JPH10323958A - Manufacture of decorative board - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a decorative board in which irregularities can be precisely generated on a veneer by a guiding pipe with a high degree of productivity. SOLUTION: A plastic sheet 4 is superposed on the surface of a veneer 5, while a veneer bonding base material 3 and the sheet 4 are being conveyed between a pair of clamping rolls 1, 2. By clamping the material 3 and sheet 4 between the rolls 1, 2 while the sheet 4 is being heated by one of the rolls 1, the sheet 4 is bonded to the surface of a veneer 5. The sheet 4 can be superposed, while the air in a space between the veneer 5 and the sheet 4 is being removed. A decorative board can be manufactured by continuously feeding the material 3 and sheet 4 between the rolls 1, 2. The sheet 4 can be formed by providing an adhesive layer having a thickness of 20-40 μm on a thermoplastic resin layer having a thickness of 50-200 μm.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a decorative board used for a building material such as a closet, an entrance frame, a door, a door and a type stand.

[0002]

2. Description of the Related Art Conventionally, decorative boards have been proposed in which a plastic sheet is attached to the surface of a veneer-attached base material to enhance surface protection and design. FIG. 14A shows an example of a method for manufacturing this type of decorative board. in this way,
A veneer plate 5 is attached to the surface of the base material to form a veneer-attached base material 3, a plastic sheet 4 made of vinyl chloride resin or the like is placed on the surface of the veneer plate 5 and laminated, and 12 at a temperature of 120 to 150
The above laminate is heated and pressed from above and below with a pair of hot plates 10 and 10 under conditions of a temperature of 10 ° C., a pressure of 10 to 60 kg / cm ² and a time of 8 to 10 minutes, and a plastic sheet 4 is adhered to the surface of the veneer 5 to be laminated. It is something to do.

FIG. 14B shows another example of a method for manufacturing a decorative board. In this method, the veneer plate 5 is attached to the surface of the base material 9 to form the veneer-attached base material 3 and the adhesive 13
A plastic sheet 4 made of vinyl chloride resin or the like is placed and laminated on the surface of the protruding plate 5, and a polyethylene film 14 that does not adhere to the plastic sheet 4 is laminated on the surface of the plastic sheet 4. 10 and the laminate is heated and pressed from above and below with the hot plates 10 and 10 under the same conditions as above, and the plastic sheet 4 is adhered to the surface of the veneer 5 with the adhesive 13. It is intended to be laminated.

[0004]

However, when the plastic sheet 4 is simply placed on the surface of the veneer 5 and laminated as in the above-described manufacturing method, air remains between the veneer 5 and the plastic sheet 4 and the veneer 5 and the plastic sheet 4 may not be able to adhere to each other.
When the veneer-attached base material 3 is depressurized in a high temperature state, the remaining air may expand, or the plastic sheet 4 may spring back, causing the plastic sheet 4 to float up from the veneer 5. In addition, there is a problem that irregularities formed by a conduit (a vessel) on the surface of the veneer plate 5 cannot be faithfully expressed on the surface of the decorative plate (plastic sheet 4).

In order to prevent the spring back of the plastic sheet 4 from occurring, the veneer base 3 and the plastic sheet 4 may be cooled while pressurizing after heating and pressing. There is a problem that it takes time and productivity is extremely low. The present invention has been made in view of the above points, and an object of the present invention is to provide a method of manufacturing a decorative board capable of manufacturing a decorative board in which unevenness due to a veneer pipe is faithfully expressed with high productivity. It is the purpose.

[0006]

According to the first aspect of the present invention, the surface of the veneer plate 5 is formed by feeding a veneer base material 3 and a plastic sheet 4 between a pair of pressing rolls 1 and 2. By laminating the sheets 4 and pressing the plastic sheet 4 between the pressing rolls 1 and 2 while heating the plastic sheet 4 with one pressing roll 1, the plastic sheet 4 is pressed onto the surface of the veneer 5. It is characterized in that the plastic sheet 4 is bonded.

According to a second aspect of the present invention, in addition to the first aspect, the plastic sheet 4 is
The thickness of the thermoplastic resin layer 6 having a thickness of 50 to 200 μm is
It is characterized by being formed by providing an adhesive layer 7 of 40 μm. Further, the invention described in claim 3 of the present invention
3. The pressing rolls 1, 2 according to claim 1,
, A rubber roll having a hardness of 20 to 90 ° is used.

According to a fourth aspect of the present invention, in addition to the constitution of the second or third aspect, the adhesive of the adhesive layer 7 is at least one selected from a hot melt adhesive and a solvent type adhesive. It is characterized by being one of them. According to a fifth aspect of the present invention, in addition to any one of the second to fourth aspects, the adhesive layer 7 is preheated before the plastic sheet 4 is laminated on the surface of the veneer plate 5. It is characterized by the following.

The invention according to claim 6 of the present invention is a contract
In addition to any one of claims 1 to 5, a plurality of consecutive clamping
Between the rolls 1 and 2, the veneer base material 3 and the plastic sheet
After the sheet 4 is pressed, the plastic sheet is
4 is cooled. The present invention
The invention according to claim 7 is any one of claims 1 to 6
And the Young's modulus of the plastic sheet 4 is 2
× 10⁸~ 2 × 10⁹dyn / cm ^TwoHeating to become
It is characterized by doing.

According to an eighth aspect of the present invention, in addition to any one of the first to seventh aspects, the surface of the veneer plate 5 is colored before the plastic sheet 4 is laminated on the surface of the veneer plate 5. Then, the surface of the colored veneer plate 5 is roll-pressed. According to a ninth aspect of the present invention, in addition to the configuration according to any one of the first to eighth aspects, before the plastic sheet 4 is laminated on the surface of the veneer plate 5, the veneer substrate 3 is heated. It is characterized by the following.

