Manufacturing equipment for decorative laminates

Abstract

The objective is to provide a decorative panel with a textured surface on the upper surface of a substrate that can be easily and inexpensively manufactured with minimal labor, and that has a textured surface with high adhesive strength that does not easily peel off. [Solution] An electron beam curable resin is applied to the entire upper surface of the substrate 2 by a coating means 10, and this is cured by a first curing means 18 to form a base layer 2a. An uneven layer 22 made of electron beam curable resin is formed on the base layer 2a by an adhesion means, a color inkjet printer 21, and this is cured by a second curing means 23 to form an embossed decorative panel B having an uneven surface on the upper surface of the substrate 2.

Description

Technical Field

[0001] This invention relates to a manufacturing apparatus for a decorative board, which is formed by forming concavo-convex portions on at least the upper surface of a base material.

Background Art

[0002] Conventionally, there is a decorative board having an embossed surface. For example, as described in Patent Document 1, an ultraviolet-blocking ink composition is printed on an uncured coat film containing a photopolymerizable compound coated on a base material for a decorative board, and the coat film printed with the ultraviolet-blocking ink composition is irradiated with ultraviolet rays, and the coat film in the region printed with the ultraviolet-blocking ink composition is removed to form an embossed surface on the decorative board.

[0003] In addition, as a method of forming concavo-convex portions with an ultraviolet-curable resin, an ultraviolet-curable resin is applied to the surface of a base material and cured to form a base layer, a primer layer is formed thereon, and then an ultraviolet-curable resin is printed in a predetermined pattern and laminated, and the laminated ultraviolet-curable resin is irradiated with ultraviolet rays and cured to form a decorative board having an embossed surface.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] However, in the case of embossing by the conventional method as described in Patent Document 1 above, sufficient adhesive strength cannot be obtained with a photopolymerizable compound or an ultraviolet-curable resin, and there is a problem that the embossed layer easily peels off from the surface of the base material.

[0006] Furthermore, as mentioned above, when forming a textured surface with UV-curing resin, if the UV-curing resin is printed directly onto the base layer, it does not adhere to the base layer and cannot be layered. Therefore, a primer layer must be laminated on top of the base layer, which increases the number of steps, time, and cost. In addition, when forming a textured pattern of UV-curing resin on top of another UV-curing resin, the adhesive strength between the substrate and the UV-curing resin, as well as the adhesive strength between the UV-curing resins themselves, is weak, and the entire textured layer formed by the UV-curing resin can easily peel off the substrate.

[0007] Furthermore, Japanese Patent Publication No. 6970218 describes forming an embossed surface on a substrate for decorative panels using an electron beam curable resin. Specifically, it describes forming a layer of a first liquid curable coating (e.g., an electron beam curable resin) over the entire surface of the substrate, laminating a separate component called an element having irregularities on top of it, curing the first liquid curable coating while the elements are being laminated to transfer the irregularities of the elements, then sequentially laminating a protective layer and a release layer of a transparent second liquid curable coating (e.g., an electron beam curable resin) on top of that, curing the protective layer, and then removing the release layer.

[0008] However, the technology described in Japanese Patent Publication No. 6970218 requires the prior preparation of a separate component called a transfer element, and also requires the formation of a protective layer to protect the transferred surface. Therefore, similar to the technology described in Patent Document 1, it has the problem of being time-consuming, labor-intensive, and costly.

[0009] This invention has been made in view of the above-mentioned problems, and aims to provide a decorative panel having a decorative surface with irregularities on the upper surface of a substrate that can be manufactured easily and inexpensively with fewer steps, and that has a decorative surface with high adhesive strength that does not easily peel off. [Means for solving the problem]

[0010] To achieve the above objective, the present invention provides a decorative panel manufacturing apparatus for manufacturing a decorative panel having irregularities formed on at least the upper surface of a base material of a predetermined length made of a long wooden board, comprising a base layer forming apparatus and an irregularity processing surface forming apparatus, wherein the base layer forming apparatus has conveying means for conveying a plurality of the base materials arranged in a predetermined conveying direction with substantially no gaps between them, and upper and lower rollers arranged to clamp the plurality of base materials conveyed by the conveying means from above and below at predetermined clamping positions, and superimposing means for superimposing a resin film of substantially the same width as the base material onto the upper surface of the plurality of base materials at the clamping positions by the upper and lower rollers, and coating means upstream of the superimposing means in the conveying direction for applying an electron beam curable resin having adhesive properties due to electron beam curing characteristics below the resin film and onto the upper surface of the plurality of base materials, below the resin film, and downstream of the coating means in the conveying direction The uneven surface forming apparatus is characterized by comprising: a first curing means disposed on the side and irradiating an electron beam from above onto the electron beam curable resin superimposed on the electron beam curable resin applied to the substrate, thereby curing the electron beam curable resin applied to the upper surfaces of the plurality of substrates to form the base layer; a peeling means disposed downstream of the first curing means in the transport direction and peeling off and recovering the resin film superimposed on the plurality of substrates; an adhesion means for forming an uneven layer by attaching an electron beam curable resin having adhesive properties due to electron beam curing characteristics to the upper surface of the base layer exposed by the peeling means in a predetermined pattern and at the same and / or different heights in the upward direction; and a second curing means disposed downstream of the adhesion means in the transport direction and irradiating an electron beam onto the upper surface of the base layer by the adhesion means to cure the uneven layer formed on the upper surface of the base layer to form an uneven surface.

