JP2003334802A - Decorative panel and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a decorative panel having a groove in which foreign matters such as dirt, dust or microorganism, are hard to be accumulated and from which the foreign matters are easily removed. <P>SOLUTION: The decorative panel is provided with a substrate 3 and a decorative material 8 attached to one side of this substrate 3. Additionally a groove 11 originating from the surface 9 of the decorative material up to the substrate 3 is formed, the wall face of this groove 11 contains a curved surface 12 formed on the substrate 3 side from the surface 9 of the decorative material, and a flat surface 18 extending from the curved surface 12 on the groove bottom 20. The curved surface 12 contains concave curves 13a, 13b recessed towards the substrate 3 side, and the flat surface 18 is formed to constitute an angle α of 45 degrees to a vertical plane 22. In the groove 11, after a V-shaped groove is machined, the opening side of this V-shaped groove is pressed by a rotating roll to form the curved surface 12. Then the surface 9 of the material, the curved surface 12 and the flat surface 18 on the groove are coated with a coating. <P>COPYRIGHT: (C)2004,JPO

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative board used as a building interior material such as a floor material or a wall material for a house or a building, and a method for manufacturing the same.

[0002]

2. Description of the Related Art As a conventional decorative plate, for example, a plate in which a decorative veneer is attached to a substrate is provided with a groove reaching the substrate on the decorative veneer side. Furthermore, a bulge roundness is provided on the edge of the groove, the veneer for makeup is pushed into the groove along the roundness of the edge of the groove, and the veneer of the groove is partially covered with the veneer for makeup. Some are known (JP 2001
No. 207629).

On the other hand, a decorative plate having a decorative veneer adhered to a substrate extends along the upper edge of the decorative veneer from the decorative veneer to the upper layer of the substrate, and its vertical cross-sectional shape projects outward. It is known that it is cut to have a curved shape (Japanese Patent Laid-Open No. 7-88992).

[0004]

However, in any of the above decorative plates, the width of the lower part of the groove is made smaller than the opening width of the groove in order to prevent the base material of the substrate in the groove from being exposed as much as possible. When the width of the lower part of the groove is made smaller than the opening width, the groove width is narrow, and thus foreign matters such as dust and dirt are likely to be accumulated. In addition, it becomes a home to mites, bacteria, and other microorganisms. As described above, in the conventional decorative plate, since the width of the lower portion of the groove is smaller than the opening width of the groove, foreign matters such as dust, dust, and microorganisms easily accumulate in the groove and are difficult to remove. If foreign matter collects in the grooves, it will impair the appearance and is not good for hygiene.

An object of the present invention is to prevent foreign matter from accumulating in the groove and to be easily removed.

[0006]

In order to solve the above problems, the present invention comprises a substrate and a decorative material attached to one side of the substrate. Further, a groove extending from the surface of the decorative material to the substrate is formed, and the wall surface of the groove has a curved surface formed from the surface of the decorative material to the substrate side and a flat surface extending from the curved surface to the bottom of the groove. The curved surface includes a concave curved surface that is concave toward the substrate side, and the flat surface is formed so that the angle formed by the vertical surface exceeds 30 degrees.

By doing so, the plane is formed so that the angle formed by the vertical plane exceeds 30 degrees, so the angle formed by the two planes on both sides of the groove exceeds 60 degrees.
The lower part of the groove has a V-shape with a large opening. Further, a curved surface extends from each end of both planes forming this V-shape. This curved surface includes a concave curved surface that is concave toward the substrate side. As a result, the groove has an opening width larger than the opening width formed by the virtual extension surface of the plane forming the V-shape at the surface position of the decorative material. Since the groove opens greatly,
Dust, dust or foreign matter such as mites, bacteria and other microorganisms is hard to collect (hard to accumulate) and is easily removed by cleaning. Therefore it is hygienic.

Further, since the curved surface is provided on the opening side of the groove and includes a concave curved surface which is concave toward the substrate side, the light reflecting direction of the concave curved surface differs from that of the other portions. Since the light reflecting direction of the concave curved surface is different from that of the other portions, the groove can be emphasized and a high-class feeling can be obtained. Further, the concave curved surface prevents the opening width from being unnecessarily widened even when the V-shaped groove below the groove is largely opened, and has an appropriate groove opening width. Further, when the present decorative board is used as a floor board, the concave curved surface of the groove provides an appropriate anti-slip property and provides a comfortable walking feeling.

