JP2008221688A - Manufacturing method of decorative plate with straight grain pattern - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing method of a decorative plate, which can manufacture stably and with a good productivity the decorative plate of the same excellent design properties and strength as resin-impregnated dressed lumber having a straight grain pattern. <P>SOLUTION: After concave grooves 4, 4'... are formed on the surface of natural wood 2 such as forested trees in which an early wood portion and a late wood portion are not clear on the surface of a decorated base material 1 by using rotating saws 6, 6'..., the concave grooves 4, 4'... and the surface 5 of the natural wood 2 except the concave grooves 4, 4'... are hit by a blast polishing agent 13 and are uniformly subjected to a blast treatment. Next, a permeable resin 8 is coated and impregnated. Further, after a coloring resin 9 is coated on the surface so as to fill at least the inside of the concave grooves 4, 4'..., an active energy beam is irradiated to cure. And the surface is ground uniformly and is coated by a transparent resin paint to form a transparent resin coated film 10 on the surface, by which the decorative plate having the straight grain pattern excellent in design properties is manufactured. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a method for manufacturing a decorative board having a checkerboard pattern, which can manufacture a decorative board having a checkered pattern having excellent design properties with high productivity.

  Conventionally, for example, as shown in Patent Document 1, a veneer made of natural wood is attached to the surface of a substrate made of fiberboard, and after dyeing the surface of the veneer, the surface is brushed to give a soft Natsume ( A decorative board is known in which the early wood part) is cut and the colored winter eyes (late wood part) are lifted. In addition, as shown in Patent Document 2, after a synthetic resin liquid is impregnated and injected into a coniferous veneer veneer that is a natural tree or an artificial wood veneer veneer that is an artificial tree, a cushioning sheet is placed on one side of the veneer veneer. There is known a floating-style decorative board formed by placing and heating and pressing between flat hot plates and compressing a soft material portion (fast material portion). Furthermore, as shown in Patent Document 3, a technique for manufacturing a decorative board by cutting soft Natsume (early material part) by sandblasting is also known.

  The decorative board obtained by such a method has an advantage that the grain of natural wood is emphasized by the color and the three-dimensional effect, and the decorative design can be further emphasized.

  On the other hand, natural trees with good grain have been depleted in recent years, and the need for utilizing planted trees that are fast growing and suitable for reproduction on the global environment and unused timber with low grain decoration is increasing. ing. However, such afforestation trees and unused timber are often unclear in the hardness and color difference between the early and late wood, and the grain of the grid is irregularly irregular and often has low design. Had the problem.

  For this reason, even if an attempt is made to produce a wood grain decorative board by applying the methods described in Patent Document 1, Patent Document 2, and Patent Document 3 to such planted trees and unused wood, the brushing and heat A technique such as a board press or sand blasting has a problem that the grid pattern that can be formed becomes unclear and the design of the resulting decorative board is lowered.

In addition, the above brushing, hot plate press, sand blasting, etc. all emphasize the grain pattern using the difference in hardness between the natural wood's original early wood part and late wood part. When trying to obtain a decorative board having a good pattern, it is necessary to carefully select and secure expensive natural wood having a decorative pattern, and the yield will be extremely poor by careful selection. Was. Furthermore, all of the processes such as the hot platen press have a problem that the production speed is slow and the productivity is deteriorated.
JP 58-84709 A JP 58-71104 A JP 53-69803 A

  The present invention has been made in view of the above points, and its purpose is to provide a decorative board having a checkered pattern by improving the manufacturing method of the decorative board, even in a hard environment such as a floor. It is an object of the present invention to provide a method for producing a decorative board having a checkerboard pattern that can be used with high productivity and can be used even for planted trees and unused wood.

  According to the first aspect of the present invention, there is provided a method for producing a decorative board having a checkerboard pattern, wherein a plurality of concave grooves extending from one side portion to another side portion are formed on a surface of a decorative substrate having a surface formed of natural wood. A groove groove cutting process provided by cutting, a blasting process in which the entire surface of the decorative substrate provided with the groove is blasted and hit with particles, and a permeable resin is applied to the entire surface of the blasted decorative substrate , Impregnating permeable resin impregnation step, applying and filling the permeable resin, coloring resin coating filling step of applying and filling the colored resin in at least the concave groove on the impregnated decorative substrate surface, applying the colored resin, A coloring process for grinding the entire surface of the filled decorative substrate and a transparent resin paint applying step for applying a transparent resin paint to the surface of the ground decorative substrate.柾 Resin Characterized in that so as to emerge as a pattern.

  In other words, in the present application, the colored resin is filled in the inside of a large number of groove grooves cut in the groove groove cutting step so that this appears as a grid pattern, so there is no need to carefully select the grain of natural wood to be used. Even unused wood with poor grain can be used as natural wood. Further, in the brushing treatment, flat plate pressing treatment, or sandblasting treatment, it is preferable to use natural wood having a clear difference in hardness and color between the early wood portion and the late wood portion. Even unclear and light planted trees can be applied well as natural wood and can be produced with high productivity.

