JP2008055719A - Manufacturing process of decorative board - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To manufacture a decorative board having an excellent design quality and strengths and also manufacturable with good productivity. <P>SOLUTION: By removing the surface 2a of the early wood part 5 of a natural wooden material 2 by brushing provided with a relief having recesses 7 having a depth of ≥0.1 mm and ≤0.4 mm. The whole of the surface 2a of the natural wooden material 2 is subjected to blast treatment. An impregnating resin 8 which combines an active energy ray curing characteristic and a moisture curing characteristic is applied on the surface. A colored, filling resin 9 which combines an active energy ray curing characteristic and a moisture curing characteristic is applied on the surface 2a to fill at least the recesses 7. They are irradiated with an active energy ray 10. The surface 2a side of the natural wooden material 2 is uniformly ground so that the colored filling resin 9 may remain at least in the recesses 7. Finally, a coating film 11 of a transparent resin is formed on the surface 2a side of the natural wooden material 2. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a method for producing a decorative board having excellent design properties.

  Conventionally, a decorative board manufactured by a manufacturing method called WPC is known as a decorative board. A decorative board manufactured by WPC has an excellent design property and is excellent in strength, and is therefore popular as a high-grade decorative material. WPC is obtained by impregnating a cured natural wood material with resin and curing it, then bonding it to a substrate such as plywood or wood fiber board, and then painting the surface with a synthetic resin paint or the like to obtain a decorative board Is the method. In WPC, in order to eliminate the uneven impregnation of the resin into the natural wood material, the resin is injected into the natural wood material by repeating the decompression and pressurization. In general, colored resin is used to fill the voids of the natural wood material. At this time, among the early wood portion and the late wood portion constituting the natural wood material, the low density early wood portion is impregnated with a lot of resin, and the high density late wood portion has few voids, Not much resin is impregnated. For this reason, the early-colored material portion, which is originally light in color, is impregnated with a large amount of colored filler resin, so that the color density of the early-material portion and the late-material portion is reversed.

  On the other hand, in the manufacturing method using WPC, since the resin injection is generally performed in a batch system, there is a problem in that the manufacturing takes time and effort, and the productivity is poor.

  Therefore, in order to improve this problem, for example, as shown in Patent Documents 1 to 3, there is a method for obtaining a decorative board having good design and strength equivalent to that produced by WPC as shown in Patent Documents 1 to 3. Proposed.

  In the manufacturing method of Patent Document 1, a so-called floating process is performed by brushing to form a recess in the early part of the surface, and after applying a colorant to the surface and drying it, a sealer agent is applied. Further, it is a method in which a coating finish is performed after further applying a resin.

  In addition, the manufacturing method of Patent Document 2 is that the surface of the natural wood material is brushed and then the resin is infiltrated into the early wood part, then the surface of the late wood part is sanded and finally finished. This is a method of painting.

Moreover, the manufacturing method of patent document 3 is the method of performing a float-making process by ejecting the fine hard particle for sandblasting from the nozzle of a hose, and making this particle collide with the surface of a natural wooden material.
Japanese Examined Patent Publication No. 58-84709 JP-A-5-77210 JP-A-53-69803

  However, in the method of Patent Document 1, the resin is filled after a sealer agent is applied to the surface after the float processing so that the natural wooden material is not impregnated with the resin. For this reason, when this decorative board is used for a long time, there exists a problem that the resin of a recessed part will delaminate in a sealer layer.

  Further, according to the method of Patent Document 2, the late material part is hardly impregnated with the resin, and the resin is applied to the early material part only by performing the brushing process. There is a problem in that makeup unevenness on the surface of the decorative plate occurs, and the brushing causes a fluff, resulting in poor design of the decorative plate.

  Further, the method of Patent Document 3 has a problem that it takes time and is very inefficient when it is floated by sandblasting. Also, if the particle ejection speed from the nozzle is increased or the large and hard particles are used in order to speed up the time, it will be ground to the late material part and cannot be effectively floated. There's a problem.

  The present invention has been made in view of the above points, and the object of the present invention is to have a design and strength equivalent to those produced by WPC by devising a method for producing a decorative board. It is to obtain a decorative plate with good productivity.

  A method for manufacturing a decorative board according to the first aspect of the present invention is a method for manufacturing a decorative board having at least a surface made of a natural wood material, and the early wood part of the early wood part and the late wood part constituting the natural wood material. The surface of the natural woody material that has been float-processed, and the surface of the natural wood material that has been float-processed by removing the surface of the surface by brushing, thereby performing a float-processing with a recess having a depth of 0.1 mm or more and 0.4 mm or less A blasting process for blasting the whole by blasting, an impregnating resin coating process for applying an impregnating resin having both active energy ray curing characteristics and moisture curing characteristics to the entire surface of the blasted natural wood material, and the above The surface side of the natural wood material coated with the impregnating resin is filled with at least the colored filling resin having active energy ray curing characteristics and moisture curing characteristics in the recesses. A colored filling resin coating step to be applied; an irradiation curing step of irradiating active energy rays to the surface side of the natural wood material to cure the impregnating resin and the colored filling resin; and the colored filling resin at least in the recesses. A grinding step for uniformly grinding the surface side of the natural wood material so that it remains, and a resin that forms a transparent resin coating film by applying and curing a transparent resin paint on the surface side of the natural wood material after the grinding And a coating film forming step.

