Decorative board manufacturing equipment

Abstract

To enable inexpensive production of decorative laminates with decorative surfaces on both sides of a substrate.SOLUTION: Coating means 7, 8 apply UV-curing resin having UV-curing characteristics to polymerized surfaces of PET films 52, 62 opposite to mat surfaces. At a predetermined clamping position where a plurality of PB2 conveyed in series without gaps are clamped vertically by upper and lower surface side rollers 51, 61, the polymerized surfaces of the PET films 52, 62 coated with the UV-curing resin are polymerized by polymerization means 5, 6 so that the polymerized surfaces overlap upper and lower surfaces of the PB2 respectively. The UV-curing resin applied to the polymerized surfaces of the PET films 52, 62 is cured by stopper means 9, 10 to form a stopper layer on each of upper and lower surfaces of a substrate. Impregnated paper 123, 133 impregnated with resin-based paint is overlaid on the stopper layer and affixed.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to an apparatus for manufacturing a decorative board, which manufactures a decorative board by adhering impregnated paper impregnated with a resin-based paint to a substrate. [Background technology]

[0002] Conventionally, decorative boards having a decorative surface are manufactured by attaching a decorative paper with a predetermined print to the surface of a base material such as particle board (PB) or chipboard such as MDF or wood fiberboard by heat and pressure (see, for example, Patent Document 1). At this time, impregnated paper is impregnated with melamine resin by immersing it in a tank filled with melamine resin (so-called dobu-duki), and the impregnated paper impregnated with melamine resin is dried and placed on the top surface of the base material and molded under heat and pressure at low pressure to produce low-pressure melamine decorative boards, and high-pressure melamine decorative boards with a thickness of about 1 mm are well known, which are made by laminating only impregnated paper impregnated with melamine resin and kraft impregnated paper impregnated with phenolic resin and molding them under high pressure. These melamine decorative boards have a high upper surface hardness, excellent resistance to contamination, abrasion resistance, heat resistance, and water resistance, and are not easily scratched, so that low-pressure melamine decorative boards are used for furniture materials and interior materials, etc., and thin high-pressure melamine decorative boards are used for surface materials for furniture and doors, shelves, counters, etc. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP2018-140629A Summary of the Invention [Problem to be solved by the invention]

[0004] However, conventional decorative boards use petroleum-derived resins such as melamine resin and phenolic resin as described above, which are impregnated, dried, and heat-pressed (180 to 220 °C), and the manufacturing process consumes a huge amount of electricity, which is a problem. It also causes the microplastic problem, which goes against the purpose of the sustainable development goals, or SDGs, that have been called for in recent years, and is a factor that hinders the prevention of environmental destruction. In addition, it is expensive, and there is also the problem that the melamine resin of the impregnated paper that is attached during heat-pressing must be removed, which is time-consuming, consumes a lot of electricity, and generates a lot of waste. This problem is not limited to low-voltage and high-pressure melamine decorative boards, but also applies to conventional decorative boards in which a resin sheet or paper sheet is simply attached to a substrate with a thermoplastic resin or thermosetting resin.

[0005] In addition, low-pressure melamine decorative boards can be finished with a decorative surface on both sides at the same time (including printed designs and plain mirror or matte surfaces). However, this requires large-scale equipment, including equipment to immerse impregnated paper, which has been pre-printed with a specified design by gravure printing or other means, in a melamine resin-filled tank to impregnate it with melamine resin and dry it, and equipment to layer the impregnated paper on both sides of the base material and mold it under heat and pressure at low pressure.As mentioned above, the problem of the need to remove the melamine resin from the impregnated paper that adheres during heat and pressure, which is costly, remains, so there is a need for the development of a manufacturing method for decorative boards with decorative surfaces on both sides that is cheaper and more in line with our environmentally conscious times.

[0006] This invention has been made in view of the above problems, and aims to make it possible to inexpensively manufacture a decorative board having decorative surfaces on both sides of a base material in as environmentally friendly a manner as possible. In particular, the invention aims to inexpensively manufacture a decorative board having decorative surfaces on both sides by simultaneously curing and bonding the biomass resin instantaneously in 0.1 to 0.5 seconds by irradiating an impregnated paper with ultraviolet light or electron beams using LEDs or the like, which has the lowest energy cost, without the need for heat bonding (heat pressing) as in conventional low-pressure melamine decorative boards. [Means for solving the problem]

[0007] In order to achieve the above object, the decorative board manufacturing apparatus of the present invention is a decorative board manufacturing apparatus for manufacturing a decorative board formed by adhering impregnated paper impregnated with a resin-based paint to a substrate, the apparatus comprising: a material spacing adjustment means for arranging a plurality of substrates of a predetermined length made of long wooden boards in a state in which there are almost no gaps between the substrates and transporting them in a predetermined transport direction; an upper surface side roller and a lower surface side roller arranged to sandwich the plurality of substrates transported by the material spacing adjustment means from above and below at predetermined sandwiching positions, and an upper surface side and lower surface side polymerization means for polymerizing a long resin film having a matte surface with no gloss on the upper surface and the lower surface of the plurality of substrates at the sandwiching positions between the upper surface side roller and the lower surface side roller so that the polymerized surfaces on the opposite sides of the matte surface are overlapped on the upper surface and the lower surface of the plurality of substrates, respectively; and upper and lower coating means for coating the polymerized surfaces of the resin films on the upper and lower sides with an ultraviolet-curing resin having at least adhesive properties due to ultraviolet-curing characteristics, and upper and lower sealing means for forming sealing layers made of the ultraviolet-curing resin on the upper and lower sides of the plurality of substrates, respectively, by curing the ultraviolet-curing resin coated on the polymerized surfaces of the resin films on the upper and lower sides, and peeling off the resin films on the upper and lower sides from the substrate, downstream in the conveying direction of the upper and lower coating means, and upper and lower impregnation means for overlapping impregnated paper impregnated with the resin-based paint on the sealing layers on the upper and lower sides of the substrate, which are provided downstream in the conveying direction of the upper and lower sealing means, respectively.