The invention according to claim 10 of the present invention provides:
In addition to the configuration of any one of the first to ninth aspects, after the plastic sheet 4 is laminated on the surface of the veneer plate 5, the surface of the plastic sheet 4 is painted. The invention described in claim 11 of the present invention is directed to claim 1
In addition to any one of the above structures, the surface of the plastic sheet 4 is painted before the plastic sheet 4 is laminated on the surface of the veneer plate 5.

[0012]

Embodiments of the present invention will be described below. FIG. 1 shows an example of a laminating apparatus used in the present invention. The laminating apparatus includes a heating roll 17, an upper pressing roll 1, and a cooling roll 8 above a conveyor belt 15 that travels in one direction (indicated by an arrow a) at a speed of 2 to 20 m / min.
Are arranged in this order along the traveling direction of the transport belt 15, and an introduction roll 18, a lower pressing roll 2, and an output roll 19 are provided below the transport belt 15. Are arranged in this order along the traveling direction.

A pair of pressing rolls 1 and 2
5 are provided so as to face each other up and down. The upper pressing roll 1 is formed, for example, by applying rubber such as silicon rubber having a Brennel hardness of 20 to 90 ° to a thickness of 5 to 30 on the outer periphery of an iron roll.
mm is a rubber roll wound about 200 mm in diameter.
m. Lower pressing roll 2
Is formed in a column having a diameter smaller than that of the upper pressing roll 1, and a rubber roll as described above can be used, but an iron roll having higher hardness than rubber may be used.
By forming the lower pressing roll 2 with an iron roll, the pressure from the upper pressing roll 1 can be applied to the veneer-attached base material 3 and the plastic sheet 4 without being dispersed. Of the protruding plate 5 and the plastic sheet 4 can be improved.

In the pressing rolls 1 and 2, at least the upper pressing roll 1 is heated to 120 to 150.degree. This heating can be performed by a heater 16 such as an infrared heater arranged above the upper pressing roll 1. The lower pressing roll 2 does not need to be heated, but may be heated in order to raise the temperature of the veneer 3 to 40 to 60 ° C.

The heating roll 17 is formed in the same manner as the upper pressing roll 1, and is heated to 120 to 150 ° C. by a heater 16 arranged above the heating roll. The cooling roll 8 is formed similarly to the upper pressing roll 1, but may be cooled by sending water. The introduction roll 18 is formed of a rubber roll or an iron roll similarly to the lower pressing roll 2, and is opposed to the heating roll 17 and the transfer belt 15.
And guides the transport belt 15. The lead-out roll 19 is formed of a rubber roll or an iron roll like the lower pressing roll 2, and is disposed so as to face the cooling roll 8 and abut the lower surface of the transport belt 15. , And guides the transport belt 15. Further, reference numeral 22 denotes a guide roll, which functions as a guide when the plastic sheet 4 is advanced. A preliminary heater 20 formed by a far infrared heater or the like is provided between the guide roll 22 and the heating roll 17. The temperature of the pre-heater 20 can be adjusted steplessly by a slider, and in this embodiment, the temperature of the pre-heater 20 is set to about 130 to 150 ° C.

The veneer-attached substrate 3 is provided on the surface (upper surface) of the substrate 9.
Is formed by adhering a veneer plate 5 to the base plate. When a wood base such as a medium density fiberboard (MDF), a plywood or a particle board, a gypsum board or a calcium silicate board is used as the base 9, the veneer-attached base 3 is as shown in FIG.
When a thin base such as Japanese paper or nonwoven fabric is used as the base material 9,
It is formed in a sheet shape as shown in FIG.

The plastic sheet 4 is formed by providing an adhesive layer 7 on a thermoplastic resin layer 6, as shown in FIG. The thermoplastic resin layer 6 is formed of a sheet (film) made of a thermoplastic resin such as a vinyl chloride resin, polypropylene, polyethylene, acrylic resin, or the like, or a fluorine-adhered vinyl chloride resin sheet. The adhesive layer 7 is formed by applying a hot-melt adhesive, a solvent-based adhesive, or a heat-active adhesive on the back surface of the thermoplastic resin layer 6. As the hot-melt adhesive, polyethylene or polyurethane is used. , Polyester, ethylene-vinyl acetate copolymer (EVA) 100% resin, and the solvent-based adhesive may be a solvent-based polyurethane adhesive.

The thickness of the thermoplastic resin layer 6 is 50 to 20.
It can be set to 0 μm. If the thickness of the thermoplastic resin layer 6 is less than 50 μm, the plastic sheet 4 is easily damaged, and the thickness of the thermoplastic resin layer 6 is 200 μm.
If it exceeds m, it will be difficult to soften by heat, and it will take time to bond the plastic sheet 4 to the veneer plate 5, and the productivity may be reduced. The thickness of the adhesive layer 7 can be set to 20 to 40 μm. If the thickness of the adhesive layer 7 is less than 20 μm, the plastic sheet 4 cannot be firmly bonded, and if the thickness of the adhesive layer 7 exceeds 40 μm, the adhesive is applied to the veneer plate 5 and the thermoplastic resin layer 6. It may protrude from the space and impair the appearance.

