JP2006116878A - Grooved decorative panel having fine appearance and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a groove-provided decorative panel excellent in aesthetic nature, in which fluffs and fine splits, which sometimes generate in the open edges of grooves at the time of grooving, are eliminated by eliminating with heat, without charging the base panel with a great burden, angles of the edges of the grooves (edge portions) produced in the decorative panel surface. <P>SOLUTION: The grooved-provided decorative panel and its manufacturing method are provided. The grooved decorative panel is that which is equipped with a base panel and a decorative material having a thermoplastic resin layer glued to one side of the base panel and which has the grooves formed so as to extend from the surface of the decorative material to the base panel. The grooves are characterized in that the angles of the open edges are eliminated by melting by heat the thermoplastic resin layer of the decorative material which stretches in the open edges. The elimination of the angles of the open edges is to form roundness of such an extent as to make the fluffs and fine splits disappear. The grooves are the ones having an almost V-shaped cross-section or a nearly pentagonal cross-section, and the angles of their open edges are eliminated. The decorative material is the one whose surface is applied with a radiation curable coating material before or after the grooves are formed, and cured. <P>COPYRIGHT: (C)2006,JPO&NCIPI

Description

  TECHNICAL FIELD The present invention relates to a method for producing a decorative plate having a groove used as a building interior material such as a flooring or wall material of a house or a building, and more specifically, a grooved decorative plate excellent in aesthetics and It relates to the manufacturing method.

In a decorative plywood formed by attaching a decorative material to the surface of a substrate, a technique is used in which the design is improved by forming a large number of parallel thin grooves on the surface of the substrate. Such a grooved decorative plate has conventionally been manufactured by cutting grooves on the surface most commonly by cutting. However, in this case, since there are difficulties in finishing the inner surface of the groove after cutting, various proposals have recently been made regarding the work of cutting the corner of the groove edge (R machining) after grooving the decorative plate. Yes.
This prior proposal technique is generally press molding using a die provided with R. For example, after applying a decorative material on the upper surface of a flat substrate and making a cut along the grooved scheduled position on the surface of the resulting decorative board, a groove having a substantially V-shaped cross section is formed at the corresponding position of the cut. A method for press-molding by pressing with a stamping roll having a convex part (Patent Document 1), a groove reaching the substrate is provided on the decorative material side, and further, a bulging round is provided at the edge of the groove. There has been proposed a method (Patent Document 2) that pushes into the groove along the edge of the groove and partially covers the groove substrate with a decorative material.
JP-A-2-188203 JP 2001-207629 A

The press molding after grooving the decorative plate described above is a problem that sufficient molding cannot be performed unless sufficient pressure is applied depending on the material of the substrate, and when excessive pressure is applied to the substrate. There is a problem that cracks occur. For example, a groove whose surface is cut by cutting is expanded by press molding, and the cut portion of the decorative sheet is widened and both side portions thereof are pushed into the groove, the substrate structure is consolidated and the surface becomes smooth. When the round surface processing is performed as described above, there is a problem that a large load is applied to the substrate due to the applied pressure.
The present invention eliminates the burden on the substrate without fouling, and fluffing and scoring that may occur at the opening edge of the groove during the cutting of the groove, and the edge of the groove appearing on the decorative board surface (edge part) by heat Glossy decorative board with excellent aesthetics that provides a comfortable walking property and design (such as improved decorativeness of the flooring) that has been eliminated, and has a grooving treatment on the decorative board. Then, it aims at providing the manufacturing method of the said decorative sheet with a groove | channel characterized by the groove | channel processing process which lose | eliminates the fuzz and the crease which does not put a big burden on a board | substrate.

Also, depending on the cross-sectional shape of the groove to be formed, there is a problem that the width of the groove is not constant due to the cutter swinging up and down, left and right, or when the decorative material has a colored opaque layer, the decorative material of the groove cross section by cutting There is a problem that the field of view extends to the exposed surface of the decorative material corresponding to the thickness of the material, and the colored opaque layer becomes visible from the outside, which makes the appearance worse.
The present invention is an architecture in which a groove is formed such that the cutter does not shake up and down, left and right, or the colored opaque layer is not visible from the outside, and is rounded to such an extent that fuzz and scalp disappear. An object of the present invention is to provide a grooved decorative board having a good gait and design (such as an improvement in the decorativeness of the flooring) and a manufacturing method thereof.