[0008] According to this configuration, the upper and lower coating means coats the polymerized surface opposite the matte surface of each of the upper and lower resin films with ultraviolet curing resin having adhesive properties due to at least ultraviolet curing properties, and at a predetermined clamping position where the multiple substrates transported by the conveying means in a continuous state with no gaps are clamped vertically by the upper and lower rollers, the upper and lower polymerization means polymerize the polymerized surface opposite the matte surface of the resin film to which the ultraviolet curing resin has been applied so that it overlaps with the upper and lower surfaces of the substrate, respectively, and the upper and lower sealing means harden the ultraviolet curing resin applied to the polymerized surface opposite the matte surface of the upper and lower resin films to form sealing layers on each of the upper and lower surfaces of the substrate. Therefore, even if small gaps occur between multiple base materials, the ultraviolet-curing resin applied by the application means on the upper surface penetrates between the consecutive base materials and the sealing layer on the lower surface acts as a receptacle to fill the gaps between the materials, so that the multiple base materials transported by the transport means can be transported in a connected state, and the impregnated paper can be stably attached when it is subsequently applied.

[0009] Furthermore, after peeling off the upper and lower resin films from the substrate on which the filling layer is formed by the upper and lower filling means, the impregnated paper impregnated with the resin-based paint is impregnated with the resin-based paint by the upper and lower impregnation means, and the impregnated paper impregnated with the resin-based paint is impregnated with a resin-based paint having electron beam curing properties or ultraviolet light curing properties, and the impregnated paper impregnated with the resin-based paint is superimposed on the upper and lower surfaces of the substrate, respectively, and irradiated with electron beams from an electron beam irradiation device or ultraviolet light from an ultraviolet LED (wavelength 405 nm), thereby forming a seal layer. The anchor effect of the matte surface (finely textured surface) can cover up the poor adhesion of resin-based paints that have electron beam or ultraviolet curing properties, making it possible to cure the resin-based paint with low power consumption and firmly adhere the impregnated paper, which contributes to preventing environmental destruction without going against the spirit of the SDGs.In addition, it makes it possible to finish both the front and back sides of the base material with a decorative surface (including printed designs and plain mirror or matte surfaces) in the same process, allowing for the production of decorative boards with decorative surfaces on both the front and back of the base material in an environmentally friendly and inexpensive manner.

[0010] Furthermore, for example, it is impossible to directly attach impregnated paper to a substrate without a filler layer. By forming a filler layer on both sides of the substrate, the surface of the ultraviolet-curing resin that has soaked into the substrate hardens due to ultraviolet rays, and if the resin also has moisture-curing properties, the resin that has soaked into the substrate hardens due to moisture. Furthermore, since the matte surface of the filler layer is finished with a finely uneven surface, it is possible to harden the polymerized impregnated paper and adhere it at the same time.

[0011] Furthermore, the upper and lower side coating means supply the ultraviolet curing resin across the width of the substrate upstream of the upper and lower side polymerization means in the transport direction to form upper and lower side ultraviolet curing resin reservoirs, and coat the ultraviolet curing resin on the polymerization surfaces of the upper and lower side resin films as the resin film passes through the upper and lower side ultraviolet curing resin reservoirs, respectively, and may have a regulating means for restricting the supplied ultraviolet curing resin from spreading beyond the width of the substrate, thereby confining it to the width of the substrate.

[0012] In this way, as the resin film passes through the upper and lower ultraviolet-curing resin reservoirs formed upstream in the conveying direction of the upper and lower polymerization means, ultraviolet-curing resin is applied to the polymerization surface opposite the matte surface of each of the upper and lower resin films, and the regulating means prevents the ultraviolet-curing resin from spreading beyond the width of the substrate, keeping it within the width of the substrate.By curing the ultraviolet-curing resin using ultraviolet LEDs (e.g., wavelength 405 nm), a sealing layer can be formed on the upper and lower surfaces of the substrate with low power consumption by the upper and lower sealing means, which can contribute to preventing environmental destruction without going against the spirit of the SDGs.

[0013] At least one of the impregnated papers attached to the upper and lower filling layers may be formed by printing a predetermined design on the paper material before it is impregnated with the resin-based paint. The resin-based paint may have electron beam curing properties, and the device may further include an electron beam irradiation means for irradiating the impregnated paper with the predetermined design printed thereon with an electron beam.

[0014] In this way, even if a predetermined design is printed on the impregnated paper before it is impregnated with the resin-based paint, by using a resin-based paint that has electron beam curing properties, the electron beams will not be blocked by the specific color of the printing ink, as is the case with ultraviolet-curing resin, and the electron beams will reach deep into the resin-based paint, allowing the resin-based paint to be sufficiently cured by the electron beams, and at the same time, the electron beams will reach the sides of each of the impregnated papers on both sides opposite the side where the electron beams are irradiated, allowing both impregnated papers to firmly adhere to the sealing layers on the upper and lower sides.

[0015] Also, a printing means may be provided that is disposed downstream of the impregnation means on the upper and lower sides in the conveying direction and prints a predetermined design on at least one of the impregnated papers superimposed on the sealing layers on the upper and lower sides. In this case, the resin-based paint has ultraviolet curing properties or electron beam curing properties, and the apparatus may further include an ultraviolet irradiation means that irradiates ultraviolet rays or an electron beam irradiation means that irradiates electron beams on the impregnated paper on which the predetermined design has been printed by the printing means.

