JPH11321064A - Manufacture of decorative plate with grooves - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a decorative plate with grooves adapted to a woody flooring by incorporating a sense of a wood of a real thing. SOLUTION: Grooves (d) of a V-shaped or substantially V-shaped cross section are formed on a surface of a woody base plate B. A rubber blanket 14 of a gravure offset printer is urged to the plate B to simultaneously decorate not only a surface of the plate B but also the grooves. A transfer layer side of a transfer sheet is opposed to the surface of the plate, and may be decorated by a suitable transferring method such as a roller transferring method, a vacuum pressing method, a method utilizing a solid collision pressure or the like. Since not only the surface of the late but also the grooves can be simultaneously decorated, the decorative plate with the grooves adapted to a woody flooring can be effectively manufactured.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative panel for building interiors such as flooring and wall material, and more particularly to a method for producing a grooved decorative panel suitably used as a wooden flooring.

[0002]

2. Description of the Related Art Generally, flooring materials for building interiors include:
Wood flooring, carpets and tatami mats are mainly used, and wooden flooring is used in living rooms and kitchens, and occupies a considerable area. This wood flooring is
It is constructed by combining slender boards, but in the past, a natural wood veneer with decorative ridges and grooves formed on both side end faces was used with a natural wood veneer attached to the surface. In addition, at the time of construction, the groove and the ridge of the adjacent plate material are fitted and arranged on the base, so that a groove is formed at the joint.

[0003]

In recent years, it has become difficult to obtain natural wood. For wood flooring, plywood is used instead of the above-mentioned plate material in which a veneer is attached to natural wood. It is becoming. In this case, a plywood surface to which a decorative sheet is adhered is used, but since there is no groove peculiar to the wooden flooring, there is no real wooden texture. Therefore, it is conceivable to attach a decorative sheet to the plywood and cut a groove on the surface with a router, but the groove formed in this way is not preferable because the base material of the plywood can be seen. Painting may be performed on these grooves, but since the shape of the grooves is a U-shaped cross section, it is difficult to paint by direct printing or transfer printing. In particular, of the inside of the groove
Since it was difficult to apply a sufficient pressure to the side wall vertically descending from the plywood surface, it was extremely difficult to paint.

[0004] The present invention has been made in view of the above-mentioned problems, and an object of the present invention is to provide a method for manufacturing a grooved decorative board having a wooden texture.

[0005]

In order to achieve the above object, a first manufacturing method according to the present invention is directed to a method of manufacturing a vehicle, comprising the steps of: forming a V-shaped or substantially V-shaped cross section on the surface of a wooden substrate; Is formed linearly, upwardly convex monotonous continuous curve, or downwardly convex monotone continuous curve in the shape of a groove descending toward the center, and pressing the rubber blanket of the gravure offset printing machine against the substrate In this case, the painting is performed not only on the surface of the substrate but also in the groove at the same time.

In a second manufacturing method, the cross section is V-shaped or substantially V-shaped, the left and right slopes are linear, the monotonous continuous curve having an upward convex, or the bottom is formed on the surface of the wooden substrate. A groove having a shape descending toward the center portion is formed in a convex monotonous continuous curve shape, and the transfer layer side of the transfer sheet including the support and the transfer layer is opposed to the surface of the substrate, and the elasticity of the transfer device is adjusted. By pressing the transfer sheet against the substrate with the body roller, painting is simultaneously performed not only on the surface of the substrate but also in the groove.

In a third manufacturing method, a cross section of a V-shaped or substantially V-shaped cross section is formed on the surface of a wooden substrate, the left and right slopes are straight, a monotonous continuous curve having an upward convexity, or a downwardly curved surface. A groove is formed in the shape of a convex monotonous continuous curve descending toward the center, and the transfer layer side of a transfer sheet including a support and a transfer layer is opposed to the surface of the substrate, and a vacuum forming transfer device is provided. By pressing the transfer sheet against the substrate by the pressure difference between the front and back sides of the transfer sheet based on suction from the substrate side, the painting is performed not only on the surface of the substrate but also in the groove at the same time.

In a fourth manufacturing method, the cross section is V-shaped or substantially V-shaped, the left and right slopes are linear, the convex monotonous continuous curve or the bottom is formed on the surface of the wooden substrate. A groove having a shape descending toward the center portion is formed in a convex monotonous continuous curve shape, the transfer layer side of the transfer sheet including the support and the transfer layer is opposed to the surface of the substrate, and the By pressing the transfer sheet against the substrate using the collision pressure of the solid particles, the painting is simultaneously performed not only on the surface of the substrate but also in the groove.

[0009]

BEST MODE FOR CARRYING OUT THE INVENTION Wood substrates include cedar, cypress, zelkova,
Veneer, plywood, glulam, particle board, MDF made of various tree species such as pine, oak, oak, lauan, teak, melapy
A wood fiber board such as (medium density fiber board) is used. Although the surface of the wooden substrate may be such that the wooden substrate itself is exposed, it is often the case that the surface of the wooden substrate is usually subjected to a known filling, coloring, sealing or the like. The thickness and dimensions are appropriately determined according to the application.

