JPH11151793A - Manufacture of decorative sheet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To enable clean coating of a decorative sheet without wrinkles through contact bonding to base surface having a recessed groove of uniform direction, even if the line speed is increased. SOLUTION: A sheet 2 is placed on a base 1, where a recessed groove 11 extending in uniform direction is processed, for continuously contact-bonding the sheet 2 through rubber rolls. At this time, the sheet 2 placed on one flat part adjacent to the recessed groove 11 of the base 1 is contact-bonded through a first rubber roll 3. Next, the sheet 2 placed on the recessed groove 11 of the base 1 is contact-bonded by pushing and pressing in multi-stage, by sequentially using two or more rubber rolls 4 for pressing into the recessed groove 11 having different depth of penetration, to the recessed groove 11 starting from a rubber roll 4a having low depth of penetration to a rubber rolls 4b and 4c having deeper penetration. And the sheet 2 placed on the other flat part adjacent to the recessed groove 11 of the base 1 is contact-bonded through a second rubber roll 5.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a decorative board comprising a substrate having a surface provided with a groove extending in a predetermined direction and a sheet-like material coated thereon.

[0002]

2. Description of the Related Art In general, interior building materials such as baseboards and edgings are often provided with concave grooves for decorative purposes. When a building material having such a groove is covered with a decorative sheet, the inner surface of the groove is also covered.

[0003] As a conventional method of coating and pressing a decorative sheet-like material on a substrate, for example, a method shown in Fig. 6 is exemplified. That is, the substrate (v) on which the concave groove (u) is formed
For the decorative sheet-like material (s) covering the surface of
A flat rubber roll is used for one flat portion (v1) adjacent to the concave groove (u).
(r1) (see a in the same figure), and then the ridge (c1), which is the connection between the flat part (v1) and the concave groove (u), is crimped with a rubber roll (r2) for holding down the corner. (Refer to (b) in the same figure), then the concave groove (u)
Insert a rubber roll (r3) smaller than the groove width of (1) into the groove (u) and press it against one side of the groove (u) (see c in the figure), and then the groove width of the groove (u) Insert a slightly thicker rubber roll (r4) into the groove (u) and press it against the bottom of the groove (see d in the same figure)
Next, a thin rubber roll (r5) is inserted again and pressed against the other side surface in the concave groove (u) (see FIG. 6E), and then the concave groove (u) and the other flat portion (v2) connected thereto are connected. Crimping rubber roll (r6) to the ridge line (c2) (see Figure 6), and finally crimping the other flat part with a flat rubber roll (r7) (see Figure 6), This completes the pressure bonding of the decorative sheet (s) to the substrate (v).

However, in such a coating method,
There are the following problems. That is, in the step of crimping the ridges (c1) and (c2) indicated by b and f in FIG. 6, the corners are broken, the fragments fall into the grooves, and the decorative sheet is sandwiched therebetween. It was sometimes covered.

Also, in the step of pressure-bonding to the side surfaces inside the concave grooves (u) of c and e in FIG. 1, wrinkles are easily generated, and furthermore, fine adjustment is required for setting the roll position, which requires skill. Yes, and it took time to change the set. Further, it has been difficult to increase the line speed in order to obtain a stable pressing force and a contact angle of the rubber roll for pressing the inner surfaces of the ridge portions (c1) and (c2) and the concave grooves (u).

As another problem, as shown in FIG. 7, a groove is formed on a substrate by simply cutting the substrate (v) to a predetermined depth. The ridges (c3) and (c4) of the opening edge of the groove (u) were defective, such as chipping, fluffing, and squeezing.

[0007]

SUMMARY OF THE INVENTION According to the present invention, a decorative sheet-like material can be coated on a substrate having a concave groove in a certain direction by press-fitting it without wrinkles, and even when the line speed is increased. An object of the present invention is to provide a method for producing a decorative plate that can be coated.

[0008]

According to the invention according to claim 1 of the present application, "a sheet-like material (2) is formed on a substrate (1) on which a concave groove (11) extending in a certain direction is formed on the surface. Is a method of manufacturing a decorative board by continuously pressing the sheet-like material (2) with a rubber roll, wherein the pressure-bonding step of the sheet-like material (2) includes a concave groove of the substrate (1). A sheet-like material (2) placed on one flat portion (1a) adjacent to (11) is rolled with a rubber roll (3).
And pressing the sheet-like material (2) placed on the concave groove (11) of the substrate (1) into at least two or more concave grooves having different depths into the concave groove (11). The rubber rolls (4b) (4b) (4b) (4a)
c) a step of pressing and pressing in a multi-stage by pressing and pressing in the concave groove (11), and the other flat portion (1) adjacent to the concave groove (11) of the substrate (1).
b) pressing the sheet-like material (2) placed on b) with a rubber roll (5). "

The base material of the substrate (1) used in the present invention may be wood, laminated wood, plywood, laminated veneer, particle board, wood fiber board such as wood fiber board, gypsum board, cement board, silicate Inorganic plates, such as a calcium plate and an inorganic fiber plate, are mentioned.