Next, a method of manufacturing a decorative board using the above laminating apparatus will be described. First, the plastic sheet 4 is unwound from the rolled sheet roll 21, pulled out, and introduced between the pressing rolls 1 and 2. As described above, before the plastic sheet 4 is introduced between the pressing rolls 1 and 2, the pre-heater 20 pre-heats the adhesive layer 7 on the back side, and the plastic sheet 4 contacts the heating roll 17 on the front side. The thermoplastic resin layer 6 is preheated. When the adhesive layer 7 is formed of a hot melt adhesive, the temperature of the adhesive layer 7 is increased by this preliminary heating so that the adhesive layer 7 is easily activated (heat-fluidized) between the pressing rolls 1 and 2. When the adhesive layer 7 is formed of a solvent type adhesive, the preliminary heating is performed to remove a small amount of the solvent from the adhesive layer 7 so that the adhesive layer 7 is easily cured between the pressing rolls 1 and 2. Further, the temperature of the thermoplastic resin layer 6 is increased by preheating so that the thermoplastic resin layer 6 is easily softened between the pressing rolls 1 and 2.

On the other hand, the veneer-attached base material 3 is placed on a conveyor belt 15 which advances at substantially the same speed (2 to 20 m / min) as the plastic sheet 4 and is introduced between the pressing rolls 1 and 2. Then, the plastic sheet 4 is laminated (laminated) between the pressing rolls 1 and 2 on the veneer bonding substrate 3 so that the adhesive layer 7 comes into contact with the surface of the veneer 5. Since this lamination is performed while the veneer-attached base material 3 and the plastic sheet 4 are advanced while being sent, the plastic sheets 4 are sequentially laminated from the front end (the end in the traveling direction) of the veneer-attached base material 3 toward the rear end. Therefore, the plastic sheet 4 can be laminated while the air between the veneer plate 5 and the plastic sheet 4 is being sent to the rear end of the veneer-attached base material 3 and removed therefrom. Air can be prevented from remaining during the operation.

The veneer base material 3 and the plastic sheet 4 thus laminated are pressed between the pressing rolls 1 and 2 with a pressure of 5 mm.
Heated and pressed at 〜１０10 kg / cm ² , the thermoplastic resin layer 6
And the adhesive layer 7 is heated to a temperature of 60 to 130 ° C. and softened, so that a plastic sheet 4
Are closely adhered. After this, plastic sheet 4
The veneer-attached base material 3 to which is bonded is pressed and cooled between the cooling roll 8 and the lead-out roll 19 to be cooled, whereby a decorative plate is manufactured. By this cooling, the adhesive layer 7 (hot melt adhesive) is cured, so that the adhesive layer 7 can exhibit an initial adhesive force, and the plastic sheet 4 can be prevented from generating springback. Further, the veneer-attached base material 3 and the plastic sheet 4 are continuously cooled without stopping and cooling the veneer-attached base material 3 to which the plastic sheet 4 is adhered between the cooling roll 8 and the lead-out roll 19. 2 can be sent to manufacture a decorative board, and productivity can be improved.

Next, a specific example of a method for manufacturing a decorative board will be described.
A 2.5 mm thick medium density fiberboard (Starwood, manufactured by Hokusin Co., Ltd.) was used as the substrate 9, and 0.25 mm thick white oak was used as the veneer 5. Then, an adhesive is applied to the surface of the substrate 9 and the veneer 5 is placed on the surface of the substrate 9, and this is heated up and down for 1 minute at a surface pressure of 3 kg / cm ² using a hot plate heated to 100 ° C. By pressing, the base material 9 and the veneer plate 5 were bonded to form the veneer-attached base material 3. The adhesive was 100 parts by weight of vinyl acetate (product number KV555 manufactured by Shoei Chemical), 40 parts by weight of urea melamine adhesive (product number UM96 manufactured by Aika Kogyo), 40 parts by weight of flour, and 15 parts by weight of water. Was prepared by mixing.

The plastic sheet 4 has a thickness of 10
On the back surface of the thermoplastic resin layer 6 of a 0 μm vinyl chloride sheet (manufactured by Riken Vinyl Co., Ltd., containing 12 parts of plasticizer), a urethane-based moisture-curable adhesive (No. 5900 manufactured by Nortape Industries Co., Ltd.) 40μm in thickness
Having the adhesive layer 7 formed thereon. The upper pressing roll 1 and the heating roll 17 were heated to a surface temperature of 135 ° C. by a heater 16 formed of an infrared heater having an output of 3 kW. Further, a far-infrared heater having a temperature adjusting function is used as the pre-heater 20, and the temperature is set to about 100 at an output of 1 kW.
１５０150 ° C. Further, water was sent to the cooling roll 8 for cooling. A rubber roll having a rubber hardness of 60 ° was used as the upper pressing roll 1, the heating roll 17, and the cooling roll 8.

Next, the plastic sheet 4 was fed between the pressing rolls 1 and 2 at a feed speed of 10 m / min. At this time, the adhesive layer 7 on the back surface of the plastic sheet 4 was heated to 50 ° C. by the preliminary heater 20, and the surface of the plastic sheet 4 was heated by contact with the heating roll 17. Simultaneously with the feeding of the plastic sheet 4, the veneer-plated base material 3, whose surface temperature is heated to 45 ° C., is placed on the transport belt 15 that advances at a feeding speed of 10 m / min, and sent between the pressing rolls 1 and 2. Was. Then, the plastic sheet 4 was laminated on the surface of the veneer base material 3 between the pressing rolls 1 and 2, and both were heated and pressed to adhere. At this time, the surface temperature of the plastic sheet 4 was 70 ° C. Thereafter, the veneer-attached base material 3 to which the plastic sheet 4 was adhered was pressed and cooled between the cooling roll 8 and the lead-out roll 19 to produce a decorative board. In this decorative plate, the plastic sheet 4 was in close contact with the surface of the veneer 5 and the irregularities due to the conduit on the surface of the veneer 5 could be faithfully reflected on the surface of the plastic sheet 4.