FIG. 1 is a perspective view showing an example of a wooden substrate having a groove formed on its surface. Groove d formed on the surface of wooden substrate B
As shown in FIG. 2 (A), when viewed in cross section (transverse cross section), both sides are sloped, and have a shape that descends toward the bottom point (deepest part) at the center of the groove. The angle of inclination θ between the sloped wooden substrate and the surface is usually preferably about 30 to 60 ° from the viewpoint of ease of forming (painting) a picture in the groove and appearance of the groove. The width of the groove may be similar to that of a conventional decorative board such as a wooden flooring, and is usually about 3 to 10 mm. A router (milling machine), a plane, or the like is used for forming the grooves.

The grooves formed on the wooden substrate in the present invention are shown in FIG.
Although the shape of (A) is basic, it is a shape deformed from the shape of FIG. 2 (A) within a range that does not impair the suitability for painting on both side surfaces (both slopes) and the design appearance of the groove. Is also good. As a specific example of such a modification, as shown in FIG. 2 (B), the left and right slopes are formed as a continuous curve having a downwardly convex monotone (used in the sense of monotone increase or monotone decrease) as shown in FIG.
As shown in (C), there is a groove shape in which both right and left slopes are curved into a monotonous continuous curve that is convex upward when viewed in a cross section. Further, as shown in FIG. 2D, the groove bottom (deepest part) may be a flat surface instead of a point. In particular, in the case of the groove shape shown in FIGS. 2A and 2C, it is preferable to make the bottom a flat surface from the viewpoint of printability on the bottom.

In the present invention, a desired pattern layer is formed (ie, painted) on the surface of the wooden substrate including the inside of the groove. As the pattern, the grain of various tree species, grain of straight grain, wood grain such as heather, stone grain of marble, granite etc. Polka dots, striped patterns, floral patterns, geometric figures, solid characters, etc. are used. Generally, the inside of the groove is often different from the outside of the groove. For example, for an array of tiles and bricks,
Normally, the inside of the groove is a solid white or gray pattern like the real thing, the outside of the groove is usually the pattern of the tile or brick itself, and in the case of a wood pattern, the inside of the groove is solid black or brown. Usually, the outside of the groove has a wood grain pattern.

As a method of painting (forming a pattern layer), the following method suitable for painting on an uneven surface is used.

[Gravure Offset Printing Method] This printing method is as shown in FIG. 3. First, ink 12 is supplied to the surface of a gravure plate cylinder 11, and the surface is scraped off with a doctor blade 13. Is filled with ink, and then the surface of the plate cylinder is pressed against the surface of a rubber blanket cylinder 14 made of rubber (the inside is an iron core) to transfer the ink in the cells to the surface of the rubber blanket once. The blanket cylinder 14 is pressed onto the wooden substrate B to transfer the ink from the rubber blanket 14 onto the substrate B. As the rubber, a rubber having high solvent resistance such as silicon rubber or fluorine rubber is selected. The hardness of the rubber used is 30 in JIS rubber hardness.
About 70 °. After transferring the ink to the wooden substrate,
The ink is dried by blowing hot air or forcibly heating such as infrared radiation as needed.

As the ink, cellulose binders such as cellulose nitrate (nitrification line), cellulose acetate and cellulose acetate propionate; acrylic resins such as polymethyl (meth) acrylate and polybutyl (meth) acrylate; and vinyl chloride-acetic acid are used as binders. Using one or a mixture of two or more of vinyl copolymer, polyvinyl butyral, urethane resin, polyester resin, and the like, and red pigment, carbon black, titanium white, ultramarine,
One or more kinds of vermilion, graphite, quinacridone red, isoindolinone yellow, phthalocyanine blue and the like are added, and if necessary, various additives are added to obtain a desired color. Although FIG. 3 shows one-color printing, multi-color printing of two or more colors may be performed as necessary.

[Transfer Printing Method] This printing method is as shown in FIG. 4, and first, as shown in FIG.
A transfer sheet S in which a transfer layer 22 is formed releasably on 1 is used, and the transfer layer side of this transfer sheet S is bonded to a wooden substrate B so as to face the same. Thereafter, as shown in FIG. 4B, the support 21 is peeled and removed, and only the transfer layer 22 is left on the wooden substrate B for painting.

As the transfer layer, a known structure having at least a picture layer and, if necessary, a release layer and an adhesive layer laminated thereon is used. The ink for the picture layer can be selected from the same ones listed for the gravure offset printing method.

As the support, polyethylene, polypropylene, polymethylpentene, ethylene-propylene-
Butene copolymer, polyolefin resin such as olefin-based thermoplastic elastomer, polyethylene terephthalate,
A sheet (film) made of a thermoplastic polyester such as polybutylene terephthalate or ethylene terephthalate isophthalate copolymer, a polyamide resin such as nylon 6, nylon 66, or polyvinyl chloride, and having a thickness of about 25 to 100 μm is used.

A release layer is formed on the transfer layer side of the support, if necessary. The release layer is a layer that is removed together with the support when the support is released, and the release occurs between the release layer and the transfer layer. On the other hand, the release layer used as necessary is one component of the transfer layer. When the support is released, the release layer is transferred to the wooden substrate together with the picture layer, and functions as a surface protection layer for the picture layer.

