JP2011025537A - Method for manufacturing decorative sheet - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method capable of manufacturing a wooden decorative plate usable for an interior material such as a flooring material, a door plate, a wall plate and the like in a simple process using a chipboard inexpensive in cost as a wooden base material. <P>SOLUTION: In the method for manufacturing the decorative plate having an uneven surface pattern, after the chipboard 1 is impregnated with water 3 from the surface, an uneven part 4 is made on the surface by drying the surface and then the surface is subjected to color application. After the impregnation with water 3 from the surface of the chipboard 1, the surface is dried to a water content of preferably not more than 10%. Further, the chipboard 1 is impregnated from the surface preferably with the water 3 to which 0.5 to 2% of a surfactant is added. <P>COPYRIGHT: (C)2011,JPO&INPIT

Description

  The present invention relates to a method for manufacturing a decorative board, and more particularly, to a method for manufacturing a decorative board that has an embossed uneven portion on the surface and can be used as a flooring, a door board, a wall board, and the like.

  In recent years, especially in the housing field, the interior of condominiums and the like has become westernized, and decorative boards having various patterns on the surface are often used as the above-described flooring, door boards, wall boards, and the like. For example, flooring the floor using a wooden board with a wood-grained surface as a flooring facilitates cleaning, etc., and the occurrence of ticks that contribute to sick house syndrome In recent years, the demand has been expanding rapidly.

  Conventionally, plywood was generally used as the base material for the above-mentioned wooden boards, but various hardwoods, conifers, and other southern materials such as lauan, which are the raw materials for plywood, are becoming scarce and prices are rising. However, in place of the above-mentioned plywood, various wooden boards such as chip boards such as MDF (medium density fiber board), particle board and oriented strand board (OSB) are used as a base material.

  For example, in JP-A-8-318596, an uneven pattern is previously formed on the surface of an MDF (medium density fiberboard) layer, and the medium density fiberboard layer on which the uneven pattern is formed is made of a wood plate. A decorative panel is disclosed in which a composite plate is formed by laminating on one side of a core material made of a product, and a decorative sheet is wrapped on both front and back surfaces of the composite plate.

  And the core material itself composed of any one kind of structure selected from the group consisting of medium density fiberboard, plywood, and particle board is not directly subjected to processing for providing an uneven pattern, Since the medium density fiberboard layer is slightly thicker than the level difference of the irregularities, it can be laminated flexibly corresponding to the state of one side of the core material, so that the density distribution of the core material is maintained in a balanced state. And the effect is described. Therefore, an effect is also described that even if a decorative sheet is wrapped on both the front and back surfaces of a composite plate composed of a medium density fiberboard layer having a concavo-convex pattern formed on the surface and a core material, it becomes difficult to warp.

JP-A-8-318596

  However, in the technique described in the above publication, the surface of the medium density fiberboard layer that is slightly thicker than the unevenness of the unevenness is preliminarily extruded, press-molded, shaved, etc. It is difficult to say that a decorative panel that is inferior in randomness and excellent in design is obtained because it requires a forming step and mechanically forms a pattern.

  On the other hand, a method of forming a concavo-convex pattern on the surface by applying a paint containing coarse particles in the extender pigment to the surface of the wooden base material has also been proposed, but the coating strength decreases due to the presence of coarse particles. There is a problem that the surface of the decorative panel is easily deteriorated.

  The present invention was invented in view of the above-described background art, using a chip board that is inexpensive in cost as a wooden base material, and having a concavo-convex pattern on the surface that can be used as an interior material such as a flooring material, a door plate, and a wall plate. It is an object of the present invention to provide a method capable of producing a wood-based decorative board having a simple process.

  In order to solve the above-mentioned problem, the manufacturing method of a decorative board having a surface irregularity pattern according to the invention of claim 1 includes the following: It is characterized by producing a part and then painting it on the surface.

  Chipboards that make up the board of the decorative board are mechanically crushed wood chips and bark, small diameter logs and construction waste materials discarded at the site of demolition work, etc. It is obtained by compression molding with an adhesive and molding it into a plate material.

  As described above, the chipboard is an aggregate of small chip-like pieces of wood, so the size and form of each chip differ, and the water from the surface of the chipboard varies depending on the fiber direction and the tree species of the chip. When the slag is included, the degree of swelling of the individual chips is different, and random uneven portions are formed on the surface layer. And after swelling, it dries and blows away moisture, so that irregularities of various forms are randomly left on the surface and the surface is decorated.