  That is, in the float forming process, the early wood part is made into a recess having a depth of 0.1 mm or more and 0.4 mm or less by brushing. The early wood part is a part that grows in the period from spring to autumn. The late wood part is a part that grows from autumn to winter, and because the growth is slow, the structure is a dense and hard part. The brushing process is a process of scraping off the early material portion of the surface with a rotating thin nylon wire or metal wire. By forming the depth of the recess in the range of 0.1 mm or more and 0.4 mm or less, and making the average depth be 0.2 mm or more and 0.3 mm or less, It becomes an excellent decorative board.

  In the blasting process, the entire surface of the natural wood material is ground. The blasting process is a process in which a hard and fine abrasive material for blasting is collided with the surface of a natural woody material to make fine scratches on the early and late parts.

  And in an impregnation resin application | coating process, an impregnation resin is apply | coated and osmose | permeated to the whole surface of a natural wood material. At that time, due to the blasting process, fine scratches are made on the entire surface of the natural wood material, and the impregnation property of the resin is high, so that the impregnation resin is easily penetrated.

  And in a resin application | coating process, coloring filling resin is apply | coated so that it may fill at least in a recessed part among the surfaces of the natural wood material which the said impregnation resin penetrate | infiltrated.

  Next, in the irradiation curing step, active energy rays are irradiated to cure the impregnating resin and the colored filling resin. Both the impregnating resin and the colored filling resin have active energy ray curing characteristics and moisture curing characteristics. For this reason, the resin filled in the bottom of the recess formed to a depth of about 0.3 mm to 0.4 mm is not only instantly cured by irradiation with active energy rays, but also active energy rays in the deep portions of the recesses. Even when it is difficult to reach, adhesion failure is suppressed by moisture curing.

  Finally, in the grinding process, the surface side of the natural wood material is uniformly ground, and in the resin coating film forming process, a transparent resin coating is applied and cured to form a transparent resin coating film.

  In this way, since the impregnation resin is applied to the entire surface of the natural wood material that has been subjected to blasting treatment to improve the impregnation property, the impregnation resin can penetrate into the natural wood material, and has excellent surface hardness. It becomes a decorative board with high strength. Moreover, it becomes the decorative board excellent in the designability by filling the colored filling resin into the concave portion formed at a depth of 0.1 mm or more and 0.4 mm or less. Furthermore, since the colored filling resin has both active energy ray curing characteristics and moisture curing characteristics, the colored filling resin is promoted to be cured, thereby preventing poor adhesion and improving the surface hardness of the decorative board. Become. And since the manufacture of a decorative board is made continuously, productivity is good.

  In the decorative board manufacturing method according to the second aspect of the present invention, the blasting abrasive used in the blasting process in the blasting process is adjusted by a sieving method so that the particle size is 90 μm or more and 150 μm or less. Is.

  According to the above configuration, by setting the particle size of the abrasive for blasting to 90 μm or more and 150 μm or less, the surface of the natural wooden material can be finely scratched by blasting, and the size of the scratch can be reduced. The size of the impregnated resin can be easily penetrated.

  In the method for producing a decorative board according to the third aspect of the present invention, the impregnating resin in the impregnating resin coating step contains 0.1% by mass or more and 1.5% by mass or less of bisacylphosphine oxide. Acylphosphine oxide is contained in an amount of 0.5% by mass or more and 5.0% by mass or less, and the active energy ray in the irradiation curing step is an ultraviolet ray having a wavelength peak in a region of 350 nm or more and 400 nm or less. It is.

  According to said structure, the bisacyl phosphine oxide or the monoacyl phosphine oxide is added to the impregnation resin as a photoinitiator. Bisacyl phosphine oxide or monoacyl phosphine oxide is excellent in reactivity with ultraviolet rays, and has an absorption maximum particularly in the vicinity of 400 nm of the wavelength of ultraviolet rays. By irradiating the impregnated resin to which the photopolymerization initiator is added with ultraviolet light having a wavelength peak in a region of 350 nm or more and 400 nm or less, curing is promoted and adhesion of the impregnated resin to the natural wood material is improved. The decorative board is further improved and has excellent surface hardness.

  According to a fourth aspect of the present invention, there is provided a decorative board manufacturing method comprising: impregnating resin curing step of irradiating active energy rays in order to cure the impregnating resin between the impregnating resin coating step and the colored filling resin coating step. Further included.

  According to said structure, before apply | coating colored filling resin, an active energy ray is irradiated and hardening of an impregnation resin is accelerated | stimulated. Then, after the impregnated resin is sufficiently adhered to the natural wood material, the colored filling resin is applied and irradiated with active energy rays again to cure the colored filling resin, and the adhesion of the colored filling resin to the natural wood material Can be improved.