[0016] In this way, a predetermined design is printed by the printing means on the impregnated paper after it has been superimposed on the filling layer of the base material, and the impregnated paper is irradiated with ultraviolet light by the ultraviolet irradiating means or electron beams by the electron beam irradiating means to harden the resin-based paint impregnated in the impregnated paper, thereby attaching the impregnated paper to the base material, so that even if it becomes necessary to change the design to be printed, the design can be easily changed. Here, the printing means corresponds to a so-called digital printing machine.

[0017] In addition, it is preferable to further provide a separating means for separating the plurality of connected base materials at the predetermined length between the materials downstream of the impregnation means on the upper and lower sides in the conveying direction. In this way, the base materials can be separated at the predetermined length to produce a decorative board with a predetermined design.

[0018] In addition, the impregnation means on the upper and lower sides supplies the resin-based paint across the width of the substrate to form resin-based paint reservoirs on the upper and lower sides, and as the substrate passes through the resin-based paint reservoirs on the upper and lower sides, the resin-based paint is impregnated into the impregnated paper attached to the upper and lower surfaces of the substrate, and it is desirable to have other regulating means for restricting the resin-based paint supplied to the resin-based paint reservoirs on the upper and lower sides from spreading beyond the width of the substrate, thereby keeping it within the width of the substrate.

[0019] In this way, the substrate passes through the upper and lower resin-based paint reservoirs formed upstream in the conveying direction of the upper and lower impregnation means, and the resin-based paint is impregnated into the impregnated paper on the upper and lower sides of the substrate, and other regulating means prevent the resin-based paint from spreading beyond the width of the substrate, keeping it within the width of the substrate.By irradiating the resin-based paint with electron beams or ultraviolet light (for example, wavelength 405 nm) to harden the resin-based paint, the upper and lower impregnated papers can be attached to the upper and lower sides of the substrate with low power consumption, which is more environmentally friendly than the conventional dipping method and can contribute to preventing environmental destruction without going against the spirit of the SDGs.

[0020] In addition, it is desirable that the ultraviolet curing resin and the resin-based paint are made of 50% or more biomass. This will enable a significant reduction in equipment costs, reduce electricity consumption and the amount of petroleum-derived resin used, and provide environmentally friendly manufacturing processes and products, which is in line with the spirit of the SDGs. Effect of the Invention

[0021] According to the present invention, when manufacturing a decorative board having decorative surfaces on both the front and back sides, there is no need to set up two large-scale facilities, as is the case when manufacturing conventional low-pressure melamine decorative boards, namely, a facility for impregnating impregnated paper with melamine resin by immersing it in a bath and drying it, and a facility for overlapping the impregnated paper on both sides of the base material and thermo-compressing it at low pressure.Furthermore, there is no need to transport materials between the two facilities, thereby reducing transportation costs.Since both the front and back sides of the base material can be finished into a decorative surface using the same series of work processes, it becomes possible to manufacture a decorative board having decorative surfaces on both the front and back sides of the base material using inexpensive equipment. [Brief description of the drawings]

[0022] [Figure 1] 1 is a schematic diagram of an embodiment of a manufacturing apparatus for a decorative board according to the present invention; [Diagram 2] FIG. 2 is a perspective view of a portion of FIG. [Diagram 3] FIG. 2 is a perspective view of another portion of FIG. [Figure 4] 2 is a flowchart illustrating the operation of FIG. 1. [Diagram 5] 1A to 1C are side views of a decorative board in different states during its manufacture. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0023] An embodiment of a decorative board manufacturing apparatus according to the present invention will be described with reference to FIGS.

[0024] The manufacturing device M for decorative boards in this embodiment is configured as shown in Fig. 1. In Fig. 1, 1 is an input device that stores particle boards (hereinafter referred to as PB) 2, which are base materials of a predetermined length, in a stacked state and inputs them into a conveying line by pushing them out one by one, 3 is a cleaner that removes dirt from the top and bottom surfaces of the input PB2, and 4 is a material interval adjustment means that includes guide rollers arranged along both sides parallel to the conveying direction indicated by the arrow in Fig. 1 of the multiple PB2 input from the input device 1 to guide the flow of the PB2 in the conveying direction, suction means that vacuum-sucks at least several points on the bottom surface of the PB2 to control the attitude of the PB2, and a sensor that measures the distance between the materials of each PB2, adjusts the attitude of each PB2 so that the material interval between each PB2 is almost zero, and conveys each PB2 arranged in a line.

[0025] Reference numerals 5 and 6 denote upper and lower side polymerization means, and each of these includes an upper side roller 51 and a lower side roller 61 at positions facing each other vertically with PB2 in between. The upper side polymerization means 5 further includes a first film roll 53 around which a PET (polyethylene) film 52, which is a long resin film having a matte surface with no gloss, is wound, and the polymerization surface opposite to the matte surface of the PET film 52 unwound from the first film roll 53 is polymerized on the upper surface of PB2 by the upper side roller 51.

[0026] The lower-side polymerization means 6 further includes a second film roll 63 on which is wound a PET film 62, which is a long resin film having a non-glossy matte surface, a guide roller 64 that guides the PET film 62 unwound from the second film roll 63, and a well-known comma head coater 67 that is composed of a backup roller 65 and a comma roller 66 and clamps the PET film 62 guided by the guide roller 64 between the backup roller 65 and the comma roller 66, and the polymerization surface opposite to the matte surface of the PET film 62 unwound from the second film roll 63 and guided by the guide roller 64 and the comma head coater 67 is polymerized on the lower surface of PB2 by the lower-side roller 61.

