocyanate, hexamethylene diisocyanate, lysine diisocyanate, cyclohexane diisocyanate, isophorone diisocyanate, dicyclohexylmethane diisocyanate, xylylene diisocyanate, and tetramethylxylylene diisocyanate.
Among these, it is preferable to use diphenylmethane diisocyanate (MDI) having a low vapor pressure during heating.

As the PUR adhesive, those having a melting point of 100 to 130 ° C. and a viscosity of 1000 to 30000 mPa · s are preferable, and among them, a polyester polyol-based PUR adhesive is particularly preferable because of excellent initial adhesive strength. In particular, such a PUR adhesive is preferably obtained by using polyester polyol in combination with polyether polyol or other polyol, such as acrylic polyol.
In addition, what is marketed can also utilize the polyurethane reactive hot melt, for example, DIC Corporation make and tie hose FH-100 are mentioned.

  The thickness of the adhesive layer 32 is, for example, 50 to 150 μm.

(Decorative sheet)
Next, the decorative sheet 33 will be described. The decorative sheet 33 is formed by sequentially laminating a decorative sheet base material 34, a colored layer 35 including a solid colored layer 35a and a pattern colored layer 35b, a decorative sheet adhesive layer 36, and a transparent resin layer 37. Further, a top coat layer 38 made of an electron beam curable resin is provided on the surface of the transparent resin layer 37 opposite to the surface in contact with the decorative layer adhesive layer 36 or the colored layer 35. ing. The adhesive 32a from the adhesive applicator 47 described above is applied to the surface (back surface 33b) of the decorative sheet 33 on the decorative sheet base 34 side.

(Base material for decorative sheet)
Of these, the decorative sheet base 34 is a base of the decorative sheet 33. Examples of the material used for the decorative sheet substrate 34 include polyolefin resins, polyester resins, acrylic resins, and polyvinyl chloride. Among these, it is preferable to use polyolefin resin and polyester resin. Since these materials do not generate chlorine-based gas when the manufactured decorative sheet 33 is disposed by incineration and disposal, they are highly safe and are preferably used from the viewpoint of the environment. A colored polyolefin resin is particularly preferably used. By using this material, the stability of the color tone of the pattern coloring layer 35b formed on the surface of the decorative sheet 33 can be secured, and the surface hue of the base material 31 to which the decorative sheet 33 is attached varies. In this case, the hue of the dispersed surface can be concealed well.

  Further, the material of the decorative sheet substrate 34 may contain various additives such as a colorant, a filler, a foaming agent, a flame retardant, a lubricant, an antioxidant, an ultraviolet absorber, and a light stabilizer, as necessary. May be.

  The decorative sheet substrate 34 is formed by molding the above-described resin material into a sheet shape by a film forming method such as a calendar method, an inflation method, or a T-die extrusion method. The thickness of the formed decorative sheet base material 34 is appropriately set based on the application in which the decorative sheet 33 is used and the required performance, and is, for example, 20 to 300 μm. The surface of the decorative sheet substrate 34 may be subjected to easy adhesion treatment such as corona discharge treatment, plasma treatment, and ozone treatment. Thereby, the adhesiveness of the coloring layer 35 mentioned later and the base material 34 for decorative sheets can be improved.

(Colored layer)
Next, the colored layer 35 will be described. As shown in FIG. 4, the colored layer 35 is composed of a solid colored layer 35a and / or a pattern colored layer 35b.

  The solid colored layer 35a is provided for the purpose of concealing the background of the base sheet 34 for the decorative sheet, and is usually formed as a solid solid colored layer having no pattern. On the other hand, the pattern coloring layer 35b can be made from wood grain pattern, stone pattern, cloth pattern, leather pattern, natural leather surface pattern, geometric figure, abstract pattern, etc., depending on figures, characters, symbols, colors, combinations thereof, etc. The pattern colored layer 35b is formed on the solid colored layer 35a as a planar, uneven, or convex layer. In addition, the pattern coloring layer 35b may also serve as the solid coloring layer 35a, and the coloring layer 35 may be constituted by only the solid coloring layer 35a or only the pattern coloring layer 35b.

Further, as shown in FIG. 4, the colored layer 35 may be composed of a solid colored layer 35a provided on the entire surface of the decorative sheet substrate 34 and a pattern colored layer 35b partially provided on the surface. Good.
If comprised in this way, a desired pattern can be provided to the decorative sheet 33. On the other hand, the colored layer 35 may be composed of a solid colored layer 35a and a pattern colored layer 35b, the pattern colored layer 35b may be provided on the decorative sheet substrate 34, and the solid colored layer 35a may be provided on the transparent resin layer 36 side. is there. In this case, the solid colored layer 35a may be colorless or colored with a colorant, but it needs to have at least transparency so that the pattern of the pattern colored layer 35b can be seen from the outside.

  The colored layer 35 is formed of a coating agent for the colored layer 35 that includes a binder resin as a main component and includes a solvent and other additives. A water-based coating agent using water or / and a water-soluble organic solvent as a solvent, or a solvent-based coating agent using a water-insoluble organic solvent or the like as a solvent can be used. In addition, as a coating agent for the colored layer 35, it is also possible to use a non-solvent type paint in addition to a paint type using a solvent.

  The colored layer 35 is formed by applying a coating agent for the colored layer 35 by coating or printing, and then drying and curing. Among these, the solid colored layer 35a is provided by coating or printing, and the pattern colored layer 35b is usually provided by printing. When applying the coating agent for the colored layer 35, various known methods such as roll coating, curtain flow coating, wire bar coating, reverse coating, gravure coating, gravure reverse coating, air knife coating, kiss coating, blade coating, smooth Methods such as coating, comma coating, spray coating, flow coating, and brush coating can be used. Usually, the coating is applied to a thickness of about 1.0 to 10.0 μm during drying. When printing the coating agent for the colored layer 35, gravure, letterpress, flexographic and other relief printing, lithographic offset and lithographic printing such as lithographic printing, silk screen and other stencil printing, electrostatic printing, ink jet printing, Various known methods such as transfer printing from a transfer sheet, and other hand-drawn methods can be used. Usually, the coating is applied to a thickness of about 1.0 to 10.0 μm during drying. In addition, you may print and provide the pattern colored layer 35b on the surface by the side of the base material 34 for decorative sheets of the material which comprises the transparent resin layer 37 mentioned later.

  The colored layer 35 may be formed of a metal thin film. The metal thin film is formed by a method such as vacuum deposition or sputtering using a metal such as aluminum, chromium, gold, silver, or copper. You may use combining these. The metal thin film can be provided on the entire surface of the decorative sheet substrate 34 or partially in a pattern.

(Adhesive layer for decorative sheet)
As shown in FIG. 4, the decorative sheet adhesive layer 36 is a layer provided between the colored layer 35 and the transparent resin layer 37, and is transparent to the decorative sheet substrate 34 on which the colored layer 35 is formed. It is a layer having a role as a primer layer or an anchor layer for improving the adhesion with the resin layer 37, and has an effect of improving durability and long-term appearance maintenance. By such an action, the formed pattern can be held for a long period of time, which is extremely effective.

  The adhesive layer 36 for decorative sheets is formed of a coating agent for the adhesive layer 36 for decorative sheets composed of a resin composition, a solvent, and other additives. The solvent is not particularly limited, and examples thereof include water-insoluble organic solvents such as toluene, xylene, ethyl acetate, butyl acetate, methyl ethyl ketone, methyl isobutyl ketone, ethylene glycol monomethyl ether, ethylene glycol monoethyl ether, methanol, ethanol, and impropyl alcohol. Water-soluble organic solvents such as normal propyl alcohol, water, or mixed solvents thereof can be used. In addition, it is also possible to use a solventless type coating agent that does not use a solvent as the coating agent for the adhesive layer 36 for the decorative sheet. Solvent-free coating agents are those that are environmentally friendly and are preferably used.

  Examples of the resin composition include rubber resins, acrylic resins, epoxy resins, and urethane resins. Of these, urethane resins are preferably used. By using a urethane-based resin, stronger adhesive strength can be obtained, and the decorative sheet 33 having excellent flexibility can be provided.

  In the case of using a solvent, the decorative layer adhesive layer 36 contains a resin composition and, if necessary, other additives in the solvent, and then dissolves, disperses, and mixes them by a known method. It is prepared by.

The decorative layer adhesive layer 36 is formed by applying the above-described coating agent for the decorative sheet adhesive layer 36 on the colored layer 35, and drying and curing it. As the coating method, various known methods such as roll coating, gravure coating, air knife coating, comma coating and the like are used. From the viewpoint of productivity, gravure coating and comma coating are preferably used. The decorative sheet adhesive layer 36 is coated such that the coating amount after drying is 0.1 to 20 g / m ² , preferably about 0.1 to 10 g / m ² .