Further, it is preferable that the surface of the decorative material and the surface of the groove are coated. By coating the surface of the decorative material and the groove, the base material of the substrate in the groove is covered, the texture of the surface of the decorative material and the surface of the groove are unified, and the value as a decorative plate can be improved. .

In the decorative board of the present invention, after the decorative material is adhered to one side of the substrate, a V-shaped groove extending from the surface of the decorative material to the substrate is formed. Is formed so that the angle between the wall surface of the and the vertical surface exceeds 30 degrees. Next, the opening side of the groove is pressed to provide a concave curved surface that is recessed toward the substrate side, whereby the decorative plate of the present invention is manufactured. According to this manufacturing method, it is possible to form grooves without fluffing or whipping, and it is possible to improve the workability.

Next, each requirement constituting the present invention will be described in more detail. The substrate has a thickness of about 2.0 to 12 mm, a laminated board, a laminated board, a single board laminated material (LVL), a particle board or a soft fiber board (insulation board), a medium fiber board (MDF), a hard fiber board ( Hardboard) or other fiber boards, or wood cement boards obtained by crushing wood into cement, inorganic impregnated wood boards, calcium silicate boards, gypsum boards, gypsum slag boards, calcium carbonate boards, glass fiber boards, and other inorganic boards. Etc. can be used.

The decorative material is attached to the surface on one side of the substrate. For example, natural veneer obtained by cutting natural wood, artificial veneer artificially produced, non-woven fabric, paper, synthetic resin, etc. It can be used and may be printed with various wood patterns or other patterns. The thickness of the decorative material is, for example, about 0.05 to 1 mm. The decorative material may be attached to the surface on one side of the substrate via an adhesive. in this case,
As the adhesive, vinyl acetate resin-based, ethylene vinyl acetate resin-based, urea resin-based, melamine resin-based, phenol resin-based, water-based vinyl urethane resin-based, rubber-based, etc. are appropriately selected in consideration of the application, use conditions and the like. .

The grooves formed on the decorative plate are symmetrical with respect to the vertical plane. The lower part of the groove is V-shaped in cross section, and the two flat surfaces of the lower walls of the V-shaped cross section abut at the bottom of the groove. The angle between the vertical plane and the bottom plane of the groove is 30
It is formed so as to exceed 35 degrees, and preferably 35 to 50 degrees (the angle between both wall surfaces of the V-shaped groove is 70 to 100 degrees). The angle between the vertical plane and the lower plane of the groove is 30.
If it is less than 100 degrees, foreign matter is likely to collect in the groove. The larger the angle formed between the vertical surface and the lower plane of the groove, the less the accumulation of foreign matter, but the less accentuated as the groove of the decorative plate, the poorer the design. The V-shaped groove is preferably formed by cutting, embossing, or a combination of both. For these processes, for example, a cutting machine or a press machine for embossing is used.

The position of the groove provided on the decorative plate is not particularly limited, but is appropriately provided depending on the use of the decorative plate. For example, when a decorative board is used as a floor board, one or a plurality of parallel grooves are provided in the longitudinal direction (or one direction) at an appropriate interval. Furthermore, one or a plurality of grooves may be provided at appropriate intervals in the short-side direction (ordinarily orthogonal) intersecting with the longitudinal direction (or the other direction intersecting with one direction).

The opening side of the groove is a curved surface, and this curved surface includes at least one concave curved surface. The concave curved surface is recessed toward the substrate side. The curved surface may be only one or more concave curved surfaces, or may be formed by appropriately combining concave curved surfaces and convex curved surfaces.
The type of curved surface is, for example, an arc, an ellipse, a parabola, a part of another curve, or a combination thereof, and is appropriately selected.

Further, the connecting portion between the concave curved surfaces or the convex curved surfaces, or the connecting portion between the concave curved surface or the convex curved surface and the straight line portion may be flexibly connected without rounding or chamfering, but the radius of curvature. It may be rounded as a small convex curved surface for smooth connection, or chamfered. The curved surface is formed by pressing the opening edge or opening side of the groove with a fixed mold or a rotating roll. In this case, it is preferable that the pressing surface of the mold or the rotating roll has a convex shape. A concave curved surface is easily formed by making the pressing surface of the mold or the rotating roll convex.