[0027] In FIG. 1, reference numeral 7 denotes an upper surface-side coating means for coating an ultraviolet curing resin having adhesiveness due to ultraviolet curing properties onto the polymerization surface of the upper surface-side PET film 52, on the upstream side of the upper surface-side polymerization means 5 in the transport direction indicated by the arrow in FIG. 1, and is configured in detail as shown in FIG. 2.

[0028] 2, the upper surface side application means 7 includes a filling tank 71 filled with an ultraviolet curing resin having adhesiveness due to ultraviolet curing characteristics, and a plurality of supply pipes 73 that supply the ultraviolet curing resin from the filling tank 71 across the width of PB2 on the upstream side of the upper surface side polymerization means 5 to form an upper surface side ultraviolet curing resin reservoir 72, and the upper surface side PET film 52 passes through the upper surface side ultraviolet curing resin reservoir 72, thereby applying the ultraviolet curing resin to the matte surface of the upper surface side PET film 52. Here, a pair of regulating plates 75 as regulating means for regulating the ultraviolet curing resin supplied to the ultraviolet curing resin reservoir 72 from spreading beyond the width of PB2 and keeping it within the width of PB2 are provided at an interval slightly shorter than the width of PB2, and the ultraviolet curing resin reservoir 72 is formed in an area surrounded by PB2 on the upstream side of the upper surface side roller 51, both regulating plates 75, 75, and the PET film 52 superimposed on PB2. An electromagnetic valve is provided at the tip of the supply pipe 73, and when the supply of the ultraviolet curing resin is stopped, the electromagnetic valve is closed to prevent leakage of the ultraviolet curing resin.

[0029] In FIG. 1, reference numeral 8 denotes a lower-side coating means for coating an ultraviolet curing resin having ultraviolet curing properties onto the polymerization surface of the lower-side PET film 62, upstream of the lower-side polymerization means 6 in the transport direction indicated by the arrow in FIG. 1, and is configured in detail as shown in FIG. 3.

[0030] As shown in FIG. 3, the coating means 8 on the lower side includes a filling tank 81 filled with an ultraviolet curing resin having ultraviolet curing properties, and a plurality of supply pipes 83 that supply ultraviolet curing resin having adhesiveness due to ultraviolet curing properties from the filling tank 81 to the width of PB2 between the backup roller 65 and the comma roller 66 on the upstream side of the comma head coater 67 constituting the polymerization means 6 on the lower side to form an ultraviolet curing resin reservoir 82 on the lower side, and the ultraviolet curing resin is applied to the polymerization surface of the PET film 62 on the lower side by passing through the ultraviolet curing resin reservoir 82 on the lower side. Note that the solid arrows in FIG. 3 indicate the normal rotation direction of the lower side roller 61 and the backup roller 65, and the comma roller 66 does not rotate but is stationary and rotates irregularly. Note that an electromagnetic valve is provided at the tip of the supply pipe 83, and when the supply of the ultraviolet curing resin is stopped, the electromagnetic valve is closed to prevent the ultraviolet curing resin from leaking.

[0031] Here, a restricting plate 84 and a pair of restricting plates 85 are provided in the length direction of the backup roller 65 as restricting means for restricting the supplied ultraviolet curing resin from spreading beyond the width of PB2 and confining it to the width of PB2. The restricting plate 84 has a length equal to or greater than the width of PB2, and both restricting plates 85 are disposed at an interval slightly shorter than the width of PB2. An ultraviolet curing resin reservoir 82 is formed in an area surrounded by the restricting plate 84, both restricting plates 85, 85, and the PET film 62 sandwiched between the backup roller 65 and the comma roller 66.

[0032] Here, the ultraviolet curing resin may have moisture curing properties in addition to ultraviolet curing properties. Such ultraviolet curing resins are those that are 50% or more biomass-based, such as acrylic resins, vinyl acetate resins, latex resins, rubber resins, vinyl urethane resins, urethane resins, and various modified resins thereof, as well as combinations of these resins with urea melamine resins, epoxy resins, phenolic resins, isocyanate resins, etc.

[0033] Resins with ultraviolet curing properties are preferably those that contain, as the main component, an oligomer or polymer such as polyester acrylate, epoxy acrylate, urethane acrylate, or polyether acrylate, either alone or in mixture, with an appropriate amount of reactive monomer added, and that have a photopolymerization initiator added to convert the active energy rays into ultraviolet light, and that are 50% or more biomass-based.

[0034] In addition, resins having moisture curing properties are mainly preferably isocyanate-based compounds, and specific examples of isocyanate-based compounds include isocyanate monomers such as hexamethylene diisocyanate, isophorone diisocyanate, tolylene diisocyanate, diphenylmethane diisocyanate, xylylene diisocyanate, and norbornene diisocyanate, as well as polyisocyanate derivatives such as biuret, isocyanurate, and trimethylolpropane adducts, as well as block products of these isocyanate monomers or polyisocyanate derivatives. In this way, if the ultraviolet curing resin has moisture curing properties in addition to ultraviolet curing properties, in a humid environment such as Japan, the ultraviolet curing resin can be naturally cured 100% by moisture without being cured 100% by the ultraviolet irradiation means described later. It is preferable to use isocyanate that is 70% or more biomassified.

[0035] In FIG. 1, 9 and 10 are upper and lower sealing means, which are equipped with upper and lower ultraviolet irradiation means 9a and 10a consisting of ultraviolet LEDs, respectively, and upper and lower peeling means 9b and 10b for peeling off the PET films 52 and 62, respectively.

