JP2008120024A - Manufacturing process of decorative plate - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To obtain a decorative plate rich in three-dimensional feeling and good in decorativeness in a manufacturing process of the decorative plate chamfered and processed suitably to be used particularly as the decorative plate for a floor of a building. <P>SOLUTION: Synthetic resin-impregnating colored paper 3 impregnating synthetic resin in kraft paper having a thickness of 0.3-0.6 mm through an adhesive 2 is placed on the front surface of a woody substrate 1, and a woody decorative single plate 5 of 0.2 mm or more having a color tone of the same as or similar to the color tone of the synthetic resin-impregnated colored paper 3 is placed to be formed as a laminate through an adhesive 4 thereon. The laminate is heated and pressurized, is adhered to be integrated, is cut in a predetermined product shape, and its side edge part is chamfered and processed so that the depth is 0.5 mm or more and becomes the depth which does not reach the interior of the woody substrate 1. Then, a transparent paint is coated on the entire front surface including the chamfered surface. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a method for producing a chamfered decorative board suitable for use as a decorative board for floors of buildings.

  DESCRIPTION OF RELATED ART Conventionally, the grooved decorative board used for the wall surface, floor surface, etc. of a house as shown to patent document 1, for example is known well. This type of grooved decorative board is formed by laminating and integrating a thin decorative layer such as a polyolefin resin decorative sheet or resin-impregnated paper on a substrate such as plywood, and performing a decorative groove or chamfering process on this surface.

  Specifically, as described in paragraph No. 0021 of Patent Document 1, for example, a decorative groove reaching a plywood substrate having a high design depth of 600 μm is formed on the surface of the decorative board to which a thin synthetic resin-impregnated decorative sheet is bonded. Cut and expose the exposed groove part of the plywood substrate with the same colored paint as the decorative sheet, wipe off the groove colored paint that is not in close contact with the decorative sheet, and dry it, so that the groove color is the substrate color and decorative sheet color It is known to form a grooved decorative board having a high design property that does not cause uneven coloring.

  As another method, as described in Paragraph No. 0022 of Patent Document 1, a thin resin sheet base paper having a thickness of 200 μm is printed and resin-coated to form a decorative sheet, and this decorative sheet is bonded to a wooden substrate. It is also known that a shallow decorative groove having a depth of 180 μm, which does not reach the wood substrate, is cut on the surface to form a grooved decorative plate having a uniform groove color and high design.

  Such a method is not limited to the application to the grooved decorative board, but can be applied to a chamfered decorative board obtained by chamfering the four peripheral edges of the decorative board without the decorative groove. A joint groove is formed at the joint when the decorative plates are joined together, so that the level difference of the joint can be made inconspicuous, and the design of the joint groove can be made uniform and its design can be improved. It is.

  However, in the method described in paragraph No. 0021 of Patent Document 1 described above, since the depth of the decorative groove is 600 μm, it is possible to form a decorative groove or joint groove having a good three-dimensional effect and decorativeness. Will reach the inside of the plywood board, so that the difference in color tone between the decorative sheet and the plywood board is not exposed on the surface of the decorative groove or joint groove, the exposed groove part of the plywood board is the same color as the decorative sheet. It takes a lot of labor to paint with coloring paint, wipe off the groove coloring paint that is not closely attached to the decorative sheet, and dry it so that the color tone of the groove does not become uneven between the plywood substrate color and the decorative sheet color. The productivity was bad.

In the method described in paragraph 0022 of Patent Document 1, a thin resin sheet base paper having a thickness of 200 μm is printed and resin-coated to form a decorative sheet, and this decorative sheet has the same surface tone as the joint grooves and decorative grooves. Although there is an advantage that the color difference is eliminated by unifying the color tone, there is a disadvantage that the appearance of the three-dimensional appearance and the decoration is poor because only a shallow groove with a depth of about 180 μm can be formed. . In addition, when using such a decorative board for a floor board, it is necessary to have excellent scratch resistance such as a dent against a fallen object and a scratch caused by sliding of a caster, and when the thickness is thin like the decorative sheet described above. In some cases, such performance could not be obtained sufficiently.
JP 2003-286768 A

  The present invention has been made in view of such conventional problems, and manufactured with good productivity, a decorative board having excellent productivity and joint groove appearance, particularly a decorative board having hardness and scratch resistance suitable for use as a flooring material. An object of the present invention is to provide a method for manufacturing a decorative board that can be used.

