JPH0890743A - Production of decorative panel - Google Patents

Abstract

PURPOSE: To provide a pattern high in design effect matched with an embossed pattern to the entire surface of a decorative panel base material having a joint part and a tongue part parallel to a longitudinal direction. CONSTITUTION: In a method for producing a decorative panel by laminating a decorative panel base material having large embossed parts parallel to a longitudinal direction and a transfer sheet 10 by a pressure bonding roll 30, a plurality of cylindrical rubber layer rings 31 having roll bearings 32 therein and different in thickness and hardness are externally fitted to an iron core 33 so as to mutually become the relation of male and female molds with respect to the embossed parts of the decorative panel base material to form the pressure bonding roll 30. The decorative panel base material and the transfer sheet 10 are bonded under heating and pressure by the pressure bonding roll 30 so that the embossed parts of the decorative panel base material and those of the pressure bonding roll 30 are regulated so as to form the relation of male and female molds to pattern the entire surface of the decorative panel base material.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a decorative board, in which a decorative board having an embossed pattern is efficiently provided with a highly-designed pattern on the entire surface of the board.

[0002]

2. Description of the Related Art Conventionally, various decorative boards have been used for building materials, but in recent years, with the trend toward higher quality, decorative boards having an embossed pattern on the surface thereof have been favored. Further, as a method for decorating a decorative sheet having this embossed pattern, there is a laminating method or a transfer method in which a laminate sheet or a transfer sheet is thermocompression-bonded to a decorative sheet substrate using a pressure bonding roll or the like.

In the conventionally used pressure-bonding roll, since the thickness and hardness of the wound rubber are constant, both the embossed convex portion and the embossed concave portion of the decorative board base material have to be thermocompressed under the same conditions. For this reason, the joints shown on the joints of wood grain, bricks, etc., and the tongues, etc., which are stepped to be stacked alternately so that rain leakage does not occur when the decorative plates are stacked, deep, edge The laminating method and the transfer method by thermocompression bonding to a portion with a gap were difficult.

[0004]

SUMMARY OF THE INVENTION The present invention has been made in view of the above-mentioned conventional problems, and the problem is that there are joints and tongues parallel to the longitudinal direction of the base material. Another object of the present invention is to propose a method for decorating a decorative plate in which a decorative pattern that is in good harmony with an embossed pattern is efficiently provided on the decorative plate base material.

[0005]

In order to achieve the above object in the present invention, a decorative sheet substrate having a large uneven portion in parallel with the longitudinal direction and a transfer sheet are laminated by using a pressure roll. A method for manufacturing a decorative plate manufactured by the method, wherein the manufacturing method has a plurality of cylindrical rubber layer rings having rolling bearings on the inside and having different thicknesses and hardnesses, and the uneven portion of the decorative plate base material. , A pressure-bonding roll that is fitted into an iron core so as to have a male-female relationship with each other, and with this pressure-bonding roll, the decorative plate base material and the transfer sheet, It is a method of thermocompression bonding while adjusting the convex and concave portions so as to have a male and female relationship, and is a method of manufacturing a decorative plate characterized by painting on the entire surface of the decorative plate base material.

[0006]

As described above, according to the present invention, heat is applied by using a pressure-bonding roll produced by inserting a plurality of cylindrical rubber layer rings having rolling bearings inside and having different thickness and hardness into an iron core. Since it is pressure-bonded, a rubber layer with low hardness is used for fine embossing of the convex portion of the base material, and a harder rubber layer is used for embossing of the deep concave base material such as joints and tongues. By using a high rubber layer, a transfer sheet or a laminate sheet can be thermocompression-bonded, and the rolls can be selectively used according to the unevenness of the decorative plate base material.

Further, since the roll portions having different outer diameters rotate independently, there is no difference in peripheral speed, and stable pressure bonding is possible.

[0008]

The present invention will be described in detail below with reference to the drawings. FIG. 1 shows a transfer sheet (1 according to an embodiment of the present invention.
In the sectional configuration view of (0), a release layer (12), a pattern layer (13), and an adhesive layer (14) are sequentially provided on the surface of a base film (11).