As the release layer, a resin having good releasability from the transfer layer is selected as a binder from resins such as silicone resin, polyolefin resin and melamine resin. The thickness is usually about 0.1 to 10 μm.

The release layer may be made of an ultraviolet or electron beam curable resin such as an unsaturated acrylate, an unsaturated methacrylate, or an epoxy resin, in addition to those listed as the binder of the pattern ink. The thickness is usually 1 to 1
It is about 0 μm.

A typical example of the adhesive is a heat-sensitive adhesive. As the heat-sensitive adhesive, polyvinyl acetate,
Vinyl chloride-vinyl acetate copolymer, ethylene-vinyl acetate copolymer, acrylic resin, polyamide resin, thermoplastic resin such as thermoplastic urethane resin, or melamine resin,
A thermosetting resin such as a two-component curable urethane resin or an epoxy resin is used.

The thickness of the adhesive layer is usually 1 to 50 μm.
It is about. In the present invention, the transfer sheet may not be provided with an adhesive layer, and the transfer may be performed after applying an adhesive to the transfer target (wood substrate) when transferring. Alternatively, when an adhesive layer is provided on the transfer sheet side and an adhesive is applied on the transfer-receiving body side, there is an effect of further improving the adhesion of the transfer layer.

By the way, as a method of transferring the image onto the transfer-receiving member using the above-described transfer sheet, a transfer method using pressure can be applied. Further, the action of heat can be used if necessary. In particular, it is preferable to use both heat and pressure in order to transfer the image onto a transfer substrate having three-dimensional groove-shaped irregularities on the surface. For example, the following various transfer methods can be used.

(1) As described in JP-B-56-45768 (overlay method), JP-B-60-58014 (vacuum pressing method), etc., a transfer sheet is formed on the surface of a wooden substrate as a transfer object. Was used, a so-called vacuum forming apparatus in which the transfer layer of the transfer sheet was transferred to the surface of the wood substrate by a pressure difference caused by vacuum suction from the wood substrate, and the transfer layer was placed opposite or placed via an adhesive as needed. Transfer method using the lamination method.

(2) As described in JP-B-60-59876, JP-A-5-139097, etc., the transfer sheet is placed so that the transfer layer faces the transfer-receiving body, and A so-called roller transfer method (see FIG. 5) in which the transfer layer is adhered to the transfer target body by applying pressure from an elastic roller, and then only the support is removed. As the roller 25 to be used, a roller in which a surface of a rigid rotating shaft core 26 such as iron is covered with a soft elastic body 27 is usually used. Rubber such as silicon rubber, fluorine rubber, natural rubber, and butadiene rubber is used as the elastic body. In particular, silicone rubber is preferable in terms of heat resistance, elasticity, and the like. In particular, when the surface (transfer surface) of the wooden substrate B has a groove-like uneven shape as in the present invention, it is possible to use an elastic body having a rubber hardness of 60 ° or less according to JIS as the transfer sheet. It is preferable in that S is formed following the concave and convex surface including the groove. The diameter of the elastic roller 25 is usually about 5 to 20 cm. In the case of performing heating in addition to pressing at the time of transfer, the roller 25 itself is heated, the transfer sheet S is heated, or the wood substrate B is heated.
Heating is performed by infrared radiation, dielectric heating, hot air blowing, or the like.

(3) This transfer method is a novel method,
This is particularly effective when transferring to an uneven surface. That is,
As shown in FIG. 6A, the transfer layer 22 side of the transfer sheet S is placed via the adhesive C toward the wooden substrate B which is the object to be transferred, and as shown in FIG. A large number of solid particles P collide with each other, the transfer layer 22 is shaped by following the surface shape of the wooden substrate B by the collision pressure, and the transfer layer 22 is adhered to the surface of the wooden substrate B.
In this method, transfer is performed by peeling and removing only the support 21 as shown in FIG.

Among these various methods, the method (1) using the vacuum pressing method and the method (3) using the solid particle collision pressure will be described.

First, the vacuum press method (1) will be described in detail.

FIG. 7 is an explanatory view of a vacuum press method as one of the transfer methods utilizing the laminating method using the vacuum forming apparatus of the above (1). This vacuum pressing method is similar to the vacuum laminating method, except that the transfer sheet is heated by a heater in that the transfer sheet is pressed against the transfer object using not only air pressure but also the compression pressure of a rubber-like elastic body. The transfer sheet is slightly different in that the transfer is performed through a rubber-like elastic film, and is characterized by uniform heating of the transfer sheet and a stronger pressing force.

The vacuum press 30 shown in FIG. 1 has an upper chamber 32 which can be moved up and down by a vertical operation means 31 such as a fluid pressure cylinder, and a lower chamber which faces the upper chamber 32. There are 33. An infrared radiation heater 34 is disposed inside the upper chamber 32. The lower opening of the upper chamber 32 is entirely covered with a rubber-like elastic film 35. The rubber-like elastic film 35 is usually made of silicon rubber or the like.
The lower chamber 33 has a table 3 having an upper surface having a plurality of exhaust holes 36.
It is 7. The upper chamber 32 and the lower chamber 33 have an air supply port 38 and an exhaust port 39, respectively, so that the internal pressure of each can be adjusted independently.

