JPS5951910B2 - Manufacturing method of edge deck - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method of manufacturing edge decking using a continuous roll laminator.

Conventionally, edge decks have been manufactured by pasting natural tree roots onto a plywood base and painting the top.
Since most of the edge decks are long, with a length of 3,600 to 4,000 layers, it has become increasingly difficult to obtain long natural tree roots without defects, and it has also become very expensive. .

Therefore, recently, as an alternative, plywood is laminated with a sheet with a structure of "transparent vinyl chloride sheet/patterned/colored vinyl chloride sheet", and it is cheaper than edge decking made of natural tree roots. It has been growing rapidly for a number of reasons.

However, in the pasting process during the manufacturing process, the continuous roll lamination method causes the vinyl chloride sheet to expand and contract due to the tension on the machine, making it difficult to operate stably, so flat pressure presses are generally required. Furthermore, since PVC sheets do not have the property of absorbing volatile substances, they must be kept pressed for a long time until the adhesive solidifies, which reduces productivity. There was one major obstacle in the way. The present invention was made in order to eliminate the drawbacks of the conventional methods as described above, and by using parchment paper instead of colored vinyl chloride sheets, it enables the use of a continuous roll laminator and allows long-term use. This eliminates the need for clamping.

A detailed explanation will be given below with reference to the drawings.

First, as shown in FIG. 1, a desired pattern 2 is applied to the back side of a transparent or translucent vinyl chloride sheet 1, and then a parchment paper 4 is pasted to that side via an adhesive 3 to form a decorative sheet 5. obtain.

Since this decorative sheet 5 has parchment paper as a part of its structure, it has very little elasticity with respect to the tension on the laminator, and is characterized by better compatibility with adhesives than vinyl chloride sheets. Next, as shown in FIG. 2, the decorative sheet 5 is laminated to a base material 7 via an adhesive 6 using a continuous roll laminator, thereby obtaining a decorative board 8 as shown in FIG. 3.

Next, this decorative board is cut to a required size, and male seeds 9 and female seeds 10 are formed on the side surfaces as shown in FIG. 4 to obtain a border plate 11.

As described above, the edge deck obtained by the present invention has a structure that has low expansion and contraction, high inter-paper strength, and contains parchment paper with remaining papery parts, so it can be attached to the base material using a continuous roll laminator. The decorative sheet does not expand or contract during the process, resulting in good adhesion accuracy, and there is no peeling of the decorative sheet due to expansion and contraction after pasting.From a production standpoint, continuous lamination using a continuous roll laminator speeds up production efficiency. Also, because the paper quality remains, the adhesive penetrates better than vinyl chloride sheets, and there is no need for a pressing process after pasting.

In addition, there are several possible configurations of the decorative sheet before it is attached to the base material other than the one shown in Figure 1. For example, as shown in Figure 5, the decorative sheet can be configured by attaching it to the surface of a transparent or translucent vinyl chloride sheet. A transparent resin 12 can be applied to eliminate the vinyl chloride feel on the surface.

Note that this transparent resin may be applied after the decorative sheet is attached to the base material. Furthermore, as shown in FIG. 6, if the desired pattern is made only by the pattern 13 with the solid pattern removed, and if the solid printing 14, which is removed by 13, is applied to the top surface of the parchment paper, an adhesive layer is interposed between them, so that it is possible to create a deep pattern. It has a pattern that closely resembles a certain type of natural wood.

Also, if solid printing is performed using ink containing metal powder pigments or pearlescent pigments, it will look more like natural wood. As a method of giving depth and making it more similar to natural wood, a configuration as shown in FIG. 7 can be used.

That is, when a desired pattern is composed of a pattern and a transparent solid layer and a white opaque solid layer 15 is formed on the back side of the parchment paper, light incident from above the decorative sheet will be transmitted to the surface of the transparent or translucent vinyl chloride sheet. Part of the light is reflected on the surface of the pattern, the transparent solid surface, the surface of the adhesive layer, and the surface of the parchment paper, and the light passes through each layer in turn, and finally the light that remains on the white opaque solid layer. Reflect everything. By reflecting the incident light in multiple stages in each laminated layer in this way, a three-dimensional effect can be created, making it possible to closely resemble natural wood. Note that a transparent solid color may be formed using an ink containing a metal powder pigment or a pearlescent pigment. Further, if colored parchment paper is used as shown in FIGS. 8 and 9, solid portions of the desired pattern can be omitted.

