GB2113604A - Method of manufacturing artificial veneers - Google Patents

Method of manufacturing artificial veneers Download PDF

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Publication number
GB2113604A
GB2113604A GB08200554A GB8200554A GB2113604A GB 2113604 A GB2113604 A GB 2113604A GB 08200554 A GB08200554 A GB 08200554A GB 8200554 A GB8200554 A GB 8200554A GB 2113604 A GB2113604 A GB 2113604A
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GB
United Kingdom
Prior art keywords
veneers
artificial
veneer
printed
wood
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
GB08200554A
Other versions
GB2113604B (en
Inventor
Kunio Iijima
Toshiaki Tanaka
Akira Imai
Kiyomi Togawa
Ryosei Takase
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Panasonic Holdings Corp
Original Assignee
Matsushita Electric Works Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority to DE3200257A priority Critical patent/DE3200257C2/en
Application filed by Matsushita Electric Works Ltd filed Critical Matsushita Electric Works Ltd
Priority to GB08200554A priority patent/GB2113604B/en
Publication of GB2113604A publication Critical patent/GB2113604A/en
Application granted granted Critical
Publication of GB2113604B publication Critical patent/GB2113604B/en
Expired legal-status Critical Current

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B32B21/14—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood board or veneer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27D—WORKING VENEER OR PLYWOOD
    • B27D1/00—Joining wood veneer with any material; Forming articles thereby; Preparatory processing of surfaces to be joined, e.g. scoring
    • B27D1/04—Joining wood veneer with any material; Forming articles thereby; Preparatory processing of surfaces to be joined, e.g. scoring to produce plywood or articles made therefrom; Plywood sheets
    • B27D1/08—Manufacture of shaped articles; Presses specially designed therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B27—WORKING OR PRESERVING WOOD OR SIMILAR MATERIAL; NAILING OR STAPLING MACHINES IN GENERAL
    • B27L—REMOVING BARK OR VESTIGES OF BRANCHES; SPLITTING WOOD; MANUFACTURE OF VENEER, WOODEN STICKS, WOOD SHAVINGS, WOOD FIBRES OR WOOD POWDER
    • B27L5/00—Manufacture of veneer ; Preparatory processing therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B21/00—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board
    • B32B21/04—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B21/08—Layered products comprising a layer of wood, e.g. wood board, veneer, wood particle board comprising wood as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/28—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer comprising a deformed thin sheet, i.e. the layer having its entire thickness deformed out of the plane, e.g. corrugated, crumpled
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B38/00—Ancillary operations in connection with laminating processes
    • B32B38/14—Printing or colouring
    • B32B38/145—Printing
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/16—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer formed of particles, e.g. chips, powder or granules
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/02—Physical, chemical or physicochemical properties
    • B32B7/022—Mechanical properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/06—Interconnection of layers permitting easy separation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C1/00—Processes, not specifically provided for elsewhere, for producing decorative surface effects
    • B44C1/16—Processes, not specifically provided for elsewhere, for producing decorative surface effects for applying transfer pictures or the like
    • B44C1/165—Processes, not specifically provided for elsewhere, for producing decorative surface effects for applying transfer pictures or the like for decalcomanias; sheet material therefor
    • B44C1/17—Dry transfer
    • B44C1/1704—Decalcomanias provided with a particular decorative layer, e.g. specially adapted to allow the formation of a metallic or dyestuff layer on a substrate unsuitable for direct deposition
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44C—PRODUCING DECORATIVE EFFECTS; MOSAICS; TARSIA WORK; PAPERHANGING
    • B44C5/00—Processes for producing special ornamental bodies
    • B44C5/04—Ornamental plaques, e.g. decorative panels, decorative veneers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B44—DECORATIVE ARTS
    • B44F—SPECIAL DESIGNS OR PICTURES
    • B44F9/00—Designs imitating natural patterns
    • B44F9/02—Designs imitating natural patterns wood grain effects
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B32B2307/402—Coloured
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2317/00—Animal or vegetable based
    • B32B2317/16—Wood, e.g. woodboard, fibreboard, woodchips

Landscapes

  • Engineering & Computer Science (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Forests & Forestry (AREA)
  • Finished Plywoods (AREA)
  • Laminated Bodies (AREA)
  • Manufacture Of Wood Veneers (AREA)

Abstract

An adhesive (2) is applied to one surface of respective material veneers (1) cut out of an inexpensive natural wood. An ink layer (4) is deposited on one surface of respective parting plastic films (3) to form printing sheets (5) and the material veneers and printing sheets are piled and compressed between flat dies (6) with the ink layer (4) opposed to the adhesive (2) to have the ink layer printed onto the respective material veneers (1). The parting film (3) is separated from the respective veneers to obtain printed veneers (7) and a number of the printed veneers (7) are stacked and then subjected to pressure in concave-convex dies (8) to form an artificial flitch (9), which is sliced by a slicer (10) into artificial veneers (11). Very clear annual rings are faithfully presented on the artificial veneer (11) by the ink layer (4) printed onto the material veneer (1) and patterns very similar to grain patterns of such natural wood of a needle-leaved tree as cryptomeria wood are developed. <IMAGE>

