JP4774983B2 - Manufacturing method for flooring - Google Patents

Description

  The present invention relates to a method for producing a flooring produced by attaching a decorative sheet to a base material having a pattern groove formed on the surface thereof.

  Conventionally, in building flooring, by forming a pattern groove consisting of vertical and horizontal grooves on the surface of the base material, and pasting a wood grain decorative sheet on it, the three-dimensional feeling of the flooring and the texture of the wood Emphasizing the above, when a floor is constructed by combining a plurality of flooring materials, a flooring material that can have a beautiful flooring finish has been adopted and put into practical use.

For example, in Patent Document 1, by applying a decorative sheet made of a thermoplastic resin continuously from the upper surface of the base material for flooring to the side surface on the entire outer periphery thereof, a design property equivalent to that of a wooden flooring material is obtained. In addition, a floor material having excellent water resistance and a method for producing the same are disclosed even in a joint portion between floor materials.
JP 2003-49530 A

  In general, a decorative sheet is attached to a base material by an apparatus called a laminator. The laminator has a roller on which a supply part for pulling out a decorative sheet wound in a roll shape, an application part for applying an adhesive to the decorative sheet drawn from the supply part, and a decorative sheet on which the adhesive is applied are arranged on a substrate. And pressing the decorative sheet to the base material. When the decorative sheet is stuck on the laminator, the substrate is moved in the laminator by the transport roller.

  The laminator can press the decorative sheet against the base material by changing the size and angle of the roller with respect to the surface parallel to the transport direction of the base material. However, it is difficult to bring the roller into contact with a surface that is not parallel to the conveyance direction of the substrate while the substrate is in progress. For this reason, in order to pressure-bond a decorative sheet to such a surface, it is necessary to change the direction of the base material so that the surface is parallel to the transport direction of the base material, and the work efficiency is poor.

  Accordingly, the present invention provides a method for manufacturing a flooring material that can make a decorative sheet press-bonded to a surface that is not parallel to the transport direction of the base material without changing the orientation of the base material, and that has high work efficiency. This is the issue.

  In order to solve the above-mentioned problem, the invention of claim 1 is a method of manufacturing a flooring material by pressing a decorative sheet onto a base material with a roller, and a groove is formed in advance on the surface of the base material. A positioning part and a convex part corresponding to the groove are formed on the outer peripheral surface of the roller, and the base material and the roller are aligned by bringing the base material into contact with the positioning part. The decorative sheet can be pressure-bonded to the groove by fitting the convex portion into the groove through the decorative sheet while relatively moving the roller and the base material.

  Thereby, a decorative sheet can be stuck also to the surface which is not parallel to the conveyance direction of a base material, without changing the direction of a base material. Needless to say, a decorative sheet is disposed on the upper surface of the base material before the base material is brought into contact with the positioning portion.

  The invention of claim 2 is characterized in that, in the invention of claim 1, the roller is temporarily stopped when the positioning portion of the roller comes to a predetermined position after the decorative sheet is pressed.

  Thereby, if a base material is conveyed to a predetermined place, since a position alignment with a base material and a roller can be performed rapidly, a flooring can be manufactured efficiently.

  The invention of claim 3 is characterized in that, in the invention of claim 1 or 2, the outer peripheral surface of the roller can be exchanged with one corresponding to the surface shape of the substrate.

  As a result, the outer peripheral portion of the roller can be exchanged according to the size and surface shape of the flooring, so that it does not take time to replace the entire roller depending on the type of flooring, and the work efficiency is improved. be able to.

  In the present invention, since the decorative sheet can be pressure-bonded to the groove on the floor material surface without changing the direction of the base material conveyed in the laminator, a method for manufacturing a floor material with good work efficiency can be provided. .

  Hereinafter, embodiments of the present invention will be described in detail with reference to the drawings. FIG. 1 is a perspective view of a flooring A manufactured according to the present invention. On the surface 3 of the base material 1 constituting the flooring A (in FIG. 1, for convenience of illustration, the surface 3 is hidden behind the decorative sheet 2 so that it cannot be seen, so the reference numeral 3 is also written in parentheses). The vertical grooves 5 and the horizontal grooves 6 are formed as pattern grooves, and the decorative sheet 2 having a wood grain pattern is attached. Thereby, the three-dimensional feeling of the flooring A and the texture of the wood are emphasized, and when used, the flooring can be finished beautifully.