[0036] The ultraviolet irradiation means 9a, 10a irradiate ultraviolet rays (for example, wavelength 405 nm) to the ultraviolet curing resin applied to the laminated surface (surface opposite to the matte surface) of the upper and lower PET films 52, 62 on the downstream side of the upper and lower coating means 7, 8 in the conveying direction indicated by the arrow in Fig. 1, respectively, to cure the ultraviolet curing resin, and form a sealing layer made of ultraviolet curing resin on the upper and lower surfaces of the connected PB2, respectively. At this time, even if a small gap occurs between the connected PB2 materials, the ultraviolet curing resin applied by the upper coating means 7 penetrates between the connected PB2 materials and cures instantly, and the sealing layer on the lower side acts as a receiver to reliably fill the gap between the materials, and the sealing layer on the lower side prevents the ultraviolet curing resin from flowing down, so that the multiple PB2 to be conveyed can be conveyed in a connected state, and the impregnated paper can be stably attached when it is attached in a later process.

[0037] The upper and lower peeling means 9b, 10b respectively have guide rollers 9b1, 10b1 and winding rollers 9b2, 10b2, and peel the upper and lower PET films 52, 62 from the upper and lower surfaces of PB2 after the sealing layer is formed, and wind them up on the winding rollers 9b2, 10b2 for recovery. The recovered PET films 52, 62 are taken back by the film manufacturer for recycling, which does not violate the spirit of the SDGs.

[0038] In Fig. 1, 12 and 13 are upper and lower impregnation means, which are provided with an upper roller 121 and a lower roller 131, respectively, at positions facing each other vertically with PB2 in between, and are provided downstream of the upper and lower sealing means 9 and 10 in the conveying direction indicated by the arrow in Fig. 1, and overlay impregnated paper impregnated with a resin-based paint having electron beam curing properties on sealing layers formed on the upper and lower sides of PB2, respectively. At this time, for example, by using impregnated paper with a predetermined design printed on it in advance, it is possible to simultaneously form a decorative surface having a predetermined design printed on the upper surface and an unprinted lower surface.

[0039] Resin-based paints having electron beam curing properties may be those containing 50% or more biomass, such as special modified acrylates including rosin-based acrylates, polyurethane acrylates, polyester acrylates, and the like.

[0040] The upper surface side impregnation means 12 overlaps the impregnated paper 123 wound around the impregnated paper roll 122 with the sealing layer on the upper surface of PB2, and has the same configuration as the upper surface side polymerization means 5 and coating means 7 shown in Fig. 2. That is, it is provided with a resin-based paint tank (not shown) filled with a resin-based paint having adhesive properties due to electron beam curing characteristics, and a plurality of supply pipes (not shown) upstream of the impregnation means 12 for supplying the resin-based paint from the resin-based paint tank across the width of PB2 to form an upper surface side resin-based paint reservoir 124, and the upper surface side impregnated paper 123 passes through the upper surface side resin-based paint reservoir 124, thereby coating the resin-based paint on the upper surface side impregnated paper 123.

[0041] Here, similar to the regulating plate 75 in FIG. 2, the upper side impregnation means 12 has a pair of regulating plates as other regulating means for regulating the resin-based paint supplied to the resin-based paint reservoir 124 from spreading beyond the width of PB2 and keeping it within the width of PB2, and these two regulating plates are arranged at a distance slightly shorter than the width of PB2.

[0042] The lower-side impregnation means 13 overlaps the impregnated paper 133 wound around the impregnated paper roll 132 onto the sealing layer on the lower surface of PB2, and has a configuration similar to the lower-side polymerization means 6 and coating means 8 shown in Figure 3.

[0043] That is, the lower-side impregnation means 13 comprises a guide roller 134 that guides the impregnated paper 133 unwound from the impregnated paper roll 132, a well-known comma head coater 137 composed of a backup roller 135 and a comma roller 136 and clamping the impregnated paper 133 guided by the guide roller 134 between the backup roller 135 and the comma roller 136, a filling tank (not shown) filled with a resin-based paint having adhesive properties due to electron beam curing characteristics, and a number of supply pipes (not shown) that supply the resin-based paint from the filling tank over the width of PB2 between the backup roller 135 and the comma roller 136 to form a lower-side resin-based paint reservoir 138, and the resin-based paint is applied to the lower-side impregnated paper 133 as it passes through the lower-side resin-based paint reservoir 138.

[0044] At this time, as another regulating means for restricting the supplied resin-based paint from spreading beyond the width of PB2 and confining it to the width of PB2, a long regulating plate and a pair of regulating plates are provided in the length direction of the backup roller 135. The regulating plate in the length direction of the backup roller 135 has a length equal to or greater than the width of PB2, and the pair of regulating plates are disposed at an interval slightly shorter than the width of PB2.

[0045] Furthermore, the impregnation means 12, 13 on the upper and lower sides do not use the resin-based paint impregnation by dipping in a hot water as in the conventional production of low-pressure melamine decorative boards, so there is an advantage that the impregnation and drying equipment can be simplified in configuration.

[0046] In Fig. 1, 15 and 16 are upper and lower film superimposing means, which are provided with an upper roller 151 and a lower roller 161 at positions facing each other vertically with PB2 in between, and are provided downstream of the upper and lower impregnating means 12 and 13 in the conveying direction indicated by the arrow in Fig. 1, and superimpose a PET film, which is a resin film, on the impregnated papers 123 and 133 superimposed on the upper and lower sides of PB2, respectively. Here, if the PET film superimposed on the impregnated papers 123 and 133 has a matte surface on the superimposed surface side, the PET film can be laminated on the impregnated papers 123 and 133 by the anchor effect, and the resin can be hardened to adhere to each other, which eliminates the need for the conventional polishing work to obtain the anchor effect, resulting in a simpler process. In addition, the surface of the PET film opposite to the surface overlapping the impregnated paper 123, 133 may or may not have a matte surface. If it has a matte surface, it can be overlapped so that the matte surface is located on the upper and lower sides of PB2, making the upper and lower surfaces of PB2 matte surfaces, and if it does not have a matte surface, the upper and lower surfaces of PB2 can be made mirror surfaces. At this time, both the ultraviolet curing resin and the electron curing resin usually need to be cured in a nitrogen gas atmosphere due to the problem of oxygen alienation, but in this embodiment, the resin coating film can be isolated from the air by overlapping the PET film on the impregnated paper 123, 133, so there is no need to cure in a nitrogen atmosphere, and it is possible to laminate PET films in multiple layers with good flatness without performing polishing treatment or the like.