FIG. 4 shows another embodiment. In this embodiment, a pair of upper and lower pressing rolls 1 and 2 are formed as a series,
A laminating apparatus is formed by providing two of these reams along the traveling direction of the transport sheet 15, and the plastic sheet 4 and the veneer paste base material 3 are clamped by the two clamping rolls 1 and 2. The adhesive strength of the plastic sheet 4 to the veneer base material 3 can be increased.

A specific example of a method for manufacturing a decorative board using this laminating apparatus will be described. The veneer-attached base material 3 was formed in the same manner as in the above specific example, except that white oak having a thickness of 200 μm was used as the veneer 5. The plastic sheet 4 was formed in the same manner as in the above specific example. The upper pressing rolls 1, 1
Is a heater 16 formed by an infrared heater and has a surface temperature of 13
Heated to 5 ° C. A rubber roll having a rubber hardness of 60 ° was used as the upper pressing roll 1. Next, the above-mentioned plastic sheet 4 is pressed at a feeding speed of 10 m / min.
Sent during At the same time as sending the plastic sheet 4, the veneer-attached base material 3 heated to a surface temperature of 45 ° C.
Was transported between the pressing rolls 1 and 2 on a transport belt 15 which was traveling at a feed speed of 10 m / min. Then, a plastic sheet 4 was laminated between the pressing rolls 1 and 2 on the surface of the veneer-attached base material 3 and both were heated and pressed to adhere to each other to produce a decorative board. In this decorative plate, the plastic sheet 4 was in close contact with the surface of the veneer 5 and the irregularities due to the conduit on the surface of the veneer 5 could be faithfully reflected on the surface of the plastic sheet 4.

FIG. 5 shows another embodiment. In this embodiment, the laminating apparatus shown in FIG.
The plastic sheet 4 is adhered to the veneer-attached base material 3 formed in a sheet shape. The sheet-shaped veneer-attached base material 3 is placed on the transport belt 15 while being released from the veneer-sheet roll 23 wound in a roll shape, and is sent between the pressing rolls 1 and 2 by the advance of the transport sheet 15. . Reference numeral 24 denotes a veneer-attached base material 3 for conveying
It is a press roll to press down on.

FIG. 6 shows another embodiment. In this embodiment, in the laminating apparatus of FIG. 4, a pre-heater 20 for pre-heating the adhesive layer 7 on the back surface of the plastic sheet 4 is provided between the guide roll 22 and the upper pressing roll 1. Things. FIG. 7 shows another embodiment. In this embodiment, in the laminating apparatus shown in FIG. 4, the veneer-attached base material 3 to which the plastic sheet 4 is adhered is cooled further behind the rear pressing rolls 1 and 2 (in the direction of travel of the conveyor belt 15). Cooling roll 8
And a lead-out roll 19 opposed thereto.

FIG. 8 shows another embodiment. In this embodiment, a pair of upper and lower pressing rolls 1 and 2 are further provided between the rear pressing rolls 1 and 2 and the cooling roll 8 in the laminating apparatus of FIG. It is a series. In this manner, by bonding the plastic sheet 4 and the veneer-attached base material 3 with the triple pressing rolls 1 and 2, the adhesive force of the plastic sheet 4 to the veneer-attached base material 3 can be increased. FIG. 9 shows another embodiment. In this embodiment, an air blowing device 25 is provided above the transport belt 15 instead of the cooling roll 8 and the lead-out roll 19 in the laminating device shown in FIG. The cooling is performed by blowing air onto the bonded board 3. In this case, as in the case where the cooling roll 8 is used,
Since a large force is not directly applied to the plastic sheet 4 or the plastic sheet 4, damage to the veneer-attached base material 3 and the plastic sheet 4 can be reduced.

In the present invention, the plastic sheet 4 is bonded to the surface of the veneer 5 between the pressing rolls 1 and 2 so that the Young's modulus of the plastic sheet 4 is 2 × 10 ⁸ to 2 × 10 ⁹ dyn / cm ^2. Preferably, the plastic sheet 4 is preheated or heated by the pressing roll 1. If the Young's modulus of the plastic sheet 4 is less than 2 × 10 ⁸ dyn / cm ² , the degree of softening of the plastic sheet 4 becomes insufficient, and the plastic sheet 4 cannot be put into the conduit on the surface of the veneer 5, The unevenness due to the conduit cannot be brought into close contact with the surface of the veneer plate 5 and the plastic sheet 4
And the plastic sheet 4 may have a Young's modulus of 2 × 10 ⁹ dy.
If it exceeds n / cm ² , the degree of softening of the plastic sheet 4 is too large to lose shape retention, and the plastic sheet 4 may not be stably bonded. There is a possibility that the gloss of the surface of the plastic sheet 4 is lost.

More specifically, when a vinyl chloride resin is used as the thermoplastic resin layer 6 of the plastic sheet 4, as shown in FIG.
At ~ 80 ° C, its Young's modulus is 2 × 10 ⁸ to 2 × 10 ⁹
dyn / cm ² , and when polypropylene is used for the thermoplastic resin layer 6 of the plastic sheet 4,
When the temperature is 68 to 123 ° C., the Young's modulus is 2 × 10 ⁸ to 2 ×
It becomes 10 ⁹ dyn / cm ² . Therefore, the pressing roll 1,
The plastic sheet 4 is preheated or heated by the pressing roll 1 so that the temperature of the plastic sheet 4 when bonded to the surface of the veneer 5 is 68 to 80 ° C. Even if the type of the thermoplastic resin layer 6 of the sheet 4 is different, the plastic sheet 4 can be bonded under a common temperature condition without changing the temperature condition.