  The flooring A is configured by attaching a decorative sheet 2 to the surface 3 of the substrate 1. The substrate 1 may be any material as long as it is approximately planar. For example, wood-based materials such as plywood, wood fiber board (MDF, etc.), particle board, veneer laminate, etc. are desirable, but styrene resin board, vinyl chloride resin board, reinforced plastic board, polystyrene foam resin board, urethane foam resin board A synthetic resin material such as wood or a composite laminate of a wood material or a synthetic resin material can be used. Although the thickness of the base material 1 can be arbitrarily selected according to the use of the flooring A, construction conditions, or the like, it can be set in a range of about 5 to 20 mm, for example.

  Hereinafter, the manufacturing method of the flooring A will be described. A pattern groove is cut on the surface 3 of the substrate 1 cut to a predetermined dimension. As the pattern groove, a longitudinal groove 5 is formed in parallel with the longitudinal direction of the substrate 1, and a transverse groove 6 is formed in a V-shaped cross section with a predetermined depth and width, respectively, perpendicular to the longitudinal direction of the substrate 1. Note that male and female seeds (not shown) are formed on the side surface of the substrate 1 by cutting.

  And the decorative sheet 2 is affixed on the base material 1 formed in this way. As a suitable decorative sheet 2, for example, a synthetic resin sheet containing an olefin resin, a vinyl chloride resin, a polyester resin, an acrylic resin, or the like can be given. Further, these decorative sheets 2 may be overcoated. The thickness of the decorative sheet 2 can be made into the range of about 0.05-1 mm, for example.

  Usually, sticking of the decorative sheet 2 to the base material 1 constituting the flooring A is performed by an apparatus called a laminator (not shown). The laminator is provided on the substrate 1 with a supply unit for pulling out the decorative sheet 2 wound in a roll shape, an application unit for applying an adhesive to the decorative sheet 2 drawn from the supply unit, and a decorative sheet 2 coated with the adhesive. And a pressure bonding part (roller 10) for pressing the decorative sheet 2 to the base material 1.

  The manufacturing method according to the present invention is characterized in that a roller 10 having a special shape on the outer peripheral surface 11 is used in pressure bonding of the decorative sheet 2 to the pattern groove. FIG. 2 is a perspective view of the roller 10 used in the present invention. The size of the roller 10 is arbitrarily selected according to the size of the base material 1 to which the decorative sheet 2 is pressure-bonded. However, the width of the roller 10 is preferably larger than the width of the base material 1, and the circumferential length of the roller 10 must be longer than the length of the base material 1 in the transport direction. As shown in FIG. 2, a positioning portion 12 and a convex portion 13 are formed on the outer peripheral surface 11 of the roller 10 in accordance with the shape of the surface 3 of the substrate 1.

  The shape of the positioning part 12 should just be what can contact | abut the end surface of the conveyed base material 1. FIG. For example, the positioning portion 12 can be formed in a protruding shape in a direction parallel to the rotation shaft 17 of the roller 10. The convex portion 13 corresponds to the pattern groove of the base material 1, has a mountain shape in cross section, and includes a vertical groove pressing portion 15 and a horizontal groove pressing portion 16. The longitudinal groove pressing portions 15 are formed along the circumferential direction at intervals and numbers corresponding to the longitudinal grooves 5 of the substrate 1. The transverse groove pressing portion 16 is formed at a position corresponding to the transverse groove 6 of the substrate 1 between the longitudinal groove pressing portions 15. That is, the circumferential length from the positioning portion 12 to the lateral groove pressing portion 16 is formed to be the same as the length from the side surface of the substrate 1 that contacts the positioning portion 12 of the roller 10 to the lateral groove 6. In other words, the configuration described above can be considered that the developed shape of the outer peripheral portion 18 of the roller 10 is substantially the same as the pattern groove of the substrate 1.

  In the present embodiment, the outer peripheral portion 18 including the outer peripheral surface 11 is separate from the roller main body 20 and is fixed to the roller main body 20 by, for example, a hook (not shown). For this reason, the outer peripheral part 18 can be removed, and can be replaced | exchanged according to the dimension of the base material 1, and the pattern groove | channel of the surface 3. FIG. The outer peripheral portion 18 can be formed of ethylene propylene rubber (EPDM), silicone rubber, or the like. Moreover, the outer peripheral part 18 does not need to exist over the perimeter of the roller 10, and only needs to exist for the length of the base material 1 in the conveyance direction.