  In the manufacturing method of the decorative board according to the fifth aspect of the present invention, in the colored filling resin coating step, the colored filling resin is coated on the surface of the natural wood material so as to cover a portion other than the concave portion, and the grinding step. Then, it grinds so that the said colored filling resin may remain on the whole surface side of the said natural wooden material.

  According to the above configuration, the colored filling resin is applied to the entire surface side of the natural wood material including the upper part of the late wood part, and is ground so that the colored filling resin remains on the entire surface. For this reason, the decorative board in which the entire surface side of the natural wooden material is covered with the colored filling resin is obtained, and the decorative board finish becomes natural.

  In the method for manufacturing a decorative board according to the sixth aspect of the present invention, in the grinding step, grinding is performed up to the late wood part on the surface of the natural wood material.

  According to the above configuration, since the late wood part on the surface of the natural wood material is ground, the portion where the colored filling resin is filled in the recess of the early wood part is emphasized, and the contrast with the part where the late wood part is exposed is clear It becomes the finish of the so-called conspicuous decorative board.

  ADVANTAGE OF THE INVENTION According to this invention, while having the outstanding designability and intensity | strength, a productive decorative board can be manufactured.

[First embodiment]

  Hereinafter, the manufacturing method of the decorative board which concerns on the 1st Embodiment of this invention is demonstrated in detail based on FIG.

(Natural wood)
As the natural wood material 2 as the surface material of the decorative board 1, coniferous trees such as pine, tsuga and hinoki, and broad-leaved trees such as oak and taro can be used.

  As shown in FIG. 1 (a), the cross section of the natural wood material 2 is composed of the early wood portion 5 and the late wood portion 6 alternately to form a grain. The early wood portion 5 is a portion that grows in the period from spring to autumn, and because the growth is fast, the tissue portion is a rough and soft portion. The late wood part 6 is a part that grows from autumn to spring, and because the growth is slow, the structure is a dense and hard part.

  The decorative board 1 may be composed of only the natural wooden material 2 or may be configured by attaching the natural wooden material 2 to the substrate 3. As the substrate 3, a plywood, a laminated wood, an MDF, a wooden board such as a particle board, an inorganic board such as a gypsum board or a volcanic glassy multilayer board, or a board in which these are combined is used.

(Floating process)
First, as shown in FIG. 1 (b), a so-called floating process is performed in which the early wood portion 5 on the surface 2 a of the natural wood material 2 is removed to form the recess 7. In order to obtain the decorative board 1 having excellent design properties equivalent to that produced by WPC, the depth of the recess 7 is preferably about 0.2 mm or more and about 0.3 mm or less. However, it is difficult to form a uniform recess 7 in the natural wood material 2. Therefore, the depth of the recess 7 is formed in the range of 0.1 mm or more and 0.4 mm or less so that the average depth is 0.2 mm or more and 0.3 mm or less.

  When the concave portion 7 is formed to a depth of 0.5 mm or more, the appearance of the decorative board is different from the case where the depth of the concave portion 7 is 0.4 mm or less, although the resin is required by that amount. Absent. Furthermore, when the recess 7 is formed to a depth of 0.5 mm or more, when the resin is applied, the resin filled in the bottom of the recess 7 is hard to be cured, and the surface of the resin may be cured in a film shape. is there. For this reason, when the surface of natural woody material 2 is ground after that, a part of colored filling resin 9 may peel off. Further, as described above, if a large amount of resin is heat-cured without applying pressure, it causes foaming, which is not preferable in design. Therefore, it is preferable that the depth of the recessed part 7 is 0.1 mm or more and 0.4 mm or less.

  In order to make the depth of the recess 7 not less than 0.1 mm and not more than 0.4 mm, the thickness of the natural wood material 2 is preferably not less than 0.3 mm and not more than 1.0 mm.

  The concave portion 7 is formed by brushing the surface 2 a of the natural wood material 2. The brushing process is a technique of scraping off the early material portion 5 on the surface 2a with a rotating thin metal wire 12 or the like. In the method of forming the concave portion 7 by consolidating the early wood portion 5 using a rubber roller, when the decorative plate is used for a long time, the compacted portion may swell due to a spring back due to moisture or the like. Therefore, it is preferable to form the recess 7 by a brushing process.

(Blasting process)
Next, as shown in FIG.1 (c), the whole surface 2a of the natural wood material 2 is blasted. The blasting process is a technique in which a hard blasting abrasive 13, which is fine particles, collides with the surface 2 a to make fine scratches 15 on the surfaces of the early part 5 and the late part 6. Examples of the blasting abrasive 13 include glass beads, glass powder, inorganic particles such as silicon, metal particles such as alumina, hard organic particles obtained by finely pulverizing walnuts and peach seeds, or dry ice obtained by finely pulverizing dry ice. Particles or the like are used.

  At this time, it is preferable that the particle size of the blasting abrasive 13 is adjusted by a sieving method so as to be 90 μm or more and 150 μm or less. Thereby, the fine flaw 15 can be made on the surface 2a of the natural wood material 2 by the blast treatment, and the size of the flaw 15 can easily be infiltrated by the impregnating resin 8 described later.