In determining the optimum laminating conditions of the plastic sheet 4 as described above, the plastic sheet 4 can be stably laminated by using the Young's modulus (viscoelastic property) of the plastic sheet 4 as a parameter. The temperature range that can be obtained can be clearly grasped, and the productivity can be increased. Although it is conceivable to use the Vicat softening temperature as a parameter, there is no problem when the thermoplastic resin layer 6 is PVC,
In the case of PP, if the temperature exceeds the Vicat softening temperature, the material rapidly enters the fluidized region, so that the appearance after lamination deteriorates and is not stabilized. Therefore, it is preferable to use Young's modulus rather than using Vicat softening temperature as a parameter.

FIG. 11 shows another embodiment. A is a foreign matter removal zone where the operation of removing foreign matter on the surface of the veneer-attached base material 3 is performed. Reference numeral 30 denotes an automatic feed conveyor having a speed adjusting function, and a foreign matter removing device 31 is provided above the automatic feed conveyor. The foreign substance removing device 31
A brush 33 is provided inside a cylindrical cover 32 whose upper and lower surfaces are open.
Are rotatably driven, and a vacuum means 41 provided with a pump and the like is provided at an opening on the upper surface of the cover 32. The brush 33 faces downward from the opening on the lower surface of the cover 32.

Reference numeral B denotes a conduit compression zone, where a press roll 34 is pressed against the surface of the veneer 5 to perform roll pressing. In the conduit compression zone B, a pair of upper and lower press rolls 34 and 35 are arranged as a series, and two of these series are provided along the traveling direction of the veneer bonding substrate 3. Press roll 3
Reference numerals 4 and 35 are formed in the same manner as the pressing rolls 1 and 2. For example, rubber such as silicon rubber having a heat resistance of 20 to 90 ° with a Brennel hardness of 20 to 90 ° is provided on the outer periphery of an iron roll or an iron roll 36. 37 is formed into a cylinder having a diameter of about 250 mm by a rubber roll wound with a thickness of 5 to 30 mm. The press rolls 34 and 35 are formed so as to be vertically driven by an air cylinder or the like.
By changing the interval of 35, it is possible to change the pressure applied to the surface of the protruding plate 5 by the press roll 34.

Reference numeral C denotes a substrate preheating zone where the surface of the veneer-attached substrate 3, particularly the surface of the veneer 5, before the plastic sheet 4 is laminated is heated. Reference numeral 38 denotes an automatic feed conveyor having a speed adjusting function. Above the automatic feed conveyor 38, a preheater 39 having a multi-stage temperature adjusting function formed by an infrared heater or the like is provided over substantially the entire length of the automatic feed conveyor 38. In addition, substrate preheat zone C
A temperature sensor 40 is provided at the end of the preheater 39. The temperature sensor 40 detects the surface of the veneer plate 5 of the veneer bonded substrate 3 that has passed below the preheater 39. Based on the result of this detection, the preheater The temperature of the heat generation 39 is adjusted to adjust the temperature of the board 3.

D is a sheet pre-heating zone where the plastic sheet 4 before being laminated on the veneer substrate 3 is heated. Reference numeral 20 denotes a preliminary heater having a multi-stage temperature adjusting function, which is disposed above the plastic sheet 4 pulled out while being unwound from the sheet roll 21 and introduced between the pressing rolls 1 and 2. The previous plastic sheet 4 is heated from above. The zone D may be provided with a tension roll function device for preventing the plastic sheet 4 from wrinkling or a meandering preventing device for preventing the plastic sheet 4 from meandering.

E denotes a laminating zone where the plastic sheet 4 is adhered and laminated on the surface of the veneer 5 of the veneer-pasted substrate 3. In the laminating zone E, a laminating apparatus is provided in which a pair of upper and lower pressing rolls 1 and 2 are arranged in series, and three of the series are provided along the traveling direction of the base plate 3. The pressing rolls 1 and 2 are formed in the same manner as described above. For example, rubber 37 such as silicon rubber having a heat resistance of 20 to 90 ° and a thickness of 5 to 90 ° is applied to the outer periphery of the iron roll 36 with a thickness of 5 to 90 °. It is formed into a cylinder having a diameter of about 250 mm with a rubber roll wound around 30 mm. The pressing rolls 1 and 2 are formed so as to be vertically movable by an air cylinder or the like. By changing the interval between the pressing rolls 1 and 2, the pressing force of the pressing roll 1 on the surface of the protruding plate 5 can be changed. Is available.
Further, in the pressing rolls 1 and 2, at least the upper pressing roll 1 is heated to 120 to 150 ° C. This heating can be performed by a heater 16 having a multi-stage temperature control function such as an infrared heater disposed above the upper pressing roll 1.

A temperature sensor 44 for detecting the surface temperature of the pressing roll 1 is provided above and in front of each pressing roll 1 (on the side opposite to the direction in which the base plate 3 is moved). Based on the result of detection by these temperature sensors 44, the heater 16
By adjusting the surface temperature (for example, 135 ° C.) of the pressing roll 1 by adjusting the heat generation temperature (for example, 165 ° C.) of the plastic sheet 4 when the plastic sheet 4 is adhered to the surface of the veneer substrate 3. The temperature and the temperature of the veneer substrate 3 are adjusted. A temperature sensor 43 is provided at the end of the laminating heat zone E, and the surface of the plastic sheet 4 laminated on the surface of the veneer substrate 3 is detected by the temperature sensor 43.