[0011] With this configuration, in the base layer forming apparatus, an electron beam curable resin is applied to the entire upper surface of the substrate by a coating means, and this is cured by a first curing means to form a base layer. In the textured surface forming apparatus, an uneven layer of electron beam curable resin is formed on the base layer by an adhesion means, and this uneven layer is cured by a second curing means. As a result, a base layer of electron beam curable resin can be firmly formed on the upper surface of the substrate by the activation of the substrate surface by the electron beam and the crosslinking reaction of the electron beam curable resin applied to the substrate for base layer formation by the electron beam. Furthermore, by forming an uneven layer of electron beam curable resin having the same electron beam curing characteristics on the base layer and curing this by a second curing means, an uneven surface (embossed) with excellent adhesive strength can be formed on the upper surface of the substrate. This allows for the easy and inexpensive manufacture of decorative surfaces with an uneven surface with fewer steps, and moreover, it is possible to form an uneven surface with high adhesive strength that does not easily peel off.

[0012] In this process, by laminating an electron beam curable resin layer with the same electron beam curing properties onto a base layer of electron beam curable resin to form a textured surface on the substrate, each layer is firmly cured by the electron beam, and strong intermolecular bonds are formed. As a result, the adhesion between layers becomes very high, and the laminated electron beam curable resin layers also have improved abrasion resistance and impact resistance. Furthermore, the multilayer structure allows for the formation of a textured surface with a deeper color and a beautiful, glossy finish.

[0013] Furthermore, the uneven surface forming apparatus may be arranged downstream of the base layer forming apparatus, and the uneven surface may be continuously formed on the plurality of substrates on which the base layer has been formed by the base layer forming apparatus.

[0014] This configuration is effective when multiple substrates can be transported at a constant speed by a transporting means while an uneven layer is formed by an adhesion means, and it can provide an inexpensive apparatus that enables the continuous manufacturing of decorative panels.

[0015] Furthermore, the base layer forming apparatus is disposed downstream of the peeling means in the transport direction and includes a separation means for curing the electron beam curable resin applied to the upper surfaces of the plurality of substrates to form the base layer, and for separating the plurality of substrates at predetermined lengths between them after the resin film has been peeled off by the peeling means, and the uneven surface forming apparatus includes a transport means for sequentially transporting the plurality of substrates separated from the separation means, and the uneven surface may be formed on the plurality of substrates transported by the transport means.

[0016] This configuration is effective when, in cases where an uneven layer cannot be formed on a base layer on a substrate being transported at a constant speed by a transporting means, multiple substrates with the base layer formed are separated by a separation means, and then the uneven layer is formed by the adhesion means while the substrates are transported by a transfer means at a transfer speed different from the transport speed of the transporting means. This configuration makes it possible to form an uneven layer according to the function of the adhesion means.

[0017] Furthermore, the coating means may form an electron beam curable resin reservoir upstream of the superimposing means in the transport direction for supplying and coating the electron beam curable resin across the entire width of the upper surface of the resin film, and the electron beam curable resin for the base layer may be coated on the upper surface of the plurality of substrates below the resin film by passing the resin film through the electron beam curable resin reservoir.

[0018] In this configuration, by passing the resin film through the electron beam curing resin reservoir upstream of the substrate transport direction, the electron beam curing resin for the base layer is applied to the upper surfaces of multiple substrates below the resin film. This allows for uniform application of the electron beam curing resin to the upper surfaces of the substrates with a simple configuration.

[0019] Furthermore, it is desirable that the superimposed surface of the resin film, which is superimposed on the electron beam-cured resin applied to the substrate, is roughened.