  In the sieving method, sieving is performed in about 3 to 5 stages. The opening diameter of the first stage sieve is set to about 180 μm, the opening diameter of the second stage sieve is set to about 150 μm, and the opening diameter of the final stage sieve is set to about 90 μm. Thus, the blasting abrasive 13 having a particle diameter of 90 μm or more and 150 μm or less is adjusted so as to include about 70% or more of the whole. In addition to this, the abrasive includes a flat shape or an acute shape, or an abrasive having a particle size of 90 μm or less that cannot be passed.

  The thus-adjusted blasting abrasive 13 is made to collide with the surface 2a of the natural wood material 2 that has been float-processed. The blasting abrasive 13 may be naturally dropped from the nozzle 14 or may be injected from the nozzle 14 by applying pressure. A plurality of nozzles 14 are arranged at an arbitrary position above the surface 2a of the natural wood material 2 so that the entire surface 2a of the natural wood material 2 is subjected to blasting.

  After the concave portion 7 is formed by the brushing process, the surface 2a of the natural wood material 2 is in a rough state due to the blemishes, and the design of the decorative board 1 is inferior as it is. However, the blasting process removes the blemishes produced by the brushing and makes fine scratches 15 on the entire surface 2a of the natural wood material 2.

  Even if blasting is performed, there is a part of the natural wood material 2 on which the surface 2a remains, so a nylon brush (for example, a grid sander) having a fine abrasive bonded to the surface is preferably used. The surface 2a may be removed in the pre-process or post-process of the blast treatment.

(Resin application process)
Here, in the manufacturing method of the decorative board 1 which concerns on the 1st Embodiment of this invention, it apply | coats using two resin of the impregnation resin 8 and the colored filling resin 9. FIG.

  Both the impregnating resin 8 and the colored filling resin 9 have both active energy ray curing characteristics and moisture curing characteristics. For this reason, compared with resin which has only an active energy ray hardening characteristic, resin can be hardened instantaneously by irradiation of an active energy ray.

  Resins 8 and 9 are mainly composed of an oligomer or polymer such as polyester acrylate, epoxy acrylate, urethane acrylate, or polyether acrylate, or a mixture of a plurality of these and a reactive monomer. Further, the resins 8 and 9 are formed by adding 1 mass% or more and 15 mass% or less of polyisocyanate with respect to the main component.

  The oligomer, polymer, and reactive monomer used for the resins 8 and 9 may be those generally used as a resin having active energy ray curing characteristics. Examples of reactive monomers used for the resins 8 and 9 include the following.

  Examples of monofunctional monomers include lauryl acrylate, 2-ethylhexyl acrylate, 2-hydroxyethyl acrylate, 1,6-hexanediol monoacrylate, dicyclopentadiene acrylate, 2-hydroxylpropyl acrylate, phenoxydiethylene glycol acrylate, isobornyl acrylate , Β-carboxyethyl acrylate, acryloyl morpholine, 2-hydroxyethyl acryloyl phosphate, tetrahydrofurfuryl acrylate, N, N-diethylaminoethyl acrylate, N, N-dimethylaminoethyl acrylate, glycidyl acrylate, benzyl acrylate and the like.

  Examples of bifunctional monomers include ethylene glycol dimethacrylate, diethylene glycol diacrylate, diethylene glycol dimethacrylate, triethylene glycol diacrylate, triethylene glycol dimethacrylate, polyethylene glycol diacrylate, polyethylene glycol dimethacrylate, dipropylene glycol diacrylate. Acrylate, dipropylene glycol dimethacrylate, tripropylene glycol diacrylate, tripropylene glycol dimethacrylate, polypropylene diacrylate, polypropylene dimethacrylate, 1,6-hexanediol diacrylate, 1,4-butanediol diacrylate, 1 , 4-Butanediol dimethacrylate, neopentylglyco Diacrylate, neopentyl glycol dimethacrylate, 1,9-nonanediol diacrylate, 1,9-nonanediol dimethacrylate and the like.

  Examples of trifunctional monomers include trimethylolpropane triacrylate, trimethylolpropane trimethacrylate, ethoxylated trimethylolpropane triacrylate, ethoxylated trimethylolpropane trimethacrylate, pentaerythritol triacrylate, pentaerythritol trimethacrylate, glycerin propoxy A triacrylate etc. are mentioned.

  Examples of tetrafunctional or higher functional monomers include pentaerythritol tetraacrylate, ethoxylated pentaerythritol tetraacrylate, propoxylated pentaerythritol tetraacrylate, ditrimethylolpropane tetraacrylate, dipentaerythritol hexaacrylate, and the like.

  It is preferable that an isocyanate compound is added to the resins 8 and 9. This isocyanate compound absorbs moisture in the air and contributes to moisture curing of the resins 8 and 9. For this reason, the adhesiveness of the resins 8 and 9 to the natural wood material 2 can be further improved.

  Specific examples of isocyanate compounds include isocyanate monomers such as hexamethylene diisocyanate, isophorone diisocyanate, tolylene diisocyanate, diphenylmethane diisocyanate, xylylene diisocyanate, norbornene diisocyanate, and biuret, isocyanurate, and trimethylolpropane adducts. And the like, and block bodies of these isocyanate monomers or polyisocyanate derivatives. Furthermore, it is preferable to use a non-yellowing type or a hardly yellowing type isocyanate compound. These isocyanate compounds are used alone or in combination.