Description

SPECIFICATION Method of manufacturing artificial veneers This invention relates generally to methods of manufacturing artificial wood veneers from inexpensive natural woods and, more particularly, to improvements in the method of manufacturing artificial veneers resembling natural veneers of such needle-leaved trees as, for example, cryptomeria or the like which distinctively clearly presenting annual ring borders.
In the case when such natural wood of needle-leaved trees among various natural woods as cryptomeria or the like is sliced in, for example, the flatsawn grain direction to cut out plate materials, a grain pattern in which annual ring borders will clearly appear in the shape of flames or as if flowered (which shall be referred to hereinafter as "flowered grain direction" and "flowered grain pattern") and such plate materials will be adapted as wall covering materials for room interior decorations. However, the resource of such natural wood as cryptomeria is not sufficient and it is generally considered that such wood is so expensive as to be unable to be easily acquired.
It has been well known, on the other hand, as a basic method to obtain an artificial wood veneer by cutting an inexpensive natural wood into veneers (which shall be referred to hereinafter as "material veneer") by means of such veneer manufacturing machine as a rotary lathe, accumulating many of the thus obtained material veneers to form a batch called "artificial flitch" and slicing this flitch in the flowered grain direction to obtain artificial veneers.There has been suggested, for example, in British Patent No. 1,391,077 a formation wherein a plurality of the laminated material veneers with an adhesive applied between them are inserted between a pair of pressing dies having pressing surfaces curved to be mutually complemental and are pressed by such pressing dies to be collected into a curved aritificial flitch and this artificial flitch is sliced in the flowered grain direction to obtain arificial veneers.
According to the method of this British patent, annual rings can be presented by respective joining surfaces of the accumulated material veneers. However, in the case of presenting the annual rings only by the joining surfaces of the material veneers, it has been totally insufficient to represent grain patterns of such natural wood in which annual rings appear very clearly as cryptomeria and it has been substantially impossible to simulate this kind of grain pattern.
A primary object of the present invention is, therefore, to provide a method of manufacturing, from inexpensive natural woods, artificial veneers having a grain pattern very similar to that obtained by slicing such high grade wood of needle-leaved trees as cryptomeria or the like which is not easy to acquire as being relatively few in the resource and having very clear annual rings of a width so narrow as to be about 10 to 15% of the annual ring intervals.
Another object of the present invention is to provide a method of manufacturing artificial veneers which can faithfully represent even such patterns that produce undulations in the annual rings, which can be obtained when a natural wood is sliced in the flowered grain direction.
Still another object of the present invention is to provide a method of manufacturing artificial veneers which can give the same appearance as grain patterns of such natural wood in which annual rings appear very clearly as cryptomeria wood, even when seen at a distance.
A further object of the present invention is to provide a method of manufacturing artificial veneers which is easy to work with an improved workability and at a reduced cost.
In this specification, the term "artificial flitch" means a pile of many veneers made by combining printed veneers with each other or the printed veneers with at least one material veneer, accumulating many combinations and collectively joining them under a pressure with an adhesive applied between the respective veneers.
The term "material veneer" means a veneer cut out of a natural wood, with such veneer manufacturing machine as a rotary lathe, to be of a predetermined width and, if so desired, defatted, bleached, dyed and dried. The term "printed veneer" means a veneer made by placing a parting plastic film having an ink layer deposited on its one surface over one surface having an adhesive applied thereto of a material veneer with the ink layer opposed to the adhesive, joining them under a pressure and removing the plastic film to print the ink layer onto the material veneer.
Further, the term "flowered grain direction" means a direction in which the joining surfaces of respective veneers appear like flames when the artificial flitch is sliced.
Detailed technical ideas, other objects and advantages of the present invention will become apparent as the following descriptions of the invention advance as detailed with reference to certain preferred embodiments of the invention shown in accompanying drawings, in which: Figure IA is a block diagram showing steps of an embodiment of the method of manufacturing artificial veneers according to the present invention; Figure IB is a fragmentary plan view as magnified showing schematically an artificial veneer obtained finally as sliced in the flowered grain direction according to the steps shown in Fig. 1A; Figure 2 is a somewhat concrete explanatory view of a main part of the steps shown in Fig. 1A, the steps proceeding in the order indicated by the arrows;; Figure 3A is a block diagram showing steps of another embodiment of the method according to the present invention; Figure 3B is a schematic plan view as magnified showing fragmentarily the artificial veneer obtained finally as sliced in the flowered grain direction according to the method shown in Fig. 3A; Figure 4A is a block diagram showing steps of still another embodiment of the method according to the present invention; Figure 4B is a schematic plan view as magnified of an artificial veneer obtained finally as sliced in the flowered grain direction in the steps according to the embodiment of Fig.
4A; Figure 5A is a block diagram showing steps of a further embodiment of the method according to the present invention; Figure 5B is a schematic plan view as magnified of an artificial veneer obtained finally as sliced in the flowered grain direction in the steps of Fig. 5A; Figures 6 and 7 are respectively a perspective view and sectioned view of a plastic film used in the steps of a still further embodiment of the method according to the present invention; and Figure 8 is a fragmentary sectioned view of a part of an artificial veneer obtained in still another embodiment of the method according to the present invention; While the present invention shall be explained in the following with reference to several embodiments shown in the accompanying drawings, it should be understood that the present invention is not to be limit only to these embodiments but is to include all modifications, alterations and equivalent arrangement possible within the scope of appended claims.