The gist of the present invention is the grooved decorative plate of the following (1) to (7).
(1) A decorative plate with a groove, comprising a substrate and a decorative material having a thermoplastic resin layer adhered to one side of the substrate, wherein a groove extending from the surface of the decorative material to the substrate is formed, A grooved decorative board, wherein the groove is formed by melting a thermoplastic resin layer of a decorative material extending to the opening edge by heat and eliminating the corner of the opening edge.
(2) The grooved decorative board according to (1), characterized in that the disappearance of the corners of the opening edge is rounded to such an extent that fuzz and scalp disappear.
(3) The grooved decorative board according to (1) or (2), wherein the groove is a groove having a substantially V-shaped cross section, and the corner of the opening edge is eliminated.
(4) The groove is formed with a lower width smaller than the opening width, and the opening edge is constituted by a corner that is substantially perpendicular to the surface of the decorative material, and the corner disappears. The grooved decorative board according to claim 1 or 2, wherein the decorative board is a groove.
(5) The groove has a wall surface constituted by a vertical plane formed on the substrate side from the surface of the decorative material and a plane extending from the vertical plane to the bottom of the groove in a substantially V shape. And the decorative board with a groove | channel of (1), (2) or (4) which lose | disappeared the corner | angular of the opening edge.
(6) The grooved decorative board according to (5), wherein the groove is a groove having a substantially pentagonal cross section, and the corner of the opening edge is eliminated.
(7) Any one of (1) to (6), wherein the decorative material is formed by applying and curing an electron beam curable paint before or after forming the groove on the surface. Grooved decorative board.

The gist of the present invention is the following method for producing a grooved decorative board (8) to (10).
(8) The groove from the surface of the decorative material having the thermoplastic resin layer adhered to the substrate and one side of the substrate to the substrate is cut, heated from the surface of the decorative plate, and the thermoplastic near the opening edge of the groove A method for producing a grooved decorative board, comprising melting a resin layer and eliminating corners of the opening edge of the groove.
(9) The method for producing a grooved decorative board according to (8), wherein the corners of the opening edge are made to have a roundness to the extent that the fuzz and the scissors disappear.
(10) The method for producing a grooved decorative board according to (8) or (9), including a step of applying and curing an ionizing radiation curable paint before or after forming a groove on the surface of the decorative material. .
(11) Heat is applied using a heat roll, and the heat roll has a convex portion wider than the groove corresponding to the position of the groove, and the tip portion does not reach the bottom of the groove ( 8) A method for producing a grooved decorative board according to (9) or (10).

The present invention provides a comfortable gait and design (such as improved decorativeness of flooring) as a flooring material for building, in which a groove that eliminates fluffing and scalp is formed without imposing a heavy burden on the substrate. It is possible to provide a decorative sheet with a groove that is superior to the above. In addition, as a flooring material for construction, the groove does not sway up and down, left and right at the time of cutting, or the colored opaque layer is not visible from the outside, and the fluff and fluff disappeared It is possible to provide a grooved decorative board excellent in aesthetics that can provide comfortable walking properties and design properties (improvement of decorativeness of floor materials, etc.).
More specifically, by making the cross-sectional shape of the groove substantially pentagonal (home base type) (see FIGS. 3 and 4), it is possible to minimize loss of uniformity of the groove width due to blurring during the groove cutting process. The limit. By making the shape of the groove substantially pentagonal, the depth of the groove can be widened, so that a sense of depth and emphasis can be obtained, and the design is excellent.
In addition, the decorative plate is made of thermoplastic resin, and only the thermoplastic resin at the corners (edges) of the grooves, especially the corners (edges) at right angles, is melted. (R processing) can be automated.
In addition, when the decorative material has a colored opaque layer, the colored opaque layer becomes perpendicular to the floor surface by making the corners of the groove approximately perpendicular to the floor surface, and the visual field is difficult to reach to the inside of the groove. It became possible to provide a decorative board flooring having an excellent groove.