  The resins 8 and 9 may further contain a catalyst such as a commonly used tin compound, zinc compound, or amine compound.

  Specifically, the impregnating resin 8 and the colored filling resin 9 are applied in the following two resin application steps.

(Impregnation resin application process)
As shown in FIG. 1 (d), the above impregnating resin 8 is applied to the entire surface 2a of the blasted natural wood material 2. The impregnating resin 8 is applied using a sponge roll coater, a natural reverse coater, a flow coater or the like. In this way, the impregnation resin 8 is applied to the entire surface 2a of the natural wood material 2 which has been subjected to blasting to make fine scratches 15 and has high impregnation properties. The decorative board 1 which can be infiltrated, has excellent surface hardness, and high strength can be obtained.

  In addition, since the entire surface 2a including not only the early material portion 5 but also the late material portion 6 is subjected to blasting, the entire surface 2a is uniformly impregnated with the impregnation resin 8, and impregnation unevenness can be suppressed. .

  Further, the impregnating resin 8 is directly applied to the surface 2a of the natural wood material 2 without forming a sealer layer. For this reason, the time and labor of applying and drying a sealer material are not required, so that productivity can be improved and delamination due to long-term use is difficult.

  The impregnating resin 8 is preferably a resin having a low viscosity and a high impregnation property. Specifically, the impregnating resin 8 preferably has a viscosity of 100 Pa · s or less when applied to the surface 2 a of the natural wood material 2. Thus, by making the impregnating resin 8 have a low viscosity, the impregnation property can be further improved. In addition, the impregnating resin 8 is adjusted to have the above-mentioned viscosity by being diluted with the above-described monomer or heated. Also, for example, the impregnated resin in which the natural wood material 2 is heated in advance so that the temperature of the surface 2a of the natural wood material 2 is 40 ° to 50 °, and is 10 ° to 20 ° lower than the temperature of the surface 2a. By applying 8, the impregnation property of the impregnating resin 8 can be further improved.

  Next, as shown in FIG.1 (e), in order to harden or semi-harden the impregnation resin 8, the active energy ray 10 is irradiated from the surface 2a side of the natural wooden material 2. FIG. The active energy ray 10 is an ultraviolet ray or an electron beam.

  When the active energy ray 10 is ultraviolet light, a photopolymerization initiator is added to the impregnating resin 8. As the photopolymerization initiator, generally used radical reaction type acetophenone-based, benzophenone-based, benzyl-based, benzoin-based carbonyl compounds, tetraalkylthiuram monosulfide, thioxanthone and other sulfur compounds are used singly or in combination. You may mix and use. However, in order to accelerate the curing of the impregnating resin 8, a resin having higher reactivity with respect to ultraviolet rays than the above general photopolymerization initiator is preferable.

  Specifically, as the photopolymerization initiator, the impregnating resin 8 contains 0.1% by mass or more and 1.5% by mass or less of bisacylphosphine oxide, or 0.5% by mass or more of monoacylphosphine oxide. It is preferable to contain 5.0% by mass or less. Bisacylphosphine oxide or monoacylphosphine oxide has an absorption maximum at a long wavelength in which the wavelength region of ultraviolet rays is around 350 nm to 400 nm. Therefore, the impregnating resin 8 can be cured more effectively by using a light emission method having an emission spectrum in a long wavelength region of 350 nm or more and 400 nm or less as a light source that emits ultraviolet rays. Specifically, a discharge lamp type metal halide lamp, an electrodeless type D bulb, a V bulb, a Q bulb, an M bulb, a pulse UV method, or the like is used.

  When the active energy ray 10 is ultraviolet light, the impregnating resin 8 may be added with an auxiliary agent such as a sensitizer, a light stabilizer, an ultraviolet absorber, and a storage stabilizer. Further, the impregnation resin 8 may be colored by adding a dye, a pigment or the like.

(Colored filling resin application process)
Next, as shown in FIG. 1 (f), the colored filling resin 9 is applied to the surface 2 a of the natural wood material 2. The colored filling resin 9 is applied by using a sponge roll coater, a rubber roll coater, a reverse coater or the like in the same manner as the impregnation resin 8. At this time, at least the colored filling resin 9 is filled in the concave portion 7 of the early material portion 5.

  As described above, the colored filling resin 9 has both the active energy ray curing characteristics and the moisture curing characteristics. Therefore, even when the active energy rays are difficult to reach the deep part of the recess 7, moisture curing causes adhesion failure. Can be suppressed.

  The colored filling resin 9 is colored with a dye or a pigment. A dye is suitable for maintaining the transparency, and a pigment is suitable for increasing the hiding property while maintaining the transparency. These dyes or pigments are added in an amount of 0.1% by mass or more and 1.0% by mass or less with respect to the colored filling resin 9.

(Irradiation curing process)
Next, as shown in FIG. 1 (g), the active energy ray 10 is irradiated again from the surface 2 a side of the natural wood material 2 in order to cure or semi-cure the impregnation resin 8 and the colored filling resin 9. Also in this case, the active energy ray 10 is an ultraviolet ray or an electron beam.