According to one aspect of the present invention, a parting plastic film having an ink layer deposited on its one surface is placed on a material veneer through an adhesive applied to a surface of the veneer so that a printed veneer will be formed and clear annual rings will be eventually presented by the ink layer.
Referring to this more specifically with reference to Figs. 1 A, 1 B and 2, a material veneer 1 cut as known per se out of a material wood with such veneer manufacturing machine as a rotary lathe is bleached as a pretreatment and is dyed in a tone (which shall be referred to as "early wood tone" hereinafter) very similar to an early wood of a natural wood (here, the "early wood" means a layer formed generally between respective annual rings in such natural wood having clear annual rings as cryptomeria wood). This material veneer 1 is dried and an adhesive 2 which is colorless or early wood colored is applied to a surface of the veneer 1.
On the other hand, a parting plastic film 3 is provided with an ink layer 4 having a tone (which shall be referred to as a "late wood color" hereinafter) very similar to a summer or late wood of a natural wood (here, the "summer wood" means an annual-ring-border forming layer in such natural wood having clear annual rings as cryptomeria wood) to form a printing ink sheet 5.
Then the material veneer 1 and printing ink sheet 5 are combined with each other, with the ink layer 4 of the printing ink sheet 5 opposed to the adhesive 2 on the material veneer 1, many combinations of the material veneer 1 and printing ink sheet 5 are piled into a stack and compressed as inserted between flat dies 6. Then, the stack is broken up into the respective combinations and the parting plastic film 3 is peeled off, after being taken out of the flat dies 6. In this state the adhesive 2 on the material veneer 1 has substantially perfectly penetrated into the ink layer 4 printed from the plastic film 3, and the ink layer 4 having the summer wood tone is transferred onto the material veneer 1 to make a printed veneer 7.
Further, many printed veneers 7 formed as above are again accumulated into a stack through the adhesive applied to each veneer and are inserted between paired concave-convex dies 8 having mutually complementarily curved pressing surfaces and are compressed to form an artificial flitch 9 which is curved as seen in Fig. 2. This artificial flitch 9 is finally sliced with a cutter 1 0 (schematically shown in Fig. 2) in the flowered grain direction, that is, in a direction inclined at an angle with respect to the plane including each printed veneer to finish artificial veneers 11 as final moldings.
The ink layer 4 to which the summer wood tone is provided is usually unstable but, accordint to the present invention, the adhesive 2 will solidify after penetrating into the ink layer 4 and, therefore, the ink layer 4 will become stable as strongly deposited on the material veneer 1. Accordingly, when the artificial flitch 9 is sliced in the flowered grain direction, clear annual rings will be presented by the ink layer 4 and, as a whole, such patterns like flames as, for example, the one very similar to grain patterns of cryptomeria wood can be developed.
In the above described embodiment, in consideration of some soaking out of the ink layer, it is preferable to adopt for the material veneers such cheap tropical wood having few vessels as, for example, an agathis wood or tilia japonica wood.
Two examples of practical conditions for achieving the above embodiment are shown in the following Tables I and ll: SPECIFICATION Method of manufacturing artificial veneers This invention relates generally to methods of manufacturing artificial wood veneers from inexpensive natural woods and, more particularly, to improvements in the method of manufacturing artificial veneers resembling natural veneers of such needle-leaved trees as, for example, cryptomeria or the like which distinctively clearly presenting annual ring borders.
In the case when such natural wood of needle-leaved trees among various natural woods as cryptomeria or the like is sliced in, for example, the flatsawn grain direction to cut out plate materials, a grain pattern in which annual ring borders will clearly appear in the shape of flames or as if flowered (which shall be referred to hereinafter as "flowered grain direction" and "flowered grain pattern") and such plate materials will be adapted as wall covering materials for room interior decorations. However, the resource of such natural wood as cryptomeria is not sufficient and it is generally considered that such wood is so expensive as to be unable to be easily acquired.
It has been well known, on the other hand, as a basic method to obtain an artificial wood veneer by cutting an inexpensive natural wood into veneers (which shall be referred to hereinafter as "material veneer") by means of such veneer manufacturing machine as a rotary lathe, accumulating many of the thus obtained material veneers to form a batch called "artificial flitch" and slicing this flitch in the flowered grain direction to obtain artificial veneers.There has been suggested, for example, in British Patent No. 1,391,077 a formation wherein a plurality of the laminated material veneers with an adhesive applied between them are inserted between a pair of pressing dies having pressing surfaces curved to be mutually complemental and are pressed by such pressing dies to be collected into a curved aritificial flitch and this artificial flitch is sliced in the flowered grain direction to obtain arificial veneers.
According to the method of this British patent, annual rings can be presented by respective joining surfaces of the accumulated material veneers. However, in the case of presenting the annual rings only by the joining surfaces of the material veneers, it has been totally insufficient to represent grain patterns of such natural wood in which annual rings appear very clearly as cryptomeria and it has been substantially impossible to simulate this kind of grain pattern.
A primary object of the present invention is, therefore, to provide a method of manufacturing, from inexpensive natural woods, artificial veneers having a grain pattern very similar to that obtained by slicing such high grade wood of needle-leaved trees as cryptomeria or the like which is not easy to acquire as being relatively few in the resource and having very clear annual rings of a width so narrow as to be about 10 to 15% of the annual ring intervals.