[0020] This method ensures that the rough surface of the resin film adheres closely to the electron beam-curable resin applied to the substrate, preventing this contact surface from coming into contact with oxygen. As a result, it becomes unnecessary to create an electron beam irradiation environment in a nitrogen atmosphere, which is generally required to prevent exposure to oxygen when irradiating with an electron beam. This simplifies the equipment configuration, and since the rough surface of the resin film is also transferred to the base layer made of electron beam-curable resin, the adhesion of the electron beam-curable resin for the uneven layer formed on the base layer can be improved.

[0021] Furthermore, the adhesion means may consist of an inkjet printer having a plurality of inkheads that spray the electron beam curable resin to form the monochromatic and / or multicolored uneven layers.

[0022] This method allows for the easy printing of a variety of monochromatic and / or multicolored textured layers onto a predetermined pattern using an inkjet printer with multiple inkheads that spray electron beam-curable resin, thereby enabling the production of decorative panels with beautifully finished textured surfaces. The inkjet printer can be either a single-pass or shuttle type.

[0023] Furthermore, the present invention relates to a decorative panel manufacturing apparatus for manufacturing a decorative panel having irregularities formed on at least the upper surface of a base material made of resin and having a predetermined length, and is characterized by comprising: an adhesion means for forming an irregular layer by attaching an electron beam curable resin having adhesive properties due to single-color and / or multi-color electron beam curing characteristics to the upper surface of the resin base material in a predetermined pattern and at the same and / or different heights in the upward direction; and a curing means disposed downstream of the adhesion means in the transport direction, which irradiates the upper surface of the base layer with an electron beam by the adhesion means to cure the irregular layer formed on the upper surface of the base layer and form an irregular processed surface.

[0024] According to such a configuration, when the base material is made of a resin such as PP (polypropylene) or PE (polyethylene), an uneven layer is formed on the upper surface of the resin base material by an adhesion means, and this uneven layer is cured by a curing means to form an uneven processed surface on the upper surface of the base material. Therefore, a resin decorative board having an uneven processed surface with excellent adhesion strength can be obtained.

[0025] Further, the base material may be in the form of a resin sheet. In this case, if it is a resin sheet-shaped decorative board, it can also be applied to wall materials and floor materials, and a sheet-shaped decorative board having an uneven processed surface that is strong, excellent in wear resistance and barrier resistance can be easily obtained, and a decorative board applicable to wall materials, floor materials, etc. can be manufactured.

Effects of the Invention

[0026] According to the present invention, in order to form an uneven processed surface on the base material by laminating an uneven layer of the same electron beam-curable resin on the base layer of the electron beam-curable resin, a decorative surface having unevenness on the upper surface of the base material can be manufactured simply and at low cost with a small number of man-hours, and moreover, a decorative board having an uneven processed surface with high adhesion strength that does not easily peel off can be provided.

Brief Description of the Drawings

[0027] [Figure 1] It is a schematic configuration diagram of a first embodiment of a manufacturing apparatus for a decorative board according to the present invention. [Figure 2] It is a partial perspective view of FIG. 1. [Figure 3] It is another partial plan view of FIG. 1. [Figure 4] It is a flowchart for explaining the operation of FIG. 1. [Figure 5] It is a diagram showing the comparison result of the adhesion strength between the uneven processed surface formed on the base material by the ultraviolet curable resin and the uneven processed surface according to the first embodiment formed on the base material by the electron beam curable resin. [Figure 6] It is a schematic configuration diagram of a second embodiment of a manufacturing apparatus for a decorative board according to the present invention.

Embodiments for Carrying Out the Invention

[0028] (First Embodiment) A first embodiment of the decorative panel manufacturing apparatus according to the present invention will be described with reference to Figures 1 to 5.

[0029] <Structure> As shown in Figure 1, the decorative panel manufacturing apparatus 1 in the first embodiment comprises a base layer forming apparatus 1A and a textured surface forming apparatus 1B, and the base layer forming apparatus 1A and the textured surface forming apparatus 1B constitute a single manufacturing line so that their respective processes are carried out continuously.

[0030] First, the configuration of the base layer forming apparatus 1A will be described. The base layer forming apparatus 1A comprises a conveying means 3, a film supply roll 5, a superposition means 7, a coating means 10, a regulating means 14, a first curing means 18, a peeling means 19, and a winding roll 20.