In the vacuum press method, first, in a state where the upper chamber 32 moves upward and is separated from the lower chamber 33, the wooden substrate B as the transfer object is placed on the mounting table 37, and the transfer sheet S is further transferred to the wooden substrate. B is placed from above. At this time, the transfer layer side of the transfer sheet S faces the wooden substrate B. When an adhesive is applied to the outer surface of the transfer sheet S or the wooden substrate B, it is applied at this stage. If the adhesive contains a solvent, it is dried at this stage.

Next, the upper chamber 32 is moved downward to move the lower chamber 3
The upper chamber 32 and the lower chamber 33 are hermetically closed by being pressed against 3.
FIG. 7 shows this state. Next, the inside of the lower chamber 33 is depressurized and the inside of the upper chamber 32 is pressurized. Further, the heater 34
Then, the transfer sheet S is heated and softened through the rubber-like elastic film 35 to make it moldable. As a result, the transfer sheet S is moved along the outer surface of the wooden substrate B along the upper chamber 32 and the lower chamber 33.
The transfer sheet S comes into close contact with the wood substrate B due to the pressure difference between the transfer sheet S and the contraction pressure of the rubber-like elastic film 35.

Finally, the pressure in the lower chamber 33 is released and the pressure in the upper chamber 32 is released to bring both chambers to atmospheric pressure.
Is moved upward, the upper chamber 32 and the lower chamber 33 are separated, the wooden substrate B to which the transfer sheet S is adhered is taken out, and the support of the transfer sheet S is peeled off. A grooved decorative board with a picture pattern can be obtained.

Next, the method (3) utilizing the solid particle collision pressure will be described in detail.

[Solid Particles] The solid particles P include non-metallic inorganic particles such as glass beads, ceramic beads, alumina beads, zirconia beads, alundum beads, corundum beads, and the like, iron, carbon steel, and stainless steel. Or other aluminum alloys such as aluminum or duralumin, metal particles such as metal beads such as titanium and zinc, or fluorine resin beads, nylon beads, silicone resin beads, urethane resin beads, urea resin beads, phenol resin beads Organic particles such as resin beads such as crosslinked rubber beads can be used. The shape is preferably spherical, but spheroidal, polyhedral, scaly, amorphous, and other shapes can also be used. The particle size of the solid particles is usually about 10 to 1000 μm.

The solid particles can also serve as a heating means and a cooling means. When heated solid particles are used, the activation of the adhesive by heating and the promotion of crosslinking and curing thereof, or the improvement of the stretchability by heating the transfer sheet can be performed together with the pressing of the transfer sheet. In this case, the transfer sheet and the substrate to be transferred may be heated to some extent by another heating method before the application of the collision pressure. For the purpose of promoting cooling after bonding, solid particles having a temperature lower than the temperature of the adhesive at the time of bonding can be used as the cooling solid particles.
The solid particles may be used in combination with a part or all of the solid particles as heated solid particles or cooled solid particles, or after colliding heated solid particles with cooled solid particles.
In addition, a transfer sheet, a substrate to be transferred, an adhesive or the like that needs to be heated by another heating method is sufficiently heated, and the molding, bonding and cooling of the transfer sheet are performed almost simultaneously using cooling solid particles. You can do it too.

In order to heat or cool the solid particles, when the solid particles are stored in a tank such as a hopper or the like, an electric heater provided in the tank or on the outer wall of the tank, a heating means using heated steam, a refrigerant, etc. What is necessary is just to perform by a cooling means. Further, these means may be provided on the outer wall of the solid particle transport tube to heat or cool the solid particle transport tube. Alternatively, when a fluid is used for accelerating the solid particles, the solid particles can be cooled or heated by heat conduction from the fluid using a cooled or heated fluid. In this case, by causing the fluid to collide with the transfer sheet, the fluid can be used as a heating or cooling unit together with the solid. Alternatively, in the case where the fluid is a liquid and a tank for storing solid particles together with the liquid is used, the solid particles and the liquid may be cooled or heated during storage.

[Application of Impact Pressure by Solid Particles] In order to strike the solid particles against the transfer sheet and apply the impact pressure to press the transfer sheet against the substrate to be transferred, the solid particles are ejected from the solid particle ejection means for ejecting the solid particles. The particles are ejected toward the transfer sheet to apply a collision pressure to the transfer sheet. As the solid particle ejecting means, for example, an ejector using a rotating impeller or an ejector using an ejection nozzle is used as a particle accelerator.
The ejector using the impeller accelerates and ejects solid particles by rotation of the impeller. An ejector using an ejection nozzle accelerates and conveys solid particles with a high-speed fluid flow of a fluid using a solid particle acceleration fluid, and ejects the solid particles together with the fluid. Sandblasting, shot blasting, shot peening and the like used in the blasting field can be used for the impeller and the blowing nozzle. For example, a centrifugal blast device is used for the impeller, and a pressurized or suction blast device, a wet blast device, or the like is used for the blowing nozzle. A centrifugal blast device accelerates and ejects solid particles by the rotational force of an impeller. The pressurized blast device ejects solid particles mixed with compressed air together with air. The suction-type blast device sucks solid particles into a negative pressure portion generated by a high-speed flow of compressed air, and ejects the solid particles together with the air. Wet blasting equipment
The solid particles are mixed with the liquid and ejected.