F is a cooling zone, where the veneer 3 and the plastic sheet 4 on its surface are cooled. Reference numeral 45 denotes an automatic feed conveyor having a speed adjusting function. Above the automatic feed conveyor 45, a cooling device 46 formed by a spot cooler or the like is provided over substantially the entire length of the automatic feed conveyor 45. The cooling air is sent from the cooling device 46 to the surface of the laminated plastic sheet 4. A temperature sensor 47 is provided at the end of the cooling zone F. The temperature sensor 47 detects the temperature of the veneer-plated substrate 3 passing under the cooling device 46 and the temperature of the plastic sheet 4 on the surface thereof. Based on the detection results of the temperature sensor 43 and the temperature sensor 47, the amount and temperature of the cooling air discharged from the cooling device 46 are adjusted to adjust the temperature of the projecting plate-attached substrate 3 and the plastic sheet 4 on the surface thereof. I have to.

Next, a method for manufacturing a decorative board using the apparatus shown in FIG. 11 will be described. First, the veneer-attached base material 3 colored by applying a coloring agent 48 such as a dye or a pigment to the surface of the veneer 5 is placed on the automatic feed conveyor 30 in the foreign material removal zone A as shown by an arrow, and The sheet is conveyed at a speed of 1 to 20 m / min while passing below the removing device 31. When passing below the foreign matter removing device 31, the surface of the protruding plate 5 is subjected to the cleaning action of the brush 33, and foreign matters such as dust and dust attached to the surface of the protruding plate 5 are removed.
These foreign substances pass through the cover 32 and pass through the vacuum means 41.
It is sucked and removed.

Thereafter, the veneer-attached base material 3 is sent to the conduit compression zone B, where it is conveyed at a speed of 1 to 20 m / min while being sandwiched by the rotating press rolls 34, 35. Surface is about 20kg from press roll 34
/ Cm ² (the value of the air pressure of the air cylinder that drives the press roll 34). Conduit compression zone B
As shown in FIG. 12 (a), the surface of the veneer plate 5 immediately after being introduced into the pipe 49 is in a state in which a colorant 48 is contained in a conduit 49. It is low density and bulky. Accordingly, if the plastic sheet 4 is adhered to the surface of the veneer 5 in the laminating zone E in this state, the plastic sheet 4 cannot be adhered to the surface of the veneer 5, and irregularities due to the conduit 49 will be formed on the surface of the plastic sheet 4. There is a possibility that the image cannot be faithfully projected.

Then, by pressing the surface of the veneer 5 with the press roll 34 and applying pressure, as shown in FIG. 12B, the colorant 48 in the conduit 49 is compressed to increase the density and decrease the bulk. As a result, the plastic sheet 4 can be brought into close contact with the surface of the veneer plate 5 so that the irregularities due to the conduit 49 can be faithfully projected on the surface of the plastic sheet 4. . Therefore, the coloring agent 48 can be used irrespective of the dye type or the pigment type, and the finished feeling of the decorative board can be remarkably improved. Also, by crushing the soft part of the surface of the veneer plate 5 with the press roll 34, the unevenness due to the conduit 49 can be raised, and the unevenness due to the conduit 49 can be faithfully and clearly projected on the surface of the plastic sheet 4. is there.

Thereafter, the veneer-attached base material 3 is introduced into the base material pre-heating zone C, is placed on the automatic feed conveyor 38 in this zone C, and passes under the pre-heater 39 at a speed of 1 to 20 m / min. Conveyed. Here, the veneer-attached base material 3 is heated by the pre-heater 39, and the surface temperature of the veneer plate 5 is raised to 70 to 90 ° C., whereby the temperature of the veneer-attached base material 3 is affected by the season and the like. The plastic sheet 4 is stabilized so as not to be received, and the adhesion of the plastic sheet 4 is improved. In order to improve the adhesiveness of the plastic sheet 4, it is conceivable to increase the capacity of the laminating apparatus in the laminating zone E to change the laminating speed, but this increases the equipment cost of the laminating apparatus. Is not preferred.

Thereafter, the veneer base material 3 passes through the sheet preheat zone D and is introduced into the laminating zone E. On the other hand, the plastic sheet 4 is pulled out while being unwound from the sheet roll 21 wound in a roll shape, and is guided by the auxiliary roll 50 while the sheet preheat zone D
After passing through the laminating zone E. When passing through the sheet preheat zone D, the plastic sheet 4 is preheated to 70 to 90 ° C. by the preheater 20. By this heating, the thermoplastic resin layer 6 on the surface side of the plastic sheet 4 is preliminarily softened, and the followability (adhesion) of the plastic sheet 4 to the unevenness of the conduit 49 of the veneer plate 5 is improved. At the same time, the temperature of the adhesive layer 7 on the back side rises, and the adhesive layer 7 is easily activated by heat between the pressing rolls 1 and 2, so that the adhesiveness of the plastic sheet 4 to the veneer plate 5 can be improved. It is.

Thereafter, the veneer-pasted base material 3 and the plastic sheet 4 introduced into the laminating zone E are successively clamped by the triple rotating pressing rolls 1 and 2 while the speed is 1-2.
It is transported at 0 m / min. At this time, the veneer base material 3 and the plastic sheet 4 are pressed between the pressing rolls 1 and 2 with a pressure of 5 to 2 mm.
0 kg / cm ² , and the thermoplastic resin layer 6 is heated to a temperature of 6 kg / cm ² by the heat of the pressing roll 1.
The temperature is raised to 0 to 130 ° C. to soften, and the adhesive layer 7 is heated to a temperature of 60 to 130 ° C. by the heat of the pressing roll 1 to be melted. It adheres instantly and adheres while following.

Thereafter, the veneer-pasted base material 3 to which the plastic sheet 4 has been bonded is introduced into the cooling zone F,
It is placed on the automatic feed conveyor 45 in this zone F and passes under the cooling device 46 while moving at a speed of 1 to 20 m /
Transported in minutes. Here, the veneer-clad base material 3 to which the plastic sheet 4 is bonded is cooled by cooling air from the cooling device 46 to about 5 mm.
The temperature is rapidly lowered to 0 ° C., which prevents the plastic sheet 4 from floating (spring back) from the surface of the veneer plate 5 and improves the adhesiveness of the plastic sheet 4.