  In the method for manufacturing a decorative board according to the first embodiment of the present invention, the recess 7 is formed to a depth of 0.1 mm to 0.4 mm in order to improve the design. In a portion where the depth of the recess 7 is about 0.3 mm to 0.4 mm, when the resin having only the active energy ray curing property is filled, the active energy ray 10 is difficult to reach the resin at the bottom of the recess 7, and the resin Since it does not cure sufficiently, adhesion failure may occur. However, in the present invention, since the impregnating resin 8 and the colored filling resin 9 have both active energy ray curing characteristics and moisture curing characteristics, even if the active energy rays 10 are not sufficient, the time elapsed after the irradiation process. By the moisture curing, the curing of the impregnating resin 8 and the colored filling resin 9 at the bottom of the recess 7 is promoted.

  When the active energy rays 10 are ultraviolet rays, it is preferable to add the above-described photopolymerization initiator to the colored filling resin 9 as well. Moreover, you may add auxiliary agents, such as a sensitizer, a light stabilizer, a ultraviolet absorber, and a storage stabilizer, to the colored filling resin 9.

(Grinding process)
Next, as shown in FIG. 1 (h), the surface 2a side of the natural wood material 2 is ground to make the surface 2a side uniform. At this time, grinding is performed so that the colored filling resin 9 remains at least in the concave portion 7 so as not to grind all the colored filling resin 9 filled in the concave portion 7 of the early material portion 5. Since the colored filling resin 9 is sufficiently cured, a part of the colored filling resin 9 is not peeled off by grinding, and the design of the decorative board is not impaired.

(Resin coating film forming process)
Next, as shown in FIG. 1 (i), a transparent resin coating is applied to the surface 2 a side of the natural wood material 2 and cured to form a transparent resin coating film 11. Since the surface 2a side of the natural wood material 2 is impregnated with the impregnating resin 8 to the inside, the decorative board 1 having excellent surface hardness and high strength can be obtained. It is not necessary to perform thick film coating such as reinforced coating. A thin coating having a thickness of less than 100 μm may be used. However, in order to improve the designability, thick film coating of 150 μm to 250 μm may be performed.

  In the first embodiment of the present invention, the active energy ray 10 is irradiated after the impregnation resin 8 is applied, but this irradiation is not necessarily performed. However, this irradiation is preferably performed in order to sufficiently cure the impregnated resin 8.

(Effects of the first embodiment)
Floating processing for forming the concave portion 7 is performed by brushing, and a blasting process is performed without forming a sealer layer thereon. By applying a low viscosity and highly impregnating impregnating resin to the entire surface 2a of the natural wood material 2 having high impregnation property by forming fine scratches by this blasting treatment, the natural wood material 2 is impregnated to the inside. The resin 8 can be permeated. For this reason, even if it does not form a thick coating film at the end, the decorative board 1 which is excellent in surface hardness and high in strength can be obtained.

  Moreover, the decorative board 1 excellent in design property can be manufactured by filling the colored filling resin 9 in the concave portion 7 of the early wood part 5 formed to a depth of 0.1 mm or more and 0.4 mm or less. it can.

  Furthermore, even in the concave portion 7 having a depth of 0.3 mm or more and a depth of about 0.4 mm or less, the colored filling resin 9 has both active energy ray curing characteristics and moisture curing characteristics. Since the curing of the resin 9 is also promoted, it is possible to obtain the decorative board 1 which is suppressed from poor adhesion and excellent in surface hardness.

That is, the decorative board 1 manufactured by the manufacturing method according to the first embodiment of the present invention can have the same designability and strength as those manufactured by WPC. And since the decorative board 1 can be produced continuously, the productivity of the decorative board 1 is good.
[Second Embodiment]

  Next, the manufacturing method of the decorative board which concerns on the 2nd Embodiment of this invention is demonstrated in detail based on FIG. The same components as those in FIG. 1 are denoted by the same reference numerals, and detailed description of the same portions as those in the first embodiment is omitted.

  First, the second embodiment is different from the first embodiment in that the colored filling resin 9 is applied to the entire surface 2a of the natural wood material 2 as shown in FIG. 2 (f). That is, the colored filling resin 9 is applied not only to fill the concave portion 7 but also to cover the late material portion 6 other than the concave portion 7. In addition, about the process shown to Fig.2 (a)-(e) and (g), it is the same as 1st Embodiment.

  Then, as shown in FIG. 2 (h), the surface 2a side of the natural wood material 2 is ground so that the colored filling resin 9 remains in the late material portion 6 portion, and the surface 2a side is made uniform. That is, grinding is performed so that the entire surface 2 a side of the natural wood material 2 is covered with the colored filling resin 9.

  Then, as shown in FIG. 2 (i), a transparent resin coating film 11 is formed on the surface 2 a side of the natural wood material 2 whose entire surface is covered with the colored filling resin 9.