The substrate (1) has at least one concave groove (11) extending in a predetermined direction on the surface thereof. Above groove
The cross-sectional shape of (11) may be any shape such as V-shaped, U-shaped, and U-shaped.

The sheet-like material (2) used in the present invention includes:
Any material may be used as long as it has a sufficient material and thickness to protect and decorate the substrate, but a cosmetic material usually used in the art is preferable, for example, a thickness of 0.02 to 1.0 mm. In addition to synthetic resin decorative sheets such as vinyl chloride resin, polyolefin resin, ABS resin, etc., coated paper and composite sheets thereof are preferably used.

The sheet-like material (2) is subjected to a treatment on its rear surface so that it can be adhered to the substrate surface by pressing. As the adhesive used for this, an adhesive suitable for each adherend is selected.For example, a room temperature such as urethane resin, epoxy resin, vinyl acetate resin, modified vinyl acetate resin, vinyl urethane resin, etc. A curable adhesive or a hot melt adhesive such as ethylene vinyl acetate resin can be used.

[0013] Further, a concave groove (11) provided in the substrate (1).
The processing may be performed by a known processing method. However, as shown in claim 2 of the present application, "a shallow concave groove (20) having a tapered side surface (20a) in a substrate plane is cut, and then this taper is formed. The bottom surface (10c) of the concave groove (20) is cut to a predetermined depth to form a deep concave groove (10d), and then the substrate surface is ground to a depth sufficient to cut off the tapered side surface (10a). The method is preferable in that defects such as chipping of the ridge portions (10f) and (10g), fluff, and scabs can be prevented.

In the pressure bonding step of the present invention, the flat portion (1
As the first and second rubber rolls (3) and (5) used in a) and (1b), ordinary flat rubber rolls are preferably used. As these flat rubber rolls, those having a roll width equal to or larger than the width of the flat portions (1a) (1b) to be applied are preferably used.

The group of rubber rolls (4) for indenting grooves is composed of a plurality of rolls having different depths of penetration into the grooves (11).
And these plurality of concave groove indentation rubber rolls (4) group,
When the sheet-like material (2) is pushed and pressed into one groove (11), the rubber roll (4a) having a shallow depth and a deep rubber roll (4) are pressed.
b) It is used to execute the indentation / pressing in multiple stages using (4c) in order. Pressing and pressing in multiple stages in this way can prevent the sheet-like material (2) from being stretched or torn due to excessive force, and as a result, the line speed can be increased. Is preferred. In addition, it is preferable that the one having the largest depth of penetration in the group of rubber grooves (4) for indenting grooves reaches almost the bottom of the groove (11).

In the above-mentioned rubber roll (4) for pushing in a concave groove, except for the final rubber roll (4c) for pushing in a concave groove (11),
A roll width slightly smaller than the width of the sheet-like material (2) is preferable in that tight friction between the side wall and the sheet-like material (2) can be prevented when the sheet-like material (2) is inserted into the groove (11). It is preferable that the concave groove pushing rubber roll (4c) has a roll width enough to make good contact with the side wall and the bottom surface of the concave groove (11).

Further, as described in claim 3 of the present application, the rubber rolls (4) for indenting the groove include a rubber roll (4c) having the largest depth of penetration having a hardness of 50 to 70 °, and other rubber rolls. The hardness of the rubber rolls (4a) and (4b) is 80-90 ° "
This makes smooth insertion of the sheet-like material (2) into the groove (11), and the final rubber roll is deformed in the groove (4c) to match the shape of the groove (11), This is preferable in that it can be pressed all the way.

The decorative board thus obtained is used as a decorative material as it is, and after a V-cut is made while leaving a sheet-like material from the back surface of the portion excluding the concave groove portion, bending is performed at the V-cut portion. By performing the above, it can be used as a working material of various shapes.

[0019]

According to claim 1 of the present application, a sheet (2) placed on a substrate (1) having a groove (11) extending in a certain direction on the surface thereof is first placed on the substrate (1). A portion corresponding to the one flat portion (1a) adjacent to the concave groove (11) of (1) is pressed by the rubber roll (3) and pressed.

Next, the sheet-like material (2) placed on the concave groove (11) of the substrate (1) firstly has a concave groove pushing rubber roll (4a) having a small depth of penetration into the concave groove (11). Thus, it is pushed into the concave groove (1) to some extent and pressed against one side wall surface (11a). While such press-in / press-up is repeated a predetermined number of times, the depth of penetration of the rubber roll (4) becomes deep, and accordingly, the concave groove is formed.
The sheet-like material (2) is pressed down to the lower part of the side wall surface in (11). Then, when the rubber roll (4c) having the deepest penetration is pushed in, the sheet-like material (2) is pressed against the bottom surface (11c) of the concave groove (11).