Thereafter, the decorative sheet is formed by applying a coating to the surface of the plastic sheet 4 (thermoplastic resin layer 6) laminated on the veneer bonding substrate 3. As the paint, a UV-curable paint (UV paint) such as urethane, polyester, or acrylic can be used.
It is preferable that the plastic sheet 4 is clear and has such a transparency that the surface of the plastic sheet 4 can be seen through. By applying the coating on the surface of the plastic sheet 4 as described above, the gloss of the surface of the decorative sheet can be adjusted, and the performance of the appearance can be improved. Physical properties can be improved.

Further, the surface of the plastic sheet 4 before being laminated on the veneer substrate 3 may be coated. In this case, it is preferable to use the above-mentioned UV paint having heat resistance such that the gloss does not change by heat. By applying the coating to the surface of the plastic sheet 4 before being laminated in this way, even if the decorative plate has a complicated surface shape that is difficult to be painted after lamination, the gloss of the surface can be adjusted, The appearance performance can be improved, and the physical properties of the surface can be improved by using the coating film as a protective layer.

When the thermoplastic resin layer 6 of the plastic sheet 4 is made of PP (polypropylene), the surface of the thermoplastic resin layer 6 is subjected to corona discharge treatment to roughen the surface, and as shown in FIG. After forming a primer 51 such as an acrylic resin on the surface of the thermoplastic resin layer 6, the primer 51
It is preferable to apply a coating to the surface of the film, whereby the adhesion of the coating film can be improved. When the thermoplastic resin layer 6 is made of PVC (polyvinyl chloride), the primer 51
Is not required.

Next, a specific example will be described. A decorative board was formed using the apparatus shown in FIG. The conditions are substrate preheat zone C
The surface temperature of the veneer-attached substrate 3 at 70 ° C., the surface temperature of the pressing roll 1 at 135 ° C., the speed of the plastic sheet 4 and the veneer-attached substrate 3 in the laminating zone E of 2.5 m / min, the pressing roll 1 The air pressure of the air cylinder was 10 kg / cm ² , and the other conditions were as described above. As the press rolls 34 and 35 and the two pressing rolls 1 and 2 on the front side of the laminating apparatus, silicone rubber (rubber 37) having a heat resistance of 70 ° and a thickness of 15 mm was used on the outer periphery of the iron roll 36. Was used. Of the series of pressing rolls 1 and 2 on the rear side of the laminating apparatus, the upper pressing roll 1 is made of a heat-resistant silicone rubber (rubber 37) having a Brennel hardness of 30 ° around the iron roll 36. A rubber roll wound around 15 mm was used. The lower pressing roll 2 was a metal roll having a diameter of 250 mm.

As specific examples 1 to 4, a UV paint (acrylic polyester urethane paint (RM manufactured by Jujo Chemical Co., Ltd.) -17)
100 parts by weight of HMDI-based isocyanate (5 parts by weight of a curing agent manufactured by Dainichi Seika Co., Ltd.) was applied thereto, and this was laminated on the surface of the veneer base material 3 under the above conditions.
Then, the glossiness of the surface of the plastic sheet 4 after lamination was measured. For comparison, as Comparative Examples 1 to 4, uncoated plastic sheets 4 were laminated on the surface of the veneer-bonded substrate 3 under the above conditions, and the change in gloss before and after the lamination was measured. Table 1 shows the results.

[0052]

[Table 1]

As is clear from Table 1, the changes in the gloss of the plastic sheet 4 were smaller in Comparative Examples 1 to 4 in Examples 1 to 4 where the coating was applied.

[0054]

As described above, according to the first aspect of the present invention, a plastic sheet is laminated on the surface of a veneer while feeding a veneer base material and a plastic sheet between a pair of pressing rolls. The plastic sheet is adhered to the surface of the veneer by pressing the veneer base material and the plastic sheet between the press rolls while heating the plastic sheet with the press roll, so that the air between the veneer and the plastic sheet The veneer can be laminated while removing the veneer, and the veneer and the plastic sheet can be closely attached to each other to produce a decorative plate in which irregularities due to the conduit of the veneer are faithfully expressed. Moreover, the veneer-bonded base material and the plastic sheet can be continuously fed between the pressing rolls to manufacture a decorative board, thereby improving the productivity. The invention according to claim 2 of the present invention Is
Since the plastic sheet is formed by providing an adhesive layer having a thickness of 20 to 40 μm on a thermoplastic resin layer having a thickness of 50 to 200 μm, it is possible to prevent the plastic sheet from being damaged and to firmly adhere the plastic sheet to the veneer. Is what you can do.

According to the third aspect of the present invention, since a rubber roll having a hardness of 20 to 90 ° is used as the pressing roll, the plastic sheet can be strongly pressed without damaging the plastic sheet. It is. In the invention according to claim 4 of the present invention, since the adhesive of the adhesive layer is at least one selected from a hot-melt adhesive and a solvent-type adhesive, the initial adhesive strength of the adhesive layer is increased. This can prevent springback from occurring in the plastic sheet.

In the invention according to claim 5 of the present invention, the adhesive layer is preheated before the plastic sheet is laminated on the surface of the veneer, so that the adhesive layer can be thermally activated before laminating. In addition, it is possible to easily perform the adhesion by the pressing roll. In the invention according to claim 6 of the present invention, the plastic sheet is cooled by the cooling roll after the veneer and the plastic sheet are pressed between the plurality of pressing rolls. By pressing with rolls, the veneer-attached base material and the plastic sheet can be firmly adhered to each other, and the plastic sheet can be firmly bonded to the veneer, and spring back occurs on the plastic sheet when cooled by the cooling roll The veneer and the plastic sheet can be in close contact with each other to produce a decorative plate in which irregularities due to the conduit of the veneer are faithfully expressed.