The base film (11) is attached to the pressure roll (3
0) by the heat of thermocompression bonding at the time of transfer.
A thermoplastic resin film that can follow the shape of the surface embossing of 0) is used. Specific examples thereof include vinyl chloride, polyethylene, polypropylene, nylon, polyester and the like. The type of resin, the thickness, etc. may be selected in consideration of the degree of embossing on the substrate surface and the transfer temperature, but according to the experiments by the inventors, at the transfer temperature of 150 to 180 ° C., the thickness is 100 μm or less. The best results have been obtained with the vinyl chloride resin film.

The release layer (12) is a base film (11).
It may be appropriately selected depending on the kind of the above. For example, when a vinyl chloride resin film is used as the base film, a release varnish containing a polyvinyl butyral resin as a main component can be preferably selected.

The pattern layer (13) is usually formed by means such as gravure printing or screen printing, and the binder of the printing ink is determined in consideration of the elongation during heating, the durability of the final product, and the like. A binder containing a copolymer resin of vinyl and vinyl acetate as a main component can be preferably selected.

As the adhesive layer (14), polyvinyl alcohol, acryl, hydroxymethyl cellulose, polyester, polyamide and the like can be preferably selected. The adhesive layer (14) is not always necessary when the step of applying the adhesive to the decorative board base material (20) in advance is assumed.

The sheet to be attached to the surface of the decorative board base material (20) is not limited to the transfer sheet, and a laminate sheet may be used.

FIG. 2 is a perspective explanatory view of the decorative board base material (20), and the base material is not particularly limited, such as wood, plastic, an inorganic base material, and a wood chip cement board. Joints (21) and tongues (22) are formed parallel to the longitudinal direction of the base material.

FIG. 3 is a perspective explanatory view of the rubber layer ring (31) which constitutes the pressure bonding roll (30), and has a rolling bearing (32) having substantially the same diameter as the iron core diameter inside.

Regarding the hardness of the rubber layer, in the rubber layer corresponding to the concave portion corresponding to the flat surface portion of the decorative plate base material, the silicone rubber having a hardness of 40 °, which is easy to follow fine embossing and has a high heat resistance, is the inventor of the present invention. Good results were obtained in these experiments. Further, in the rubber layer corresponding to the protrusions corresponding to the joints and tongues of the decorative plate base material, since it is not necessary to follow the fine embossing, the rubber layer has relatively high hardness, heat resistance, It is sufficient to select a durable one, and in the experiments conducted by the inventors, the hardness is 8
Good results have been obtained with 0 ° silicone rubber.

As the elastic body used for the rubber layer, neoprene rubber, styrene-butadiene rubber (SBR) or the like can be used in addition to silicone rubber, and a plastic body can also be used.

FIG. 4 is a perspective explanatory view of the pressure-bonding roll (30), showing a state in which five rubber layer rings (31) having different thicknesses, hardnesses, and widths are fitted into the iron core (33) and assembled. . It is necessary to change the thickness, hardness and width of the rubber layer ring (31) fitted in the iron core (33) at any time depending on the pattern in the longitudinal direction of the decorative board substrate (20) to be bonded.

In FIG. 5, the adhesive layer (14) in the transfer sheet (10) is transferred to the decorative plate substrate (2) by the pressure bonding roll (30).
0) and set it so that it overlaps with the transfer sheet (1
It is a model explanatory view which shows the state which has been thermocompression-bonded to 0) and the decorative board base material (20). Crimping roll (30) as described above
And the concave portion and the convex portion of the decorative plate base material (20),
It is necessary to adjust so that a male type and a female type have a relationship and perform thermocompression bonding. The transfer sheet (10) is attached, and the base film (1
After peeling off 1), clear coating can be applied on the surface for the purpose of surface protection.