  Further, in the present invention, after cutting the groove on the surface of the decorative plate by cutting, the operation of dropping the corner of the groove edge (R processing) applies heat to the surface of the decorative plate, and the thermoplasticity of the opening edge of the groove Manufacture of grooved decorative board characterized by a groove processing process that eliminates the need to apply strong pressure on the substrate as in the past by melting at the resin layer and rounding to a degree that eliminates fuzz and scalp A method can be provided. Groove machining that does not cause the cutter to shake up and down, left and right during groove cutting, or that the colored opaque layer is not visible from the outside in the cross section of the groove, and that the fluffing and flaking are eliminated. It is possible to provide a method for producing a grooved decorative board characterized by a process.

The decorative board of the present invention comprises a substrate and a decorative material having a thermoplastic resin layer attached to one side of the substrate, and a number of grooves extending from the surface of the decorative material to the substrate are formed by cutting. A grooved decorative board. The cut grooves are characterized in that the corners of the opening edges (edge portions appearing on the surface of the decorative plate) are eliminated by melting with heat and rounded. The thermoplastic resin layer of the decorative material extending to the opening edge is melted by heat, and the corners of the opening edge disappear together with the fluff and the scalp. The disappearance of the corners of the opening edge is to give the roundness to such an extent that the fuzz and the scissors disappear.
Substrates are suitable for flooring, such as plywood, laminated wood, single-layer laminate (LVL), particle board or soft fiber board (insulation board), medium fiber board (MDF), hard fiber board (hard board) Such as fiber boards, or wood cement boards made of finely ground wood and cemented, mineral-impregnated wood boards, calcium silicate boards, gypsum boards, gypsum slag boards, calcium carbonate boards, glass fiber boards, etc. can do.

The decorative material is attached to the surface on one side of the substrate, and is characterized by using a decorative material having a thermoplastic resin layer. Various wood grain patterns and other patterns may be printed. The thickness of the decorative material is, for example, about 0.05 to 1 mm. As a decorative material having a thermoplastic resin layer, for example, a material provided with a colored opaque layer on the bonding surface side with a substrate, a printed layer on the upper side, and a transparent thermoplastic resin layer is preferably used.
The colored opaque layer is preferably made of a polyolefin resin mixed with a pigment, and a polypropylene resin for a decorative sheet that is particularly excellent in adhesiveness to an adhesive layer or a printed layer is exemplified. There are no particular restrictions on the type of pigment to be included. For example, it is possible to impart concealment by blending titanium oxide as a white pigment, or concealment by blending carbon black as a black pigment. Furthermore, the desired color tone and density can be concealed by blending a white pigment and another colored pigment.
The transparent thermoplastic resin layer is a transparent polymer layer such as polyolefin, and for example, polypropylene is used.

  The decorative material may be attached to the surface on one side of the substrate via an adhesive. In this case, as an adhesive, the vinyl acetate resin system, ethylene vinyl acetate resin system, urea resin system, melamine resin system, phenol resin system, aqueous vinyl urethane resin system, rubber system, etc. select.

  It is desirable that the decorative material is obtained by applying and curing an ionizing radiation curable paint on the surface of the decorative material before or after forming the grooves. The ionizing radiation curable coating is a coating that can be cured by irradiating the coating film with ionizing radiation such as an electron beam, X-rays, and ultraviolet rays, and is commercially available. For example, acrylic urethane, polyester urethane, polyurethane, vinyl chloride-vinyl acetate copolymer, ethylene-vinyl acetate copolymer, and other resins can be used. good.

As an example of the decorative material, a colored opaque layer is provided on the bonding surface side with the substrate, a printed layer is further provided thereon, and a transparent thermoplastic resin layer is provided, and the total thickness is 0.05 to 1 mm (50 to 1000 μm). ). The surface of the decorative material may be painted and cured with an EB paint (electron beam curable paint, eg, acrylic), in which case the thickness is about 20 μm.
When the specific structural example of a decorative material is shown, a thermoplastic resin layer is transparent polymer layers, such as polyolefin, for example, a polypropylene is used and thickness is about 60-100 micrometers. Gravure printing is disposed under the thermoplastic resin layer. Furthermore, a layer having a thickness of about 50 to 100 μm made of polyolefin and titanium oxide, for example, is provided as a colored opaque layer (concealing layer) for clearly showing gravure printing underneath (on the side to be bonded to the substrate). Further, a backer sheet made of a polyester resin of about 350 to 450 μm may be laminated under this (colored opaque layer), and this may be included as a cosmetic material.
Even in the R processing by the hot roll, the layer in which the EB coating is cured does not melt, so it remains coated on the melted and rounded polyolefin layer.