Furthermore, the curved surface may be processed in several stages. In the initial stage, a die or a rotating roll having a pressing surface with a small radius of curvature is pressed, and in later stages, a die or a rotating roll having a pressing surface with a large radius of curvature is sequentially used. When the opening edge or the opening side of the V-shaped groove is pressed by the mold or rotating roll, the pressing force is
In the case of a concave curved surface, pressure is applied to the extent that the decorative material or the substrate is concave. In the case of a convex curved surface, the pressure is applied to the extent that the decorative material or the substrate is not depressed. The wall surface of the groove of the present invention is formed by a curved surface and a flat surface, and has a decorative material exposed surface corresponding to the thickness of the decorative material and a substrate exposed surface on which the substrate is exposed.

The surface of the decorative material and the surface of the groove are coated. In this case, the coating material is, for example, acrylic urethane, polyester urethane, polyurethane, vinyl chloride-vinyl acetate copolymer, ethylene-vinyl acetate copolymer. Resins such as are used, and may be appropriately selected in consideration of the application of the decorative board, usage conditions, and the like.

[0019]

BEST MODE FOR CARRYING OUT THE INVENTION Embodiments of a decorative board and a method for manufacturing the same according to the present invention will be described below in detail with reference to the drawings. 1 to 4, the same or equivalent parts are designated by the same reference numerals.

FIG. 1 is a cross-sectional view of essential parts showing an embodiment of a decorative board according to the present invention. The decorative board 1 of this embodiment is used as a flooring material for a house or the like, and includes a substrate 3 and a decorative material 8 attached to one side of the substrate 3. Further, a groove 11 extending from the surface 9 of the decorative material to the substrate 3 is formed. The groove 11 is bilaterally symmetrical with respect to the central vertical surface 22. The wall surface of the groove 11 is formed by the curved surface 12 and the flat surface 18.

The curved surface 12 includes concave curved surfaces 13a and 13b which are recessed from the surface 9 of the decorative material toward the substrate 3 side. The flat surface 18 extends from the end 15 on the substrate side of the curved surface 12 to the bottom 20 of the groove, and
It is formed so that the angle α with 2 is 45 degrees. Therefore, the angle β sandwiched between the two flat surfaces 18 on both lower walls of the groove is 90 degrees.

Further, in the present embodiment, the position of the curved surface 12 on the substrate side 15 is located on the substrate side with respect to the position corresponding to the thickness of the decorative material 8, but it may not be located on the substrate side ( It may be located on the decorative material 8). Furthermore, although the curved board-side end 15, the decorative material-side end 16 and the intermediate end 17 are not smoothly connected to each other, they may be rounded and smoothly connected by a convex curved surface or an arc surface having a small radius of curvature. , You may add a chamfer. The curved surface 12 is
It is formed so as not to project outward from the virtual extension surface 19 of the flat surface 18. The wall surface of the groove 11 has a decorative material exposed surface 10 corresponding to the thickness T of the decorative material and a substrate exposed surface 7 corresponding to the substrate 3. Incidentally, the cosmetic material exposed surface 10 and the substrate exposed surface 7 do not necessarily correspond to the curved surface 12 and the flat surface 18, respectively.

In the decorative board 1 of this embodiment, the surface of the decorative material 9 and the surfaces of the grooves 11 are coated. Also,
The position of the groove 11 provided on the decorative plate 1 is appropriately provided according to the conditions under which the floor material is used. For example, a plurality of grooves 11 extending in the longitudinal direction of the floor material are provided in parallel at appropriate intervals. Furthermore, the grooves 11 extending in the lateral direction orthogonal to the longitudinal direction may be provided at appropriate intervals.

The substrate 3 is, for example, plywood or laminated wood having a thickness of 12 mm. The decorative material 8 is attached to the surface on one side of the substrate 3. As the decorative material 8, for example, a natural veneer obtained by cutting natural wood, an artificial veneer manufactured artificially, or the like is used. Various wood grain patterns and other patterns are formed on the decorative material 8. The thickness of the decorative material 8 is, for example, about 0.1 to 0.5 mm.