Another object of the present invention is to provide a method of manufacturing artificial veneers which can faithfully represent even such patterns that produce undulations in the annual rings, which can be obtained when a natural wood is sliced in the flowered grain direction.
Still another object of the present invention is to provide a method of manufacturing artificial veneers which can give the same appearance as grain patterns of such natural wood in which annual rings appear very clearly as cryptomeria wood, even when seen at a distance.
A further object of the present invention is to provide a method of manufacturing artificial veneers which is easy to work with an improved workability and at a reduced cost.
In this specification, the term "artificial flitch" means a pile of many veneers made by combining printed veneers with each other or the printed veneers with at least one material veneer, accumulating many combinations and collectively joining them under a pressure with an adhesive applied between the respective veneers.
The term "material veneer" means a veneer cut out of a natural wood, with such veneer manufacturing machine as a rotary lathe, to be of a predetermined width and, if so desired, defatted, bleached, dyed and dried. The term "printed veneer" means a veneer made by placing a parting plastic film having an ink layer deposited on its one surface over one surface having an adhesive applied thereto of a material veneer with the ink layer opposed to the adhesive, joining them under a pressure and removing the plastic film to print the ink layer onto the material veneer.
Further, the term "flowered grain direction" means a direction in which the joining surfaces of respective veneers appear like flames when the artificial flitch is sliced.
Detailed technical ideas, other objects and advantages of the present invention will become apparent as the following descriptions of the invention advance as detailed with reference to certain preferred embodiments of the invention shown in accompanying drawings, in which: Figure 1A is a block diagram showing steps of an embodiment of the method of manufacturing artificial veneers according to the present invention; Figure 1B is a fragmentary plan view as magnified showing schematically an artificial veneer obtained finally as sliced in the flowered grain direction according to the steps shown in Fig. 1A; Figure 2 is a somewhat concrete explanatory view of a main part of the steps shown in Fig. 1A, the steps proceeding in the order indicated by the arrows;; Figure 3A is a block diagram showing steps of another embodiment of the method according to the present invention; Figure 3B is a schematic plan view as magnified showing fragmentarily the artificial veneer obtained finally as sliced in the flowered grain direction according to the method shown in Fig. 3A; Figure 4A is a block diagram showing steps of still another embodiment of the method according to the present invention; Figure 4B is a schematic plan view as magnified of an artificial veneer obtained finally as sliced in the flowered grain direction in the steps according to the embodiment of Fig.
4A; Figure 5A is a block diagram showing steps of a further embodiment of the method according to the present invention; Figure 5B is a schematic plan view as magnified of an artificial veneer obtained finally as sliced in the flowered grain direction in the steps of Fig. 5A; Figures 6 and 7 are respectively a perspective view and sectioned view of a plastic film used in the steps of a still further embodiment of the method according to the present invention; and Figure 8 is a fragmentary sectioned view of a part of an artificial veneer obtained in still another embodiment of the method according to the present invention; While the present invention shall be explained in the following with reference to several embodiments shown in the accompanying drawings, it should be understood that the present invention is not to be limit only to these embodiments but is to include all modifications, alterations and equivalent arrangement possible within the scope of appended claims.
According to one aspect of the present invention, a parting plastic film having an ink layer deposited on its one surface is placed on a material veneer through an adhesive applied to a surface of the veneer so that a printed veneer will be formed and clear annual rings will be eventually presented by the ink layer.
Referring to this more specifically with reference to Figs. 1 A, 1 B and 2, a material veneer 1 cut as known per se out of a material wood with such veneer manufacturing machine as a rotary lathe is bleached as a pretreatment and is dyed in a tone (which shall be referred to as "early wood tone" hereinafter) very similar to an early wood of a natural wood (here, the "early wood" means a layer formed generally between respective annual rings in such natural wood having clear annual rings as cryptomeria wood). This material veneer 1 is dried and an adhesive 2 which is colorless or early wood colored is applied to a surface of the veneer 1.
On the other hand, a parting plastic film 3 is provided with an ink layer 4 having a tone (which shall be referred to as a "late wood color" hereinafter) very similar to a summer or late wood of a natural wood (here, the "summer wood" means an annual-ring-border forming layer in such natural wood having clear annual rings as cryptomeria wood) to form a printing ink sheet 5.
Then the material veneer 1 and printing ink sheet 5 are combined with each other, with the ink layer 4 of the printing ink sheet 5 opposed to the adhesive 2 on the material veneer 1, many combinations of the material veneer 1 and printing ink sheet 5 are piled into a stack and compressed as inserted between flat dies 6. Then, the stack is broken up into the respective combinations and the parting plastic film 3 is peeled off, after being taken out of the flat dies 6. In this state the adhesive 2 on the material veneer 1 has substantially perfectly penetrated into the ink layer 4 printed from the plastic film 3, and the ink layer 4 having the summer wood tone is transferred onto the material veneer 1 to make a printed veneer 7.
Further, many printed veneers 7 formed as above are again accumulated into a stack through the adhesive applied to each veneer and are inserted between paired concave-convex dies 8 having mutually complementarily curved pressing surfaces and are compressed to form an artificial flitch 9 which is curved as seen in Fig. 2. This artificial flitch 9 is finally sliced with a cutter 10 (schematically shown in Fig. 2) in the flowered grain direction, that is, in a direction inclined at an angle with respect to the plane including each printed veneer to finish artificial veneers 11 as final moldings.