[0031] In detail, Figure 1 shows a conveying means 3 for conveying a base material 2, which is a particleboard (hereinafter also referred to as PB), a wood-based board of a predetermined length, that is conveyed in a long, continuous manner without gaps between materials. The conveying means 3 consists of a plurality of conveying rollers 4 arranged in the conveying direction indicated by the arrows in Figure 1, and conveys a plurality of base materials 2 in a continuous manner without gaps between materials. A PET (polyethylene terephthalate) film 6, which is a resin film slightly wider than the width of the base material 2, is wound around a film supply roll 5. A superimposing means 7, which has an upper main roller 7a and a lower secondary roller 7b arranged below the film supply roll 5, places the PET film 6 unwound from the film supply roll 5 onto the upper surface of the base material 2 being conveyed, and pressurizes the base material 2 from above and below with a predetermined pressure by both rollers 7a and 7b.

[0032] Here, the axial lengths of both rollers 7a and 7b are set to be greater than the width of the base material 2 and the PET film 6, as shown in Figure 2. Note that the base material 2 may be a medium-density fiberboard (MDF) in addition to the particleboard described above.

[0033] Furthermore, as shown in Figure 1, the coating means 10 applies an electron beam curable resin having adhesive properties due to its electron beam curing characteristics to the upper surface of the substrate 2. Here, the material tank 11 is filled with electron beam curable resin, one end of a plurality of supply pipes 12 is connected to the material tank 11 and the other end is positioned upstream of the main roller 7a of the superimposing means 7 (upstream in the transport direction of the substrate 2), and the electron beam curable resin from the material tank 11 is supplied to the upper surface of the substrate 2 across the width of the substrate 2 via each supply pipe 12 just before the PET film 6 on the upstream side of the superimposing means 7 is superimposed, forming the electron beam curable resin reservoir described later.

[0034] Here, as an electron beam curing resin having electron beam curing properties, it is preferable to use a paint containing 50% or more biomass, such as special modified acrylates including rosin-based acrylates, polyurethane acrylates, polyester acrylates, etc.

[0035] Furthermore, as shown in Figure 1, a restricting means 14 is provided to prevent the electron beam curable resin supplied from the material tank 11 of the coating means 10 from spreading beyond the width of the substrate 2, keeping it within the width of the substrate 2. As shown in Figure 2, the restricting means 14 is arranged on the upstream side of the main roller 7a of the superimposing means 7 and is placed on both ends in a direction parallel to the transport direction of the substrate 2. It is equipped with restricting plates 15, 15, the downstream arc-shaped end faces of which are arranged along the circumferential surface of the main roller 7a. The two restricting plates 15, 15 are spaced narrower than the width of the substrate 2, and this spacing is variable. On the upstream side of the main roller 7a (upstream side in the transport direction of the substrate 2), an electron beam curable resin reservoir 16 is formed in the area surrounded by the substrate 2, the two restricting plates 15, 15, and the PET film 6 superimposed on the substrate 2.

[0036] Here, as shown by the hatching in Figure 3, it is desirable to adjust the spacing between the two restricting plates 15, 15 of the restricting means 14, taking into account the pressing force exerted by the clamping of both rollers 7a, 7b, so that the electron beam curing resin spreads across the entire width of the substrate 2 in the width direction of the substrate 2.

[0037] Then, the electron beam curing resin supplied from the material tank 11 accumulates in the electron beam curing resin reservoir 16, and as the main roller 7a of the superposition means 7 rotates in the direction of the arrow in Figures 1 and 2, the electron beam curing resin adheres to the upper surface of the substrate 2 and the lower surface of the PET film 6 in the width direction. With the electron beam curing resin applied to the lower surface of the PET film 6, the pressure applied by both rollers 7a and 7b of the superposition means 7 is controlled, causing the electron beam curing resin applied to the lower surface of the PET film 6 to spread in the width direction of the PET film 6 and the substrate 2, and to be applied to the entire upper surface of the substrate 2.

[0038] Incidentally, it is desirable to roughen the superimposed surface of the PET film 6 that is superimposed on the electron beam curable resin applied to the substrate 2, for example, by sandblasting. By roughening the superimposed surface of the PET film 6 in this way, the rough surface of the PET film 6 adheres closely to the electron beam curable resin applied to the substrate 2, and this adhesion surface is prevented from coming into contact with oxygen. Therefore, it becomes unnecessary to create an electron beam irradiation environment in a nitrogen atmosphere, which is generally required to prevent exposure to oxygen when irradiating with an electron beam, and the equipment configuration can be simplified accordingly. Moreover, since the rough surface of the PET film 6 is transferred to the base layer of the electron beam curable resin formed on the substrate 2 (described later), there is an advantage in that the adhesion of the electron beam curable resin for the uneven layer formed on the base layer (described later) can be improved. Note that the method for roughening the PET film 6 is not limited to the sandblasting method described above, and other roughening methods may be used.