  Further, in the blasting process, the surface of the decorative substrate provided with the groove is beaten with particles, so that it is possible to give a natural roundness to the opening corner of the monotonous groove formed by cutting. The design can be improved by giving a natural texture to the groove. Furthermore, the surface of the decorative substrate surface is reinforced by the impregnated permeable resin so that the surface of the decorative substrate can be impregnated in the next process with good productivity by giving small scratches on the surface of the decorative substrate by such blasting treatment. In addition, it can be formed on a decorative board having a grid pattern that can be suitably used for hard applications such as flooring.

  Moreover, the outstanding surface protection can be provided by the following grinding process and transparent resin coating application process. In this grinding process, a design change can be given to the surface color and the shape of the groove groove by adjusting the grinding amount.

  The method for producing a decorative board having a checkerboard pattern according to the invention of claim 2 is characterized in that, in the method for manufacturing a decorative board having a checkerboard pattern according to claim 1, active energy ray curing characteristics as the permeable resin and the colored resin. And an active energy ray irradiating step of irradiating the applied permeable resin and the colored resin with an active energy line between the colored resin coating and filling step and the grinding step. It is characterized by that.

  As described above, since the resin having active energy ray curing characteristics and moisture curing characteristics is used for both the permeable resin and the colored resin, the active energy rays are irradiated after the colored resin coating and filling step. Curing of the permeable resin penetrating into the surface and at least the colored resin filled in the groove can be promoted at the same time without causing problems such as foaming of the resin. And even if the penetrating resin or colored resin where the active energy ray is hard to reach remains in a state where it is not sufficiently cured, it can be cured sufficiently within a few days due to the moisture curing action, resulting in poor effect It can be prevented well.

  Here, after applying and impregnating the permeable resin and before applying the colored resin, active energy rays can be irradiated. In this case, curing of the permeable resin coated and impregnated on the entire surface of the decorative substrate can be further promoted, and poor adhesion occurs between the permeable resin impregnated at the bottom of the groove and the colored resin. Can also be prevented.

  The method for producing a decorative board having a checkerboard pattern according to the invention of claim 3 is the method for manufacturing a decorative board having a checkerboard pattern according to claim 1 or 2, wherein the permeable resin is applied in the colored resin coating and filling step. The colored resin is applied to the entire surface including the inside of the groove of the impregnated decorative substrate, and grinding is performed so that the colored resin remains on the entire surface of the decorative substrate in the grinding step.

  As a result, there is a disadvantage that the amount of the colored resin to be used is increased compared to the case where it is manufactured by a complicated and difficult process of accurately applying and filling the colored resin only in the groove formed in a natural shape. Productivity can be greatly improved. In addition, the decorative board having a checkerboard pattern to be obtained should be formed into a decorative board having a checkered pattern with a natural texture, in which the grooves are dark and the other surface has a slightly smaller light contrast difference. Can do.

  The method for manufacturing a decorative board having a checkerboard pattern according to the invention of claim 4 is the method for manufacturing a decorative board having a checkerboard pattern according to claim 1 or 2, wherein a permeable resin is applied in the colored resin application and filling step. It is characterized in that the colored resin is applied to the entire surface including the inside of the groove groove of the impregnated decorative substrate and is ground so as to remove the colored resin applied to the surface other than the groove groove in the grinding step. To do.

  As a result, it is possible to obtain a decorative board having a well-decorated checkerboard pattern in which the contrast between colors other than the groove and the groove is clear and the checkered pattern is emphasized.

  The method for producing a decorative board having a checkerboard pattern according to the invention of claim 5 is the method for manufacturing a decorative board having a checkerboard pattern according to any one of claims 1 to 4, wherein the cutting is performed in the groove cutting process. The groove width of the groove is a plurality of types in the range of 0.8 mm to 3.0 mm.

  Accordingly, a plurality of concave grooves having different groove widths can be provided, and a natural design with a higher design and a natural feeling can be revealed. In addition, if the groove width of the groove is less than 0.8 mm, the grid pattern becomes inconspicuous and the design property becomes low, and cutting with a saw blade or the like makes the blade thin and makes stable cutting difficult, which is not preferable. In addition, if the groove width exceeds 3.0 mm, the appearing meshes are unnaturally widened and the design property is lowered, and the cutting resistance is increased and the productivity is deteriorated. Further, when machining with a width exceeding 2.0 mm, the cutting resistance increases, so it is preferable to use a combination of a plurality of blades having a width of about 1.0 mm.

  In the manufacturing method of the decorative board which has a checkerboard pattern concerning invention of Claim 6, in the manufacturing method of the decorative board which has a checkerboard pattern of any one of Claims 1-5, it uses in a concave groove cutting process. A decorative substrate having a surface formed of wood is composed of a wood base material, a barrier layer formed on the surface of the wood base material, and a wood single plate having a thickness of 0.2 mm to 1.0 mm attached to the surface of the barrier layer. The groove is formed and cut so that the groove has a depth that does not reach the barrier layer.