As the means for ejecting solid particles, a method of accelerating solid particles using free fall due to gravity, a method of accelerating magnetic particles by a magnetic field, and the like may be employed other than the blowing nozzle and the impeller. Is also possible. In the case of an impeller, a solid particle ejecting unit using gravity and a magnetic field, the solid particles can be ejected toward the transfer sheet in a vacuum.

[Ejector: Impeller] FIGS. 8 to 11 are explanatory views showing an example of an impeller which can be used as a particle accelerator of the ejector. This impeller corresponds to a centrifugal blast device used in the blasting field.

In the drawing, the impeller 812 includes a plurality of blades 8.
13 is fixed on both sides by two side plates 814, and the center of rotation is a hollow portion 815 without blades 813. Further, a direction controller 816 is provided inside the hollow portion 815. The direction controller 816 has a hollow cylindrical shape having an opening 817 that is partially open in the circumferential direction.
The rotation axis is the same as the rotation axis 12 and is rotatable independently of the impeller. When the impeller is actually used, the opening is fixed in an appropriate direction. Further, inside the direction controller 816, another impeller having a hollow axis and the same rotation axis as the rotation axis of the impeller 812 is provided.
8 (see FIG. 10). The spreader 818 rotates with the outer impeller 812. Then, the side plate 814
A rotation shaft 819 is fixed to a rotation center of the rotation shaft 819. The rotation shaft 819 is rotatably supported by a bearing 820, and is driven and rotated by a rotation power source (not shown) such as an electric motor to rotate the impeller 812. I do. Further, the rotating shaft 819 is
13 does not penetrate between the two side plates 814 having a space between them, forming a space without a shaft.

Then, the solid particles P
Is supplied from a hopper or the like through a transport pipe. Usually, the solid particles P are supplied from above (directly above or obliquely above) the impeller 812. The solid particles P supplied into the sprayer 818 scatter outside by the impeller of the sprayer 818. The scattered solid particles P are emitted only in the direction permitted by the opening 817 of the direction controller 816, and the blades 8 of the outer impeller 812 are discharged.
13 and the blade 813. And feather 8
13, is accelerated by the rotational force of the impeller 812, and is ejected from the impeller 812.

The ejection direction of the solid particles is shown in FIGS.
, But may be horizontal or obliquely downward (not shown). FIGS. 11A and 11B are conceptual diagrams of ejection direction control for adjusting the ejection direction of the solid particles P by setting the direction of the opening 817 of the direction controller 816 (FIGS. 11A and 11B). The direction controllers 816 are respectively fixed at the positions shown in the figure). Note that the direction controller 8
16 adjusts the size of the opening 817 in the circumferential direction and the width direction, so that the ejection amount of the solid particles P can be adjusted.

In FIG. 9, the rotating shaft 819 is configured so as to be only outside the side plate 814 and not penetrate to the hollow portion 815. In addition, the rotating shaft 819 is thinner than the diameter of the hollow portion 815. Penetrating to the hollow part 815,
It is also possible to adopt a configuration in which the inside of the hollow cylindrical rotary shaft having an opening for passing through solid particles on the outer periphery is formed as a hollow portion (not shown).

The shape of the blade of the impeller is typically a rectangular flat plate (a rectangular parallelepiped) as shown in FIGS. 8 to 11, but in addition, a curved curved plate, a propeller shape such as a screw propeller, or the like may be used. It is also possible to select according to the application and purpose. Further, the number of blades is usually selected from a plurality of blades in a range of up to about 10 blades. And the shape of the impeller, the number of blades, the rotation speed, the mass and supply speed and supply direction of the solid particles,
The ejection direction, ejection speed, projection density, ejection diffusion angle, etc. of the accelerated solid particles are adjusted by the combination of the opening size and orientation of the direction controller.

FIG. 12 is a conceptual diagram showing another example of the impeller. The impeller 812a shown in the drawing has a structure in which a plurality of flat blades 813a are fixed on both sides by two side plates 814a. Usually, the solid particles P are supplied from above (directly above or obliquely above) the impeller. Also, the side plate 81
4a also regulates the ejection direction in the width direction with respect to the rotating shaft 819a. By adjusting the shape, the number, the rotational speed, the mass of the solid particles, the supply speed and the supply direction of the impeller, the ejection direction of the accelerated solid particles P, the ejection speed, the projection density, the ejection diffusion angle, and the like are adjusted. . The ejection direction of the solid particles P can be vertically downward (not shown), horizontal (FIG. 12), obliquely downward (not shown), or the like.

Further, the impeller described above is further provided with an ejection guide (not shown) for opening only the ejection and ejection portion of the solid particles and covering the periphery of the other impellers as necessary. And the ejection direction of solid particles can be controlled. The shape of the opening of the ejection guide is, for example, a hollow cylindrical shape, a polygonal column shape, a conical shape, a polygonal pyramid shape, a fish tail shape, or the like.