  In order to achieve the above object, the decorative board manufacturing method according to the invention of claim 1 is characterized in that an adhesive is applied to the surface of a large-sized woody substrate, and a thickness of 0.3 mm to A synthetic resin impregnated colored paper impregnated with a synthetic resin is placed on a 0.6 mm thick kraft paper, an adhesive is applied on the placed synthetic resin impregnated colored paper, and a thickness of 0 is formed on the adhesive-coated surface. A wooden veneer veneer of 2 mm or more is placed to form a laminated body, and the laminated body is heated and pressed to cure the synthetic resin in the synthetic resin-impregnated colored paper and to be bonded and integrated to form a laminated board, The laminated board is cut into a predetermined product shape, and then the side edge of the cut laminated board is chamfered to a depth not less than 0.5 mm and not reaching the wood substrate, and then the surface including the chamfered surface It is characterized by applying a transparent paint on the entire surface to form a transparent coating layer. .

  Moreover, the manufacturing method of the decorative board which concerns on invention of Claim 2 apply | coats an adhesive agent to the surface of a large-sized wooden board | substrate, and is thick with a thickness of 0.3 mm-0.6 mm on this adhesive agent coating surface After placing synthetic resin impregnated colored paper impregnated with synthetic resin on kraft paper, heat and press to cure the synthetic resin in the synthetic resin impregnated colored paper and to bond and integrate the wooden substrate and synthetic resin impregnated colored paper, then An adhesive is applied onto the synthetic resin-impregnated colored paper integrated with the adhesive, and a wooden decorative veneer having a thickness of 0.2 mm or more is further placed on the adhesive-coated surface to form a laminate. The body is heated and pressed to form a laminated plate by bonding and integration, then the laminated plate is cut into a predetermined product shape, and then the side edges of the cut laminated plate are 0.5 mm deep and on a wooden substrate Chamfered to a depth that does not reach, and then the entire surface including the chamfered surface Wherein the Akirasei paint is applied to form a transparent coating layer.

  The decorative board manufacturing method according to claim 3 is the decorative board manufacturing method according to claim 1 or 2, wherein the synthetic resin-impregnated colored paper is colored in a color tone similar to that of the wood decorative veneer. It is characterized by being.

  Furthermore, the manufacturing method of the decorative board according to the invention of claim 4 is the manufacturing method of the decorative board of the inventions of claims 1 to 3, wherein the wood substrate of the large plate is laminated with planted wood veneers having a specific gravity of 0.4 or less. It is characterized by being formed of a single plate laminated plate such as a plywood or LVL formed by bonding.

  According to the manufacturing method of the decorative board according to the invention of claim 1 or 2, the decorative layer is made of thick synthetic resin-impregnated colored paper using thick kraft paper having a thickness of 0.3 mm to 0.6 mm and a thickness of 0. Since it is formed with a wood decorative veneer of 2 mm or more and a transparent coating layer, and its side edge is chamfered to a depth of 0.5 mm or more and not reaching the wood substrate, When a plurality of decorative plates are joined to form a construction surface such as a floor surface, the depth of the joint groove is 0.5 mm or more, and it has a three-dimensional effect, and its inner surface is excellent in decorativeness with a uniform color tone A plate can be formed.

  In addition, after forming a decorative layer composed of a synthetic resin-impregnated colored paper and a wooden decorative veneer on the surface of a large-sized wood substrate, it is cut into a plurality of predetermined rectangular shapes that are product shapes, and then chamfered, Since the transparent coating film layer is formed on the entire surface including the chamfered surface, the decorative board can be produced with higher production efficiency compared to the case where a decorative layer is provided for each surface of the wooden substrate cut into a normal product size. Can be manufactured.

  Furthermore, since the synthetic resin-impregnated colored paper has a thickness, when chamfering is performed at a depth of 0.5 mm or more and does not reach the wood substrate, the bottom of the joint groove formed at the joint portion between the decorative plates Can be formed in a synthetic resin-impregnated colored paper, and it can be formed on a decorative board having excellent three-dimensional effect and decorativeness, and having no uneven color on the inner surface of the joint groove.

  According to the method for producing a decorative board of the invention of claim 1, a synthetic resin-impregnated colored paper and a wooden decorative veneer are sequentially laminated on the surface of a wooden substrate via an adhesive to form a laminated body. By applying the heat and pressure, it is possible to form a laminate by bonding and integration, so that a decorative board can be produced with high production efficiency.