[0039] Furthermore, the electron beam curing resin applied to the upper surface of the substrate 2 is preferably white. This has the advantage of making the color and design of the later-described textured layer 22, which is laminated on the white base layer 2a, stand out even more, and making it possible to finish the textured surface beautifully.

[0040] Furthermore, as shown in Figure 1, a first curing means 18, which consists of an electron beam irradiation means, is arranged downstream of the coating means 10 and the superposition means 7 (downstream in the transport direction of the substrate 2). The first curing means 18 irradiates the substrate 2 and the PET film 6 superimposed thereon with an electron beam from above, and the electron beam curable resin applied to the upper surface of the substrate 2 by the coating means 10 hardens to form the base layer 2a.

[0041] Furthermore, as shown in Figure 1, a peeling means 19 consisting of a peeling roller is arranged downstream of the first curing means 18 (downstream in the transport direction of the substrate 2), and after the electron beam curing resin on the substrate 2 is cured and the base layer 2a is formed, the PET film 6 is peeled off from the substrate 2. Note that 20 is a winding roll that winds up and recovers the PET film 6 peeled off by the peeling means 19.

[0042] Next, the configuration of the uneven surface forming apparatus 1B will be described. The uneven surface forming apparatus 1B includes an inkjet printer 21 which is an adhesion means, a second curing means 23, and a cutting means 24.

[0043] In detail, as shown in Figure 1, a so-called single-pass inkjet printer 21 constituting the adhesion means is arranged downstream of the peeling means 19 (downstream in the transport direction of the substrate 2), and has multiple ink heads that spray electron beam curable resin onto the base layer 2a on the substrate 2. The inkjet printer 21 sprays electron beam curable resin of the same and / or different colors from the multiple ink heads onto the upper surface of the base layer 2a on the substrate 2 that is exposed by peeling off the PET film 6, and the electron beam curable resin adheres in a predetermined pattern and at the same and / or different heights in the upward direction, forming an uneven layer 22.

[0044] Furthermore, as shown in Figure 1, a second curing means 23, which consists of an electron beam irradiation means, is arranged downstream of the inkjet printer 21 (downstream in the transport direction of the substrate 2). The second curing means 23 irradiates the uneven layer 22 attached to the base layer 2a on the substrate 2 with an electron beam from above, and the electron beam curable resin of the uneven layer 22 attached by the inkjet printer 21 is cured, causing the uneven layer 22 to adhere tightly to the base layer 2a.

[0045] Furthermore, as shown in Figure 1, the cutting means 24 is arranged downstream of the second hardening means 23 (downstream in the direction of transport of the base material 2). This cutting means 24 includes a cutter that cuts the base material 2, in the state where the uneven layer 22 has hardened, to a predetermined length, and an actuator that moves it up and down. The cutting means 24 cuts the base material 2 to a predetermined length, forming an embossed decorative panel B having an uneven surface.

[0046] <Manufacturing Procedure> Next, the steps for forming the embossed decorative panel B will be explained with reference to the flowchart in Figure 4.

[0047] As shown in Figure 4, a long, continuous substrate 2 is supplied with no gaps between the continuous PB materials (Step S1), the electron beam curable resin filled in the material tank 11 is applied to the upper surface of the substrate 2 by the coating means 10 (Step S2), the electron beam curable resin is cured by the first curing means 18 to form a base layer 2a (Step S3), and the electron beam curable resin is applied to the base layer 2a in a predetermined pattern by the color inkjet printer 21 to form a textured layer 22 (Step S4).

[0048] Then, the electron beam curable resin of the uneven layer 22 attached to the base layer 2a is cured by the second curing means 23 (step S5), and the substrate 2 with the uneven layer 22 attached to the base layer 2a is cut to a predetermined length by the cutting means 24 (step S6), forming an embossed decorative panel B having an uneven surface of a predetermined length, thus completing the series of steps.

[0049] <Comparative Verification Results> Incidentally, the inventors of this application compared and verified the adhesive strength of an embossed surface formed on a substrate using ultraviolet-curable resin and an embossed surface formed on a substrate 2 using electron-beam-curable resin with the apparatus according to the inventors' invention. As a result, as shown in Figure 5, they confirmed that using the electron-beam-curable resin according to the inventors' invention yielded overwhelmingly higher adhesive strength, and also superior abrasion resistance and impact resistance. In Figure 5, "○" and "×" indicate whether the adhesive strength is high or low, and whether the abrasion resistance and impact resistance are high or low, respectively.