(Transparent resin layer)
As shown in FIG. 4, the transparent resin layer 37 is laminated | stacked on the colored layer 35 through the adhesive layer 36 for decorative sheets. The transparent resin layer 37 is laminated for the purpose of protecting the colored layer 35 from scratches, improving the surface strength of the decorative sheet 33, and imparting a feeling of painting.

  The resin constituting the transparent resin layer 37 is not particularly limited as long as it is a transparent resin formed on the colored layer 35 with good adhesion via the above-described adhesive layer 36 for decorative sheets. Polyester resins are preferred. The polyester resin can make organic gas generated when the manufactured decorative sheet 33 is incinerated and disposed of with high safety, and is preferably used from the viewpoint of the environment. Here, the polyester resin is an aromatic dicarboxylic acid such as terephthalic acid, isophthalic acid or naphthalenedicarboxylic acid as an acid component, and an aliphatic diol such as ethylene glycol, diethylene glycol, butanediol or haysandiol as an alcohol component. Examples of specific resins used in the present invention include polyethylene terephthalate, polybutylene terephthalate, and ethylene / terephthalate / isophthalate copolymer. Moreover, as resin other than the polyester resin that can be used as the resin for the transparent resin layer 37, the same resin material as that used for the decorative sheet base material 34 can be used. If necessary, known additives such as a colorant, a filler, an ultraviolet absorber, a light stabilizer, a matting agent, an antioxidant, and an antiblocking agent are added to the resin forming the transparent resin layer 37. Also good.

  A method of forming the transparent resin layer 37 by laminating a colorless or colored transparent resin film separately formed on the decorative sheet adhesive layer 36 by various lamination methods such as dry lamination and thermal lamination. Examples thereof include a method of forming a film by extrusion coating of a resin by extrusion and other known methods. Among these, a method of forming a film in advance and performing dry lamination is preferable.

  In order to increase dimensional stability, strength, and crystallinity, the film may be stretched during film formation, and in order to increase adhesion, primer coating or corona treatment may be performed.

  The thickness of the transparent resin layer 37 is usually about 10 to 500 μm, and preferably about 30 to 300 μm.

  The surface of the transparent resin layer 37 can be embossed. By forming the embossed pattern, the design of the decorative sheet can be improved. The pattern by such embossing is not specifically limited, What is necessary is just a pattern according to the use of the decorative sheet. For example, wood grain conduit groove, wood grain annual ring unevenness, float age unevenness, wood surface unevenness, sand grain, pear texture, hairline, line-like groove, granite cleaved surface texture, textured surface texture, squeezing, text, geometry Examples include academic patterns. In addition, in order to give a clear image to the surface, pressure may be applied with a mirror roll, which can further increase the smoothness.

  When this transparent resin layer 37 and the above-mentioned decorative sheet substrate 34 are formed of a polyolefin resin, a harmful gas such as dioxin is generated at the time of disposal / combustion like a decorative sheet formed of a vinyl chloride resin. There is no. For this reason, the environmental load of the decorative sheet 33 can be reduced, and therefore, a polyolefin-based resin is preferably used.

  In addition, about transparency of the transparent resin layer 37 in this invention, this invention does not strictly prescribe | regulate, it is sufficient if it is substantially transparent, and there may be some cloudiness and an opaque feeling.

(Topcoat layer)
The top coat layer 38 protects the colored layer 35 from scratches and the like, as well as the transparent resin layer 37 laminated thereunder, and also provides the decorative sheet 33 with friction resistance, stain resistance, and chemical resistance. It is a layer which can provide. When the decorative sheet 33 is mirror-finished or when the primary color layer 35 is used, it is a layer that can prevent the appearance of rainbow-colored interference fringes caused by light from a fluorescent lamp or the like.

  The topcoat layer 38 is formed of a coating agent for the topcoat layer 38 that is mainly composed of an electron beam curable resin and includes a solvent and other additives. Here, a solvent is not specifically limited, It is possible to use the solvent similar to having demonstrated the coating agent for the adhesive layers 36 for decorative sheets. In addition, as the coating agent for the topcoat layer 38, it is also possible to use a solventless type coating agent that does not use a solvent. Solvent-free coating agents are those that are environmentally friendly and are preferably used.

  As an electron beam curable resin, a resin obtained by a crosslinking reaction using at least one of urethane acrylate, epoxy acrylate, acrylic polyol and polyester acrylate and a curing agent, and an electron beam curable resin described later as it is or as a curing agent And a resin cured by cross-linking using As the coating agent for the topcoat layer 38, at least one kind of crosslinkable resin selected from these resins can be used. Among these resins, it is preferable to use a resin obtained by a crosslinking reaction with at least one selected from urethane acrylate, epoxy acrylate, acrylic polyol and polyester acrylate and a curing agent.

  In order to form the topcoat layer 38, a resin, prepolymer or oligomer having a functional group or / and a polymerizable double bond used in the above-described crosslinkable resin is applied as a mixture in which a curing agent or a polymerization catalyst is mixed. You can also. It can also be applied after the mixture has cured and has reached a viscosity suitable for application.

  The top coat layer 38 is formed by coating the coating agent for the top coat layer 38 on the transparent resin layer 37, and then irradiating with an electron beam to crosslink and cure the resin. As the coating method, a method similar to the coating method for forming the above-described colored layer 35 in a solid state, such as roll coating or gravure coating, is used.

  The thickness of the top coat layer 38 is not particularly limited, but is preferably 3 μm or more, and particularly preferably 6 μm or more during drying. Note that the upper limit of the thickness of the top coat layer 38 is not particularly limited and may be set as appropriate, but in the normal case, it may be 20 μm or less. This is because even if it is made thicker than this, the cost is increased and the flexibility may be affected.

As mentioned above, although the structure of the decorative sheet 33 of this invention was demonstrated, it is not limited only to this, For example, the electroconductive layer for providing electroconductivity to the decorative sheet 33, the adhesiveness between each layer, etc. are improved. A primer layer or the like may be optionally provided as necessary.
For example, a primer layer (not shown) for enhancing the adhesiveness with the adhesive 32 can be provided on the back surface 33b of the makeup base sheet 34 constituting the makeup sheet 33, if necessary. The binder resin of the adhesion primer is not particularly limited as long as the adhesive force with the decorative base sheet 34 is obtained. For example, a polyurethane resin can be used.
The primer layer for adhesion may contain additives such as fillers such as silica fine powder, light stabilizers and the like in addition to the resin. Moreover, the resin component which has an isocyanate group at the both terminal of resin at least may be included as the composition. The primer layer is formed by applying these compositions and drying and curing as necessary, and the coating amount (thickness) is, for example, in the range of 0.01 to 10 μm.

  Next, the operation of the present embodiment having such a configuration will be described. Here, the manufacturing method of the decorative board 30 is demonstrated.

  First, as shown in FIG. 1, a base material 31 having a flat surface is prepared and sent out between the pair of pressure-bonding rolls 2 a and 2 b by the transport roll 6. On the other hand, the decorative sheet supply roll 8 around which the decorative sheet 33 is wound is prepared, and then the decorative sheet 33 from the decorative sheet supply roll 8 is wound around the backup roll 50. Thereafter, as shown in FIG. 1, in the backup roll 50, the adhesive 32 a is applied to the back surface 33 b of the decorative sheet 33 by the die head 47 a of the adhesive applicator 47. Next, the decorative sheet 33 with the adhesive 32a applied to the back surface 33b is sent between the pair of pressure-bonding rolls 2a and 2b.

Thereafter, as shown in FIG. 1, a decorative sheet 33 in which an adhesive 32 a is applied to the back surface 33 b is laminated on the base material 31 between the pair of press rolls 2 a and 2 b. Next, the laminated base material 31 and the decorative sheet 33 are pressed while being heated by the pair of pressure-bonding rolls 2a and 2b. In this case, as described above, a pair of crimping rolls 2a, the surface of the 2b are each covered by an elastic body such as rubber, Therefore pair of crimping rolls 2a, the nip length L ₁ in 2b, the surface of the roll Is longer than when made of a hard material such as metal. Thereby, the base material 31 and the decorative sheet 33 can be pinched more uniformly over time.

  Next, as shown in FIG. 1, the base material 31 and the decorative sheet 33 that are sandwiched while being heated are sandwiched and cooled by the pair of first cooling rolls 3 a and 3 b and the pair of second cooling rolls 4 a and 4 b. To do. Thereby, the adhesive agent 32a interposed between the base material 31 and the decorative sheet 33 can be hardened, and as a result, the adhesive agent layer 32 is formed. Thereby, the decorative board 30 which consists of the decorative sheet 33, the base material 31, and the adhesive bond layer 32 interposed between the decorative sheet 33 and the base material 31 can be obtained.