  According to the method for producing a decorative board of claim 2, the synthetic resin-impregnated colored paper is placed on the surface of the wooden substrate via an adhesive, and once heated and pressed, Since the synthetic resin can be cured and the wood substrate and the synthetic resin impregnated colored paper can be bonded and integrated, it is bonded to the surface of the synthetic resin impregnated colored paper that is bonded and integrated with the wooden substrate in the subsequent steps. There is an advantage that even if it is a woody veneer of various tree species and thicknesses, it can be reliably bonded by heating and pressing.

  According to the method of manufacturing a decorative board according to the invention of claim 3, in the decorative board manufacturing method of the invention of claim 1 or 2, the synthetic resin-impregnated colored paper is colored in a color tone similar to the color tone of the wood decorative veneer. Therefore, it can form in the decorative board with the good decoration which further unified the color tone of the inner surface of the joint groove formed when the decorative boards were joined.

  Furthermore, according to the manufacturing method of the decorative board according to the invention of claim 4, since the synthetic resin-impregnated colored paper can be formed to be thick and tough, the wood substrate has a specific gravity as low as 0.4 or less, hardness and scratch resistance. Such a resource can be formed into a decorative board having sufficient scratch resistance to be used as a floor board, even if a single board laminated board made of afforestation tree plywood such as a low plantation tree plywood or afforestation tree LVL is used. The use of renewable plantation trees can contribute to the conservation of the global environment.

  Hereinafter, the manufacturing method of the decorative board of this invention is demonstrated based on drawing which shows the manufacturing method of the decorative board A for floor boards which is an Example. The present invention is not limited to the description of the present embodiment.

  FIG. 1 shows an adhesive 2 coated on the surface of a large-sized wood substrate 1 made of light planted wood plywood having an air-drying specific gravity of less than 0.4 such as Falkata, Radiata Pine, etc., and a thickness of 0.3 mm The fragmentary sectional view explaining the process of mounting the synthetic resin impregnation colored paper 3 which impregnated the synthetic resin in the thick kraft paper of .about.0.6 mm is shown. In addition, as the large-sized wood substrate 1 here, in addition to this, a replantable tree such as acacia mangum having an air-dry specific gravity exceeding 0.4, a plywood using ordinary conifers, broad-leaved trees, LVL It is also possible to use a wood material such as MDF, particle board, laminated wood, wood veneer, or a composite wood material formed by combining two or more of these wood materials. The adhesive 2 is not particularly limited, and for example, a thermosetting resin adhesive such as a melamine resin adhesive, a urea resin adhesive, a urea melamine resin adhesive, or a phenol resin adhesive is used. it can.

  As the synthetic resin impregnated colored paper 3, a thick kraft paper having a thickness of 0.3 mm to 0.6 mm impregnated with a resin solution for impregnation such as melamine resin, phenol resin, DAP resin, isocyanate, or the like What was dried by the semi-hardened state etc. can be used. In particular, kraft paper impregnated with melamine resin, DAP resin, etc. and dried so that the impregnated synthetic resin is in a semi-cured state has moderate strength and stability, so it is easy to handle in the production process It is preferable. In the present embodiment, the color tone of the synthetic resin-impregnated colored paper 3 is colored so as to be similar to the color tone of the wood veneer veneer 5 described later. Such coloring of the synthetic resin-impregnated colored paper 3 may be performed by coloring the kraft paper, may be performed by coloring the synthetic resin to be impregnated, or may be performed by coloring both. .

  Here, when the thickness of the kraft paper used for the synthetic resin-impregnated colored paper 3 is less than 0.3 mm, a chamfering process is performed to form a normal joint groove having a depth of 0.5 mm or more and a good stereoscopic effect. In the case of an attempt, the bottom of the chamfer reaches the inside of the wooden substrate 1, and the color tone of the uneven wooden substrate 1 becomes a color tone different from the color tone of the synthetic resin-impregnated colored paper 3. As a result, the decorativeness of the decorative board is impaired, which is not preferable. In this case, since the thickness and thickness of the synthetic resin impregnated colored paper 3 are thin and low in strength, particularly in the case of manufacturing a decorative sheet for flooring using a light planting tree plywood as in this embodiment as the wooden substrate 1, It is not preferable because the surface of the decorative board for floors is easily damaged by the impact of falling objects, sliding of casters, and the like. On the other hand, even if the thickness of the kraft paper exceeds 0.6 mm, the amount of the synthetic resin to be impregnated increases, which is not preferable.