[0050] Therefore, according to the first embodiment described above, the electron beam curable resin is applied to the entire upper surface of the substrate 2 by the coating means 10, cured by the first curing means 18 to form a base layer 2a, and then the uneven layer 22 made of electron beam curable resin is laminated on the base layer 2a by the inkjet printer 21 and cured by the second curing means 23. As a result, an embossed decorative panel B having an uneven surface on the upper surface of the substrate 2 can be manufactured easily and inexpensively with fewer steps, and an uneven surface with high adhesive strength that does not easily peel off can be formed.

[0051] Furthermore, by laminating a textured layer 22 of the same electron beam curable resin onto a base layer 2a of the electron beam curable resin to form a textured surface on the substrate 2, each layer 2a and 22 of the electron beam curable resin is firmly cured by the electron beam, and strong intermolecular bonds are formed. As a result, the adhesion between layers becomes very high, and the laminated electron beam curable resin layers also have improved abrasion resistance and impact resistance. Moreover, the multilayer structure allows for the formation of a textured surface with a deeper color and a beautiful glossy finish.

[0052] Incidentally, the following reasons can be considered for the high adhesive strength obtained between the substrate 2, the electron beam curable resin base layer 2a, and the uneven layer 22.

[0053] As the electron beam for curing reaches the upper surface of the substrate, the upper surface of the substrate 2 undergoes fine irregularities and chemical changes due to the electron beam. This crosslinking reaction modifies the surface of the substrate 2, making it easier for the electron beam-cured resin to adhere physically and chemically. Furthermore, the electron beam crosslinking reaction of the electron beam-cured resin applied to the substrate 2 for the formation of the base layer 2a allows for a stronger formation of the base layer 2a on the upper surface of the substrate 2. In addition, since electron beam curing is performed at relatively low temperatures such as room temperature, the effects of thermal expansion and contraction are minimized, improving the adhesion between the electron beam-cured resin and the substrate 2. Moreover, electron beam irradiation creates stronger bonds between the molecules of the base layer 2a and the uneven layer 22, which have the same electron beam curing properties. As a result, it can be inferred that a textured surface with a beautiful finish, possessing wear resistance and impact resistance, is formed on the upper surface of the substrate with high adhesive strength.

[0054] In this way, by laminating a textured layer 22 of the same electron beam curable resin onto a base layer 2a of the electron beam curable resin, a textured surface can be formed on the substrate 2, thereby enabling the easy and inexpensive manufacture of an embossed decorative panel B having a textured surface with high adhesive strength that does not easily peel off, with minimal labor.

[0055] Furthermore, by passing the PET film 6 through the electron beam curing resin reservoir 16 upstream of the conveying direction of the substrate 2, the electron beam curing resin for the base layer 2a is applied to the upper surface of the continuously conveyed substrate 2 below the PET film 6. Therefore, the electron beam curing resin can be uniformly applied to the upper surface of the substrate 2 with a simple configuration.

[0056] Furthermore, by roughening the superimposed surface of the PET film 6 that is superimposed on the electron beam curable resin applied to the substrate 2, the rough surface of the PET film 6 adheres closely to the electron beam curable resin applied to the substrate 2, preventing this adhered surface from coming into contact with oxygen. This eliminates the need to create an electron beam irradiation environment in a nitrogen atmosphere, which is generally required to prevent exposure to oxygen when irradiating with an electron beam, thereby simplifying the apparatus configuration. Moreover, since the rough surface of the PET film 6 is also transferred to the base layer 2a of the electron beam curable resin formed on the substrate 2, the adhesion of the electron beam curable resin for the uneven layer 22 formed on the base layer 2a can be improved.

[0057] Furthermore, by forming a white electron beam curable resin base layer 2a on the upper surface of the substrate 2, the color and design of the uneven layer of the predetermined pattern formed by laminating electron beam curable resin on top of it can be further accentuated, resulting in a beautifully finished uneven surface.

[0058] Furthermore, by using a color inkjet printer 21 having multiple inkheads that spray single-color and / or multi-color electron beam-curable resins, a variety of textured layers 22 can be easily printed in a predetermined pattern, making it possible to manufacture an embossed decorative panel B with a beautifully finished textured surface.

[0059] (Second Embodiment) A second embodiment of the decorative panel manufacturing apparatus according to the present invention will be described with reference to Figure 6. Note that the same reference numerals as in Figures 1 to 3 indicate the same or equivalent components, and the following description will mainly focus on aspects consistent with the first embodiment.

[0060] The base layer forming apparatus 1A and the uneven surface forming apparatus 1B of the decorative panel manufacturing apparatus 1 according to the second embodiment differ significantly from the first embodiment in that they do not constitute a single line, as shown in Figure 6.