  The base material 1 is conveyed in the laminator, and a decorative sheet 2 coated with an adhesive is disposed on the base material 1 by a known method, and the decorative sheet 2 is pressure-bonded to the surface 3 of the base material 1. 3A to 3C are cross-sectional views showing a state in which the decorative sheet 2 is pressure-bonded to the substrate 1. After the decorative sheet 2 is pressure-bonded to the surface 3, as shown in FIG. 3A, the substrate 1 is conveyed through the apparatus (laminator pressure-bonding portion) and abuts against the positioning portion 12 of the roller 10. The roller 10 is fixed at a predetermined position, and the rotation is temporarily stopped in a state where the positioning portion 12 is directly below. After the base material 1 comes into contact with the positioning portion 12, the roller 10 starts to rotate.

  Then, the base material 1 is conveyed by the conveyance roller which is not shown in figure along the extension direction of the vertical groove 5, and the roller 10 also rotates synchronously. The longitudinal groove pressing portions 15 of the roller 10 are formed at intervals and numbers corresponding to the longitudinal grooves 5 of the substrate 1, and the roller 10 rotates while pressing the decorative sheet 2 against the longitudinal grooves 5 by the longitudinal groove pressing portion 15. To do. Further, in the roller 10, the lateral groove pressing portion 16 has a circumferential length from the positioning portion 12 to the lateral groove pressing portion 16 that is equal to the length from the side surface of the substrate 1 contacting the positioning portion 12 of the roller 10 to the lateral groove 6. It is formed to be the same. Therefore, when the roller 10 rotates, the transverse groove pressing portion 16 is fitted into the transverse groove 6 of the substrate 1 as shown in FIG. Thereby, since the horizontal groove 6 is pressed by the horizontal groove pressing part 16, the decorative sheet 2 can be crimped | bonded with respect to the horizontal groove 6. FIG.

  In the present embodiment, the decorative sheet 2 is once pressure-bonded to the surface 3 of the substrate 1, and then the decorative sheet 2 is pressure-bonded to the vertical grooves 5 and the horizontal grooves 6. However, the present invention is limited to this. It is not something. For example, the decorative sheet 2 may be crimped to the front surface 3 simultaneously with the crimping of the decorative sheet 2 to the longitudinal grooves 5 and the lateral grooves 6 by the concave portions 14 of the outer peripheral surface 11 of the roller 10 shown in FIG. In this embodiment, the roller 10 is fixed at a predetermined position and transports the base material 1. However, the roller 10 may be moved with respect to the fixed base material 1.

  Further, as shown in FIG. 3C, the roller 10 is braked once, and the rotation is temporarily stopped. In the present embodiment, due to the relationship between the circumferential length of the roller 10 and the length of the substrate 1 in the conveyance direction, the roller 10 is temporarily stopped when it rotates once, but the present invention is limited to this. is not. For example, if the length of the base material 1 in the transport direction is not more than half of the circumference of the roller 10, it may be temporarily stopped every half rotation.

It is a perspective view of the flooring manufactured by the present invention. It is a perspective view of the roller used for this invention. (A) is sectional drawing of the roller and flooring which show the state which the end surface of the conveyed base material contact | abutted the positioning part of the roller, (b) is a horizontal groove press part of a roller through a decorative sheet It is sectional drawing of the roller and flooring which show the state which presses the horizontal groove of a base material, (c) is sectional drawing of the flooring to which the roller which temporarily stopped rotation after crimping | bonding of the decorative sheet, and the decorative sheet were crimped | bonded is there.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Base material 2 Decorative sheet 3 Surface 5 Vertical groove 6 Horizontal groove 10 Roller 12 Positioning part 13 Convex part 15 Vertical groove pressing part 16 Horizontal groove pressing part 18 Peripheral part 20 Roller body A Floor material

Claims (3)

A method of manufacturing a flooring material by pressing a decorative sheet on a base material with a roller,
A groove is formed in advance on the surface of the base material,
On the outer peripheral surface of the roller, a positioning portion and a convex portion corresponding to the groove are formed,
After aligning the base material and the roller by bringing the base material into contact with the positioning portion,
A method for producing a flooring material, wherein the decorative sheet can be pressure-bonded to the groove by fitting the convex portion into the groove through the decorative sheet while relatively moving the roller and the base material.   The method for manufacturing a flooring according to claim 1, wherein the roller is temporarily stopped when the positioning portion of the roller comes to a predetermined position after the decorative sheet is pressed.   The floor material manufacturing method according to claim 1 or 2, wherein the outer peripheral surface of the roller can be exchanged with one corresponding to the surface shape of the substrate.

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