  The position of the groove provided in the decorative plate by cutting 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 grooves parallel to each other in the longitudinal direction (or one direction) are provided by cutting. Further, one or a plurality of grooves may be provided at an appropriate interval in the short direction (usually orthogonal) intersecting with the longitudinal direction (or the other direction intersecting one direction).

  The depth at which the grooving cutter is inserted varies depending on the thickness of the substrate and the decorative material, but is usually set in the range of 0.5 to 3 mm.

The cross-sectional shape of the groove is not particularly limited as long as it can be cut by cutting. A groove having a substantially V-shaped cross section (FIGS. 1 and 2), the width of the lower part being smaller than the opening width, and the opening edge of which is a groove formed at an angle substantially perpendicular to the surface of the decorative material, preferably A groove whose wall surface is constituted by a vertical plane formed on the substrate side from the surface of the decorative material and a plane extending from the vertical plane to the bottom of the groove in a substantially V shape, more specifically, a cross section A substantially pentagonal groove (FIGS. 3 and 4) is illustrated.
The groove is formed by melting the thermoplastic resin layer of the decorative material extending to the opening edge with heat, and disappearing the corner of the opening edge together with fluffing and flaking. The disappearance of the corners of the opening edge is to give a roundness to such an extent that fuzz and scalp disappear by only applying heat.

  For example, a groove having a substantially V-shaped cross section is formed by cutting (see FIGS. 1 and 2), and thereafter, a process for eliminating the corners of the groove edge 31 by heat is performed. The groove having a V-shaped cross section has a decorative material exposed surface corresponding to the thickness of the decorative material on the wall surface of the groove, so that the visual field and the colored opaque layer (B) can be seen from the outside to the inside of the groove. It is necessary to devise the color tone of the colored opaque layer (B) so that the appearance does not deteriorate.

  2 and 4 are image diagrams of a grooving (grooving) process according to the present invention. The present invention is characterized in that the roundness formed on the opening edge of the groove is not the shape of the groove formed on the decorative plate, but the roundness formed by melting the thermoplastic resin layer in the vicinity of the opening edge of the groove. In order to heat from the surface of the decorative plate, melt the thermoplastic resin layer near the opening edge of the groove, and round the opening edge of the groove, the groove shape may be V-shaped as shown in FIG. Although the width of the lower part is formed smaller than the opening width, the opening edge is configured with an angle that is substantially perpendicular to the surface of the decorative material, more specifically, from the surface of the decorative material to the substrate side. A wall having a vertical plane formed and a plane extending in a substantially V shape from the vertical plane to the bottom of the groove, preferably a substantially pentagonal cross section as shown in FIG. The shape is more advantageous because the corners are easier to melt.

FIG. 3 is a cross-sectional view of an essential part showing a preferred embodiment of a decorative board according to the present invention. The decorative board 1 of the present embodiment is used as a flooring material for a house or the like, and includes a substrate (A) and a decorative material [(B) + (C) attached to one side of the substrate (A). ] Is provided. Further, a groove from the surface of the decorative material to the substrate (A) is formed by cutting. The groove has a lower width that is smaller than the opening width, and the opening edge has a substantially pentagonal cross section (home base shape) formed by an angle that is substantially perpendicular to the surface of the decorative material. . The wall surface of the groove is composed of a vertical plane formed on the substrate side from the surface of the decorative material and a plane extending from the vertical plane to the bottom of the groove in a substantially V shape, It has a decorative material exposed surface corresponding to the thickness of [(B) + (C)] and a substrate exposed surface from which the substrate (A) is exposed. Incidentally, the decorative material exposed surface and the substrate exposed surface do not necessarily correspond to the vertical plane and the plane extending in a substantially V shape, for example, the vertical plane is a position where the substrate (A) is exposed. May be formed. If the exposed surface of the decorative material corresponding to the thickness of the decorative material [(B) + (C)] is included in the vertical plane of the groove, the colored opaque layer becomes perpendicular to the floor surface, and the field of view extends to the inside of the groove. It becomes difficult and it becomes a decorative board having grooves that are excellent in appearance.
In addition, when the cross section is a substantially pentagonal shape (home base type), as shown in FIG. 4, the blade portion of the grooving cutter enters into the depth of the groove, so that the lateral deflection of the cutter during groove formation is minimized. be able to.