  For example, when an oriented strand board (OSB), which is one of chipboards, is used, a piece of wood (strand) that has been pulverized largely in length and thickness is bonded and processed by arranging the fiber directions in an orthogonal state. The surface of the conductive strand board is a random rough surface. Therefore, when water is included in the cork-patterned surface layer, it swells and large irregularities appear three-dimensionally, and after drying, it is colored and painted including the irregularities on the surface. An embossed decorative board with excellent design can be obtained.

  The method for coloring the chipboard surface including the uneven portions after drying is not particularly limited, and a known coating method is applied. For example, an aqueous colored paint is prepared by mixing an aqueous resin, a colored pigment, and an extender pigment, and the surface of the chipboard is painted using a rubber roll coater or the like.

  As the aqueous resin, a water-dispersible resin or a water-soluble resin can be used. Examples of the resin include acrylic resin, urethane resin, vinyl acetate resin, silicon resin, fluorine resin, acrylic / vinyl acetate resin, acrylic / urethane resin, acrylic / silicone resin, polyvinyl alcohol, and cellulose derivatives. These 1 type (s) or 2 or more types can be used. Such a water-dispersible resin or water-soluble resin may have a property of causing a crosslinking reaction after the coating film is formed. By having such crosslinking reactivity, coating film properties such as water resistance and adhesion can be enhanced.

  The water-dispersible resin or water-soluble resin is mixed with a pigment for coloring in a desired color according to the use of the cosmetic material. Examples of the color pigment include titanium oxide, zinc oxide, carbon black, yellow iron oxide, titanium yellow, aluminum pigment, pearl pigment, and the like. These are mixed and toned and used as a desired color pigment.

  Usually, an extender pigment is added to the colored pigment. Examples of extender pigments include heavy calcium carbonate, cold water stone, light calcium carbonate, white carbon, talc, kaolin, clay, porcelain clay, china clay, diatomaceous earth and the like, and one or more of these are used. can do.

  The invention according to claim 2 of the present application is characterized in that, in the method for producing a decorative board according to claim 1, the surface moisture content is dried to 10% or less after water is included from the surface of the chipboard. Yes.

  Examples of the method of adding water from the surface of the chipboard include a method of spraying water on the surface of the chipboard using a spray coating machine. Not only the spray method but also a method of applying water to the surface of the chipboard using a rubber roll coater, or water may be applied using a flow coater.

  It is preferable to dry the surface of the chip board on which the irregularities are generated by including the water so that the moisture content is 10% or less. Usually, a natural drying method in which only moisture is allowed to escape is preferable because uneven portions formed by chip swelling can be left on the surface as it is. However, you may heat-dry with a drying furnace etc. so that a surface moisture content may be 10% or less.

  The invention according to claim 3 of the present application is the method for producing a decorative board according to claim 1 or 2, wherein water containing 0.5 to 2% of a surfactant is added from the surface of the chipboard. It is characterized by. The surfactant is not particularly limited, and an anionic surfactant, a nonionic surfactant, a cationic surfactant, an amphoteric surfactant, and the like are used.

  In the manufacturing method of the decorative board according to the first aspect of the present invention, since water is included from the surface of the chipboard, the size and form of each chip constituting the chipboard, the fiber direction, and the tree species of the chip A difference occurs in the water absorption, and the swelling degree of each chip constituting the surface of the chip board becomes random and the uneven part appears.

  And since the uneven | corrugated | grooved part remains after drying the surface, the surface can be finished in the embossed tone with a three-dimensional effect. Therefore, unlike the cold sensation given by a conventional smooth decorative board, the concavo-convex part improves the feeling of touch and walking, and when the decorative board is used as a floor board, a comfortable stimulus can be given to the soles. .

  Furthermore, since the chip board is formed from cheap chips as raw materials, it can be manufactured advantageously in terms of cost, and the burden on the natural environment can be reduced by recycling the wood resources.

  In the method for producing a decorative board according to the second aspect of the present invention, after water is included from the surface of the chipboard, the surface moisture content is dried to 10% or less by natural drying or the like. When a color finish is performed with a water-based colored paint, the absorbability of the colored paint is improved and good paintability is obtained.

  In the method for producing a decorative board according to the third aspect of the present invention, the surface tension of water is reduced and wetted by including water containing 0.5 to 2% of a surfactant from the surface of the chipboard. As a result, the individual chips near the surface easily swell to form a three-dimensional concavo-convex portion, and the surface of the chip board can be finished in a random embossed tone.