  During this time, the surface of the pressure-bonding roll 2 a on the decorative sheet 33 side is heated by the heaters 10 a to 10 i of the heating unit 10. In this case, first, the temperature of each of the temperature sensors 20a to 20c of the detection unit 20 is detected at a total of three temperatures in the central portion and both end portions in the axial direction of the pressure-bonding roll 2a. Information on the temperatures detected by the temperature sensors 20 a to 20 c is sent to the control unit 22.

  The controller 22 detects the temperature in each of the heaters 10a to 10i of the heating unit 10 so that the temperatures at the central portion and both end portions in the axial direction of the pressure-bonding roll 2a detected by the temperature sensors 20a to 20c are substantially uniform. The degree of heating of the pressure-bonding roll 2a is controlled for each of the heaters 10a to 10i. At this time, the control unit 22 controls the outputs of the heaters 10a to 10i based on the correspondence between the heaters 10a to 10i and the temperature sensors 20a to 20c. That is, when the temperature detected by one temperature sensor is higher or lower than the temperature detected by another temperature sensor, the control unit 22 changes each heater so as to change the output of the heater corresponding to this temperature sensor. 10a to 10i are controlled. By performing such control, the pressure roll 2a can be heated so that the temperature of the pressure roll 2a becomes uniform along the axial direction of the pressure roll 2a. For this reason, the degree of expansion coefficient of the pressure-bonding roll 2a in the axial direction of the pressure-bonding roll 2a can be made uniform, whereby the diameter of the pressure-bonding roll 2a can be made uniform in the axial direction. As a result, the laminated base material 31 and the decorative sheet 33 can be uniformly pressed over the entire surface, and as a result, the decorative board 30 having a mirror-like surface can be obtained.

  As described above, according to the present embodiment, the plurality of heaters 10a to 10i arranged in the vicinity of the pressing roll 2a on the decorative sheet 33 side in the axial direction of the pressing roll 2a out of the pair of pressing rolls 2a and 2b. A heating unit 10 is provided. For this reason, the heating degree with respect to the said press roll 2a in each heater 10a-10i can be adjusted for every heater 10a-10i, and, thereby, the temperature of the said press roll 2a is along the axial direction of the press roll 2a. The pressure-bonding roll 2a can be heated so as to be uniform. For this reason, the degree of expansion coefficient of the pressure-bonding roll 2a in the axial direction of the pressure-bonding roll 2a can be made uniform, whereby the diameter of the pressure-bonding roll 2a can be made uniform in the axial direction. As a result, the laminated base material 31 and the decorative sheet 33 can be uniformly pressed over the entire surface, and as a result, the decorative board 30 having a mirror-like surface can be obtained.

  Moreover, according to this Embodiment, each heater 10a-10i of the heating unit 10 is arrange | positioned so that the whole or at least one part may extend diagonally with respect to the rotation direction and axial direction of the crimping | compression-bonding roll 2a by the side of the decorative sheet 33. Yes. For this reason, compared with the case where each heater 10a-10i is arrange | positioned so that it may extend in parallel with the rotation direction of the press roll 2a, the area | region heated by each heater 10a-10i in the axial direction of the said press roll 2a is each. Can be bigger. Thereby, the surface of the press-bonding roll 2a can be heated without any gap along the axial direction of the press-bonding roll 2a by the respective heating units 10a to 10i. Accordingly, the temperature of the pressure-bonding roll 2a can be made more uniform along the axial direction of the pressure-bonding roll 2a, and thereby the diameter of the pressure-bonding roll 2a can be made more uniform in the axial direction.

  Further, according to the present embodiment, as described above, the heaters 10a to 10i of the heating unit 10 are entirely or at least partially inclined with respect to the rotation direction and the axial direction of the pressure-bonding roll 2a on the decorative sheet 33 side. It is arranged to extend. For this reason, compared with the case where each heater is arrange | positioned so that it may extend in parallel with the rotation direction of the press roll 2a, the distance between each heater 10a-10i and the surface of the press roll 2a can be made small. Thereby, the surface of the press roll 2a can be efficiently heated by the heaters 10a to 10i.

Second Comparative Example Next, the effect of the present invention will be described in comparison with the second comparative example. As a second comparative example, FIG. 6 shows a heating unit 15 having heaters 15a to 15l arranged to face the pressure roll 2a so as to extend in parallel with the rotation direction of the pressure roll 2a (vertical direction in FIG. 6). Show. In the second comparative example shown in FIG. 6, the length _{t 4} of each heater 15a~15l, the heater 10a to distance from the end of each heater 15a~15l to the surface of the press roll 2a is shown in FIG. 2 (b) Is selected to be equal to the distance s ₃ from the end of the surface to the surface of the pressure-bonding roll 2a. For this reason, as is clear from the case of the first comparative example shown in FIGS. 5A and 5B, the length t ₄ of each heater 15a to 15l is the length s _{1 of} each heater 10a to 10i. Is shorter. Therefore, in the second comparative example, the amount of heat obtained from one of the heaters 15a to 15l is smaller than the amount of heat obtained from one of the heaters 10a to 10i of the present invention. Therefore, in order to obtain the amount of heat equivalent to the amount of heat given to the press roll 2a by the heaters 10a to 10i of the present invention, it is necessary to increase the number of heaters provided. For example, as shown in FIG. In the comparative example, a total of 12 heaters 15a to 15l are provided. For this reason, it is possible that the manufacturing cost and maintenance cost of an apparatus will become large.

  On the other hand, according to the present invention, each of the heaters 10a to 10i of the heating unit 10 is disposed so that the whole or at least a part thereof extends obliquely with respect to the rotation direction and the axial direction of the pressure-bonding roll 2a on the decorative sheet 33 side. ing. For this reason, compared with the case where each heater is arrange | positioned so that it may extend in parallel with the rotation direction of the press roll 2a, the distance between each heater 10a-10i and the surface of the press roll 2a can be made small, and this Thus, the surface of the pressure-bonding roll 2a can be efficiently heated by the heaters 10a to 10i. As a result, the number of heaters provided can be reduced, and thereby the manufacturing cost and maintenance cost of the apparatus can be reduced.

Third Comparative Example Next, the effect of the present invention will be described in comparison with a third comparative example. As a third comparative example, FIG. 7 shows a heating unit 16 having heaters 16a and 16b arranged to face the pressure roll 2a so as to extend parallel to the axial direction of the pressure roll 2a (the left-right direction in FIG. 7). Show. In the third comparative example shown in FIG. 7, the degree of heating from the heating unit 16 to the pressure-bonding roll 2a is uniform along the axial direction of the pressure-bonding roll 2a.

  By the way, in the crimping | compression-bonding roll 2a, generally the heat radiation amount to the external air from the crimping | compression-bonding roll 2a differs in the center part and both ends of the axial direction. This is because heat is radiated from the side to the outside air at both ends of the crimping roll 2a in the axial direction, whereas such heat radiation is not generated at the central portion of the crimping roll 2a in the axial direction. is there. Here, as described above, in the third comparative example, the degree of heating from the heating unit 16 to the pressing roll 2a is uniform along the axial direction of the pressing roll 2a. For this reason, in the 3rd comparative example, it is thought that the temperature in the axial direction both ends of press-bonding roll 2a becomes lower than the temperature in the central portion of press-bonding roll 2a in the axial direction. For this reason, it is conceivable that the diameter of the pressure-bonding roll 2a is different between both end portions and the center portion in the axial direction of the pressure-bonding roll 2a, and the specularity of the decorative plate 30 thus obtained is deteriorated.

  On the other hand, according to the present invention, a plurality of heaters 10a to 10i arranged in the axial direction of the pressure-bonding roll 2a in the vicinity of the pressure-bonding roll 2a on the decorative sheet 33 side of the pair of pressure-bonding rolls 2a and 2b. The heating unit 10 is provided, and the degree of heating of the heaters 10a to 10i with respect to the pressure-bonding roll 2a can be adjusted for each of the heaters 10a to 10i. Thus, even if the heat radiation amount from the pressure roll 2a to the outside air is different between the central portion and both end portions in the axial direction of the pressure roll 2a, the degree of heating of the pressure roll 2a is adjusted for each heater 10a to 10i. By doing so, the temperature of the surface of the press roll 2a can be made uniform in the axial direction. As a result, the degree of thermal expansion of the crimping roll 2a can be made uniform in the axial direction, and therefore the diameter of the crimping roll 2a can be made uniform in the axial direction. As a result, the laminated base material 31 and the decorative sheet 33 can be uniformly pressed over the entire surface, and as a result, the decorative board 30 having a mirror-like surface can be obtained.