[0047] The upper-side film superimposing means 15 unwinds the PET film 153 wound around the third film roll 152 and superimposes it on the impregnated paper 123 on the upper surface of PB2, and has the same configuration as the upper-side polymerization means 5 and application means 7 shown in Fig. 2. That is, it is provided with a filling tank (not shown) filled with an electron beam curable resin having electron beam curing properties, and a plurality of supply pipes (not shown) upstream of the film superimposing means 15 that supply the electron beam curable resin from the filling tank across the width of PB2 to form an upper-side electron beam curable resin reservoir 154, and the upper-side PET film 153 passes through the upper-side electron beam curable resin reservoir 154 to apply the electron beam curable resin to the upper-side PET film 153.

[0048] Here, similar to the regulating plate 75 in FIG. 2, the upper side film superimposing means 15 has a pair of regulating plates as another regulating means for regulating the electron beam curable resin supplied to the electron beam curable resin reservoir 154 from spreading beyond the width of PB2, thereby keeping it within the width of PB2, and these two regulating plates are arranged at a distance slightly shorter than the width of PB2.

[0049] The lower-side film overlapping means 16 pays out the PET film 163 wound around the fourth film roll 162 and overlaps it on the impregnated paper 133 on the lower surface of PB2, and has the same configuration as the lower-side overlapping means 6 and coating means 8 shown in Fig. 3. At this time, the impregnated paper 133 is first impregnated with electron beam curable resin from the lower surface and pressed with a roller, and then impregnated from the upper surface and pressed again with a roller, so that the minimum amount of resin is impregnated and degassed, and at the same time, all excess resin is swept away with the roller.

[0050] That is, the lower-side film superimposing means 16 includes a guide roller 164 that guides the PET film 163 unwound from the fourth film roll 162, a well-known comma head coater 167 that is composed of a backup roller 165 and a comma roller 166 and that clamps the PET film 163 guided by the guide roller 164 between the backup roller 165 and the comma roller 166, a filling tank (not shown) filled with electron beam curable resin having electron beam curing properties, and a plurality of supply pipes (not shown) that supply the electron beam curable resin having electron beam curing properties from the filling tank to the width of PB2 between the backup roller 165 and the comma roller 166 to form a lower-side electron beam curable resin reservoir 168, and the electron beam curable resin is applied to the lower-side PET film 163 as the lower-side PET film 163 passes through the lower-side electron beam curable resin reservoir 168.

[0051] At this time, as another regulating means for regulating the supplied electron beam curable resin so as not to spread beyond the width of PB2 and for keeping it within the width of PB2, a long regulating plate and a pair of regulating plates are provided in the length direction of the backup roller 165. The regulating plate in the length direction of the backup roller 165 has a length equal to or greater than the width of PB2, and the pair of regulating plates are disposed at an interval slightly shorter than the width of PB2.

[0052] Furthermore, because the electron beam curable resin has electron beam curing properties, even if a design has been printed on the impregnated paper 123 in advance, when the electron beam curable resin is cured by irradiation with electron beams, the electron beams are not blocked by a specific color of printing ink as is the case with ultraviolet curable resin, and the electron beams reach deep into the electron beam curable resin, causing it to cure sufficiently.

[0053] In FIG. 1, 17 and 18 are upper and lower protective layer forming means, which respectively include upper and lower electron beam irradiation means 17a and 18a and upper and lower peeling means 17b and 18b for peeling off PET films 153 and 163, respectively.

[0054] The upper and lower electron beam irradiation means 17a and 18a irradiate the electron beam curable resin applied to the upper and lower PET films 153 and 163 with electron beams at the downstream side in the transport direction indicated by the arrow in Figure 1 of the upper and lower film superimposing means 15 and 16, respectively, to cure the electron beam curable resin and form protective layers made of electron beam curable resin on the upper and lower surfaces of the connected PB2, respectively.

[0055] The upper and lower peeling means 17b, 18b each have a guide roller 17b1, 18b1 and a winding roller 17b2, 18b2, and peel the upper and lower PET films 153, 163 from the upper and lower surfaces of PB2 after the protective layer is formed, and wind them up on the winding rollers 17b2, 18b2 for recovery. The recovered PET films 153, 163 are taken back by film manufacturers and recycled, just like the PET films 52, 62, so they do not go against the spirit of the SDGs. In addition, in conventional decorative boards, thin parts of the protective layer formed on the surface of the resin sheet may be hardened by electron beam irradiation, but in this embodiment, it is possible to solidify the entire impregnated paper 123, 133 and then bond them without the conventional pressing.

[0056] In Figure 1, reference numeral 20 denotes a separation means provided downstream of the upper protective layer forming means 17, which is equipped with a cutter that cuts PB2 to a predetermined length after impregnated papers 123, 133 are laminated on the upper and lower surfaces and a protective layer made of electron beam curable resin is formed, and an actuator that moves the cutter up and down. PB2 is separated to a predetermined length by the separation means 20 to form decorative board B.

[0057] Next, a procedure for manufacturing the decorative board B will be described with reference to Figures 4 and 5. Figure 4 is a flow chart, and Figure 5 is a side view showing a different state during manufacturing.