The ink layer 4 to which the summer wood tone is provided is usually unstable but, accordint to the present invention, the adhesive 2 will solidify after penetrating into the ink layer 4 and, therefore, the ink layer 4 will become stable as strongly deposited on the material veneer 1. Accordingly, when the artificial flitch 9 is sliced in the flowered grain direction, clear annual rings will be presented by the ink layer 4 and, as a whole, such patterns like flames as, for example, the one very similar to grain patterns of cryptomeria wood can be developed.
In the above described embodiment, in consideration of some soaking out of the ink layer, it is preferable to adopt for the material veneers such cheap tropical wood having few vessels as, for example, an agathis wood or tilia japonica wood.
Two examples of practical conditions for achieving the above embodiment are shown in the following Tables I and II: Table I 1. For Material Veneers: (a) Natural wood: Tropical wood agathis of 1 mm. thick.
(b) Dyeing For 25 minutes in a metallic complex dye solution having an early wood tone kept at 90to.
(c) Adhesive: Urethane series synthetic resin (Product No. KU661 sold by Japanese corpora tion Konishi Co., Ltd.) made to have a spring wood tone by mixing brown pigment.
2. For Printing Ink Sheet: (a) Plastic film: Polyester film 40,u thick.
(b) Ink layer: 3e thick with nitrocellulose as a vehicle and a ferrous pigment as a coloring component.
3. For Forming Printed Veneer: (a) Pressing dies: Flat dies.
(b) Compressing pressure, time and temperature: Under 22 kg./cm2. for 50 minutes at room temperature.
(c) Total number of veneers: 30 4. For Forming Artificial Flitch: (a) Pressing dies: Concavo-convex dies.
(b) Compressing pressure, time and temperature: Under 10 kg./cm2. for 12 hours at room temperature.
(c) Adhesive: Epoxy series synthetic resin (Product No. E250 sold by Japanese corpora tion Konishi co., Ltd.) made to have an early wood tone by mixing a brown pigment.
(d) Total number of veneers: 500 5. For Slicing Artificial Flitch: 0.25 mm. thick. Slicing angle of 1/200 in inclination.
Table II 1. For Material Veneers: (a) Natural wood: Tropical tilia japonica wood 0.8 mm.
thick.
(b) Dyeing: For 30 minutes in an acid dye solution having an early wood tone at 90"C.
(c) Adhesive: Epoxy series synthetic resin (Product No. E250 of Japanese corporation Ko noshi Co., Ltd.) made to have an early wood tone by mixing a brown pigment.
2. For Printing Ink Sheet: (a) Plastic film: Polypropylene film 401l thick.
(b) Ink layer: it thick with cellulose acetate as a vehicle and titanium oxide mixed in a ferrous pigment as a coloring compo nent.
3. For Forming Printed Veneer: (a) Pressing dies: Flat dies.
(b) Compressing pressure, time and temperature: Under 25 kg./cm2. for 1 hour at the normal temperature.
(c) Total number of veneers: 35 4. For Forming Artificial Flitch: (a) Pressing dies: Concavo-convex dies.
(b) Compressing pressure, time and temperature: Under 1 2 kg./cm2. for 3 hours at the normal temperature.
(c) Adhesive: Urethane series synthetic resin (Product No. KU661 sold by Japanese corpora tion Konishi Co., Ltd.) made to have an early wood tone by mixing a brown pigment.
(d) Total number of veneers: 500 5. Slicing Artificial Flitch: 0.6 mm. thick. Slicing angle of 1/200 in inclination.
In either of the above two examples of Tables I and 11, the material veneers, printed veneers and artificial veneers were properly dried to make the water content to be in a range of 20 to 70% as required.
According to another aspect of the present invention, another material veneer is further combined with a printed veneer so as to be able to simulate variations in the width between the respective annual rings of a natural wood of a- needle-leaved tree. With reference to Fig. 3A and 3B, the step of obtaining printed veneers 27 from material veneers painted with the adhesive and printing ink sheets is subtantially the same as in the above described embodiment shown in Figs. 1 A, 1 B and 2. In the present embodiment, material veneers 21 dyed in an early wood tone are combined with the respective printed veneers 27 at a combining ratio of 1 to 6:1, the printed veneers 27 and other material veneers 21 to be incorporated are painted with the adhesive, and many of them are piled into a stack, then inserted between concavo-convex dies and compressed to form an artificial flitch 29.Further, this artificial flitch 29 is sliced in the flowered grain direction to obtain artificial veneers 31.
In the present embodiment, further, the width of the early wood layer portion of the grain pattern can be expanded in response to the incorporating ratio of the other material veneers 21 and a desired pattern very similar to the grain pattern of the natural wood.
Excellent artificial veneers 31 could have been obtained by adopting the conditions in the above referred Tables I and Il for practising the manufacturing steps. In this case, it has been found that natural woods of the same or different kinds may be used as the material veneers for forming the printed veneers and other material veneers to be incorporated thereto, and that such wood having no vessel or less vessel to be not remarkable as, for example, an agathis wood or tilia japonica wood can be used alone or as a combination of two or more kinds.
According to a further aspect of the present invention, the fidelity of the close similarity to the grain pattern of a natural wood can be further promoted by undulating the printed veneers after being formed. With reference to Figs. 4A and 4B, substantially the same manufacturing steps up to that of forming the printed veneers 47 as in the above described embodiment shown in Figs. 1A, 1 B and 2 are also employed in the present embodiment.
When the printed veneers 47 are obtained, in the present instance, undulations or many grooves are formed on these veneers 47 with a tenderizer, then the adhesive is applied to them, a stack of such printed veneers 47 are then inserted between concavo-convex dies and are compressed to form an artificial flitch 49, which is sliced in the flowered grain direction to obtain artificial veneers 51.
When such natural wood of a needle-leaved tree as, for example, cryptomeria wood is sliced in the flowered grain direction, the annual rings will usually slightly rise. According to this embodiment, due to the pattern very similar to such grain pattern, that is, the undulations of the printed veneer 47, as shown in Fig. 4B, rises will appear particularly in the parts representing annual rings. Excellent artificial veneers 51 could have been also obtained by adopting the conditions in the above mentioned Tables I and II for practising the manufacturing steps.