  Thereby, impregnation of the permeable resin is prevented by the barrier layer, and the amount of the permeable resin impregnated can be made uniform and constant.

  As described above, according to the present invention, a decorative board having an excellent design with a checkered pattern can be produced with high productivity even if it is an unclear tree planted tree or unused wood. Can do.

[First Embodiment]
Hereinafter, the manufacturing method of the decorative board concerning the 1st Embodiment of this invention is demonstrated in detail based on FIG.

(Base material)
The base material 3 constituting the decorative substrate 1 is a wood base material such as wood, plywood, laminated wood, MDF (medium specific gravity wood fiber board), particle board, or an inorganic base material such as gypsum board, volcanic glassy multilayer board, etc. It can be used by selecting from materials or composite base materials obtained by combining these materials.

(Natural wood)
The decorative substrate 1 can be formed by sticking a wood veneer that is the natural wood 2 to the surface of the base material 3. As such natural wood 2, there can be suitably used afforested trees that have no great difference in hardness and color between the early wood part and the late wood part, and the difference is unclear, or unused wood that does not have a good grain appearance. . Specifically, aspen, poplar, cottonwood, aegiriaceae, gills of scorpionaceae, maple family soft maple red maple, silver maple, box elder, big leaf maple It is desirable to select. The thickness can be about 0.2 mm to 3.0 mm, usually about 0.20 mm to 1.0 mm, preferably about 0.25 mm to 0.6 mm. Is most suitable for reducing the load on the resin curing process described later and increasing the productivity.

  First, as shown in FIG. 1A, the natural wood 2 is attached to the surface of the base material 3 to form the decorative substrate 1.

(Concave groove cutting process)
Next, as shown in FIG. 1 (b), the surface 2 a of the natural wood 2, which is the surface of the obtained decorative substrate 1, is longitudinally extended from one end to the other with a plurality of rotary saws 6, 6 ′. A number of substantially parallel grooves 4, 4 ',... Communicating in the direction are provided. The step of forming such a large number of concave grooves 4, 4 ′,... Can be performed in a single step, or can be performed in a plurality of steps. Moreover, although the above-mentioned many grooved grooves 4, 4 '... may have the same groove width, the grooved grooves 4, 4 of different widths can be obtained by changing the thickness of the blades of the rotary saws 6, 6' .... It is preferable from the viewpoint of design to be formed in a '··. In addition, in FIG. 1, the groove shape of the concave grooves 4, 4 ′ is approximately U-shaped, but the present invention is not limited to this, and the groove shape is substantially V-shaped or U-shaped. It can also be formed, and furthermore, the concave grooves 4, 4 ′ having various cross-sectional shapes can be used in combination. In this way, by changing the cross-sectional shape of the groove grooves 4, 4 ′,..., The colored resin 9 filled in the groove grooves 4, 4 ′,. A decorative feeling can be given and it can form in the decorative board A which has a good design.

  In the first embodiment described above, the rotary saws 6 and 6 'are used as the cutting tools for the concave grooves 4 and 4'. Such cutting of the concave grooves 4, 4 'by the rotary saws 6, 6' is preferable because the productivity is very good. Furthermore, when forming the concave groove 4, 4 'of a complicated shape, a cutting tool such as a router can be used.

  Further, the groove width of the concave grooves 4, 4 ′ is in the range of about 0.8 mm to 3.0 mm, and the concave groove is satisfactorily concave due to the design of the grid pattern to be revealed and the rotary saws 6, 6 ′. As described above, it is desirable to cut the grooves 4, 4 ′,.

(Blasting process)
Next, as shown in FIG. 1 (c), the surface of the natural wood 2 including the groove grooves 4, 4 ′,... And the surface 5 other than the groove grooves 4, 4 ′,. A blasting abrasive 13, which is a fine particle, is caused to collide and blasting is performed. As abrasives used for such blasting treatment, glass beads, glass powder, inorganic particles such as silicon, metal particles such as alumina, hard organic particles pulverized with walnuts and peach seeds, etc., or finely pulverized dry ice Dry ice particles or the like can be used.

  The particle size of the blasting abrasive 13 used here is preferably adjusted to 90 μm or more and 150 μm or less. For example, when inorganic particles are used, the sieving method performs sieving in about 3 to 5 stages. For example, if 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 third stage sieve is set to 90 μm, 90 μm to It can be adjusted to a blasting abrasive 13 containing about 70% or more of a particle size of 150 μm. The remaining less than about 30% includes those having a flat shape or a sharp shape, or those having a size of not more than 90 μm.