According to a seventh aspect of the present invention, the plastic sheet has a Young's modulus of 2 × 10 ⁸ to 2 × 10 ^9.
Since the plastic sheet is heated to dyn / cm ² , the veneer and the plastic sheet are brought into close contact with each other without causing the plastic sheet to whiten or lose its gloss. It can be manufactured.

In the invention according to claim 8 of the present invention, the surface of the veneer is colored before the plastic sheet is laminated on the surface of the veneer, and the surface of the veneer after coloring is roll-pressed. To produce a decorative board that can be compressed to increase the density and reduce the bulk, make it possible to adhere the plastic sheet to the surface of the veneer, and that the irregularities due to the veneer's conduit are faithfully expressed. Can be done.

According to the ninth aspect of the present invention, before the plastic sheet is laminated on the surface of the veneer, the veneer-clad base material is heated. It is possible to stabilize the plastic sheet so that the adhesiveness of the plastic sheet can be improved. In the invention according to claim 10 of the present invention, the surface of the plastic sheet is coated after the plastic sheet is laminated on the surface of the veneer, so that the gloss of the surface of the plastic sheet is adjusted by the coating film formed by the coating. Can be performed to improve the appearance performance, and the coating film can serve as a protective layer to improve the physical properties of the surface of the plastic sheet.

The invention according to claim 11 of the present invention provides:
Before laminating the plastic sheet on the surface of the veneer, the surface of the plastic sheet is painted, so even if it has a complicated surface shape that is difficult to paint after lamination, it is necessary to apply a paint film to the plastic sheet before lamination Thereby, the gloss of the surface of the plastic sheet can be adjusted, the performance of the appearance can be improved, and the coating film can serve as a protective layer to improve the physical properties of the surface of the plastic sheet. Things.

[Brief description of the drawings]

FIG. 1 is a schematic diagram showing an example of an embodiment of the present invention.

FIG. 2 (a) is a cross-sectional view showing a veneer-attached base material of the above,
(B) is sectional drawing which shows another veneer sticking base material.

FIG. 3 is a cross-sectional view showing the plastic sheet according to the first embodiment.

FIG. 4 is a schematic view showing another embodiment of the above.

FIG. 5 is a schematic diagram showing still another embodiment of the above.

FIG. 6 is a schematic diagram showing still another embodiment of the above.

FIG. 7 is a schematic diagram showing still another embodiment of the above.

FIG. 8 is a schematic view showing still another embodiment of the above.

FIG. 9 is a schematic view showing still another embodiment of the above.

FIG. 10 is a graph showing a relationship between the temperature of the plastic sheet and the Young's modulus.

FIG. 11 is a schematic view showing still another embodiment of the above.

FIGS. 12A and 12B are enlarged cross-sectional views each showing a part of a colored veneer-attached substrate according to the first embodiment;

FIG. 13 is a sectional view showing another embodiment of the plastic sheet of the above.

14A and 14B are cross-sectional views showing a conventional example.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Pressing roll 2 Pressing roll 3 Veneer-plated base material 4 Plastic sheet 5 Veneer 6 Thermoplastic resin layer 7 Adhesive layer 8 Cooling roll

 ──────────────────────────────────────────────────続 き Continuing on the front page (72) Inventor Toshi Nagai 1048 Kadoma Kadoma, Osaka Prefecture Matsushita Electric Works, Ltd.

Claims (11)

[Claims] 1. A plastic sheet is laminated on a surface of a veneer while feeding a veneer-bonded base material and a plastic sheet between a pair of pressurizing rolls. And veneering the plastic sheet to the surface of the veneer by pressing the veneer-attached base material and the plastic sheet. 2. The method according to claim 1, wherein the plastic sheet has a thickness of 50 to 50.
The method for producing a decorative board according to claim 1, wherein the adhesive sheet is formed by providing an adhesive layer having a thickness of 20 to 40 µm on a thermoplastic resin layer of 200 µm. 3. The pressing roll according to claim 1, wherein the pressing roll has a hardness of 20 to 9.
The method for producing a decorative board according to claim 1, wherein a 0 ° rubber roll is used. 4. The method for producing a decorative board according to claim 2, wherein the adhesive of the adhesive layer is at least one selected from a hot melt adhesive and a solvent type adhesive. 5. The method for manufacturing a decorative board according to claim 2, wherein the adhesive layer is preheated before laminating the plastic sheet on the surface of the veneer. 6. The plastic sheet is cooled by a cooling roll after the veneer-attached base material and the plastic sheet are pressed between a plurality of pressing rolls. Production method of decorative board. 7. The plastic sheet has a Young's modulus of 2 × 1.
0 ⁸ ~2 × 10 ⁹ dyn method for producing a decorative sheet according to any one of claims 1 to 6, characterized in that heating to be / cm ^2. 8. The method according to claim 1, wherein before the plastic sheet is laminated on the surface of the veneer, the surface of the veneer is colored and the surface of the veneer after coloring is roll-pressed. Manufacturing method of decorative board. 9. The method for manufacturing a decorative plate according to claim 1, wherein the veneer-attached base material is heated before the plastic sheet is laminated on the surface of the veneer. 10. The method for manufacturing a decorative board according to claim 1, wherein after the plastic sheet is laminated on the surface of the veneer, the surface of the plastic sheet is painted. 11. The method according to claim 1, wherein the surface of the plastic sheet is painted before the plastic sheet is laminated on the surface of the veneer.