  In the present embodiment, the heating unit 10 for heating the surface of the pressure-bonding roll 2a in the vicinity of the pressure-bonding roll 2a on the decorative sheet 33 side of the pair of pressure-bonding rolls 2a, 2b and the surface temperature of the pressure-bonding roll 2a are detected. An example in which the detection unit 20 is provided is shown. However, the present invention is not limited to this, and as shown by a two-dot chain line in FIG. 1, the surface of the pressure-bonding roll 2 b is also heated in the vicinity of the pressure-bonding roll 2 b on the substrate 31 side among the pair of pressure-bonding rolls 2 a and 2 b. You may provide the heating unit 10 and the detection unit 20 which detects the temperature of the surface of the press roll 2b. Furthermore, you may provide the heating unit (not shown) which heats the base material 31 in the upstream of the crimping | compression-bonding roll 2b.

  Moreover, in this Embodiment, each heater 10a-10i of the heating unit 10 showed the example arrange | positioned so that the whole might extend diagonally with respect to the rotation direction and axial direction of the crimping | compression-bonding roll 2a. However, the present invention is not limited to this, and as a heating unit, as shown in FIG. 8, the heating unit 11 has a heater 11 a arranged so that a part thereof extends obliquely with respect to the rotation direction and the axial direction of the pressure-bonding roll 2 a. May have ˜11h. Moreover, as shown in FIG. 9, the heating unit 12 may have heaters 12a to 12i arranged to extend in a curved shape instead of a linear shape. In this case, each of the heaters 12a to 12i is disposed so as to be inclined with respect to the rotational direction and the axial direction of the pressure-bonding roll 2a, and extends so as to be curved along the surface of the roll-shaped pressure-bonding roll 2a. In this case, the distance from the ends of the heaters 12a to 12i to the surface of the press roll 2a can be reduced, whereby the surface of the press roll 2a can be heated more efficiently.

  Moreover, in this Embodiment, the example to which the control part 22 controlled the degree of the heating with respect to the press roll 2a in each heater 10a-10i based on the information from each temperature sensor 20a-20c was shown. However, it is not restricted to this, You may preset the degree of the heating with respect to the press roll 2a in each heater 10a-10i.

Modified Example of Detection Unit In the present embodiment, the example in which the detection unit 20 includes a plurality of temperature sensors 20a to 20c provided along the axial direction of the pressure-bonding roll 2a is shown. However, the present invention is not limited to this, and the detection unit 20 may include a plurality of displacement sensors (not shown) that detect the diameter of the pressure roll 2a instead of the plurality of temperature sensors 20a to 20c. .

  In such a modification, each displacement sensor of the detection unit 20 detects the diameter of a location (a location at the center portion and a location at both end portions) in the axial direction of the pressure-bonding roll 2a facing the displacement sensor. At this time, each displacement sensor is provided to correspond to each heater 10a to 10i. More specifically, the first displacement sensor is provided to correspond to the three heaters 10a to 10c, the second displacement sensor is provided to correspond to the three heaters 10d to 10f, and the third displacement sensor is 3 Two heaters 10g to 10i are provided.

  When a plurality of displacement sensors are used as the detection unit 20, the controller 22 detects the diameters of the three portions of the central portion and both end portions in the axial direction of the pressure-bonding roll 2 a detected by each displacement sensor so as to be substantially uniform. The degree of heating with respect to the roll 50 in each heater 10a-10i of the heating unit 10 is controlled for each heater 10a-10i. At this time, the control unit 22 controls the outputs of the heaters 10a to 10i based on the correspondence between the heaters 10a to 10i and the displacement sensors. That is, when the diameter detected by a certain displacement sensor is larger or smaller than the diameter detected by another displacement sensor, the control unit 22 changes each heater so as to change the output of the heater corresponding to this displacement sensor. 10a to 10i are controlled. By performing such control, the pressure-bonding roll 2a can have a uniform diameter along the axial direction.

Second Embodiment Next, a second embodiment of the present invention will be described with reference to FIGS. 1 and 10 to 12. 10 is a diagram showing a positional relationship when the die head and the backup roll shown in FIG. 1 are viewed from the left-right direction (arrow C), and FIG. 11 shows the backup roll heating unit shown in FIG. FIG. 12 is a diagram showing a backup roll detection unit.

  The second embodiment shown in FIGS. 1 and 10 to 12 includes a backup roll heating unit having a plurality of backup roll heating units arranged in the vicinity of the backup roll along the axial direction of the backup roll. The only difference is the provided point, and the other configuration is substantially the same as that of the first embodiment shown in FIGS. In the second embodiment shown in FIG. 1 and FIG. 10 to FIG. 12, the same parts as those in the first embodiment shown in FIG. 1 to FIG.

  In order to ensure the specularity on the surface of the decorative plate 30, in addition to uniformly pressing the base material 31 and the decorative sheet 33 over the entire surface between the pair of pressure-bonding rolls 2 a and 2 b, between the base material 31 and the decorative sheet 33. It is also important to make the thickness of the adhesive layer 32 interposed between them uniform over the entire surface. For this reason, it is important to apply the adhesive 32a constituting the adhesive layer 32 to the decorative sheet 33 by the adhesive applicator 47 so that the film thickness becomes uniform.

Adhesive Application Machine As described in the first embodiment shown in FIGS. 1 to 9, the adhesive application machine 47 applies the adhesive 32a to the back surface 33b of the decorative sheet 33 wound around the backup roll 50. A die head 47a to be used, and an adhesive supply unit 47b for supplying the adhesive 32a to the die head 47a (FIG. 1). The die head 47 a is provided to face the backup roll 50 so as to extend along the axial direction (width direction) of the backup roll 50. In this case, the adhesive 32a is applied to the back surface 33b of the decorative sheet 33 by the die head 47a while being heated to the softening temperature or higher.

As shown in FIG. 1, in the vicinity of the backup roll 50, a backup roll heating unit 40 for heating the surface of the backup roll 50 and a backup roll detection for detecting the temperature of the surface of the backup roll 50. A unit 45 is provided. As will be described later, the degree of heating of the backup roll 50 by the backup roll heating unit 40 is controlled by the control unit 22 based on the detection result by the backup roll detection unit 45. The backup roll heating unit 40 is preferably controlled by the control unit 22 so as to heat the surface of the backup roll 50 when the backup roll 50 is rotating.
Further, as shown in FIG. 1, a film thickness detection unit 48 for detecting the thickness of the adhesive 32 a applied to the back surface 33 b of the decorative sheet 33 is provided in the vicinity of the backup roll 50. The film thickness detection unit 48 has a plurality of, for example, nine film thickness sensors (not shown) provided along the width direction of the decorative sheet 33 (the direction orthogonal to the conveyance direction of the decorative sheet 33). Each film thickness sensor can detect the film thickness of the adhesive 32a applied to the decorative sheet 33 at a location facing each film thickness sensor.

As shown in FIG. 10, the die head 47 a is provided to face the backup roll 50 so as to extend along the axial direction of the backup roll 50. Here, a gap L ₂ having a predetermined size is provided between the die head 47 a and the backup roll 50, and the film thickness of the adhesive 32 a applied to the decorative sheet 33 is generally the die head 47 a and the backup roll 50. It is determined by the size of the distance L ₂ between the roll 50. For this reason, in order to make the film thickness of the adhesive 32 a applied to the decorative sheet 33 uniform, it is necessary to make the distance L ₂ uniform in the axial direction of the backup roll 50.

By the way, as in the case of the pressure-bonding roll 2a in the first embodiment shown in FIGS. 1 to 9, in the backup roll 50, the heat radiation amount from the backup roll 50 to the outside air is different between the central portion and both end portions in the axial direction. It is possible that For this reason, when the backup roll 50 is heated uniformly in the axial direction, the temperature of the backup roll 50 becomes non-uniform in the axial direction, which may cause the diameter of the backup roll 50 to be non-uniform in the axial direction. . If the diameter of the backup roll 50 becomes non-uniform in its axial direction, the distance L ₂ above becomes uneven, resulting in the thickness of the adhesive 32a applied to the decorative sheet 33 becomes uneven.

In addition, when the backup roll 50 is used for a long time, the processing accuracy such as roundness and straightness of the backup roll 50 deteriorates due to aging deterioration or the like, or the assembly accuracy of the backup roll 50 deteriorates. It is conceivable that the diameter of the backup roll 50 varies in the axial direction. When variations in the diameter of the backup roll 50 occurs, it will be spacing L ₂ between the die head 47a and the backup roll 50 varies, thereby, possibly also varies the thickness of the adhesive 32a applied to the decorative sheet 33 is there.