2A and 2B show a method of manufacturing the decorative plate 1 shown in FIG. 1, in which FIG. 2A is a sectional view of a main part of the substrate 3, and FIG.
A cross-sectional view of a main part in which a decorative material 8 is attached to the decorative plate 1, (C) is a decorative plate 1
It is a principal part sectional view in which the V-shaped groove | channel 11a was formed in. On one side of the substrate 3 as shown in FIG.
As shown in, the decorative material 8 is attached using an adhesive such as vinyl acetate resin. Next, as shown in FIG. 2C, a V-shaped groove 11a extending from the surface 9 of the decorative material to the substrate 3 is cut. At this time, the plane 18 of the groove and the vertical surface 22 form an angle of 45 degrees. V
The V-shaped groove 11a is formed by using a cutting machine such as a moulder.

FIG. 3 shows a method for manufacturing the decorative plate 1 following FIG. 2. (D) is a sectional view of a main part where the opening edge 21 is pressed by the first roll 23, and (E) is the second roll. 29 is a cross-sectional view of the main part where the opening side is further pressed by 29, (F) is the decorative plate 1 and the groove 1
1 is a cross-sectional view of a main part in which 1 is formed. As shown in FIG. 3D, the processing of the curved surface 12 is performed by pressing the roll surface of the first roll 23 against the opening edge 21 of the V-shaped groove 11a and pressing it. This is the indented one
A concave curved surface 13b which is a secondary arc surface is formed. Groove 11a
After the concave curved surface 13b is formed on the concave surface 13b, the roll surface of the second roll 29 is pressed against the opening edge of the concave curved surface 13b as shown in FIG. 3 (E), and as shown in FIG. 3 (F). The concave curved surface 13a which is the final secondary arc surface is formed, and the groove 11 is finally obtained.

In FIGS. 3D and 3E, the first roll 23 and the second roll 29 are respectively the shaft 2 thereof.
While rotating around 6, 33, it is pressed against the edge of the V-shaped groove 11a or the edge formed thereafter. In addition, the roll surfaces of the first roll 23 and the second roll 29 have convex swelled surfaces, and the radius of curvature R1 of the roll surface of the first roll 23 is the second roll 29. Is smaller than the radius of curvature R2 of the roll surface. In the present embodiment, the first
However, the present invention is not limited to this, and may be formed by using three or more rotating rolls. In this case, the radius of curvature of the roll surface (R
1, R2 ...) are made larger as used in the subsequent process.

The decorative plate 1 of this embodiment described above operates as follows. That is, in FIG. 1, the wall surface of the groove 11 is the curved surface 1 formed on the substrate 3 side from the surface 9 of the decorative material.
2 and a flat surface 18 extending from the curved surface 12 to the bottom 20 of the groove
Have and. Since the plane 18 is formed at an angle α with the vertical plane 22 of 45 degrees, the angle β between the two planes of the lower wall surfaces of the groove 11 is naturally 90 degrees, and the bottom of the groove is largely opened.

Further, the flat surface 1 forming the V-shaped groove
A curved surface 12 extends from both ends of 8 to the surface 9 of the decorative material.
Since the curved surface 12 has concave curved surfaces 13a and 13b that are concave toward the substrate 3, the groove 11 is the flat surface 1 forming the V-shaped groove.
The virtual extension surface 19 of 8 has a larger opening width than the opening width formed at the position of the surface 9 of the decorative material. Since the groove 11 is thus opened wide, foreign matters such as dust, dust, mites, bacteria, and other microorganisms are hard to collect. Even if foreign matter collects in the groove 11, the groove 11
Has a large opening width and the wall surface forming the V-shape at the bottom of the groove is wide open, so that it can be removed by cleaning. Therefore it is hygienic.

Further, since the curved surface 12 includes the concave curved surfaces 13a and 13b, the reflection of light at this portion is different from the other portions, so that the groove 11 is emphasized and a high-class feeling can be obtained. Further, since the groove 11 includes the concave curved surfaces 13a and 13b, the V at the bottom of the groove is
Even if the character-shaped groove 11a (shown in FIGS. 2 and 3) is largely opened, the opening width of the groove 11 is not unnecessarily widened.

Further, the surface of the decorative material 8, the curved surface 12 and the flat surface 18 of the groove are coated to cover the base material of the decorative material 8 and the substrate 3, so that the surface of the decorative material 8 and the surface in the groove 11 are covered. The texture is unified and a high-class appearance is obtained.
Further, if the decorative board 1 is used as a floor board, the concave curved surface 13
A and 13b serve as a suitable anti-slip and become a floor board with a good walk feeling.