As shown in FIG. 5, after the grooving step, an operation (R processing) for cornering the edge of the groove, which is a feature of the present invention, is performed by, for example, applying a hot roll 41. FIG. 5 shows a state in which R processing is performed by a hot roll. The heat roll 41 is preferably provided with a plurality of convex portions wider than the grooves corresponding to the positions of the groove forming portions. The heating temperature of the hot roll is preferably around the melting point of the thermoplastic resin layer (C). For example, in the case of polypropylene, it is heated to 80 to 170 ° C. and used. At this time, since the groove edge 32 formed by the thermoplastic resin layer (C) is melted and rounded by heat, it is not necessary to apply a large pressure unlike the conventional press formation.
A hot roll 41 having a convex portion shown in FIG. 5 is rotated while being applied to the groove edge 32. When the convex portion of the heated heat roll 41 hits the groove edge 32, the corner is taken and rounded. After the edge chamfering (disappearance of the edge), the groove is painted as necessary. In this embodiment, an acrylic electron beam curable paint (acrylic urethane) is used, but the present invention is not limited to this.

It is explanatory drawing of the V-shaped groove | channel of this invention. It is explanatory drawing of the formation process of the V-shaped groove | channel of this invention. It is explanatory drawing of the substantially pentagonal groove | channel of this invention. It is explanatory drawing of the formation process of the substantially pentagonal groove | channel of this invention. It is explanatory drawing of the R process process of this invention.

Explanation of symbols

21, 22 Groove cutter 31, 32 Groove edge 33, 34 Colored opaque layer exposed portion 41 Heat roll

Claims (11)

  A decorative plate with a groove comprising a substrate and a decorative material having a thermoplastic resin layer attached to one side of the substrate, wherein a groove extending from the surface of the decorative material to the substrate is formed, A grooved decorative board, characterized in that a thermoplastic resin layer of a decorative material extending to the opening edge is melted by heat so that corners of the opening edge disappear.   2. The grooved decorative board according to claim 1, wherein the disappearance of the corner of the opening edge is rounded to such an extent that the fluff and the scissors disappear.   The grooved decorative board according to claim 1 or 2, wherein the groove has a substantially V-shaped cross section and has corners of the opening edge disappeared.   The groove is formed such that the width of the lower portion is smaller than the opening width, and the opening edge is constituted by an angle that is substantially perpendicular to the surface of the decorative material, and the angle is eliminated. 3. A grooved decorative board according to claim 1 or 2.   The groove has a wall surface constituted by a vertical plane formed on the substrate side from the surface of the decorative material, and a plane extending in a substantially V shape from the vertical plane to the bottom of the groove, and The grooved decorative board according to claim 1, 2, or 4, wherein corners of the opening edge are eliminated.   6. The grooved decorative board according to claim 5, wherein the groove is a groove having a substantially pentagonal cross section, and the corner of the opening edge is eliminated.   The grooved decorative board according to any one of claims 1 to 6, wherein the decorative material is obtained by applying and curing an ionizing radiation curable paint before or after forming a groove on the surface of the decorative material.   A groove extending from the surface of the decorative material having the thermoplastic resin layer adhered to one side of the substrate to the substrate is cut, heated from the decorative plate surface, and the thermoplastic resin layer near the opening edge of the groove is removed. A method for producing a grooved decorative board, characterized by melting and eliminating corners of the opening edge of the groove. 9. The method for manufacturing a grooved decorative board according to claim 8, wherein the corners of the opening edge are made to be rounded to such an extent that the fluff and the scissors disappear.   The method for producing a grooved decorative board according to claim 8 or 9, further comprising a step of applying and curing an ionizing radiation curable paint before or after forming the groove on the surface of the decorative material.   The heat application uses a heat roll, and the heat roll has a convex part wider than the groove corresponding to the position of the groove, and the tip part does not reach the bottom of the groove. A manufacturing method of a decorative board with 9 or 10 grooves.