[0061] Specifically, as shown in Figure 6(a), the base layer forming apparatus 1A is equipped with a separation means S located downstream of the peeling means 19 in the transport direction (downstream of the transport direction of the base material 2). This separation means S allows the electron beam curable resin applied to the upper surfaces of multiple base materials 2 to be cured by the first curing means 18 to form a base layer 2a, and then separates the multiple base materials 2, which have been peeled off by the peeling means 19, at predetermined lengths between them.

[0062] Furthermore, as shown in Figure 6(b), the textured surface forming apparatus 1B does not constitute the same production line as the base layer forming apparatus 1A, but operates as a separate production line. It is equipped with a transfer means 25 consisting of numerous transfer rollers 25a that sequentially transfer multiple base materials 2 separated one by one by the separation means S. A single-color electron beam curable resin is sprayed from an ink head, which moves perpendicular to the transfer direction, onto the base layer 2a formed on the upper surface of the base material 2 by an adhesion means, such as a shuttle-type inkjet printer 26, forming a textured layer 22. The textured layer 22 is then cured by a second curing means (corresponding to the "curing means" in this invention) 23, which consists of an electron beam irradiation means, forming a textured surface on the upper surface of each base material 2. Note that at least three ink heads may be provided in the shuttle-type inkjet printer 26 to spray three primary color electron beam curable resins separately to form a multi-colored textured layer 22.

[0063] In this case, the transfer means 25 transfers the substrate 2 at a transfer speed completely different from the transfer speed of the transfer means 3 of the base layer forming apparatus 1A. The transfer of the substrate 2 is temporarily stopped while the ink head of the inkjet printer 26 moves in one pass, and after the ink head has moved in one pass and before the ink head returns to its initial position, the substrate 2 is transferred for the next pass. Thus, the substrate 2 is transferred intermittently by the transfer means 25.

[0064] Furthermore, the electron beam irradiation by the second curing means 23 creates stronger bonds between the molecules of the base layer 2a and the uneven layer 22, which have the same electron beam curing characteristics. As a result, similar to the first embodiment, uneven surfaces with abrasion resistance, impact resistance, and a beautiful finish are formed on the upper surface of the substrate 2 with high adhesive strength, one layer at a time.

[0065] Therefore, according to the second embodiment, the same effects as those of the first embodiment described above can be obtained.

[0066] (Third embodiment) In a third embodiment of the present invention, the base material 2 may be made of resin such as PP or PE instead of wood-based board such as PB (particleboard). In this case, the base layer forming apparatus 1A is unnecessary for the decorative panel manufacturing apparatus, and the decorative panel manufacturing apparatus 1 only needs to have the uneven surface forming apparatus 1B shown in Figure 1 or Figure 6.

[0067] According to the third embodiment, since the base material 2 is made of resin, the base layer forming apparatus 1A is not required, which simplifies the apparatus configuration. Furthermore, since the base material 2 is made of resin such as PP or PE, the adhesion means consisting of inkjet printers 21 and 26 can directly form an uneven layer on the upper surface of the resin base material 2, and this uneven layer can be cured by electron beam irradiation to form an uneven surface on the upper surface of the base material. As a result, a resin decorative panel with an uneven surface and excellent adhesive strength can be obtained.

[0068] Furthermore, if the base material is a resin sheet-like decorative panel, it can be applied to wall and floor materials, and a decorative panel with a strong, abrasion-resistant, and barrier-resistant textured surface can be easily obtained.

[0069] It should be noted that the present invention is not limited to the embodiments described above, and various modifications other than those described above can be made without departing from the spirit of the invention.

[0070] For example, in the embodiment described above, a PET film 6 was used as the resin film, but it is not limited to a PET resin film.

[0071] Furthermore, in the above-described embodiment, inkjet printers 21 and 26 were used as the adhesion means, but other adhesion means such as digital printing means like 3D printers may also be used.

[0072] Furthermore, the base material 2 is not limited to the PB (particle board) described above; medium-density fiberboard or other wood-based boards may also be used.