The embodiment of the present invention will be described more specifically. After a release varnish containing a polyvinyl butyral resin as a main component is applied as a release layer (12) to the surface of a 70 μm thick semi-rigid vinyl chloride sheet (11) which is a base film, a salt is used as a pattern layer (13). By the gravure printing method using an ink using a vinyl acetate copolymer resin as a binder,
A pattern in conformity with the embossed shape of the decorative board substrate (20) was printed, and an appropriate amount of polyester resin was applied as an adhesive layer (14) to prepare a transfer sheet (10).

On the other hand, it has an embossed shape on the surface such as a wood grain pattern, and has joints (21) and tongues (22) parallel to the longitudinal direction.
A calcium silicate board having the above was prepared as a decorative board base material (20), dust-removed, and treated with a sealer. A proper amount of urethane adhesive is applied to the surface of the calcium silicate plate (20) and dried, and then the calcium silicate plate (20) and the transfer sheet (10) are heated to 150 ° C. to form a pressure roll ( In 30), thermocompression bonding was performed. In this case, in the rubber layer ring of the pressure-bonding roll of the portion corresponding to the convex portion of the calcium silicate plate, a silicone rubber having a surface hardness of 40 ° is formed in the portion corresponding to the concave portion (that is, the joint portion and the tongue portion). Silicone rubber having a surface hardness of 80 ° was used for the rubber layer ring of the pressure roll. Further, the iron core (33) is provided with a mechanism capable of being heated by oil, electricity, etc. (not shown).

Then, an acrylic urethane top coat was applied as a surface protective layer to the surface of the decorative decorative board obtained by peeling off the semi-rigid vinyl chloride sheet which is the base film (11). The decorative decorative board thus obtained had an extremely high designability, following a fine embossed shape and having a synchronized pattern.

[0023]

EFFECTS OF THE INVENTION According to the present invention, a rubber layer ring having a low hardness is used for fine embossing of a convex portion of a decorative plate base material, and a hardness of a rubber layer ring having a low hardness for an embossing of a base material concave portion having deep edges Since a decorative plate is manufactured using a crimping roll in which a highly elastic rubber layer ring is inserted in an iron core, a beautiful pattern in synchronization with the embossed shape can be attached to the surface of the embossed shape, and the designability is extremely high. A high decorative decorative board can be manufactured.

Further, since the crimping roll can be crimped over the entire surface of the decorative plate base material, it is possible to produce a decorative plate with the entire surface painted.

[Brief description of drawings]

FIG. 1 is a cross-sectional explanatory diagram of a transfer sheet according to an embodiment of the present invention.

FIG. 2 is a perspective explanatory view of a decorative board base material according to an embodiment of the present invention.

FIG. 3 is a perspective explanatory view of a rubber layer ring.

FIG. 4 is a perspective explanatory view of a pressure bonding roll.

FIG. 5 is a schematic explanatory view showing a state in which a transfer sheet and a decorative board substrate are thermocompression bonded.

[Explanation of symbols]

 10 Transfer sheet 11 Base film 12 Release layer 13 Picture layer 14 Adhesive layer 20 Decorative base material 21 Joint area 22 Tongue section 30 Crimping roll 31 Rubber layer ring 32 Rolling bearing 33 Iron core

Claims (1)

[Claims] 1. A method of manufacturing a decorative plate, which comprises manufacturing a decorative plate base material having a large uneven portion parallel to a longitudinal direction and a transfer sheet by using a pressure roll, and manufacturing the decorative plate. A plurality of cylindrical rubber layer rings having rolling bearings inside and different in thickness and hardness, and the iron core so as to have a male-female relationship with the concave-convex portion of the decorative plate base material. Into a pressure-bonding roll, and with this pressure-bonding roll, the decorative plate base material and the transfer sheet are
It is a method of thermocompression bonding while adjusting the concave and convex portions of the decorative board base material and the convex and concave parts of the pressure bonding roll so as to have a male and female relationship, and is characterized by painting the entire surface of the decorative board base material. A method for manufacturing a decorative board.