  The abrasive material 13 for blasting obtained in this way is naturally dropped from a plurality of nozzles 7 arranged at an arbitrary position above the decorative substrate 1 or sprayed by applying air pressure to the decorative substrate 1. Blasting is performed by colliding with the surface of the natural wood 2 on the surface.

  By such a blasting process, fine scratches 15 are formed on the surface of the natural wood 2 of the decorative substrate 1, thereby improving the impregnation of the permeable resin 8 described later into the natural wood 2. Further, the opening corners of the concave grooves 4, 4 ',... Are preferentially removed by the collision of the blasting abrasive 13, and the opening corners can be formed into a substantially R-shaped cross section. Furthermore, even when a planted tree having a clear difference in hardness and color between the early wood portion and the late wood portion is used as the natural wood 2 as in the first embodiment, the early wood portion is soft by blasting. Since the subtle unevenness can be generated on the surface of the natural wood 2 between the part and the slightly hard part of the late material part, it is possible to reveal a design with rich natural feeling.

(Penetration resin application process)
Next, as shown in FIG.1 (d), the permeable resin 8 is apply | coated and impregnated to the whole surface including the grooved groove | channels 4 and 4 'of the said blasted decorative board | substrate 1. FIG. For example, a sponge roll coater, a natural reverse coater, or a flow coater (not shown) can be used as a means for applying such a permeable resin 8. Since fine scratches are formed by blasting as described above, the permeable resin 8 can be satisfactorily impregnated into the natural wood 2.

  In this case, the permeable resin 8 is mainly composed of a material obtained by appropriately adding a reactive monomer to an oligomer or polymer such as polyester acrylate, epoxy acrylate, urethane acrylate, or polyether acrylate alone or mixed. When the active energy ray is ultraviolet, a photopolymerization initiator is added, and further, a polyisocyanate is added at about 1% by mass to 15% by mass.

  Among the monomers used, examples of monofunctional monomers include lauryl acrylate, 2-ethylhexyl acrylate, 2-hydroxyethyl acrylate, 1,6-hexanediol monoacrylate, dicyclopentadiene acrylate, 2-hydroxylpropyl acrylate, phenoxy (dioxy ) Ethylene glycol acrylate, isobornyl acrylate, β-carboxyethyl acrylate, acryloyl morpholine, 2-hydroxyethyl acryloyl phosphate, tetrahydrofurfuryl acrylate, N, N-diethylaminoethyl acrylate, N, N-dimethylaminoethyl acrylate, glycidyl Examples include acrylate and benzyl acrylate.

  Examples of bifunctional monomers include ethylene glycol dimethacrylate, diethylene glycol di (meth) acrylate, triethylene glycol di (meth) acrylate, polyethylene glycol di (meth) acrylate, dipropylene glycol di (meth) acrylate, and tripropylene. Glycol di (meth) acrylate, polypropylene di (meth) acrylate, 1,6-hexanediol diacrylate, 1,4-butanediol di (meth) acrylate, neopentyl glycol di (meth) acrylate, 1,9-nonanediol Examples include di (meth) acrylate.

  Examples of the trifunctional monomer include trimethylolpropane tri (meth) acrylate, ethoxylated trimethylolpropane tri (meth) acrylate, pentaerythritol tri (meth) acrylate, glycerin propoxytriacrylate, and the like.

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

  Further, a moisture-reactive curing agent is added to the obtained permeable resin 8 to impart moisture curing characteristics. As a specific example of the moisture curing type curing agent, an isocyanate compound is preferably used. These isocyanate compounds react with moisture in the air or wood, and accelerate the curing of the deep permeable resin 8 where the active energy rays are difficult to reach.

  Specific examples of such isocyanate compounds include isocyanate monomers such as hexamethylene diisocyanate, isophorone diisocyanate, tolylene diisocyanate, diphenylmethane diisocyanate, xylylene diisocyanate, norbornene diisocyanate, biurets, isocyanurates, and trimethylolpropane of these compounds. And polyisocyanate derivatives such as adducts, or block bodies of these isocyanate monomers and polyisocyanate derivatives. Furthermore, it is desirable to use a non-yellowing type or a hardly yellowing type as such an isocyanate compound. And these isocyanate type compounds can also be used individually or in mixture of multiple types.

  When ultraviolet rays are used as the active energy rays, a photopolymerization initiator is added to the permeable resin 8. Specific examples of such photopolymerization initiators include generally used radical reaction type acetophenone-type, benzophenone-type, benzyl-type, benzoin-type carbonyl compounds, tetraalkylthiuram monosulfide, thioxanthone and other sulfur compounds. These can be used alone or as a mixture of two or more thereof.

  Specifically, the photopolymerization initiator contains bisacylphosphine oxide in an amount of 0.1 to 1.5% by mass, or monoacylphosphine oxide in an amount of 0.5 to 5.0% by mass. It is desirable to include the following. Furthermore, these two may be mixed and used. Bisacylphosphine oxide and monoacylphosphine oxide have an absorption maximum in a long wavelength region where the ultraviolet wavelength region is around 350 nm to 400 nm. Therefore, the permeable resin 8 can be further efficiently cured by using a light emission method having an emission spectrum in a long wavelength region of 350 nm to 400 nm as light emitting ultraviolet light. Specifically, a metal halide lamp, an electrodeless D bulb, a V bulb, a Q bulb, an M bulb, a pulse UV method, or the like is used.