[0073] Furthermore, the present invention can be broadly applied to a decorative panel manufacturing apparatus that produces decorative panels having irregularities formed on at least the upper surface of the base material. [Explanation of Symbols]

[0074] 1 ... Manufacturing equipment for decorative panels 1A…Base layer forming device 1B…Uneven surface forming device 2. PB (Particleboard / Base Material) 2a…Base layer 3. Conveying means 6. PET film (resin film) 7 ... Superposition method 7a ... Main roller (upper roller) 7b ... Subordinate roller (lower roller) 10 ... Coating means 14… Regulatory measures 16 ... Electron beam cured resin reservoir 18 ...First curing means 19 ... means of peeling 21, 26 ... Inkjet printer (adhesion method) 22...Concave and convex layer 23 ...Second curing method 24…cutting means S…separation means B... Embossed decorative sheet

Claims

1. In a decorative panel manufacturing apparatus for producing a decorative panel having irregularities formed on at least the upper surface of a base material of a predetermined length made of a long wooden board, Equipped with a base layer forming apparatus and an uneven surface forming apparatus, The aforementioned base layer forming apparatus is A conveying means for conveying the aforementioned substrates in a predetermined conveying direction, with multiple substrates arranged in a manner that is virtually seamless between them, The conveying means has an upper roller and a lower roller arranged to clamp the plurality of substrates being conveyed by the conveying means vertically at predetermined clamping positions, and the superimposing means superimposes a resin film having substantially the same width as the substrates onto the upper surface of the plurality of substrates at the clamping positions by the upper roller and the lower roller, Upstream of the superimposing means in the transport direction, there is a coating means for applying an electron beam curable resin having adhesive properties due to electron beam curing characteristics to the upper surfaces of the plurality of substrates below the resin film, A first curing means is disposed downstream of the coating means in the transport direction and irradiates an electron beam from above the resin film superimposed on the electron beam curable resin coated on the substrate, thereby curing the electron beam curable resin coated on the upper surfaces of the plurality of substrates to form the base layer. A peeling means is disposed downstream of the first curing means in the transport direction for peeling off and recovering the resin film superimposed on the plurality of substrates. It has, The aforementioned uneven surface forming apparatus is An adhesion means for forming an uneven layer by attaching an electron beam curable resin having adhesive properties due to electron beam curing characteristics to the upper surface of the base layer exposed by peeling off the resin film by the peeling means, in a predetermined pattern and at the same and / or different heights in the upward direction; A second curing means is disposed downstream of the adhesion means in the transport direction and irradiates the upper surface of the base layer with an electron beam by the adhesion means to harden the uneven layer formed on the upper surface of the base layer and form an uneven surface. A manufacturing apparatus for decorative laminates, characterized by having the following features.

2. The aforementioned uneven surface forming apparatus is The decorative panel manufacturing apparatus according to claim 1, which is disposed downstream of the base layer forming apparatus and is characterized by continuously forming the uneven surface on the plurality of substrates on which the base layer has been formed by the base layer forming apparatus.

3. The aforementioned base layer forming apparatus is Displaced downstream of the peeling means in the transport direction, the separation means is provided for curing the electron beam curable resin applied to the upper surfaces of the plurality of substrates to form the base layer, and for separating the plurality of substrates at predetermined lengths between the materials after the resin film has been peeled off by the peeling means. The aforementioned uneven surface forming apparatus is The system includes a transfer means for sequentially transferring the plurality of substrates separated from the separation means, The manufacturing apparatus for decorative panels according to claim 1, characterized in that the uneven surface is formed on the plurality of substrates that are transported by the transport means.

4. The coating means is The decorative panel manufacturing apparatus according to any one of claims 1 to 3, characterized in that, upstream of the superimposing means in the transport direction, an electron beam curable resin reservoir is formed for supplying and applying the electron beam curable resin over the entire width of the upper surface of the resin film, and the resin film passes through the electron beam curable resin reservoir so that the electron beam curable resin for the base layer is applied below the resin film to the upper surfaces of the plurality of substrates.

5. The aforementioned resin film is The apparatus for manufacturing decorative panels according to any one of claims 1 to 3, characterized in that the superimposed surface superimposed on the electron beam curable resin applied to the substrate is roughened.

6. The aforementioned adhesion means is The apparatus for manufacturing decorative laminates according to any one of claims 1 to 3, comprising an inkjet printer having a plurality of ink heads that spray the electron beam curable resin to form the monochromatic and / or multicolored uneven layer.

7. In a decorative panel manufacturing apparatus for manufacturing a decorative panel having irregularities formed on at least the upper surface of a base material made of resin and having a predetermined length, An adhesion means for forming an uneven layer on the upper surface of the resin substrate by applying electron beam curable resin having adhesive properties due to single-color and / or multi-color electron beam curing characteristics in a predetermined pattern and at the same and / or different heights in the upward direction, A curing means is disposed downstream of the adhesion means in the transport direction and irradiates the upper surface of the base layer with an electron beam by the adhesion means to harden the uneven layer formed on the upper surface of the base layer and form an uneven surface. A manufacturing apparatus for decorative laminates, characterized by comprising the following features.

8. The apparatus for manufacturing decorative panels according to claim 7, characterized in that the base material is a sheet made of resin.

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