  FIG. 2 shows an example in which an adhesive 4 is applied on a synthetic resin-impregnated colored paper 3 placed on the surface of the large-sized wood substrate 1 via an adhesive 2, and the thickness is further increased on the adhesive 4. The fragmentary sectional view explaining the process of mounting the wooden decorative veneer 5 of 0.2 mm or more is shown. Here, when the thickness of the wooden decorative veneer 5 is less than 0.2 mm, the wood decorative veneer 5 is easily damaged, and the total thickness with the synthetic resin-impregnated colored paper 3 may be less than 0.5 mm. In such a case, when a chamfering process having a three-dimensional depth of 0.5 mm or more is performed, the bottom of the chamfer 8 reaches the inside of the wooden substrate 1, and the chamfered 8 surface is caused by the color tone inside the wooden substrate 1. Color unevenness occurs, which is not preferable. Moreover, since the wooden decorative veneer 5 becomes expensive even if the thickness becomes 0.6 mm or more, it is preferable that the thickness is practically in the range of 0.2 mm to 0.6 mm. The adhesive 4 is not particularly limited, and the same adhesive as the adhesive 2 can be used. In addition, when the synthetic resin-impregnated colored paper 3 that is dried in a semi-cured state is used, the wood substrate 1 can be smoothed by sanding before the adhesive 4 is applied to the surface.

  Next, in this order from the bottom, the laminated body in which the large-sized wood substrate 1, the adhesive 2, the synthetic resin-impregnated colored paper 3, the adhesive 4, and the wood decorative veneer 5 are sequentially laminated is heated in FIG. As shown in the partial cross-sectional view for explaining the pressurizing step, heat and pressure are applied by the heating and pressurizing means 6 to cure the adhesives 2 and 4 and the synthetic resin impregnated with the synthetic resin impregnated colored paper 3 respectively. They are integrated into a large laminate 7.

  Next, the large laminate 7 is cut into an actual product size with a saw or the like. For example, if the laminate 7 has a width of about 900 mm and a length of about 1800 mm, it is possible to obtain three laminates 7 ′ for a floor plate having a product size of about 300 mm in width and about 1800 mm in length, so that production efficiency can be obtained. Very good. FIG. 4 shows a cross-sectional view of a rectangular floorboard laminate 7 'obtained by this cutting step.

  Next, the chamfering 8 is processed using a chamfering machine on the four-side edges of the floor board laminate 7 ′ thus obtained. FIG. 5 shows a cross-sectional view of the intermediate decorative plate 9 for floor boards obtained by the processing step of the chamfer 8. Here, the depth h of the chamfer 8 is formed to be 0.5 mm or more, and the deepest part does not reach the inside of the wooden substrate 1 but reaches the inside of the synthetic resin-impregnated colored paper 3. It is formed as follows.

  Further, here, as shown in FIG. 5, it is desirable that the male and female real parts 10 and the female real part 11 are formed on the four-sided end face of the intermediate decorative plate 9 for floor board by subjecting the actual processing of male and female. The floorboards can be firmly joined together. Further, as shown in FIG. 5, a decorative groove 12 having the same depth as the depth of the chamfer 8 can be formed in the vertical or vertical and horizontal directions on the surface of the intermediate decorative plate 9 for floorboard, and the construction was carried out thereby. The joints between the floor boards at the time become less noticeable, and the decorativeness of the construction surface can be improved. Such actual processing 10 and 11 of the male and female and the processing of the decorative groove 12 may be performed simultaneously with the chamfering processing, or may be performed as a previous step or a subsequent step.

  Next, a transparent coating layer 13 is formed by applying a transparent coating to the entire surface of the intermediate decorative plate 9 for floorboard thus obtained, including the chamfered surface 8 and the inner surface of the decorative groove 11. The decorative board A for floor boards as shown in FIG. The paint used here is not particularly limited, but there is no problem of VOC, and as a paint having good scratch resistance and abrasion resistance for floor use, solvent-free ultraviolet rays such as urethane acrylate, epoxy acrylate and polyester acrylate are used. It is preferable to use a curable paint, and by using such a paint, the pencil hardness of the coating layer 13 after curing is B or more and the thickness of the coating layer 13 is 40 μm or more. It is preferable to form the coating layer 13.

The floor panel decorative board A thus formed has a transparent coating layer 13 on the inner surface of the joint groove 15 formed at the joint when the side end faces are joined as shown in FIG. The end of the wood-made decorative veneer 5 and the colored resin-impregnated sheet 3 colored in a similar color appears, so that there is no color unevenness or color difference, and the depth is 0.5 mm. As described above, even if there are some steps in the joint, it does not stand out, and a joint groove appearance with good decorativeness and three-dimensional appearance can be revealed.