  Furthermore, when the active energy ray is ultraviolet as described above, a reaction aid such as a sensitizer, a light stabilizer, an ultraviolet absorber, and a storage stabilizer may be appropriately added to the permeable resin 8. Coloring can also be performed by adding dyes, pigments, and the like. In addition, when using an electron beam as an active energy ray, it is not necessary to add the said photoinitiator to the permeable resin 8. FIG.

  Furthermore, commonly used catalysts such as tin compounds, zinc compounds, and amine compounds can be added to the permeable resin 8.

  Further, the permeable resin 8 is desirably a resin having a low viscosity and a high permeability. Specifically, it is desirable that the viscosity when applied to the surface of the natural wood 2 is 100 Pa · s or less. Thus, permeability can be improved by making the permeable resin 8 low viscosity. In addition, the permeable resin 8 is adjusted so that it may become said viscosity by diluting with the monomer mentioned above, or heating. Moreover, for example, the surface temperature of the decorative substrate 1 is preliminarily heated so as to be 50 ° C. to 70 ° C., and the permeable resin 8 adjusted to a temperature 10 ° C. to 20 ° C. lower than the surface temperature is applied. The impregnation property of the resin 8 can be further improved.

  In this way, when the resin curable with active energy rays is used as the permeable resin 8, the resin impregnated into the decorative substrate 1 can be quickly and surely cured by irradiating the active energy rays. Productivity can be increased, which is preferable. In the case where the permeable resin 8 has both the action of curing with active energy rays and the action of curing with moisture, even if a portion where the curing is insufficient due to the irradiation of active energy rays occurs, the moisture can be removed within a short period of time. It can be fully cured by the curing action.

(Coloring resin coating and filling process)
Next, as shown in FIG. 1 (e), the colored resin 9 is applied to the entire surface of the decorative substrate 1 including the concave grooves 4, 4 ',. Colored resin 9 is filled into the grooves 4, 4 '. The coloring resin 9 can be applied using a sponge roll coater, natural reverse coater, rubber roll coater, knife coater or the like. Here, when the colored resin 9 is applied only in the concave grooves 4, 4 ′, and the colored resin 9 is filled only in the concave grooves 4, 4 ′, the nozzle can be used.

  Such a colored resin 9 does not need to be permeable like the permeable resin 8, but the same resin as the permeable resin 8 can be used. Can be used as an essential component. In the case of the colored resin 9 as well, if the resin having both active energy ray curing characteristics and moisture curing properties is used as in the case of the permeable resin 8, the colored resin 9 is rapidly cured by irradiation with the active energy rays. In addition to the above, even if there is a part where the active energy ray did not reach sufficiently, it can be sufficiently cured in a short period of time by the moisture curing action. Here, the amount of the colorant added to the colored resin 9 is usually about 0.1% by mass to 1.0% by mass. However, when an electron beam is used as the active energy ray, the colorant is inhibited from curing. Since the influence is small, it can be increased to about 5% by mass.

(Active energy ray irradiation process)
Next, the surface of the decorative substrate 1 to which the permeable resin 8 and the colored resin 9 are applied is irradiated with active energy rays made of ultraviolet rays or electron beams. Such irradiation of active energy rays may be performed only once after the colored resin 9 is applied as in the first embodiment, or after the permeable resin 8 is applied and after the colored resin 9 is applied. You may do it two times later. In addition, it cannot be overemphasized that this active energy ray irradiation process is unnecessary when using the permeable resin 8 and the colored resin 9 which are not accelerated | stimulated even if it irradiates an active energy ray.

In addition, when the groove grooves 4, 4 ′,... Are deeper than 0.4 mm, the groove grooves 4, 4 ′ are repeated by repeating the colored resin coating and filling step and the active energy ray irradiation step twice or more. It is possible to satisfactorily fill and cure the colored resin 9 therein, and to prevent problems such as foaming of the filled colored resin 9.
In addition, when the depth of the concave grooves 4, 4 ′ is deep as described above, when an electron beam is used as the active energy ray, the colored resin or the permeable resin can be cured with a small number of times. In this case, a low energy electron beam irradiation apparatus of about 50 to 300 keV is generally used. Since the active energy rays are stronger than ultraviolet rays, the filled colored resin 9 is sufficiently cured by a single irradiation process even when the concave grooves 4, 4 ′ having a depth of about 1.0 mm are provided. Can do. Furthermore, in this case, since the permeable resin 8 impregnated in the natural wood 2 on the surface can be sufficiently cured at the same time, there is an advantage that there is no fear of causing an adhesion failure immediately after manufacture and peeling.