  In the present embodiment, the surface of the backup roll 50 is appropriately heated by the backup roll heating unit 40, and thereby the diameter of the backup roll 50 is kept uniform in the axial direction, whereby the decorative sheet 33 is formed. It aims at making the film thickness of the adhesive agent 32a apply | coated uniform over the whole surface.

Backup Roll Heating Unit The backup roll heating unit 40 will be described. As shown in FIG. 11, the backup roll heating unit 40 includes a plurality of heaters (backup roll heating units) 40 a to 40 i provided along the axial direction of the backup roll 50 (the horizontal direction in FIG. 11). ing. Here, as shown in FIG. 1 and FIG. 11, each heater 40a-40i is provided so as to oppose the backup roll 50 through the decorative sheet 33 and the adhesive 32a, respectively, and by these heaters 40a-40i, The portions of the backup roll 50 that face the heaters 40a to 40i are heated. Each heater 40a-40i is comprised, for example from infrared heaters, such as a short wavelength infrared heater and a medium wavelength infrared heater (carbon heater). In addition, you may use heaters other than an infrared heater as each heater 40a-40i.

As shown in FIG. 11, the heaters 40 a to 40 i are arranged so that the whole extends obliquely with respect to the rotation direction (vertical direction in FIG. 11) and the axial direction (horizontal direction in FIG. 11) of the backup roll 50. ing. That is, the angle φ between the direction in which each heater 40a to 40i extends and the axial direction of the backup roll 50 (indicated by a two-dot chain line in FIG. 11) is 0 ° <φ <90 ° or 0 °>φ> −90. It is the size of °. In this case, the angle φ is preferably in the range of 30 ° ≦ φ ≦ 60 ° or −30 ° ≧ φ ≧ −60 °, for example, the angle φ is 60 °.
The extending directions of the heaters 40a to 40i are parallel to each other. As shown in FIG. 11, each heater 40a-40i is connected to the control part 22, respectively, and the degree of the heating with respect to the backup roll 50 in each heater 40a-40i is mutually independent for each heater 40a-40i by the control part 22. To be controlled.

Backup Roll Detection Unit Next, the backup roll detection unit 45 will be described. As shown in FIG. 1, the backup roll detection unit 45 is provided so as to face the backup roll 50 at a place where the decorative sheet 33 is not wound, and the backup roll detection unit 45 is shown in FIG. 12. As shown, a plurality of temperature sensors 45 a to 45 c arranged to face the backup roll 50 are provided. Each temperature sensor 45a-45c detects the temperature of the location (location of a center part and the location of both ends) of the backup roll 50 which opposes the said temperature sensor 45a-45c in the axial direction. Here, each temperature sensor 45a-45c is provided so as to correspond to each heater 40a-40i, respectively. More specifically, the first temperature sensor 45a is provided so as to correspond to the three heaters 40a to 40c, and the second temperature sensor 45b is provided so as to correspond to the three heaters 40d to 40f. 45c is provided to correspond to the three heaters 40g to 40i.

  In FIG. 12, three temperature sensors 45a to 45c are shown, but the number of temperature sensors in the backup roll detection unit 45 is the same as the number of heaters 40a to 40i in the backup roll heating unit 40. Alternatively, the number of heaters 40a to 40i in the backup roll heating unit 40 may be larger. As shown in FIG. 12, each temperature sensor 45 a to 45 c is connected to the control unit 22, and information related to the temperature of the backup roll 50 detected by each temperature sensor 45 a to 45 c is sent to the control unit 22.

  Next, the operation of the present embodiment having such a configuration will be described. Here, a method of applying the adhesive 32 a to the back surface 33 b of the decorative plate 33 in the backup roll 50 so that the film thickness in the width direction of the decorative plate 33 is uniform will be described.

  First, the decorative sheet supply roll 8 around which the decorative sheet 33 is wound is prepared, and then the decorative sheet 33 is wound around the backup roll 50. As shown in FIG. 1, in the backup roll 50, the adhesive 32 a is applied to the back surface 33 b of the decorative sheet 33 by the die head 47 a of the adhesive applicator 47.

  During this time, the surface of the backup roll 50 is heated by the heaters 40a to 40i of the backup roll heating unit 40 via the decorative sheet 33 and the adhesive 32a. In this case, first, the temperature of the backup roll 50 is detected by the temperature sensors 45a to 45c of the backup roll detection unit 45 at the central portion and both end portions in the axial direction of the backup roll 50. Information relating to the temperature of the backup roll 50 detected by each of the temperature sensors 45 a to 45 c is sent to the control unit 22.

  The controller 22 detects the heaters 40a of the backup roll heating unit 40 so that the temperatures at the central portion and both end portions in the axial direction of the backup roll 50 detected by the temperature sensors 45a to 45c are substantially uniform. The degree of heating of the backup roll 50 by ~ 40i is controlled for each heater 40a-40i. At this time, the control unit 22 controls the outputs of the heaters 40a to 40i based on the correspondence between the heaters 40a to 40i and the temperature sensors. That is, when the temperature detected by a certain temperature sensor is larger or smaller than the temperature detected by another temperature sensor, the controller 22 changes each heater so as to change the output of the heater corresponding to this temperature sensor. The control of 40a-40i is performed. By performing such control, the degree of thermal expansion of the backup roll 50 can be made uniform at each location in the axial direction, thereby making the diameter of the backup roll 50 uniform in the axial direction. it can. Thus, the distance between the backup roll 50 and the die head 47a can be made uniform along the axial direction of the backup roll 50, and thereby the film of the adhesive 32a applied to the decorative sheet 33. The thickness can be made uniform along the width direction of the decorative sheet 33. In addition, you may confirm whether the film thickness of the adhesive agent 32a apply | coated to the decorative sheet 33 is uniform along the width direction of the decorative sheet 33 using the above-mentioned film thickness detection unit 48.

  As described above, according to the present embodiment, the backup roll heating unit 40 including the plurality of heaters 40 a to 40 i arranged in the axial direction of the backup roll 50 is provided in the vicinity of the backup roll 50. For this reason, the heating degree with respect to the said backup roll 50 in each heater 40a-40i can be adjusted for every heater 40a-40i, and, thereby, of adhesive 32a apply | coated to the decorative sheet 33 on the backup roll 50 The diameter of each location in the axial direction of the backup roll 50 can be adjusted so that the film thickness is uniform.

  Further, according to the present embodiment, each of the heaters 40 a to 40 i of the backup roll heating unit 40 is arranged so that the whole or at least a part thereof extends obliquely with respect to the rotation direction and the axial direction of the backup roll 50. For this reason, compared with the case where each heater is arrange | positioned so that it may extend in parallel with the rotation direction of the backup roll 50, the distance between each heater 40a-40i and the surface of the backup roll 50 can be made small, and this. Thus, the surface of the backup roll 50 can be efficiently heated by the heaters 40a to 40i.

  In the present embodiment, the example in which the heaters 40a to 40i of the backup roll heating unit 40 are arranged so as to extend obliquely with respect to the rotation direction and the axial direction of the backup roll 50 has been shown. However, the present invention is not limited to this, and in the first embodiment shown in FIGS. 1 to 9, the backup roll heating unit 40 is the same as the case of the heating unit 11 and the heating unit 12 shown in FIGS. 8 and 9. May have a plurality of heaters (not shown) arranged so as to extend obliquely with respect to the rotation direction and the axial direction of the backup roll 50, and arranged so as to extend in a curved shape instead of a linear shape. A plurality of heaters (not shown) may be provided.

  Moreover, in this Embodiment, the example to which the control part 22 controlled the degree of the heating with respect to the backup roll 50 in each heater 40a-40i based on the information from each temperature sensor 45a-45c was shown. However, the present invention is not limited to this, and the degree of heating of the backup roll 50 in each of the heaters 40a to 40i may be set in advance.

  Moreover, in this Embodiment, the example to which the control part 22 controls the degree of the heating with respect to the backup roll 50 in each heater 40a-40i based on the information from the detection unit 45 for backup rolls which has temperature sensor 45a-45c. Indicated. However, the present invention is not limited to this, and a plurality of displacement sensors arranged so as to oppose the backup roll 50 along the axial direction of the backup roll 50 with respect to the degree of heating of each of the heaters 40 a to 40 i with respect to the backup roll 50. The control unit 22 may perform control based on information from a backup roll detection unit (not shown). Hereinafter, a case where a displacement sensor is provided (modified example) will be described.