As described above, the decorative board 1 manufactured by the decorative board manufacturing method according to the second embodiment of the present invention has a finish in which the entire surface 2a side of the natural wood material 2 is covered with the colored filling resin 9. The decorative panel 1 has a natural appearance.
[Third embodiment]

  Next, the manufacturing method of the decorative board which concerns on the 3rd Embodiment of this invention is demonstrated in detail based on FIG. The same components as those in FIGS. 1 and 2 are denoted by the same reference numerals, and detailed description of the same portions as those in the first embodiment is omitted.

  In the third embodiment, as shown in FIG. 3 (h), the first embodiment is such that the colored filling resin 9 is ground so as not to remain on the surface side of the late wood portion 6 of the natural wood material 2. And different.

  That is, the colored filling resin 9 on the evening material portion 6 is scraped while leaving the colored filling resin 9 filled in the recess 7 to expose the evening material portion 6 impregnated with the impregnation resin 8.

  And as shown in FIG.3 (i), the transparent resin coating film 11 is provided in the surface 2a side of the natural wood material 2 comprised by the recessed part 7 with which the colored filling resin 9 was filled, and the exposed late material part 6. FIG. Form. In addition, about the process shown to Fig.3 (a)-(g), it is the same as 1st Embodiment.

  Thus, the decorative board 1 manufactured by the decorative board manufacturing method according to the third embodiment of the present invention has a colored filling resin in the concave portion 7 of the early wood portion 5 compared to the portion where the late wood portion 6 is exposed. The portion filled with 9 is emphasized, the color contrast becomes clear, and the so-called conspicuous decorative panel 1 is obtained.

  In addition, the above-mentioned embodiment is an illustration of this invention, Comprising: This invention is not limited to this example.

(Example 1)
As a natural wood material, a 0.47 mm thick rice rugged single plate is used. The substrate is a plywood substrate having a thickness of 15 mm. These single plates and the plywood substrate were bonded using a vinyl acetate adhesive.

  First, the surface of the veneer was shaved by brushing. The brushing was performed using a metal wire brush having a wire diameter of 0.2 mm, and the early material portion was ground to form a recess. The maximum depth of the recess was 0.4 mm.

  Next, a blast treatment was performed on the surface of the single plate in which the concave portion was formed. Sandblasting abrasives (Fuji Glass Beads # 150: manufactured by Fuji Seisakusho) were used for the blasting treatment.

  Next, 40 parts by mass of epoxy acrylate, 30 parts by mass of tripropylene diacrylate, 30 parts by mass of 2-hydroxypropyl methacrylate, 20 parts by mass of hexamethylene diisocyanate, 10 parts by mass of polyol, and 0. 5 parts by mass and 3 parts by mass of 2-hydroxy-2-methyl-1-phenyl-propan-1-one as a photopolymerization initiator were blended.

  The surface of the single plate was irradiated with an infrared heater and heated until the surface temperature of the single plate reached 45 ° C. The impregnation resin adjusted to 35 ° C. was applied to the surface of the blasted veneer. The impregnating resin was applied at 100 g / m 2 with a natural roll coater of soft rubber. After curing for 1 minute, excess impregnated resin on the surface of the veneer was scraped off by a natural roll coater. At this time, when the amount of the impregnated resin impregnated in the veneer was measured, it was 70 g / m2.

  Next, 60 parts by mass of epoxy acrylate, 40 parts by mass of tripropylene diacrylate, 5 parts by mass of acryloyl morpholine, 0.7 parts by mass of dye, 5 parts by mass of hexamethylene diisocyanate as a colored filling resin, start photopolymerization As an agent, 3 parts by mass of 2-hydroxy-2-methyl-1-phenyl-propan-1-one and 0.7 parts by mass of bisacylphosphine oxide were blended.

  And the said colored filling resin was apply | coated so that the surface might become smooth, making it fill a recessed part.

  Next, the surface side of the veneer was irradiated with ultraviolet rays to cure the colored filling resin, and then the entire surface of the veneer was ground to the extent that the colored filling resin in the recesses was slightly cut.

  On the surface side of the ground single plate, undercoating, intermediate coating, and topcoating were performed with an ultraviolet curable transparent resin coating to form a transparent resin coating film of 85 g / m 2.

  Thereafter, the decorative plate was irradiated with ultraviolet rays from the surface side of the veneer to cure the paint.

  The decorative board manufactured as described above has a beautiful finish in which the color contrast between the recessed portion of the early wood portion filled with the colored filling resin and the late wood portion is emphasized. Further, this decorative board has sufficient surface hardness as a decorative material. Specifically, the surface hardness was 2H in the pencil hardness test (Japanese Industrial Standard JIS K5400).

(Example 2)
As a natural wood material, a 0.3 mm thick rice pine grain veneer is used. The substrate is a plywood substrate having a thickness of 15 mm. These single plates and the plywood substrate were bonded using a vinyl acetate adhesive.

  First, the surface of the veneer was shaved by brushing. The brushing was performed using a metal wire brush having a wire diameter of 0.2 mm, and the early material portion was ground to form a recess. The maximum depth of the recess was 0.4 mm.

  Next, a blast treatment was performed on the surface of the single plate in which the concave portion was formed. Sandblasting abrasives (Fuji Glass Beads # 150: manufactured by Fuji Seisakusho) were used for the blasting treatment.