The dimensions of the impeller are usually about 5 to 60 cm in diameter, the width of the impeller is about 5 to 20 cm, the length of the impeller is about the diameter of the impeller, and the rotation speed of the impeller is 500 to 5000 r.
pm. The ejection speed of the solid particles is 10 to 50 m /
For about a second, the projection density is about 10 to 150 kg / m ² .

The material of the blades of the impeller may be appropriately selected from ceramics, metals such as steel, high chromium cast steel, titanium, and titanium alloy, depending on the type of solid particles. Solid particles are accelerated by contact with the blades, so if metal beads or inorganic particles are used for the solid particles, the particles are hard, so the blades should be made of high-chromium cast steel or ceramic with good wear resistance. . When resin beads are used as the solid particles, steel may be used because they are softer than metal particles.

[Blowing Nozzle] FIG. 13 is an explanatory view of an example of a blowing device 840 using a blowing nozzle as a solid particle blowing means for blowing solid particles together with a fluid. Note that the ejector 840 shown in the figure is an example of an ejector that uses a gas as a solid particle accelerating fluid and mixes and ejects the gas and the solid particles when ejecting the solid particles. Spouter 840 in FIG.
A guide chamber 841 for mixing the solid particles P and the fluid F, an internal nozzle 842 for jetting the fluid F into the guide chamber 841,
It comprises a blowing nozzle 844 that blows out the solid particles P and the fluid F from the nozzle opening 843. When the fluid F sent from a compressor or a blower (not shown) through a pressurized tank (not shown) as appropriate is ejected from the internal nozzle 842 through the induction chamber 841 through the nozzle opening 843 of the blowing nozzle 844, the guide chamber is used. At 841, a negative pressure is created by the action of the fluid flow flowing at a high speed, the solid particles are introduced into the fluid flow by the negative pressure and mixed, and the solid particles are accelerated and conveyed by the fluid flow, and the nozzle opening 843 of the blowing nozzle 844 is formed. And is ejected together with the fluid flow.

The blow nozzle includes a blow nozzle using a liquid as a solid particle accelerating fluid. In the case of liquid, the fluid and solid particles are mixed and stored in a pressurized tank (not shown) by, for example, a pump (not shown, when the fluid is a liquid), and the mixed liquid is discharged from the nozzle opening of the blowing nozzle. What gushes etc. is used.

The shape of the nozzle opening includes a hollow cylindrical shape, a polygonal column shape, a conical shape, a polygonal pyramid shape, a fish tail shape and the like. The blowing nozzle may have a single opening, or may have an inside partitioned into a honeycomb shape. Fluid pressure is spraying pressure, usually 0.1-100 kg / cm
^{About 2} . The flow velocity of the fluid flow is usually 1 to 20 for the liquid flow.
m / sec, and about 5 to 80 m / sec for air flow.

The material of the ejector such as the induction chamber and the nozzle may be appropriately selected from ceramics, steel, titanium, titanium alloys and the like according to the type of solid particles and fluid. When metal beads or inorganic particles are used as the solid particles, the particles are hard, so that a ceramic having good wear resistance is preferably used. If the fluid is a liquid, select a material that does not cause rust, dissolution, corrosion, etc. For example, if the fluid is water, stainless steel, titanium, a titanium alloy, a synthetic resin, or ceramic is used. However, steel or the like may be used if the surface is waterproofed.

[Fluid] The fluid is used when the solid particles are accelerated and conveyed by the fluid flow, and the solid particles are ejected together with the fluid from the solid particle ejection means (eg, an ejection nozzle). The fluid is a solid particle acceleration fluid that accelerates the solid particles. Either a gas or a liquid can be used as the fluid, but usually a gas that is easy to handle is used. The gas is typically air, but may be carbon dioxide, nitrogen or the like. On the other hand, the liquid is not necessarily limited, but is nonflammable,
Water is one of the preferred materials because of its ease of drying, non-toxicity, low cost, and availability. In addition, nonflammable liquids such as Freon oil can also be used. Liquids (as well as gases) can collide with the solid particles along with the transfer sheet. Naturally, liquids have a higher density than gases, so liquids are easier to accelerate than solids when accelerating solid particles in a fluid flow.

[0056]

Next, embodiments of the present invention will be described.

(Example 1) Based on 100 parts by weight of crystalline isotactic polypropylene as a hard segment, 20 parts by weight of a partially crosslinked hydrogenated styrene-butadiene rubber as a soft segment was mixed with olefin-based thermoplastic resin. An elastomer was obtained. Then, the olefin-based thermoplastic elastomer has a thickness of 100
The film was extruded to a thickness of μm to obtain a film as a support for the transfer sheet.

On this support, a release layer made of an acrylic resin is formed by gravure coating at a coating amount (solid basis, the same applies hereinafter) of 2 g / m ² , and then the binder is made of the acrylic resin and nitrocellulose. The gravure printing is used to form a wood-grained pattern layer consisting of a mixed resin of resin-based resin and a pigment consisting of red-and-black and carbon black, and the gravure adhesive layer made of a polyamide-based resin formed by condensation polymerization of ethylenediamine and dimer acid. A transfer sheet was obtained by forming a coat with a coating amount of 30 g / m ² .