FIG. 4 shows another embodiment of the decorative plate according to the present invention. In FIG. 4A, the curved surface 12 is the concave curved surface 1 from the decorative material 8 side.
3a, a cross-sectional view of a main part of the decorative plate 1 formed in the order of the convex curved surface 14, (B) is a cross-sectional view of the main part of the decorative plate in which the curved surface 12 is formed in the order of the convex curved surface 14 and the concave curved surface 13b from the decorative material 8 side. Is. The decorative plate 1 shown in FIG. 4 (A) differs from the decorative plate shown in FIGS. 1 to 3 in that the curved surface 12 of the groove is a concave curved surface 1.
3a and the convex curved surface 14. Also, FIG.
The decorative plate 1 shown in (B) is that the curved surface 12 is formed by the convex curved surface 14 and the concave curved surface 13b.

As described above, the curved surface 12 of the groove may be a concave curved surface or a convex curved surface. In addition, the cosmetic material side end 16 of the curved surface 12 of FIG. 4 (A) and the substrate side end 15 of the curved surface 12 of FIG. 4 (B).
Is formed on a convex curved surface or an arc surface having a small radius of curvature so as to be rounded or chamfered. FIG. 4 (A),
In the decorative plate 1 shown in (B), by changing the shape of the curved surface 12 of the groove, the reflection of light in this portion differs from that in the other portions, so that the groove is emphasized and a high-class appearance is obtained. To be Further, similarly to the groove of the decorative plate shown in FIGS. 1 to 3, since the curved surface 12 includes the concave curved surface 13a or the concave curved surface 13b, even if the V-shaped groove below the groove is largely opened, the groove 11 Does not unnecessarily widen. Note that FIG.
The structure and operation of the other parts of (A) and (B) are shown in FIGS.
Since it is the same as the case of the decorative plate 1 listed in No. 3, its description is omitted.

Although the present invention has been described in detail with reference to the illustrated embodiments, it is not intended to limit the present invention to those embodiments only, and various modifications can be made without departing from the spirit of the present invention. In addition, it goes without saying that various modifications can be made.

[0035]

EFFECTS OF THE INVENTION According to the present invention, foreign matters such as dust, dust, and microorganisms are less likely to accumulate in the groove and are easily removed.

[Brief description of drawings]

FIG. 1 is a cross-sectional view of essential parts showing an embodiment of a decorative board according to the present invention.

FIG. 2 shows a method for manufacturing the decorative board 1 shown in FIG.
(A) is a cross-sectional view of the main part of the substrate, (B) is a cross-sectional view of the main part in which a decorative material is attached to the substrate, and (C) is a cross-sectional view of the main part in which a V-shaped groove is formed on the decorative plate. is there.

FIG. 3 shows a method for manufacturing a decorative plate following FIG. 2, and (D) is a cross-sectional view of essential parts in a state where an opening edge is pressed by a first roll,
(E) is a cross-sectional view of an essential part in a state where the opening side is further pressed by a second roll, and (F) is a cross-sectional view of an essential part in which a groove is formed on a decorative plate.

FIG. 4 shows another embodiment of a decorative board according to the present invention,
(A) is a cross-sectional view of a main part of a decorative plate having a curved surface formed in this order from a decorative material side to a concave curved surface, and (B) is a decorative plate having a curved surface formed in order from a decorative material side to a convex curved surface and a concave curved surface. FIG.

[Explanation of symbols]

1 Veneer 3 substrates 8 Cosmetics 9 surface 11 grooves 12 curved surface 13a, 13b concave curved surface 14 Convex curved surface 18 plane 20 bottom 22 Vertical plane Thickness of decorative material

Claims (3)

[Claims] 1. A substrate, and a decorative material attached to one side of the substrate, a groove extending from the surface of the decorative material to the substrate is formed, and the wall surface of the groove is the surface of the decorative material. Has a curved surface formed on the substrate side from the curved surface, and a flat surface extending from the curved surface to the bottom of the groove, the curved surface includes a concave curved surface recessed toward the substrate side, and the flat surface forms an angle with a vertical surface. A decorative plate that is formed to exceed 30 degrees. 2. The decorative plate according to claim 1, wherein the surface of the decorative material and the surfaces of the grooves are coated. 3. When a V-shaped groove extending from the surface of the decorative material to the substrate is formed after a decorative material is attached to one side of the substrate, a surface perpendicular to the wall surface of the groove is formed. And a concave curved surface that is concave toward the substrate side when the opening side of the groove is pressed, and the concave curved surface is provided on the substrate side.