  Next, 25 parts by mass of urethane acrylate, 35 parts by mass of epoxy acrylate, 25 parts by mass of tripropylene diacrylate, 15 parts by mass of acryloylmorpholine, 20 parts by mass of hexamethylene diisocyanate, and 0. 5 parts by mass and 3 parts by mass of 2-hydroxy-2-methyl-1-phenyl-propan-1-one as a photopolymerization initiator were blended.

  The surface of the single plate was irradiated with an infrared heater and heated until the surface temperature of the single plate reached 45 ° C. The impregnation resin adjusted to 35 ° C. was applied to the surface of the blasted veneer. The impregnating resin was applied with a soft rubber natural roll coater at 50 g / m 2. After curing for 1 minute, all the impregnated resin had penetrated into the veneer.

  Next, the colored filling resin was applied to the veneer impregnated with the impregnating resin. The same resin as in Example 1 was used as the colored filling resin. A colored filling resin was applied with a metal reverse coater so that the surface was smooth while filling the recess.

  Next, the surface side of the veneer was irradiated with ultraviolet rays to cure the colored filling resin, and then the entire surface of the veneer was ground to the extent that the colored filling resin in the recesses was slightly cut.

  On the surface side of the ground single plate, a transparent resin coating film of 70 g / m 2 was formed by applying an undercoat, an intermediate coat and an overcoat with an ultraviolet curable transparent resin paint.

  Thereafter, the decorative plate was irradiated with ultraviolet rays from the surface side of the veneer to cure the paint.

  The decorative board manufactured as described above has a beautiful finish in which the color contrast between the recessed portion of the early wood portion filled with the colored filling resin and the late wood portion is emphasized. Further, this decorative board has sufficient surface hardness as a decorative material. Specifically, the surface hardness was 2H in the pencil hardness test (Japanese Industrial Standard JIS K5400).

  As described above, the present invention is useful for a method of manufacturing a decorative board having excellent design and strength and high productivity.

It is a figure which shows the manufacturing process of the decorative board which concerns on the 1st Embodiment of this invention. It is a figure which shows the manufacturing process of the decorative board which concerns on the 2nd Embodiment of this invention. It is a figure which shows the manufacturing process of the decorative board which concerns on the 3rd Embodiment of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Decorative board 2 Natural wood material 2a Surface 5 Early wood part 6 Late wood part 7 Recessed part 8 Impregnation resin 9 Colored filling resin 10 Active energy ray 11 Transparent resin coating film

Claims (6)

A method for producing a decorative board having at least a surface made of a natural wood material,
Floating process having a recess of 0.1 mm or more and a depth of 0.4 mm or less by removing the surface of the early wood part and the late wood part constituting the natural wood material by brushing treatment. Floating process process to apply,
A blasting process for blasting the entire surface of the floated natural wood material by blasting;
An impregnation resin application step of applying an impregnation resin having both active energy ray curing characteristics and moisture curing characteristics to the entire surface of the blasted natural wood material;
A colored filling resin coating step of coating the surface of the natural wood material coated with the impregnating resin so as to fill at least the recessed portion with a colored filling resin having both active energy ray curing characteristics and moisture curing characteristics;
An irradiation curing step of irradiating the surface side of the natural wood material with active energy rays in order to cure the impregnating resin and the colored filling resin;
A grinding step of uniformly grinding the surface side of the natural wood material so that the colored filling resin remains in at least the recess;
Applying and curing a transparent resin coating on the surface side of the natural wood material after grinding, and forming a transparent resin coating film,
The manufacturing method of a decorative board containing this. In the manufacturing method of the decorative board of Claim 1,
The method for producing a cosmetic material, wherein the abrasive for blasting used in the blasting process in the blasting process is adjusted by a sieving method so that the particle size is 90 μm or more and 150 μm or less. In the manufacturing method of the decorative board of Claim 1 or 2,
The impregnating resin in the impregnating resin coating step contains bisacylphosphine oxide in an amount of 0.1% by mass or more and 1.5% by mass or less, or a monoacylphosphine oxide in an amount of 0.5% by mass or more and 5%. 0.0 mass% or less,
The said active energy ray in the said irradiation hardening process is a manufacturing method of the decorative board which is an ultraviolet-ray which has a wavelength peak in 350 nm or more and 400 nm or less area | region. In the manufacturing method of the decorative board of any one of Claim 1 to 3,
A method for producing a decorative board, further comprising an impregnation resin curing step of irradiating an active energy ray to cure the impregnation resin between the impregnation resin application step and the colored filling resin application step. In the manufacturing method of the decorative board of any one of Claim 1 to 4,
In the colored filling resin application step, the colored filling resin is applied so as to cover a portion other than the concave portion on the surface of the natural wood material,
In the grinding step, a decorative board manufacturing method for grinding so that the colored filling resin remains on the entire surface side of the natural wood material. In the manufacturing method of the decorative board of any one of Claim 1 to 4,
The said grinding process WHEREIN: The manufacturing method of the decorative board which grinds to the said late-wood part of the surface of the said natural wooden material.

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