Next, a sheet-like material (2) corresponding to the other flat portion (1b) adjacent to the concave groove (11) of the substrate (1) is pressed and pressed by a second rubber roll (5), This makes the decorative board
(A) will be manufactured.

According to the invention of claim 2 of the present application,
When processing the concave groove (11) on the surface of the substrate (1), first, a shallow concave groove (10) having a tapered side surface (10a) on the substrate plane is cut. Next, the bottom surface portion (10c) of the tapered groove (10) is cut to a predetermined depth to form a deep groove (10d). After that, the surface of the substrate is tapered
(10a) is ground to a depth sufficient to cut it, and the ridge (10
f) The concave groove (10e) in which (10g) is formed clearly will be processed.

According to the invention of claim 3 of the present application,
Since the rubber rolls (4a) and (4b) having a shallow depth of penetration in the grooved groove pressing rubber rolls (4) group are relatively hard, the sheet-like material (2) is smoothly pressed into the grooved groove (11), The final rubber roll (4c), which has a deep penetration, is relatively soft and easily deformed in the groove (11) according to the shape of the groove.Therefore, the sheet-like material (2) is not covered with every corner in the groove (11). It will be pressed and crimped.

[0024]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail with reference to the illustrated embodiments, but the present invention is not limited thereto. FIG.
FIG. 2 is a schematic perspective view of an apparatus for performing the manufacturing method of the present invention, and FIG.
FIG. 3 is a schematic plan view of a main part of FIG. 1, FIG. 3 is a schematic front view of a main part of FIG. 1, and FIG. In these figures, (1) is a substrate with a concave groove (11), (2) is a decorative sheet material, (3)
Is the first flat rubber roll, (4) is a group of rubber rolls for indenting grooves,
(5) is a second flat rubber roll, (6) is a guide roller, (7) is a conveyor, and (A) is a decorative plate.

In this example, the substrate (1) with a concave groove has an MD.
F plate is used, and the thickness of the decorative sheet material (2) is
A urethane-based adhesive applied to a 0.2 mm polyolefin-based decorative sheet by a roll coater and air-dried is used.

The group of rubber rolls (4) for indenting grooves includes three rubber rolls (4a), (4b), and (4c) having different depths into the grooves. As shown in FIGS. The substrates are arranged in order from the shallower to the deeper in the transport direction of the substrate (1) according to (7). Of these concave groove pressing rubber rolls, the groove width of the concave groove (11) is the lowest for the concave groove pressing rubber roll (4a) and the medium depth of the concave groove pressing rubber roll (4b). A little thinner and about 8 in hardness
0 °. The deepest grooved rubber roll (4c) is substantially the same as the groove width of the groove (11) and has a hardness of about 60 °.

In the apparatus configured as described above, the decorative sheet material (2) is placed on the upper surface of the substrate (1) conveyed from the conveyor (7) in the direction of the drawing, and the substrate ( The decorative sheet material (2) placed on the flat portion (1a) connected to the concave groove (11) of (1) is first pressed by the first flat rubber roll (3) and is pressed.

Next, as the substrate (1) is transported, the rubber roll (4a) for pushing the concave groove having the shallowest depth is moved to the concave groove (1) of the substrate (1).
The decorative sheet material (2) placed on 1) is pressed and started to be pushed into the groove (11). At this time, this rubber roll (4
Since a) is relatively hard, the decorative sheet material (2) is smoothly pushed along one side wall (11a) in the concave groove (11).

Next, as the substrate (1) is conveyed, the rubber roll (4b) for indenting the concave groove having a medium depth is moved to the decorative sheet material (2) in the concave groove (11) which has already been pushed in shallowly. ) And will be pushed further. Also at this time, since the rubber roll (4b) is relatively hard, the decorative sheet material (2) is smoothly pushed along the other side wall (11b) in the concave groove (11).

When the substrate (1) is further conveyed, the deepest grooved rubber press (4c) is pressed into the decorative sheet material (2) in the groove which has already been pressed down to the middle of the groove. And press it in further. And rubber roll (4
When c) reaches the bottom of the groove, the rubber roll (4c) is relatively soft and deforms in the groove (11) according to the shape of the groove. Thereby, the decorative sheet material (2) is applied with an appropriate tension or pressing force, and both side walls (11a) (11b) in the concave groove (11) are applied.
And the bottom surface (11c).

If the transfer of the substrate (1) proceeds further, the second
The flat rubber roll (5) presses the decorative sheet material (2) on the other flat portion (1b) connected to the concave groove (11) of the substrate (1) and press-bonds the same, whereby the decorative plate is It will be manufactured.