(A) is a partial cross-sectional explanatory view schematically showing the first step of the manufacturing method of the decorative board of the present invention in which water is included from the surface of the chipboard, and (b) is formed by impregnating the surface of the chipboard with water. The fragmentary sectional view which shows the decorative board which concerns on this invention obtained by naturally drying the made uneven part, (c) is a fragmentary sectional view which shows the state which coated the surface of the chipboard containing an uneven part with the coloring paint.

  Hereinafter, an embodiment of a manufacturing method of a decorative board according to the present invention will be described in detail with reference to the drawings. FIG. 1A is a partial cross-sectional explanatory view schematically showing the first step of the method for manufacturing a decorative board of the present invention in which water is included from the surface of the chipboard.

  In FIG. 1A, as the chip board 1, chips 2 crushed into strands are arranged in a state where the fiber directions are orthogonal, and a board body (plate material) is pressed under pressure using a thermosetting adhesive. A formed oriented strand board (OSB) is used. The thermosetting adhesive is appropriately selected from various thermosetting adhesives such as isocyanate, phenol, urea, and melamine.

  As shown in FIG. 1 (a), the strand-shaped chips 2 are different in size and form, and the fiber direction and the tree species of the chips 2 are different. It has become. In this case, when the chip 2 is not sufficiently exposed, the surface of the chip board 1 is polished to sufficiently expose the chip 2. In the method of the present invention, first, water 3 is sprayed or applied to the surface of the chipboard 1 by a spray coating machine, a roll coater, a flow coater or the like, and the water 3 is infiltrated from the surface.

  At this time, the amount of water 3 included in the chip board 1 is 0.5 to 5 g / scale × scale. Further, it is preferable to add 0.5 to 2% of a surfactant such as an alkyl ether sulfate ester salt to water 3. By adding the surfactant, the surface tension of the water 3 is reduced and the wettability is improved, and the water 3 easily penetrates from the surface of the chip board 1, and each chip 2 easily absorbs moisture. . And each chip | tip 2 which comprises the surface vicinity swells, and the surface becomes uneven | corrugated shape with a three-dimensional effect, Thus, the surface of the chip board 1 can be finished in random embossed tone.

  FIG. 1B is a partial cross-sectional view showing a decorative board A according to the present invention obtained by naturally drying the uneven portion 4 formed by impregnating the surface of the chip board 1 with water 3 as described above. It is. Here, the dryness of the surface is adjusted so that the moisture content is 10% or less. At this time, moisture may be blown off using a drying furnace or the like as necessary. When using a water-based colored paint, it is desirable to adjust the surface dryness so that the water content is 8% or less.

  If the said decorative board A is used as a flooring, for example, it coats in desired colors, such as oak tone, oak tone, cypress tone. The coating method is performed by a known method using, for example, a rubber roll coater. As the colored paint, an aqueous colored paint containing the above-described water-dispersible resin or water-soluble resin as a main constituent is used. Here, since the said decorative board A is dried so that the moisture content may be 10% or less, the water-based colored paint can be sucked in well and good paintability can be obtained.

  FIG. 1C is a partial cross-sectional view showing a state in which the surface of the chip board 1 including the concavo-convex portion 4 is coated with the colored paint 5. The surface of the chip board 1 including the concavo-convex portion 4 is surface-coated so that a random embossed colored decorative board B can be obtained.

  In the above-described embodiment, the case where an oriented strand board (OSB) is used as the chip board has been described, but a particle board may be used. Further, other types of chipboards may be used, and thus the method for manufacturing a decorative board according to the present invention can be modified in design, and the technology of the present invention is used in any case without departing from the scope of the claims. Belong to the scope.

A A decorative board according to the present invention B A colored decorative board according to the present invention 1 Chip board 2 Chip 3 Water 4 Uneven portion 5 Colored paint

Claims (3)

  A method for producing a decorative board having a surface asperity pattern, characterized in that water is contained from the surface of the chipboard, the surface is dried to form irregularities on the surface, and then the surface is colored and painted.   A method for producing a decorative board, comprising the steps of adding water from the surface of a chipboard and then drying the surface moisture content to 10% or less.   The method for producing a decorative board according to claim 2 or 3, wherein water containing 0.5 to 2% of a surfactant is contained from the surface of the chipboard.

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