[0058] As shown in the flow chart of FIG. 4, the material interval adjustment means 4 adjusts the material interval W (see FIG. 5(a)) between the multiple base materials PB2 to nearly zero, and multiple PB2 are transported in a connected state (step S1). The polymerization means 5 and 6 form filling layers L1 and L2 (see FIG. 5(b)) on the upper and lower surfaces of PB2 in the same process (step S2). The filling layers L1 and L2 on the upper and lower surfaces of PB2 are each made of a resin-based paint having electron beam curing properties. The soaked impregnated papers 123, 133 (see Figure 5 (c)) are attached in the same process (step S3), protective layers L3, L4 (see Figure 5 (d)) made of electron beam curable resin are formed on the impregnated papers 123, 133 on the upper and lower surfaces of PB2 in the same process (step S4), and the continuous PB2 with the impregnated papers 123, 133 and protective layers L3, L4 layered on the upper and lower surfaces is separated at a predetermined length (step S5), forming a decorative board B of a predetermined length and completing the series of processes.

[0059] In this case, by using impregnated paper 123 on the upper surface side that has a predetermined design printed thereon in advance, decorative board B having a decorative surface with a predetermined design on the upper surface side and a plain mirror or matte surface on the lower surface side can be manufactured inexpensively with fewer steps. If impregnated paper 133 on the lower surface side is also used that has a predetermined design printed thereon, decorative board B having decorative surfaces on both the top and bottom sides can be manufactured.

[0060] Therefore, according to the embodiment described above, the upper and lower coating means 7, 8 coat the upper and lower PET films 52, 62 with ultraviolet curing properties on their respective matte surfaces and their respective polymerization surfaces. At a predetermined clamping position where the multiple PB2s conveyed in a continuous state with no gaps are clamped vertically by the upper roller 51 and the lower roller 61, the upper and lower polymerization means 5, 6 polymerize the polymerization surfaces of the PET films 52, 62 coated with the ultraviolet curing resin so as to overlap the upper and lower surfaces of the PB2, respectively, thereby sealing the upper and lower sides. The ultraviolet-curing resin applied to the matte surface and the polymerized surface opposite the upper and lower PET films 52, 62 is hardened by the application means 9, 10 to form a sealing layer on each of the upper and lower surfaces of the substrate. Therefore, even if a small gap occurs between multiple PB2 materials, the ultraviolet-curing resin applied by the application means 7 on the upper side penetrates between the successive PB2 materials and the sealing layer on the lower side acts as a receiver to fill the gaps between the materials. As a result, the multiple PB2 materials can be transported in a connected state, and the impregnated paper 123, 133 can be stably attached thereto afterwards.

[0061] Furthermore, the upper and lower PET films 52, 62 are peeled off from PB2 on which the filling layer has been formed by the upper and lower sealing means 9, 10, and then the impregnated papers 123, 133 impregnated with a resin-based paint are superimposed on the upper and lower filling layers of PB2 by the upper and lower coating means 7, 8. In order to do this, the impregnated papers 123, 133 are impregnated with a resin-based paint, for example, one having electron beam curing properties, and the impregnated papers 123, 133 impregnated with the resin-based paint are superimposed on the upper and lower surfaces of PB2, respectively, and irradiated with electron beams. This makes it possible to harden the resin-based paint with low power consumption and firmly bond the impregnated papers 123, 133, which contributes to preventing environmental destruction without going against the spirit of the SDGs. In addition, it becomes possible to finish both the front and back surfaces of the substrate into a decorative surface in the same process, and a decorative board having a decorative surface on both the front and back surfaces of the substrate can be manufactured inexpensively with a small number of processes.

[0062] In addition, even if a predetermined design is printed on the impregnated paper 123, 133 before the resin-based paint is impregnated, by using a resin-based paint having electron beam curing properties, the electron beam is not blocked by a specific color of the printing ink as in the case of ultraviolet curing resin, and the electron beam penetrates deep into the resin-based paint, so that the resin-based paint is sufficiently cured by the electron beam and at the same time reaches the impregnated paper 123, 133 on both sides, and both impregnated papers 123, 133 can be firmly attached to the upper and lower sealing layers L1, L2. Furthermore, although the electron beam irradiated resin and the ultraviolet curing resin have the same composition, the resin cured alone has no toughness and is easily cracked, but by impregnating the impregnated paper 123, 133, the toughness is dramatically improved, making it hard and less likely to crack.

[0063] The present invention is not limited to the above-described embodiment, and various modifications other than those described above can be made without departing from the spirit of the present invention.

[0064] For example, in the above embodiment, a case has been described in which a predetermined design is printed on the upper impregnated paper 123, but in another embodiment, neither the impregnated paper 123, 133 is printed, and instead the impregnated paper is printed by a printing means such as an inkjet printer downstream of the upper and lower impregnating means 12, 13 in the transport direction shown by the arrows in Figure 1 and upstream of the film superposing means 15, 16. In this way, even if it becomes necessary to change the design to be printed, the design can be easily changed.

[0065] In this case, the PET films 153, 163 are superimposed on the impregnated papers 123, 133 which have been printed by applying an ultraviolet curing resin having adhesiveness due to ultraviolet curing properties to the PET films 153, 163 in the upstream and downstream film superimposing means 15, 16, and the ultraviolet curing resin of the PET films 153, 163 is cured by irradiating it with ultraviolet light from an ultraviolet LED as an ultraviolet irradiation means. Note that printing in the post-process may be performed only on either the impregnated paper 123 on the upper surface side or the impregnated paper 133 on the lower surface side.