According to still another aspect of the present invention, the width of the early wood layer part to be developed is expanded and the parts representing the annual rings are made to rise, that is, the fidelity of the close similarity to the natural wood grain pattern is further elevated by having the features of both of the foregoing embodiments of Figs. 3A, 3B, 4A and 4B. Referring now to Figs. 5A and 5B, in this embodiment, too, printed veneers 67 are obtained through substantially the same steps as in the embodiment of in Figs. 1A, 18 and 2 and undulations or many grooves are formed on them with the tenderizer.Then, other material veneers 61 dyed in the early wood tone are combined with the undulated printed veneers 67 at a combining ratio of 1 to 6:1 and the printed veneers 67 and other material veneers 61 to be incorporated are provided with an adhesive. Many of such combined veneers are heaped up into a stack which is then inserted between concavoconvex dies and compressed to form an artificial flitch 69. Further, this artificial flitch 69 is sliced in the flowered grain direction to provide artificial veneers 71 having patterns high in the fidelity to a natural wood of a needleleaved tree. In this case, too, very favourable artificial veneers 71 could have been obtained by adopting the conditions in the foregoing Tables I and Il for practising the method.
Further optimum artificial veneers can be provided by such various features as in the following of the present invention.
In developing the grain patterns in the foregoing embodiments, annual ring representing zones of both lateral sides of the artificial veneer in which annual ring lines appear as substantially parallely extending patterns will appear to be relatively narrower in width than the annual ring representing zone in the middle area of the artificial veneer in which the annual ring lines appear as flame-shaped or flowered patterns and, therefore, the tone will appear to be thin as seen at a distance. Therefore, according to another aspect of the present invention, artificial veneers which will give a uniform tone feeling even when seen at a distance can be provided.
That is, with reference to Fig. 6, the thickness of the summer wood tone can be made somewhat different in the middle part and both lateral sides of the ink layer adopted in the above described respective embodiments.
More particularly, the middle part 84a of the ink layer 84 is formed to be band-shaped as an ink layer zone relatively thinner in tone than both lateral sides 84b. The middle part 84a of the ink layer 84 will be positioned as band-shaped in the middle part of a printed veneer when it is formed through the same steps as in the embodiments of Figs. 1A, 18 and 2 and will therefore extend like a strip over the top of a convexed artificial flitch when it is formed by inserting the stack of printed veneers between concavo-convex dies.
If this artificial flitch is sliced, the annual ring representing zones on both lateral sides of the artificial veneer in which the annual ring lines appear as substantially parallely extending patterns will be thicker in the summer wood tone than those in the middle part of the artificial veneer in which the annual ring lines appear as flame-shaped patterns and, particularly, as seen at a distance, a uniform feeling can be provided to the entire grain pattern of the artificial veneer.
On the other hand, in order to further promote the uniform feeling in the grain pattern, it is preferable to vary the summer wood tone thickness between the printed veneers for forming the artificial flitch.
Further in the respective foregoing embodiments, if a film material very high in parting ability is used for the plastic film of the printing ink sheet, the ink layer will be likely to peel off during the work. On the other hand, if a film low in parting ability is used, no favourable printing can be realized. Therefore, according to another aspect of the present invention, a printing ink sheet high in both of parting and printing abilities is em ployed. That is, with reference to Fig. 7, a plastic film 103 is formed by joining a polyester film layer 103a which is high in the ink depositing and parting abilities but low in tearing strength with a polypropylene film layer 1 03b high in tearing strength through such an adhesive layer as a polyethylene or urethane layer 103c.As a result of practising the respective foregoing embodiments by using such plastic film 103, printed veneers high in the ability of retaining ink layer 104 on the film and having less troubles upon peeling off the printing ink sheet could be provided.
In addition, in the respective foregoing embodiments, the ink layer on the printed veneer may happen to be seen through the spring wood tone layer of the printed veneer or another material veneer placed above the ink layer and the annual ring representing zone may not be clear enough, since the slicing thickness is made less than 1 mm. in obtaining the artificial veneers from the artificial flitch. Therefore, according to another aspect of the present invention, the annual ring representing zone can be assured to be clear enough.That is, with reference to Fig. 8, a shielding layer 1 32 is provided on the ink layer 1 24 placed on the spring wood layer 121a of a printed veneer so as to prevent the ink layer 1 24 from being seen through the spring wood layer 1 21 b of the upper positioned printed veneer. In this case, the shielding layer 1 32 is deposited on the ink layer 1 24 after the printed veneers are formed in the respective foregoing embodimets and before the st7eps of applying the adhesive and laminating the veneers to form an artificial flitch.Instead f the shielding layer 132, an adhesive or paint colored to be of the early wood tone and placed above the ink layer 1 24 or even a metallic foil adhered onto the ink layer could substantially perfectly prevent the ink layer 1 24 from being seen from the exterior.
According to the present invention, further, various modifications can be made. For example, such plastic film colored in a summer wood tone as, for example, a polyester or urethane film may be used in place of the ink layer to be applied onto the parting plastic film, as joined with the same parting plastic film so as to be transferred onto the material veneer, in forming the printed veneer. Further, the provision of the undulations or grooves to the printing veneers may be performed by means of grooves made in the pressing surfaces of the concavo-convex dies, instead of such separate step therefor by means of the tenderizer as has been disclosed.
According to the method of munufacturing artificial veneers according to the present invention as described above, the artificial veneers faithfully simulating the grain patterns that can be obtained particularly upon slicing the natural wood of needle-leaved trees can be provided, and the artificial veneers having patterns very similar to the grain patterns of high grade woods can be continuously massproduced from inexpensive tropical woods.