(Grinding process)
Next, the surface of the decorative substrate 1 on which the permeable resin 8 and the colored resin 9 are cured in the active energy ray irradiation step is ground. In this grinding step, grinding is performed so that the colored resin 9 filled in the concave grooves 4, 4 ′,. In this embodiment, the case where the colored resin 9 is applied to the entire surface of the natural wood 2 which is the surface of the decorative substrate 1 is shown. After grinding, as shown in FIG. In this example, grinding is performed so that the colored resin 9 remains on the surface 5 of the decorative substrate 1 other than the groove grooves 4 ', 4', and 4 '. In this case, the grooves 4, 4 ′... Are dark and the surface 5 of the decorative substrate 1 other than the grooves 4, 4 ′. It can be formed on the decorative board A having a small and excellent natural pattern.

  In this grinding step, the colored resin 9 applied to the surface of the decorative substrate 1 other than the groove grooves 4, 4 ′,... Is removed, and only the colored resin 9 filled in the groove grooves 4, 4 ′,. It is also possible to grind so that it remains. In this case, it is possible to form the decorative board A in which the surface other than the groove grooves 4, 4 ',... And the surface of the groove grooves 4, 4',.

(Transparent resin coating application process)
Next, as shown in FIG. 1 (f), a transparent resin coating is applied to the surface of the natural wood 2 on the surface of the decorative substrate 1 that has been uniformly ground, and then cured to form a transparent resin coating film 10. Form. In this embodiment, since the permeable resin 8 is impregnated, a decorative board having a surface strength sufficient to withstand use as a flooring material, for example, without performing thick film coating such as general reinforced coating. A can be obtained. However, in order to further improve the design properties, a thick film coating of 150 μm to 250 μm can be performed, and a colored layer made of a colorant such as a pigment is provided in the lowermost layer of the transparent resin coating film 10. You can also.

(Effect of the first embodiment)
Thus, in this 1st Embodiment, since the groove groove 4, 4 '... is cut with the rotary saw 6, 6' ..., production speed is high, and this groove groove 4, 4 '. '··· Since colored resin 8 is filled, a decorative substrate 1 having a natural wood 2 with a small difference in hardness and color between the early wood part and the late wood part such as an early plantation tree is used. Even in this case, the colored resin-filled concave grooves 4, 4 ′,. Further, by performing blasting, it is possible to give a natural roundness to the opening corners of the groove groove to impart design properties, and to improve the impregnation of the permeable resin 8 to thereby improve the surface of the decorative substrate 1. It can be reinforced with good productivity.

  Furthermore, as the permeable resin 8 and the colored resin 9, those having both active energy ray curing characteristics and moisture curing characteristics are used, so that they are produced on a continuous line without causing defects such as poor curing and resin foaming. A decorative board A having a square pattern can be produced with good quality.

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

  In the second embodiment, first, as shown in FIG. 2A, a base material 3 having a barrier layer 11 on its surface is used, and a wood veneer is pasted as a natural wood 2 on the surface of this barrier layer 11. The decorative substrate 1 is worn. Such a barrier layer 11 prevents the excessive impregnation of the permeable resin 8 into the base material 3 to form a homogeneous impregnation layer, and the surface strength so that it can be applied to hard conditions such as flooring. It can be provided between the base material 3 and the decorative substrate 1 for the purpose of improving the quality.

  Examples of such a barrier layer 11 include a hot-melt resin coating layer, a resin plate, a resin-impregnated paper, and the like that are coated with a hot-melt resin and cured. Other configurations and effects are the same as those of the first embodiment.

(Example 1)
A use veneer having a thickness of 0.6 mm as a natural wood was bonded to the surface of a rectangular base material made of plywood having a thickness of 10 mm, a length of 1850 mm, and a width of 130 mm using a vinyl urethane adhesive to form a decorative substrate.

  Next, a concave groove having a depth of 0.5 mm communicating with the longitudinal direction was formed on the surface of the decorative substrate by a three-step concave groove cutting process shown below.

  That is, in the first groove cutting process, five substantially parallel grooves are cut by a rotary saw device having one 4.0 mm wide rotary blade and four 3.0 mm wide rotary blades. Next, in the second groove groove cutting step, two 2.5 mm wide rotary blades and a 2.0 mm wide blade are positioned so as not to overlap the groove grooves formed in the first groove groove cutting step. Five substantially concave grooves are cut by a rotary saw device having three rotary blades, and then in the third concave groove cutting process, the first and second concave grooves are cut. Seven substantially parallel groove grooves are cut by a rotary saw device provided with seven 1.0 mm wide rotary blades at positions that do not overlap with the formed groove grooves, and the depth is 0.5 mm with a U-shaped cross section. 17 parallel grooves having a width of 1.0 mm to 4.0 mm were formed.