As in the case of the backup roll detection unit 45 having the modified temperature sensors 45 a to 45 c, the backup roll detection unit (not shown) having a plurality of displacement sensors is wound around the decorative sheet 33 of the backup roll 50. Each displacement sensor (e.g., three displacement sensors, not shown) is provided in a position in the axial direction of the backup roll 50 that faces the displacement sensor (a central portion and a position). Detect the diameter of both ends. Here, each displacement sensor is provided to correspond to each heater 40a-40i, respectively. More specifically, the first displacement sensor is provided to correspond to the three heaters 40a to 40c, the second displacement sensor is provided to correspond to the three heaters 40d to 40f, and the third displacement sensor is 3 Two heaters 40g to 40i are provided.

  The controller 22 detects each of the heaters 40a to 40i of the backup roll heating unit 40 so that the diameters at the three portions of the central portion and both end portions in the axial direction of the backup roll 50 are substantially uniform. The degree of heating of the backup roll 50 is controlled for each of the heaters 40a to 40i. At this time, the control unit 22 controls the outputs of the heaters 40a to 40i based on the correspondence between the heaters 40a to 40i and the displacement sensors. That is, when the diameter detected by a certain displacement sensor is larger or smaller than the diameter detected by another displacement sensor, the control unit 22 changes each heater so as to change the output of the heater corresponding to this displacement sensor. The control of 40a-40i is performed. By performing such control, the diameter of the backup roll 50 can be made uniform along the axial direction. Thus, the distance between the backup roll 50 and the die head 47a can be made uniform along the axial direction of the backup roll 50, and thereby the film of the adhesive 32a applied to the decorative sheet 33. The thickness can be made uniform along the width direction of the decorative sheet 33.

Third Embodiment Next, a third embodiment of the present invention will be described with reference to FIGS. Here, FIG. 13 is a front view showing an apparatus for manufacturing a decorative board in the third embodiment of the present invention, and FIG. 14 shows a pressure-bonding roll on the decorative sheet side in the third embodiment of the present invention. FIG. 15 is a view showing a rotary joint provided on a pressure-bonding roll on the decorative sheet side in the third embodiment of the present invention.

  The third embodiment shown in FIGS. 13 to 15 differs only in that the pressure-bonding roll on the decorative sheet side of the pair of cooling rolls is made of a metal pressure-bonding roll having a water pipe through which a heat medium passes. The other configuration is substantially the same as that of the first embodiment shown in FIGS. 1 to 9 and the second embodiment shown in FIGS. In the third embodiment shown in FIGS. 13 to 15, the same parts as those in the first embodiment shown in FIGS. 1 to 9 and the second embodiment shown in FIGS. Detailed description will be omitted.

Crimping Roll A pair of crimping rolls 60a and 60b will be described in detail with reference to FIGS. As shown in FIG. 1, the pair of press rolls 60 a and 60 b includes a press roll 60 a on the decorative sheet 33 side and a press roll 60 b on the base 31 side.

As shown in FIG. 14, the surface 63 of the pressure roller 60a on the decorative sheet 33 side of the pair of pressure rollers 60a and 60b contains metal, and the pressure roller 60a has a plurality of passages through which a heat medium passes. A water pipe 64 is provided. As described above, the surface 63 of the pressure roll 60a generally includes a metal having a small specific heat, so that the thermal conductivity of the surface 63 of the pressure roll 60a can be increased, and thereby the temperature of the surface 63 of the pressure roll 60a. Can be easily made uniform in the axial direction. In addition, rubber or resin may be wound around the outermost surface of the surface 63 of the pressure-bonding roll 60a on the decorative sheet 33 side. Thereby, the grip force with respect to the decorative sheet 33 in the pressure-bonding roll 60a can be improved, and the releasability of the decorative sheet 33 from the pressure-bonding roll 60a can be secured.
The surface of the pressure roll 60b on the base member 31 side of the pair of pressure rolls 60a and 60b is made of an elastic body such as rubber as in the case of the pressure roll 2b in the first embodiment shown in FIGS. Covered.
As shown in FIG. 14, the surface 63 of the pressure-bonding roll 60a on the decorative sheet 33 side of the pair of pressure-bonding rolls 60a, 60b is formed of metal, and the pressure-rolling roll 60a has a plurality of heat mediums passing therethrough. The water pipe 64 is provided. As described above, the surface 63 of the pressure roll 60a is generally formed of a metal having a small specific heat, and the temperature of the surface 63 of the pressure roll 60a is easily made uniform in the axial direction by passing a heat medium therethrough. Is possible. In addition, rubber | gum or resin may be wound around the outer periphery of the surface 63 of the crimping | compression-bonding roll 60a by the side of the decorative sheet 33, and coating may be given. Further, the surface of the pressure-bonding roll 60b on the substrate 31 side is covered with an elastic body such as rubber as in the case of the pressure-bonding roll 2b in the first embodiment shown in FIGS. By these, the improvement with respect to the decorative sheet 33 in the press roll 60a and the improvement of the release property of the decorative sheet 33 from the press roll 60a can be ensured.

  As shown in FIGS. 13 and 15, a heat medium is supplied to the water pipe 64 through the rotating shaft 62 of the pressure roll 60 a at the end of the pressure roll 60 a, and the heat medium from the water pipe 64 is supplied to the end of the pressure roll 60 a. A rotary joint 61 for discharging is provided. In this case, as shown in FIG. 15, the rotary joint 61 is provided on one side 62 a of the rotating shaft 62, and is provided on the supply-side rotary joint 61 a that supplies a heat medium to the water flow pipe 64 and the other side 62 b of the rotating shaft 62. And a discharge-side rotary joint 61b for discharging the heat medium from the water pipe 64. Thus, the surface 63 of the pressure roll 60a can be heated uniformly by circulating the heat medium through the water pipe 64 inside the pressure roll 60a using the rotary joint 61. The supply amount of the heat medium from the supply-side rotary joint 61a to the water pipe 64 is adjusted by a supply valve (not shown).

  As shown in FIG. 14, a thermocouple 65 for measuring the temperature of the surface 63 is embedded in the pressure-bonding roll 60a. As will be described later, the degree of heating of the surface 63 of the pressure-bonding roll 60 a is controlled by the control unit 22 based on the temperature information from the thermocouple 65.

  As the heat medium, various fluids such as liquid or gas can be used. For example, water can be used. In this case, it is preferable that the inner surfaces of the rotary joints 61a and 61b, the rotating shaft 62, and the water pipe 64 serving as a heat medium path are subjected to appropriate rust prevention treatment. The rust inhibitor used in this case is not particularly limited, and a general rust inhibitor can be used.

  Next, the operation of the present embodiment having such a configuration will be described. Here, the manufacturing method of the decorative board 30 is demonstrated.

  First, as shown in FIG. 13, a base material 31 having a flat surface is prepared and sent out between the pair of press rolls 60 a and 60 b by the transport roll 6. On the other hand, the decorative sheet supply roll 8 around which the decorative sheet 33 is wound is prepared, and then the decorative sheet 33 from the decorative sheet supply roll 8 is wound around the backup roll 50. Thereafter, as shown in FIG. 13, in the backup roll 50 of the adhesive application mechanism 46, the adhesive 32 a is applied to the back surface 33 b of the decorative sheet 33 by the die head 47 a of the adhesive application machine 47 of the adhesive application mechanism 46. Next, the decorative sheet 33 with the adhesive 32a applied to the back surface 33b is sent between the pair of pressure-bonding rolls 60a and 60b.

  Thereafter, as shown in FIG. 13, a decorative sheet 33 in which an adhesive 32 a is applied to the back surface 33 b is laminated on the base material 31 between the pair of pressure rolls 60 a and 60 b. Next, the laminated base material 31 and decorative sheet 33 are pinched while being heated by a pair of pressure-bonding rolls 60a and 60b. Next, as shown in FIG. 13, the base material 31 and the decorative sheet 33 that are sandwiched while being heated are sandwiched and cooled by the pair of first cooling rolls 3 a and 3 b and the pair of second cooling rolls 4 a and 4 b. To do. Thereby, the adhesive agent 32a interposed between the base material 31 and the decorative sheet 33 can be hardened, and as a result, the adhesive agent layer 32 is formed. Thereby, the decorative board 30 which consists of the decorative sheet 33, the base material 31, and the adhesive bond layer 32 interposed between the decorative sheet 33 and the base material 31 can be obtained.