On the other hand, a wood substrate made of a medium density fiberboard (MDF) and having a plurality of V-shaped grooves cut in parallel on the surface as shown in FIG. 1 was prepared. The inclination angle between the substrate surface and both slopes of the groove is 45 °, the width of the groove opening is 5 mm,
The distance between the grooves was 10 cm. Using the above transfer sheet, transfer was performed on the surface of the wooden substrate by a vacuum press method using a vacuum press apparatus as shown in FIG. As a result, the transfer sheet follows the uneven surface including the inside of the groove of the wooden base material, without causing a transfer defect, and preventing the transfer layer from being distorted due to uneven elongation of the support and the temperature unevenness during heating of the transfer sheet. A grooved decorative board excellent in aesthetic appearance without unevenness or distortion of the pattern due to the influence was obtained.

(Example 2) An olefin-based thermoplastic made of a soft polypropylene which is a mixture of 75 parts by weight of an isotactic polypropylene hard segment and 25 parts by weight of an atactic polypropylene soft segment described in JP-B-6-23278. A composition comprising an elastomer (“E2900” manufactured by Idemitsu Petrochemical Co., Ltd.) and erucamide 1000 PPM as a lubricant was extruded from a T-die to a thickness of 70 μm to obtain a film serving as a transfer sheet support.

After a release layer made of a urethane resin is formed on the support by a gravure coat at a coating amount (solid basis, the same applies hereinafter) of 2 g / m ² , the binder is made of an acrylic resin and nitrocellulose. A mixed resin of a series resin, a pigment, a pattern pattern of a wood pattern consisting of a red pattern, isoindolinone and carbon black are formed by gravure printing, and an adhesive layer made of the same polyamide resin as in Example 1 is formed into a gravure coat. Then, a transfer sheet was obtained by forming at a coating amount of 30 g / m ² .

Using this transfer sheet, transfer was performed to a wooden substrate made of a 10 mm-thick Lauan plywood by a roller transfer method as shown in FIG. A groove having a cross section as shown in FIG. 2 (B) was formed on the surface of the wooden substrate. The width of the opening of the groove is 6 mm, and the slope (dotted line) having an inclination angle of 45 ° with the substrate surface in FIG. A groove having a cross section indicated by. The curve was an arc having a radius of curvature of 60 mm.

Then, a transfer sheet is superimposed on a substrate which has been subjected to a filling treatment with a urethane resin in advance so that the transfer layer is in contact with the substrate.
The transfer sheet and the substrate were cooled to room temperature by pressing with an elastic roller having a silicone rubber on the surface at 0 °, and then the support was peeled off. After the transfer, the particle size (average) is 25 on the surface of the transfer layer.
30 g / m ^{2 of} a two-part curable urethane resin paint containing 10% by weight of μm spherical α-alumina was applied. As a result, the transfer sheet followed the uneven surface including the inside of the groove of the wooden substrate, and a grooved decorative board excellent in aesthetics without transfer defects, irregularities in the pattern, distortion, etc. was obtained.

Example 3 A polypropylene-based thermoplastic elastomer consisting of 75% by weight of a hard segment made of isotactic polypropylene, 25% by weight of a soft segment made of atactic polypropylene, and 1000 ppm of erucamide was added to a T-die having a thickness of 10%.
The film was extruded at 0 μm to obtain a film serving as a support for the transfer sheet.

On this support, a binder is a mixture of vinyl chloride-vinyl acetate copolymer and an acrylic resin in a ratio of 1: 1 by weight, and a pigment is red petal, isoindolinone, phthalocyanine blue, titanium white and carbon black. The pattern of the brick-laying pattern was directly formed by rotogravure printing using a pattern ink consisting of: and a transfer sheet having a pattern layer as a transfer layer was obtained.

On the other hand, as a wood substrate serving as an object to be transferred, as shown in the plan view of FIG. 14A and the partially enlarged view of FIG. Groove-like concave portion 401 and flat convex portion 402 of a brick portion
(Medium density fiberboard) having fine irregularities 403 on flat convex portions 402 was prepared. The inclined surface of the groove had an inclination angle of 60 ° with the substrate surface, and the bottom of the groove was formed as a flat portion having a width of 2.5 mm.

Then, using the above-mentioned transfer sheet, transfer was carried out on the wooden substrate by using the solid particle collision pressure as described below. Specifically, first, a urethane-based adhesive was spray-coated on the surface of the wooden substrate, and the transfer sheet was covered on the substrate such that the transfer layer side faced the substrate side. Next, the transfer sheet is heated to 100 ° C. to soften it, and then solid particles made of spherical zinc spheres having an average particle diameter of 0.3 mm are made to collide with the support side of the transfer sheet at an average speed of 35 m / sec, so that the transfer sheet becomes Was pressed. Then, after cooling to room temperature (25 ° C.), transfer was performed by peeling off the support sheet (see FIG. 6). As a result, the transfer sheet follows the uneven surface including the inside of the groove of the wood substrate, without causing a transfer drop defect, and further, without occurrence of tearing due to necking of the support, no uneven distortion of the pattern is recognized, A grooved decorative plate was obtained as a transfer product having excellent appearance. Finally, an acrylic polyol and hexamethylene diisocyanate are used.
Using a transparent urethane paint with a weight% of 1
A protective layer was formed on the surface at 0 g / m ² .