[0066] In addition, the resin-based paint having ultraviolet curing properties and moisture curing properties is not limited to the above-mentioned ones as long as it is 50% or more biomass. Furthermore, the ultraviolet curing resin and the electron beam curing resin are not limited to the above-mentioned ones as long as it is 50% or more biomass.

[0067] Moreover, instead of the PET films 52, 62, 153, and 163, other resin films that are transparent to ultraviolet light may be laminated.

[0068] The present invention can be widely applied to a manufacturing apparatus for a decorative board in which a decorative board is manufactured by adhering an impregnated paper impregnated with a resin-based paint to a substrate. [Explanation of symbols]

[0069] M …Decorative board manufacturing equipment 2...PB (particle board / base material) 4…Spacing adjustment means 5, 6...Upper and lower overlapping means 7, 8...Upper and lower coating means 9, 10...Sealing means on the upper and lower sides 9a, 10a...Upper and lower ultraviolet ray irradiation means 9b, 10b...Separation means on the upper and lower sides 12, 13...Upper and lower impregnation means 52, 62...PET film (resin film) 72, 82…UV curing resin reservoir 75, 84, 85...Restriction plate (restriction means) 123,133…impregnated paper W…between timbers L1, L2: Filling layer B: Decorative board

Claims

1. In a manufacturing apparatus for decorative panels, a decorative panel is manufactured by attaching impregnated paper impregnated with a resin-based paint to a substrate, A material spacing adjustment means for arranging a plurality of base materials each having a predetermined length, each being made of a long wooden board, in a state in which the materials are connected together with almost no gaps therebetween and conveying the same in a predetermined conveying direction; an upper surface side and a lower surface side polymerization means, which has an upper surface side roller and a lower surface side roller arranged to sandwich the plurality of substrates conveyed by the material interval adjustment means at a predetermined sandwiching position, and which polymerizes a long resin film having a non-glossy matte surface at the sandwiching position between the upper surface side roller and the lower surface side roller so that the polymerized surfaces on the opposite sides of the matte surfaces overlap with the upper surfaces and lower surfaces of the plurality of substrates, respectively; an upper surface side and a lower surface side coating means for coating an ultraviolet curing resin having at least adhesiveness due to ultraviolet curing characteristics on the polymerization surfaces of the upper surface side and the lower surface side of the resin film, the upper surface side and the lower surface side being located upstream of the polymerization means in the conveying direction; upper and lower sealing means for curing the ultraviolet curing resin applied to the polymerized surfaces of the upper and lower resin films downstream of the upper and lower coating means in the conveying direction to form sealing layers made of the ultraviolet curing resin on the upper and lower surfaces of the plurality of substrates, respectively, and peeling off the upper and lower resin films from the substrates; upper and lower impregnation means that are provided downstream in the conveying direction of the sealing means on the upper and lower sides, respectively, and that overlap the sealing layers on the upper and lower sides of the base material with impregnated paper impregnated with the resin-based paint; A decorative board manufacturing apparatus comprising:

2. The decorative board manufacturing apparatus according to claim 1, the upper and lower coating means supply the ultraviolet curing resin across the width of the base material upstream of the upper and lower polymerization means in the transport direction to form upper and lower ultraviolet curing resin reservoirs, and the resin film passes through the upper and lower ultraviolet curing resin reservoirs, respectively, thereby coating the ultraviolet curing resin onto the polymerization surfaces of the upper and lower resin films; 13. A decorative board manufacturing apparatus comprising: a restricting means for restricting the supplied ultraviolet curing resin from spreading beyond the width of the base material, thereby confining the resin to the width of the base material.

3. The decorative board manufacturing apparatus according to claim 1 or 2, A manufacturing apparatus for decorative panels, characterized in that at least one of the impregnated papers attached to the filling layers on the upper and lower sides is formed by printing a predetermined design on the paper material before it is impregnated with the resin-based paint.

4. The decorative board manufacturing apparatus according to claim 3, The resin-based coating material has electron beam curing properties, The decorative board manufacturing apparatus further comprises an electron beam irradiation means for irradiating the impregnated paper on which the predetermined design is printed with an electron beam.

5. The decorative board manufacturing apparatus according to claim 1 or 2, A decorative board manufacturing apparatus characterized in that it is provided with a printing means arranged downstream in the conveying direction of the impregnation means on the upper and lower sides, and which prints a predetermined design on at least one of the impregnated papers superimposed on the sealing layers on the upper and lower sides.

6. The decorative board manufacturing apparatus according to claim 5, The resin-based coating material has ultraviolet ray curing properties or electron beam curing properties, The decorative board manufacturing apparatus further comprises an ultraviolet ray irradiation means for irradiating ultraviolet rays or an electron beam irradiation means for irradiating electron beams onto the impregnated paper on which the predetermined design has been printed by the printing means.

7. The decorative board manufacturing apparatus according to claim 1, A decorative board manufacturing apparatus characterized in that it further comprises a separation means for separating the multiple connected base materials at the specified length between the materials, downstream of the impregnation means on the upper and lower sides in the conveying direction.

8. The decorative board manufacturing apparatus according to claim 1, The impregnation means on the upper and lower sides are This decorative panel manufacturing device supplies the resin-based paint across the width of the substrate to form upper and lower resin-based paint reservoirs, and as the substrate passes through the upper and lower resin-based paint reservoirs, the resin-based paint impregnates the impregnated paper attached to the upper and lower surfaces of the substrate, and is characterized in that it also has other regulating means for regulating the resin-based paint supplied to the upper and lower resin-based paint reservoirs from spreading beyond the width of the substrate, thereby keeping it within the width of the substrate.

9. The decorative board manufacturing apparatus according to claim 1, The manufacturing apparatus for decorative panels is characterized in that the ultraviolet curing resin and the resin-based paint are made of biomass at 50% or more.

Images