  During this time, the surface 63 of the pressure-bonding roll 60a on the decorative sheet side is heated by the heat medium circulating in the water pipe 64 inside. In this case, first, the temperature near the surface 63 of the pressure-bonding roll 2a is detected by the thermocouple 65. Information on the temperature detected by the thermocouple 65 is sent to the control unit 22. The control unit 22 adjusts the supply valve based on information from the thermocouple 65, and thereby adjusts the supply amount of the heat medium from the supply-side rotary joint 61 a to the water conduit 64. Thus, the degree of heating of the pressure-bonding roll 60a by the heat medium can be controlled, and thereby the surface 63 of the pressure-bonding roll 60a can be controlled to a predetermined temperature. In this case, as described above, the surface 63 of the pressure-bonding roll 60a generally contains a metal having a small specific heat. Therefore, the temperature of the surface 63 of the pressure-bonding roll 60a can be easily made uniform in the axial direction. .

  Thus, according to the present embodiment, the surface 63 of the pressure-bonding roll 60a on the decorative sheet 33 side of the pair of pressure-bonding rolls 60a, 60b contains a metal, and the pressure-bonding roll 60a contains a heat medium therein. A plurality of water pipes 64 are provided. A supply-side rotary joint 61a for supplying a heat medium to the water flow pipe 64 is provided on one side 62a of the rotary shaft 62 of the crimping roll 60a, and heat from the water flow pipe 64 is provided on the other side 62b of the rotary shaft 62. A discharge-side rotary joint 61b that discharges the medium is provided. For this reason, the temperature of the surface 63 of the pressure-bonding roll 60a can be made uniform in the axial direction, whereby the degree of thermal expansion of the pressure-bonding roll 60a can be made uniform in the axial direction. Therefore, the diameter of the press roll 60a can be made uniform in the axial direction. Thereby, the laminated base material 31 and the decorative sheet 33 can be uniformly clamped over the entire surface by the pair of pressure-bonding rolls 60a and 60b, and as a result, the decorative board 30 having a specular surface can be obtained. .

  In addition, in this Embodiment, as shown in FIG. 14, the example which the water flow pipe 64 extended along the axial direction of the press roll 60a was shown inside the press roll 60a. However, the present invention is not limited to this. For example, the water flow pipe 64 is arranged so that the distance from the surface of the pressure-bonding roll 60a to the water flow pipe 64 is different between the central portion and both end portions of the pressure-bonding roll 60a. It may be bent or curved. Thus, the degree of heating from the heat medium can be made different between the central portion and the both end portions on the surface of the pressure-bonding roll 60a. In addition, a predetermined number of water pipes bent and curved in this way and water pipes extending along the axial direction of the pressure roll 60a are provided in the pressure roll 60a, respectively, and a heat medium is selectively passed through each water pipe. For this purpose, each water pipe may be provided with water selection means (not shown) such as an on-off valve. Thus, even when the heat radiation amount from the surface of the pressure-bonding roll 60a to the outside air is different between the center portion of the surface of the pressure-bonding roll 60a and the both end portions, the degree of heating with respect to the surface of the pressure-bonding roll 60a It can be adjusted independently at both end portions, whereby the temperature of the surface 63 of the pressure-bonding roll 60a can be made uniform in the axial direction. Therefore, the diameter of the press roll 60a can be made uniform in the axial direction. As a result, the laminated base material 31 and the decorative sheet 33 can be uniformly pressed over the entire surface, and as a result, the decorative board 30 having a mirror-like surface can be obtained.

  In the present embodiment, a supply-side rotary joint 61a for supplying a heat medium to the water pipe 64 is provided on one side 62a of the rotary shaft 62 of the press roll 60a, and on the other side 62b of the rotary shaft 62 of the press roll 60a. The example in which the discharge side rotary joint 61b which discharges the heat medium from the water flow pipe 64 is provided is shown. However, the present invention is not limited to this, and both the supply-side rotary joint 61a and the discharge-side rotary joint 61b may be provided on one side 62a or the other side 62b of the rotating shaft 62.

In the present embodiment, as in the second embodiment shown in FIGS. 10 to 12, the backup roll heating unit 40 provided in the vicinity of the backup roll 50 extends along the axial direction of the backup roll 50. A plurality of heaters (heating units for backup rolls) 40a to 40i arranged side by side. In this case, each of the heaters 40 a to 40 i is arranged so as to extend obliquely with respect to the rotation direction and the axial direction of the backup roll 50.
Further, the backup roll detection unit 45 provided in the vicinity of the backup roll 50 may have a plurality of temperature sensors 45 a to 45 c arranged so as to face the backup roll 50. Moreover, each heater 40a-40i may be controlled by the control part 22 based on the information from each temperature sensor 45a-45c.
Further, a backup roll detection unit (not shown) having a plurality of displacement sensors may be provided. In this case, each heater 40a-40i is controlled by the control part 22 based on the information from each displacement sensor.
Since the backup roll heating unit 40, the backup roll detection unit 45, and the control unit 22 are substantially the same as those in the second embodiment shown in FIGS. 10 to 12, detailed description thereof will be omitted.

  Moreover, in each said embodiment, the example in which a pair of press roll 2a, 2b; 60a, 60b was provided was shown. However, the present invention is not limited to this, and a plurality of pairs of crimping rolls may be provided. In this case, the pair of crimping rolls provided at least on the most upstream side of the plurality of pairs of crimping rolls is the pair of crimping rolls 2a, 2b or the third embodiment in the first or second embodiment. It is comprised from a pair of crimping | compression-bonding roll 60a, 60b in a form.

  In each of the above embodiments, the adhesive application mechanism 46 adheres to the backup roll 50 around which the decorative sheet 33 from the decorative sheet supply roll 8 is wound, and the back surface 33b of the decorative sheet 33 wound around the backup roll 50. The example comprised from the adhesive agent coating machine 47 which apply | coats the agent 32a was shown. However, the present invention is not limited to this, and the adhesive application mechanism 46 sends the decorative sheet 33 from the decorative sheet supply roll 8 to the decorative sheet 33 while applying a certain tension to the decorative sheet 33 in the traveling direction. Guide rolls (not shown) and a coating device (not shown) which is provided approximately in the middle of the pair of guide rolls and applies the adhesive 32a to the back surface 33b of the decorative sheet 33 by a kiss coat method. Also good.

  Moreover, the application method of the adhesive 32a by the coating apparatus is not limited to the kiss coat type, and various types and methods can be used depending on the shape and operation of the coating apparatus. For example, forward roll coater, reverse roll coater, gravure coater, knife coater, blade coater, rod coater, die coater (fountain type), kiss coater, dip coating, screen coating, spin coater, cast coating, spray coating, extrusion coating, Rod coating, 3 reverse coaters, 2 reverse coaters (slit reverse coaters), kiss reverse coaters, direct gravure coaters, reverse gravure coaters, kiss reverse gravure coaters, smoothing bars, direct roll coaters, and the like can be used.

  EXAMPLES Next, although an Example demonstrates this invention further more concretely, this invention is not limited to description of a following example, unless the summary is exceeded.

Introduction heating roll, a result of heating the roll by using the heating unit 10 in the first embodiment described above, was measured roll diameter and the temperature at that time, and, passing in the third embodiment described above The result of heating the roll using the water pipe 64 and measuring the diameter and temperature of the roll at that time will be described. Table 1 shows the rolls used and the heating method, and the temperature measurement results and roll diameter measurement results in that case.

  As the roll, as shown in Table 1, a roll having a surface formed of silicone rubber or a roll having a surface formed of chrome-plated iron was used. Each roll had a diameter of 200 mm and an axial length of 1000 mm.

  As a heating method, a method of heating a roll using the heating unit 10 of the present invention shown in FIG. 2 (“divided heater type” in Table 1) or a water pipe 64 of the present invention shown in FIG. 14 is used. A method of heating the roll (“water pipe type” in Table 1) was used. For comparison, measurement was also performed using a method of heating a roll using the conventional heating unit 14 shown in FIG. 5 (“conventional heater type” in Table 1).

  As shown in Table 1, the set temperature for heating the roll was 25, 40, 60, 70 or 90 degrees.

  In addition, the symbol shown in the leftmost column of Table 1 is a symbol representing the material of the roll surface, the heating method, and the set temperature used for the measurement. In the symbol, “R” represents that the material of the roll surface is silicone rubber, and “M” represents that the material of the roll surface is chrome-plated iron. “S” indicates that the heating method is a split heater type, “B” indicates that the heating method is a conventional heater type, and “T” indicates that the heating method is a water pipe type. Represents that. Moreover, the number in the said symbol represents the preset temperature at the time of heating a roll.

  Therefore, for example, the symbol “RS40” represents that a roll whose surface material is silicone rubber was heated at a set temperature of 40 degrees using the heating unit 10 of the present invention shown in FIG.