Claims (14)

1. A method of manufacturing artificial veneers having patterns simulated to grain patterns of such natural woods as a needleleaved tree, said method comprising the steps of preparing material veneers from natural wood cut out into slices and providing to them an early wood tone, applying an adhesive to said material veneers, preparing printing sheets by depositing a very thin synthetic resin layer having a summer wood tone on a parting plastic film, preparing printed veneers by joining and pressing the material veneer to said printing sheet with said synthetic resin layer of the printing sheet opposed to a surface having said adhesive of the material veneer and peeling the plastic film off the printing sheet, forming an artificial flitch by stacking a plurality of said printed veneers and pressing said stacked veneers with concavo-convex dies, and slicing said artificial flitch into said artificial veneers.
2. A method according to claim 1, wherein said synthetic resin layer of said printing sheet is an ink layer having said summer wood tone.
3. A method according to claim 1, wherein said synthetic resin layer of said printing sheet is a plastic film having said summer wood tone.
4. A method according to any preceding claim, wherein the step of forming said artificial flitch includes a step of combining at least one of said material veneers with each of said printed veneers before stacking the printed veneers.
5. A method according to any preceding claim, wherein undulations are provided at least to the synthetic resin layer of each printed veneer.
6. A method according to claim 5, wherein said step of forming said artificial flitch includes a step of combining at least one of said material veneers with a printed veneer provided with said undulations.
7. A method according to any preceding claim, wherein the middle part of said synthetic resin layer of said printing sheet is made thinner in said summer wood tone than both side parts.
8. A method according to claim 7, wherein said plastic film of said printing sheet comprises a first plastic film low in tearing strength and a second plastic film high in tearing strength, said first and second films being joined through an adhesive.
9. A method according to any one of claims 1 to 6, wherein said printing sheet preparing step prepares said printing sheets respectively having different summer wood tones with said synthetic resin layers respectively different in the summer wood tone.
10. A method according to claim 9, wherein said plastic film of said printing sheet is made by joining a first plastic film low in tearing strength with a second plastic film high in tearing strength through an adhesive layer.
11. A method according to any preceding claim, wherein a shielding layer is interposed on the synthetic resin layer transferred to said printed veneer.
1 2. A method according to claim 11, wherein said shielding layer is an adhesive colored in an early wood tone.
1 3. A method according to any preceding claim, wherein the artificial flitch is sliced in the flowered grain direction to form said artificial veneers.
14. A method of manufacturing artificial veneers substantially as described herein with reference to the drawings.
1 5. A method of manufacturing artificial veneers substantially as described herein with reference to the examples given in the tables.
GB08200554A 1982-01-07 1982-01-08 Method of manufacturing artificial veneers Expired GB2113604B (en)