  In addition, in the manufacturing method of the decorative board A for floorboards of the said Example, in order from the bottom, the large-sized wooden board | substrate 1, the adhesive agent 2, the synthetic resin impregnation colored paper 3, the adhesive agent 4, and the wooden decorative veneer board 5 are ordered. Although the example which manufactures the laminated board 7 by heating-pressing the laminated body by the heating-pressing means 6 was shown, it does not restrict to this, For example, the adhesive agent 2 is apply | coated to the surface of the large-sized wooden substrate 1 After the synthetic resin-impregnated colored paper 3 is placed on the adhesive application surface, the synthetic resin-impregnated colored paper 3 is cured by heating and pressurizing the synthetic resin-impregnated colored paper 3 and curing the synthetic resin. After adhering integrally to the wooden substrate 1 and subsequently applying the adhesive 4 on the cured synthetic resin-impregnated colored paper 3 and placing the wooden decorative veneer 5 on the adhesive 4, The laminate 7 can be manufactured by heating and pressing the laminate.

The fragmentary sectional view explaining the process of mounting the colored resin impregnated sheet 3 on the surface of the wooden substrate 1. The fragmentary sectional view explaining the process of mounting the wooden decorative veneer 5 on the surface of the colored resin impregnated sheet 3. The fragmentary sectional view explaining the process of heat-pressing a laminated body. Sectional drawing which shows the laminated body 7 'for floor boards obtained by the cutting process. Sectional drawing which shows the intermediate | middle decorative board 9 for floor boards obtained by the chamfering process. Sectional drawing which shows the decorative board A whole. The fragmentary sectional view which shows the joining state of the decorative boards A.

Explanation of symbols

A decorative board 1 wood substrate 2 adhesive 3 synthetic resin impregnated colored paper 4 adhesive 5 wood decorative veneer 6 heating and pressing means 7 laminate 7 'laminate for floor board 8 chamfer 9 intermediate decorative board for floor board 10 male part 11 Female real part 12 Cosmetic groove 13 Transparent coating layer 14 Heating and pressing device 15 Joint groove

Claims (4)

  An adhesive is applied to the surface of a large-sized wood substrate, and a synthetic resin-impregnated colored paper impregnated with a synthetic resin is placed on a thick kraft paper having a thickness of 0.3 mm to 0.6 mm on the adhesive application surface. Then, an adhesive is applied to the placed synthetic resin-impregnated colored paper, and a wooden decorative veneer having a thickness of 0.2 mm or more is placed on the adhesive-coated surface to form a laminated body. The synthetic resin in the synthetic resin impregnated colored paper is cured by heating and pressurizing and bonded and integrated to form a laminated board, then the laminated board is cut into a predetermined product shape, and then the side edges of the cut laminated board Is chamfered to a depth of 0.5 mm or more and does not reach the wood substrate, and then a transparent coating is applied to the entire surface including the chamfered surface to form a transparent coating layer. A method for producing a decorative board.   An adhesive is applied to the surface of a large-sized wood substrate, and a synthetic resin-impregnated colored paper impregnated with a synthetic resin is placed on a thick kraft paper having a thickness of 0.3 mm to 0.6 mm on the adhesive application surface. Then, the synthetic resin in the synthetic resin-impregnated colored paper is cured by heating and pressurizing, and the wood substrate and the synthetic resin-impregnated colored paper are bonded and integrated. Then, a laminate of a wooden decorative veneer having a thickness of 0.2 mm or more is placed on the adhesive application surface to form a laminated body, and the laminated body is heated and pressed to form a laminated board. The laminated board is cut into a predetermined product shape, and then the side edge of the cut laminated board is chamfered to a depth not less than 0.5 mm and not reaching the wood substrate, and then the surface including the chamfered surface Apply a transparent paint over the entire surface to form a transparent coating layer Method for manufacturing a decorative laminate according to claim.   The method for producing a decorative board according to claim 1 or 2, wherein the synthetic resin-impregnated colored paper is colored in a color tone similar to that of the wood decorative veneer.   The large-sized woody substrate is formed of a single plate laminated plate such as a plywood or LVL formed by laminating and bonding planted wood single plates having an air-drying specific gravity of 0.4 or less. The manufacturing method of the decorative board as described in any one of.

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