  As shown in Table 1, the variation in roll surface temperature in the roll axis direction when the heating unit 10 of the present invention is used is more than the variation in roll surface temperature in the roll axis direction when the conventional heating unit 14 is used. It was generally small. Also, as shown in Table 1, the roll diameter variation in the roll axis direction when the heating unit 10 of the present invention is used is generally larger than the roll diameter variation in the roll axis direction when the conventional heating unit 14 is used. It was getting smaller.

Manufacture of decorative board Next, the result of manufacturing the decorative board 30 using the roll shown in Table 1 will be described.

An MDF having a width of 500 mm × length of 1800 mm and a thickness of 18 mm was prepared as the base material 31, and a flat surface was formed on the base material 31 by subjecting the base material 31 to buffing.
A decorative sheet 33 having a thickness of 0.2 mm made of PIAFORTE manufactured by Dai Nippon Printing Co., Ltd. was prepared. As the adhesive 32a, a polyester PUR adhesive manufactured by DIC Corporation was used.

Table 1 shows combinations of the pressure-bonding roll and the cooling roll used. In the column of “crimping roll and cooling roll” in Table 1, the numeral “1” represents the crimping rolls 2a and 2b installed at the most upstream, and the numerals “2”, “3”, and “4” The rolls arranged on the downstream side of the crimping rolls 2a and 2b installed on the most upstream side are shown in order from the upstream side. In addition, the meaning of the symbol (for example, “RS40”) in Table 2 is the same as the meaning of the symbol in Table 1. For example, in Example 1, as the pressure-bonding rolls 2a and 2b installed at the most upstream, the surface is formed of silicone rubber, and the roll is heated at a set temperature of 40 degrees using the heating unit 10 of the present invention ( RS40) is used, and as a downstream roll, a roll (MB40) is used that is formed of chrome-plated iron and heated at a set temperature of 40 degrees using a conventional heating unit 14. ing.

  As shown in Table 2, in Examples 1 to 5, silicone heated at a set temperature of 40 degrees or 70 degrees using the heating unit 10 of the present invention as the pressure-bonding rolls 2a and 2b disposed on the most upstream side. A roll having a rubber surface was used. Further, as shown in Table 2, in Comparative Examples 1 to 4, the pressure rolls 2a and 2b arranged on the most upstream side are heated at a set temperature of 25 degrees, 40 degrees or 70 degrees using a conventional heating unit 14. A roll having a surface made of silicone rubber was used.

  First, the adhesive 32a was heated to 120 degrees in the adhesive supply part 47b, and then the heated adhesive 32a was applied from the die head 47a to the back surface 33b of the decorative sheet 33 with a film thickness of 0.1 mm. Thereafter, the decorative sheet 33 having the back surface 33b coated with the adhesive 32a was sent between the pair of pressure-bonding rolls 2a and 2b.

  Next, between the pair of pressure-bonding rolls 2a and 2b, the decorative sheet 33 coated with the adhesive 32a on the back surface 33b is laminated on the base material 31, and then the laminated base material 31 and decorative sheet 33 are It clamped, heating with a pair of press roll 2a, 2b.

  Next, the base material 31 and the decorative sheet 33 were further clamped with the rolls shown in Table 2 and cooled. Thus, the decorative board 30 was manufactured.

  The specularity of the surface of the obtained decorative board 30 was determined visually. As a result, as shown in Table 2, in the case of Examples 1 to 5, that is, as the pressure-bonding rolls 2a and 2b arranged at the most upstream, the heating unit 10 of the present invention is used at a set temperature of 40 degrees or 70 degrees. When the roll which has a surface which consists of silicone rubber while being heated was used, it confirmed that the surface of the decorative board 30 had sufficient specularity.

DESCRIPTION OF SYMBOLS 1 Manufacturing apparatus 2a Decorative sheet side press roll 2b Base material side press roll 3a Decorative sheet side first cooling roll 3b Base material side first cooling roll 3c Rotary joint 4a Decorative sheet side second cooling roll 4b Base material Side second cooling roll 4c rotary joint 6 transport roll 8 decorative sheet supply roll 10 heating unit 10a to 10i heater 11 other heating unit 11a to 11h heater 12 other heating unit 12a to 12i heater 14 according to the first comparative example Heating unit 14a-14i Heater 15 Heating unit 15a-15l according to the second comparative example Heater 16 Heating unit 16a, 16b according to the third comparative example Heater 20 Detection unit 20a-20c Temperature sensor 22 Control unit 30 Decorative plate 31 Base Material 32 Adhesive layer 32a Adhesive 33 decorative sheet 33a decorative sheet surface 33b decorative sheet back surface 34 decorative sheet substrate 35 colored layer 35a solid colored layer 35b pattern colored layer 36 decorative sheet adhesive layer 37 transparent resin layer 38 top coat layer 40 heating unit for backup roll 40a-40i Heater 45 Backup roll detection unit 45a-45c Temperature sensor 46 Adhesive application mechanism 47 Adhesive application machine 47a Die head 47b Adhesive supply unit 48 Film thickness detection unit 50 Backup roll 60a Bonding roll 60b on decorative sheet side Base material Side pressure roll 61 Rotary joint 61a Supply side rotary joint 61b Discharge side rotary joint 62 Rotating shaft 62a One side of rotating shaft 62b The other side of rotating shaft 63 Surface of the pressing roll on the decorative sheet side 64 Water pipe 65 Thermocouple

Claims (6)

In a method for producing a decorative board laminated with a decorative sheet,
Preparing a substrate having a flat surface;
A step of applying an adhesive to the back surface of the decorative sheet by an adhesive application mechanism;
A process of laminating a decorative sheet with an adhesive applied to the back surface on a substrate;
A step of pressing the laminated base material and the decorative sheet while heating with at least a pair of pressure-bonding rolls;
A step of cooling the base material and the decorative sheet sandwiched while being heated by at least a pair of cooling rolls,
Of the pair of pressure-bonding rolls, the pressure-bonding roll on the decorative sheet side is composed of a metal pressure-bonding roll having a plurality of water pipes through which the heat medium passes.
Each of the plurality of water pipes extends along the axial direction of the metal pressure-bonding roll, and is arranged along the rotation direction of the metal pressure-bonding roll,
A decorative board comprising a supply-side rotary joint that supplies a heat medium to a water pipe of the pressure-bonding roll and a discharge-side rotary joint that discharges the heat medium from the water-flow pipe at an end of the pressure-bonding roll. Manufacturing method. The plurality of water pipes are bent or curved so that the distance from the surface of the metal pressure-bonding roll to the water pipe is different between the central portion and both end portions in the axial direction of the metal pressure-rolling roll. The method for manufacturing a decorative board according to claim 1, further comprising a water pipe. The adhesive application mechanism has a backup roll around which the decorative sheet is wound, and an adhesive applicator for applying an adhesive to the back surface of the decorative sheet wound around the backup roll,
The manufacturing method of the decorative board according to claim 1 or 2 , wherein, in the step of applying the adhesive, the adhesive is applied to the back surface of the decorative sheet wound around the backup roll by an adhesive applicator. Method. In an apparatus for manufacturing a decorative plate by laminating a decorative sheet on a substrate having a flat surface, an adhesive application mechanism for applying an adhesive to the back surface of the decorative sheet;
At least a pair of pressure-bonding rolls provided on the downstream side of the adhesive application mechanism and sandwiching the decorative sheet with the adhesive applied to the back surface and the substrate while heating;
Provided at the downstream side of the pair of pressure-bonding rolls, and includes at least a pair of cooling rolls that sandwich and cool the base material and the decorative sheet,
Of the pair of pressure-bonding rolls, the pressure-bonding roll on the decorative sheet side is composed of a metal pressure-bonding roll having a plurality of water pipes through which the heat medium passes.
Each of the plurality of water pipes extends along the axial direction of the metal pressure-bonding roll, and is arranged along the rotation direction of the metal pressure-bonding roll,
A decorative board comprising a supply-side rotary joint that supplies a heat medium to a water pipe of the pressure-bonding roll and a discharge-side rotary joint that discharges the heat medium from the water-flow pipe at an end of the pressure-bonding roll. Manufacturing equipment. The plurality of water pipes are bent or curved so that the distance from the surface of the metal pressure-bonding roll to the water pipe is different between the central portion and both end portions in the axial direction of the metal pressure-rolling roll. The decorative board manufacturing apparatus according to claim 4, further comprising a water pipe. The adhesive applying mechanism, according to claim 4, characterized in that it comprises the a backup roll decorative sheet is wound, and an adhesive applicator for applying adhesive to the rear surface of the decorative sheet wound around the backup roll Or the manufacturing apparatus of the decorative board of 5 .

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