Example 4 A wood substrate similar to that of Example 1 was prepared, and an acrylic resin-based emulsion was used as a binder, titanium white, red stalk, quinacridone, and isoindone were used as the binder over the entire surface of the substrate including the inside of the groove. A coating composed of linone was applied and dried to form a colored coating and filling treatment layer. Next, a wood grain pattern was printed on the substrate surface using a gravure offset printing machine as shown in FIG. As the ink, a binder composed of a vinyl chloride-vinyl acetate copolymer and an acrylic resin in a ratio of 2 to 8 by weight, and a pigment composed of a red iron oxide and carbon black were used. A rubber blanket having a JIS rubber hardness of 55 ° was used. The obtained grooved decorative board had a pattern on the entire surface of the substrate including the inside of the groove.

[0069]

As described above, according to the present invention,
Since the painting can be simultaneously performed not only on the surface of the wooden substrate but also in the groove, it is possible to produce a grooved decorative board having a real wooden feeling and suitable for wooden flooring.

[Brief description of the drawings]

FIG. 1 is a perspective view showing an example of a wooden substrate having a groove formed on a surface.

FIG. 2 is a cross-sectional view illustrating a groove formed on the surface of a wooden substrate.

FIG. 3 is an explanatory diagram of a gravure offset printing method.

FIG. 4 is an explanatory diagram of a transfer printing method.

FIG. 5 is an explanatory diagram of a roller transfer method.

FIG. 6 is an explanatory diagram of a transfer method using a solid particle collision pressure.

FIG. 7 is an explanatory view of a vacuum press method.

FIG. 8 is a perspective view showing an example of an ejector using an impeller.

FIG. 9 is a front view of the ejector of FIG. 8;

FIG. 10 is an explanatory view of the inside of the ejector of FIG. 8;

FIG. 11 is an explanatory diagram for adjusting a jetting direction by the jetting device of FIG. 8;

FIG. 12 is a conceptual diagram showing another example of the impeller.

FIG. 13 is a cross-sectional view showing an example of an ejector using an ejection nozzle.

FIG. 14 is a perspective view showing a top view for explaining the surface of a wooden substrate.

[Explanation of symbols]

 B Wood substrate C Adhesive F Fluid P Solid particles S Transfer sheet d Groove θ Tilt angle 11 Gravure plate cylinder 12 Ink 13 Doctor blade 14 Blanket cylinder 21 Support 22 Transfer layer 25 Elastic roller 26 Rotating shaft core 27 Elastic body 30 Vacuum Pressing device 31 Vertical movement means 32 Upper chamber 33 Lower chamber 34 Heater 35 Elastic film 36 Exhaust hole 37 Mounting table 38 Air supply port 39 Exhaust port 812,812a Impeller 813,813a Blade 814,814a Side plate 815 Hollow part 816 Direction controller 817 Opening part 818 Sprayer 819, 819a Rotating shaft 820 Bearing 840 Ejector 841 Induction chamber 842 Internal nozzle 843 Nozzle opening part 844 Blowing nozzle 401 Groove part 402 Flat convex part 403 Fine convex part

Claims (4)

[Claims] 1. A wooden substrate having a V-shaped or substantially V-shaped cross section, a left and right slope having a linear shape, an upwardly convex monotone continuous curve, or a downwardly convex monotone continuous curve on the surface of a wooden substrate. A groove having a shape descending toward the center is formed, and the rubber blanket of the gravure offset printing machine is pressed against the substrate to simultaneously paint not only on the surface of the substrate but also in the groove. Manufacturing method of decorative board with grooves. 2. The surface of the wood substrate has a V-shaped or substantially V-shaped cross section, and the left and right slopes are linear, upwardly convex monotonically continuous curve, or downwardly convex monotone continuous curve. A groove having a shape descending toward the center is formed, and the transfer layer side of the transfer sheet including the support and the transfer layer is opposed to the surface of the substrate. A method for producing a decorative plate with grooves, characterized in that painting is performed simultaneously not only on the surface of the substrate but also in the grooves by pressing the substrate. 3. The surface of the wood substrate has a V-shaped or substantially V-shaped cross section, and the left and right slopes are linear, upwardly convex monotonically continuous curve, or downwardly convex monotone continuous curve. A groove having a shape descending toward the center is formed, and the transfer layer side of the transfer sheet including the support and the transfer layer is opposed to the surface of the substrate. A method for manufacturing a grooved decorative board, characterized in that a transfer sheet is pressed against a substrate by a pressure difference between the front and back surfaces of the transfer sheet based on suction, thereby simultaneously painting not only on the surface of the substrate but also in a groove. 4. On the surface of the wooden substrate, the cross section is V-shaped or substantially V-shaped, the left and right slopes are linear, upwardly convex monotone continuous curve, or downward convex monotone continuous curve. A groove having a shape descending toward the center is formed, and the transfer layer side of the transfer sheet including the support and the transfer layer is opposed to the surface of the substrate, and the collision pressure of the solid particles from the support is used. Pressing the transfer sheet against the substrate, thereby simultaneously painting not only the surface of the substrate but also the inside of the groove.