In the decorative plate on which the decorative sheet material (2) is pressed as described above, the concave groove (11) and the flat portions on both sides thereof are provided.
At (1a) and (1b) the ridge portions (11d) and (11e) connected to each other, the decorative sheet material (2) is neatly adhered along its corners,
The decorative sheet material (2) is also tightly pressed on the side walls (11a) (11b) and the bottom surface (11c) of the concave groove (11) without wrinkles.

Embodiment 2 This embodiment relates to an example of the manufacturing method according to claim 2 of the present application, and is the same as Embodiment 1 except that a groove forming step for the substrate is added.
Only the groove processing step will be described.

The groove forming step in this embodiment will be described with reference to FIG. First, a tapered side surface (21
A shallow concave groove 21 having a) is formed by cutting (see FIG. 5A). Next, the bottom surface (2) of the shallow tapered groove (21)
1c) is cut to a predetermined depth to form a deep concave groove (22) (see FIG. 5B). Furthermore, the deep groove obtained above (22)
The attached substrate is slid from its surface enough to cut off the tapered side surface (21a) (see FIG. 5C).
In this way, a grooved substrate (10) having a groove (21) with a predetermined depth is formed.

The grooved substrate (1) obtained as described above
0) is missing in both ridge portions (211) and (212) of the concave groove (21),
There is no fuzz, fluff, etc., and therefore, when the decorative sheet material is crimped, the ridge portion is finished more clearly, and a decorative plate with higher commercial value can be provided.

[0036]

According to the invention of claim 1 of the present application, the sheet-like material is pressed and pressed by the rubber roll in the order of one flat portion, the concave groove, and the other flat portion of the substrate surface, and In the press-fitting process into the concave groove, at least two or more concave groove pushing rubber rolls having different depths of penetration are used. Since it is pressed and pressed, the decorative sheet can be finished neatly without stretching, tearing or wrinkling due to excessive force applied to the sheet. In addition, the line speed can be increased without the occurrence of the troubles described above.

According to the invention of claim 2 of the present application,
In addition to the effect of the first aspect, it is possible to provide a decorative plate which is clean and has high commercial value without defects such as chipping at the ridge line of the opening edge of the concave groove, fluff, and scabs.

According to the invention of claim 3 of the present application,
For the rubber roll group for indenting grooves, a relatively hard rubber roll is used for the rubber roll with a shallow depth of penetration, and a relatively soft rubber roll is used for the final rubber roll with a deep depth of penetration. It can be pressed and crimped properly without any trouble.

[Brief description of the drawings]

FIG. 1 is a schematic perspective view illustrating a manufacturing method of the present invention.

FIG. 2 is a schematic plan view of a sheet pressing step in FIG.

FIG. 3 is a schematic front view of a main part of FIG. 1;

FIG. 4 is a process explanatory view for explaining a step of pressing the sheet material step by step.

FIG. 5 is a process explanatory view step-by-step explaining the groove processing step in the manufacturing method according to the “claim 2” of the present application;

FIG. 6 is a process explanatory view showing step by step a conventional decorative board manufacturing process.

FIG. 7 is a process explanatory view for explaining a problem of the conventional example.

[Explanation of symbols]

 (1)… Substrate with concave groove (2)… Decorative sheet material (3)… First flat rubber roll (4)… Rubber roll group for pressing concave groove (5)… Second flat rubber roll (6)… Guide roller (7) … Conveyor (10)… Shallow groove (11)… Groove

Claims (3)

[Claims] 1. A method of manufacturing a decorative board, comprising placing a sheet on a substrate having a surface provided with a groove extending in a predetermined direction, and continuously pressing the sheet with a rubber roll. The step of pressing the sheet-like object includes the step of pressing a sheet-like object placed on one flat surface portion adjacent to the groove of the substrate with a first rubber roll, and the step of placing the sheet-like material on the groove of the substrate. A sheet-like material is inserted and pressed in multiple stages with deep rubber rolls in order from a shallow rubber roll having at least two or more concave groove indenting rubber rolls having different depths of penetration into the grooves, and pressed into the grooves. And a step of pressing a sheet-like material placed on the other flat portion adjacent to the concave groove of the substrate with a second rubber roll. 2. A groove forming process for a substrate having a groove formed on a surface thereof extending in a predetermined direction, the step of cutting a shallow groove having a tapered side surface in a plane of the substrate, and then forming a bottom surface of the tapered groove. 2. The method according to claim 1, wherein a deep groove is formed by cutting to a predetermined depth, and then the substrate surface is ground to a depth sufficient to cut off a tapered side surface. 3. The rubber roll having the greatest depth of penetration among the rubber rolls for indenting grooves has a hardness of 50 to 70 °,
The method for producing a decorative board according to claim 1 or 2, wherein the hardness of the other rubber roll is 80 to 90 °.