FIG. 8 shows the case where a colored parchment paper 16 is used, and FIG. 9 shows the case where a two-layer parchment paper 19 consisting of an uncolored upper layer 17 and a colored lower layer 18 is used. Example 1 On the back side of a transparent vinyl chloride sheet with a thickness of 0.15 mm, a 3-color Karamatsu straight-grain pattern was printed using a vinyl chloride-vinyl acetate-based gravure ink in the opposite direction to the normal printing order.

Next, the printed surface and brown parchment paper having a thickness of 0.25 mm were laminated with an acrylic urethane adhesive using a dry laminator to obtain a decorative sheet. Next, this decorative sheet was continuously laminated to a 12 mm thick plywood board using a roll laminator using a modified ethylene vinyl acetate adhesive, and the resulting decorative board was cut to a predetermined size, and the side surface was actually processed. I applied it and got the edge deck.

Example 2 One side of a transparent vinyl chloride sheet for flooring with a thickness of 0.12 mm was coated with acrylic urethane resin at 15 g/m (dry) using a reverse roll coater, and then vinyl chloride vinyl acetate was applied to the non-painted side of the sheet. A three-color Japanese cypress straight-grain pattern was printed using Gravure ink in the opposite direction to the normal printing order.

Next, the printed surface and 0.3 mm thick white parchment paper, which had been printed all over with ink containing pearlescent pigments, were laminated with an acrylic urethane adhesive using a dry laminator to form a decorative sheet. Obtained. Thereafter, in the same manner as in Example 1, the material was continuously laminated to plywood using a roll laminator, and then actual processing was performed to obtain an edge deck.

[Brief explanation of drawings]

Figures 1 and 5 to 9 are cross-sectional views of the decorative sheet used in the present invention, Figure 2 is an explanatory diagram of the decorative sheet and base material being laminated using a continuous roll laminator, and Figure 3 is a cross-sectional view of the decorative sheet used in the present invention. FIG. 4 shows a cross-sectional view of the edge deck obtained by the present invention before actual processing, and FIG. 4 shows a partially cutaway perspective view of the edge deck after actual processing. 1... Vinyl chloride sheet, 2... Pattern, 3... Adhesive, 4... Parchment paper, 5... Decorative sheet, 6... Adhesive, 7... Base material, 8... Decorative board, 9...
... Male fruit, 10... Female fruit, 11...
・Edge deck, 12...Transparent resin, 13...
・Pattern pattern, 14... Solid printing, 15...
- Opaque solid layer, 16... Colored parchment paper, 17... Upper layer, 18... Lower layer, 19
・・・・・・Two layers of parchment paper.

Claims (1)

[Scope of Claims] 1. A decorative sheet with small elasticity, which is made by applying a desired pattern to the back side of a transparent or translucent vinyl chloride sheet and then pasting parchment paper to the patterned surface using an adhesive, is rolled into a continuous roll. A method for producing an edge deck, characterized in that it is continuously laminated to a base material via an adhesive while applying tension using a laminator, and then subjected to actual processing. 2. Claim 1, characterized in that a transparent resin that eliminates the vinyl chloride feel is applied to the surface of the transparent or translucent vinyl chloride sheet before or after laminating the decorative sheet to the base material. Manufacturing method of edge deck. 3. Claim 1, characterized in that the desired pattern consists only of patterns excluding solid patterns, and solid printing is performed on the surface of the parchment paper that is adhered to the vinyl chloride sheet. or the manufacturing method of the edge deck described in any of paragraph 2. 4. The method for manufacturing an edge deck according to claim 3, wherein the solid printing is a solid printing with pearlescent luster. 5. A patent characterized in that the desired pattern is composed of a pattern and a transparent solid color with or without pearlescent luster, and the white solid color is applied to the surface to be laminated to the base material of parchment paper. A method for manufacturing an edge deck according to claim 1 or 2. 6. The edge deck according to claim 1 or 2, wherein the desired pattern consists only of pattern patterns excluding solid patterns, and the parchment paper is colored parchment paper. Manufacturing method. 7. Claim 1, characterized in that the desired pattern consists only of patterns excluding solid patterns, and the parchment paper is a two-layer parchment paper consisting of an uncolored upper layer and a colored lower layer. or the manufacturing method of the edge deck described in any of paragraph 2.