  Next, blasting was performed on the entire surface including the groove groove of the decorative substrate on which the groove groove was formed. Sandblasting abrasives (Fuji Glass Beads # 150: manufactured by Fuji Seisakusho) were used for this blasting treatment. By this blasting treatment, the entire surface of the decorative substrate was struck, and the opening corners of the 17 concave grooves were naturally rounded and formed into a surface property that was easily impregnated with the next permeable resin.

  Next, a penetrating resin having an ultraviolet curing property is obtained by using 40 parts by mass of epoxy acrylate, 30 parts by mass of tripropylene glycol diacrylate, 30 parts by mass of 2-hydroxypropyl methacrylate, 20 parts by mass of hexamethylene diisocyanate, 10 parts by mass of polyol, and dye. 0.5 parts by mass and 3 parts by mass of 2-hydroxy-2-methyl-1-phenyl-propan-1-one were added for adjustment.

  Then, the decorative substrate after the blasting treatment is cured for 60 seconds in a ventilated dryer set at 80 ° C., taken out from the dryer and its surface temperature is adjusted to 40 ° C., and then the permeable resin adjusted as described above is used as a flow coater. Was applied at 80 g / m 2. This was allowed to stand for 60 seconds under normal temperature (25 ° C.) conditions to impregnate the applied single plate on the surface of the decorative substrate with the applied permeable resin.

  Next, a colored resin having ultraviolet curing properties is prepared by adding 60 parts by mass of epoxy acrylate, 40 parts by mass of tripropylene glycol diacrylate, 5 parts by mass of acryloylmorpholine, 5 parts by mass of hexamethylene diisocyanate, 0.7 parts by mass of dye, and bisacyl. It was prepared by blending 0.7 parts by mass of phosphine oxide and 3 parts by mass of 2-hydroxy-2-methyl-1-phenyl-propan-1-one.

  Then, the colored resin is applied twice on the entire surface of the decorative substrate impregnated with the permeable resin using a rubber roll coater, and the surplus resin on the surface other than the groove groove is further applied using an iron reverse coater. The groove was scraped to fill the groove with a colored resin. Then, the surface of the decorative substrate was irradiated with ultraviolet rays to cure the permeable resin impregnated on the decorative substrate surface and the colored resin applied to the inside of the groove and the surface other than the groove.

  Next, the surface of the decorative substrate obtained in this way is slightly scraped off the surface of the colored resin filled in the groove, that is, the colored resin adhering to the surface other than the groove is completely removed. Make up with a wide belt sander to the extent that it is scraped off, apply a colorant to the entire surface of the ground decorative board, and then apply a transparent resin paint on the surface to cure it. I got a plate.

(Example 2)
As a decorative substrate, a melamine resin impregnated paper is bonded to the surface of the base material, and a 0.15 mm thick barrier layer is formed on the surface as natural wood, and a 0.3 mm thick used veneer is bonded with a vinyl urethane adhesive What was done was used.

  Next, a substantially V-shaped concave groove having a depth of 0.3 mm communicating in the longitudinal direction was formed on the surface of the decorative substrate by a rotary saw by a three-stage concave groove cutting process shown below.

  That is, in the first groove cutting process, five substantially cross-sectionally V-shaped sections that are substantially parallel by a rotary saw device including one 4.0 mm wide rotary blade and four 3.0 mm wide rotary blades. Next, in the second groove groove cutting step, two 2.5 mm wide rotary blades are positioned so as not to overlap with the groove groove formed in the first groove groove cutting step. And 5 substantially V-shaped groove grooves which are substantially parallel to each other by a rotary saw device provided with three rotary blades having a width of 2.0 mm and the third groove groove cutting step, And seven substantially V-shaped groove grooves which are substantially parallel by a rotary saw device provided with seven 1.0 mm-wide rotating blades at positions not overlapping with the groove grooves formed in the second groove groove cutting step. Were cut to form 17 substantially V-shaped concave grooves having a V-shaped cross section, a depth of 0.3 mm, and an opening width of 1.0 mm to 4.0 mm.

  Next, the entire surface including the groove groove of the decorative substrate on which the groove groove is formed is blasted in the same manner as in the first embodiment, and the opening angle of the 17 groove grooves in the same manner as in the first embodiment. The surface was naturally rounded and formed into a surface property that was easily impregnated with the next permeable resin.

  Next, a penetrating resin having an ultraviolet curing property was added to 25 parts by mass of urethane acrylate, 35 parts by mass of epoxy acrylate, 25 parts by mass of tripropylene glycol diacrylate, 15 parts by mass of acryloylmorpholine, 20 parts by mass of hexamethylene diisocyanate, and dye 0. .5 parts by mass and 3 parts by mass of 2-hydroxy-2-methyl-1-phenyl-propan-1-one were prepared and adjusted.