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DE3200257A DE3200257C2 (en) 1982-01-07 1982-01-07 Process for the production of artificial veneers
GB08200554A GB2113604B (en) 1982-01-07 1982-01-08 Method of manufacturing artificial veneers

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DE3200257A DE3200257C2 (en) 1982-01-07 1982-01-07 Process for the production of artificial veneers
GB08200554A GB2113604B (en) 1982-01-07 1982-01-08 Method of manufacturing artificial veneers

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CN102152365A (en) * 2011-01-30 2011-08-17 福建省建瓯市华宇竹业有限公司 Processing technique of bamboo billet boards for bamboo floors
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CN105479559A (en) * 2016-01-16 2016-04-13 杭州富丽来装饰材料有限公司 Production technology of laminated board
WO2017137644A1 (en) * 2016-02-10 2017-08-17 Eurogroup Belcaire, S.L. Method for producing a wood laminate product and resulting product
WO2017137648A1 (en) * 2016-02-10 2017-08-17 Eurogroup Belcaire, S.L. Method for producing a laminar product and resulting product
CN111823337A (en) * 2020-08-21 2020-10-27 苏州皇家整体住宅系统有限公司 Large-section arc-shaped laminated wood splicing method
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GB1391077A (en) * 1971-07-09 1975-04-16 Aaronson Bros Ltd Methods of forming blocks of wood veneer laminations
DE3148577C2 (en) * 1981-12-08 1986-05-07 Matsushita Electric Works, Ltd., Kadoma, Osaka Process for the production of an artificial wood veneer

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EP1275481A2 (en) 2001-07-12 2003-01-15 Giovanna Senzani Method for manufacturing multi-laminar wood sheets with printed patterns
SG99405A1 (en) * 2001-07-12 2003-10-27 Giovanna Senzani Method for manufacturing multi-laminar wood sheets with printed patterns
US7108763B2 (en) 2001-07-12 2006-09-19 Giovanna Senzani Method for manufacturing multi-laminar wood sheets with printed patterns
EP1275481A3 (en) * 2001-07-12 2007-08-01 Giovanna Senzani Method for manufacturing multi-laminar wood sheets with printed patterns
EP2536542A1 (en) * 2010-02-15 2012-12-26 HD Wood Technologies Limited Method for producing a veneer
CN102152365A (en) * 2011-01-30 2011-08-17 福建省建瓯市华宇竹业有限公司 Processing technique of bamboo billet boards for bamboo floors
CN104942906A (en) * 2015-06-12 2015-09-30 柳州市骏马木业有限公司 Method for processing environment-friendly high-performance eucalyptus plywood
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US11370144B2 (en) 2019-10-08 2022-06-28 Goodrich Corporation Method and system for sequencing veneer to lumbercore
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