  Then, the decorative substrate after the blasting treatment is cured for 60 seconds in a ventilated dryer set at 80 ° C., taken out from the dryer and its surface temperature is adjusted to 40 ° C., and then the permeable resin adjusted as described above is used as a flow coater. To 70 g / m 2. This was allowed to stand for 60 seconds under normal temperature (25 ° C.) conditions to impregnate the applied single plate on the surface of the decorative substrate with the applied permeable resin. The permeable resin was not impregnated inside the base material below the barrier layer.

  Next, the surface of the decorative substrate impregnated with the permeable resin was irradiated with ultraviolet rays to cure the impregnated permeable resin.

  Next, a colored resin having an ultraviolet curing property was prepared in the same manner as in Example 1, and the surface of the decorative substrate in which this colored resin was impregnated and cured with the above permeable resin was applied in the same manner as in Example 1. The decorative substrate was applied twice using a roll coater to fill the groove with the colored resin and to which the colored resin was applied to the portion other than the groove. Then, the surface of the decorative substrate was irradiated with ultraviolet rays to cure the permeable resin impregnated on the decorative substrate surface and the colored resin applied to the inside of the groove and the surface other than the groove.

  Next, the surface of the decorative substrate thus obtained is ground with a wide belt sander so that the colored resin in portions other than the grooves is left on the surface, and a colorant is applied to the entire surface of the ground decorative substrate. Then, a transparent resin paint was applied to the surface and cured to obtain a decorative board having a natural contrast and a small contrast between the grooves of the grooves and the other surfaces. .

  INDUSTRIAL APPLICATION This invention is especially useful in manufacturing the decorative board suitable for floors, such as WPC which was excellent in the designability which has a checkerboard pattern, with sufficient productivity.

The figure which shows the manufacturing process of the decorative board A which concerns on the 1st Embodiment of this invention. The figure which shows the manufacturing process of the decorative board B which concerns on the 2nd Embodiment of this invention.

Explanation of symbols

A, B Decorative plate 1 Decorative substrate 2 Natural wood 2a Natural timber surface 3 Base material 4, 4 'Concave groove 5 Surface 6, 6' of the decorative substrate 1 other than the dent groove Rotary saw 7 Nozzle 8 Penetration resin 9 Coloring Resin 10 Transparent resin coating film 11 Barrier layer 13 Blasting abrasive 15 Fine scratch

Claims (6)

  A grooved groove cutting step in which a number of grooved grooves extending from one side to the other side of the decorative substrate having a surface formed of natural wood are cut by cutting, and the decorative substrate provided with the grooved groove A blasting process in which the entire surface of the substrate is blasted and hit with particles, a permeable resin impregnating step in which a permeable resin is applied and impregnated on the entire surface of the blasted decorative substrate, and the permeable resin is applied and impregnated. A colored resin coating and filling step of applying and filling a colored resin in at least the concave groove on the surface of the decorative substrate, a grinding step of grinding the entire surface of the decorative substrate coated and filled with the colored resin, and the ground makeup A transparent resin paint application process for applying a transparent resin paint on the surface of the substrate, and the colored resin filled in the groove is made to appear as a square pattern. Have Method of manufacturing a decorative plate.   The method for producing a decorative board having a checkerboard pattern according to claim 1, wherein a resin having active energy ray curing characteristics and moisture curing characteristics is used as the permeable resin and the colored resin, and a colored resin application filling step and a grinding step. The manufacturing method of the decorative board which has a checkered pattern characterized by including the active energy ray irradiation process of irradiating and hardening | curing the said penetrating resin and coloring resin which apply | coated to the active energy line.   3. The method of manufacturing a decorative board having a checkerboard pattern according to claim 1 or 2, wherein the colored resin is applied to the entire surface including the inside of the groove of the decorative substrate coated and penetrated with the permeable resin in the colored resin coating and filling step. Is applied so that the colored resin remains on the entire surface of the decorative substrate in the grinding step.   3. The method for producing a decorative board having a checkerboard pattern according to claim 1 or 2, wherein the colored resin is applied to the entire surface including the inside of the groove of the decorative substrate coated and impregnated with the permeable resin in the colored resin coating and filling step. The method for producing a decorative board having a checkerboard pattern is characterized in that grinding is performed so as to remove the colored resin applied to the surface other than the groove groove portion in the grinding step.   In the manufacturing method of the decorative board which has a grid pattern of any one of Claim 1 to 4, the groove width of many grooved grooves cut by a grooved groove cutting process is the range of 0.8 mm-3.0 mm. A method for producing a decorative board having a checkerboard pattern, characterized by comprising a plurality of types.   The method for producing a decorative board having a checkerboard pattern according to any one of claims 1 to 5, wherein a decorative substrate having a surface formed of natural wood includes a wooden substrate, a barrier layer formed on the surface, and the barrier layer. It is formed with a wood veneer with a thickness of 0.2mm to 1.0mm attached to the surface of the barrier layer, and the groove has been cut to a depth that does not reach the barrier layer. A method for producing a decorative board having a checkerboard pattern characterized by the above.

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