JP3027516B2 - Method for manufacturing flexible decorative board - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a flexible decorative board suitable for use as a flooring material for buildings.

[0002]

2. Description of the Related Art Conventionally, as a rectangular floor material to be constructed on a floor substrate, an appropriate depth crossing a width direction on a back surface thereof in order to improve the familiarity with the floor substrate having unevenness or the like. A large number of back grooves are engraved at desired intervals in the length direction to reduce the bending rigidity, so that the flexible long plate can be deformed to follow unevenness by its own weight in direct bonding etc. Are known. On the other hand, in order to impart good decorativeness to a flooring made of such a flexible long plate, a paint is applied to the surface of the decorativeing material.

[0003]

However, since the back groove provided on the back surface of the long floor plate is provided in a direction perpendicular to the long side, the long floor plate is formed using a roll coater. When applying an undercoat or overcoat to the surface, there is a problem that application unevenness occurs and the commercial value is reduced. That is, when the long floorboard is fed between the upper and lower rolls of the roll coater in the longitudinal direction, the axial direction of the roll and the length direction of the back groove of the long floorboard pass while overlapping in parallel. When the back groove portion of the shaku floor plate is located between the upper and lower rolls, the thin portion between the groove bottom having weak bending strength and the floor plate surface is pressed down while slightly opening the back groove by the roll pressure, and the direction in which the back groove closes when passing therethrough And the long floorboard will undulate. Therefore, the coating amount of the paint on the floor plate surface by the roll coater becomes non-uniform, and the paint is applied in a striped and shaded state.

[0004] The waving phenomenon as described above is particularly likely to occur at the end portion of the long floor plate. Further, when the cushioning elastic sheet material is adhered to the back surface of the long floor plate, the waving phenomenon occurs between the rollers. There has been a problem that the waving phenomenon becomes more remarkable and coating unevenness is further increased. On the other hand, if a flow coater or a spray method is adopted as the application means, the above-mentioned application unevenness is unlikely to occur. However, such an application means adjusts the application amount, applies groove coating, and graining (wiping). You may not be able to work.

Further, when a plurality of grooves in the width direction are formed on the back surface of the long floor plate at predetermined intervals in the length direction, when both ends of the long floor plate are supported at the time of handling, the length is increased. There is a problem that the bending load concentrates on the central portion in the direction, and there is a possibility that the bending may occur from the back groove portion. An object of the present invention is to provide a method for manufacturing a flexible decorative board that can completely solve the above-mentioned problems.

[0006]

In order to achieve the above object, a method for manufacturing a flexible decorative board according to the present invention comprises the steps of: After forming a large number of skewed grooves obliquely to the sides of the body and engraving them in parallel with each other, the plate-like body is fed to a roll coater in the length direction, and paint is applied to the surface of the decorative material of the plate-like body. Is applied. In this method, as described in claim 2, a plurality of skewed grooves intersecting with the skewed grooves may be formed on the back surface of the plate-shaped body in parallel with each other. Further, the invention according to claim 3 is characterized in that, in the above method, after the oblique groove is formed on the back surface of the plate, a sheet is adhered to the back of the plate, and then the roll is formed. The paint is applied to the surface of the plate-shaped decorative material by a coater.

[0007]

[Function] When a plate-like body having a large number of skewed grooves on the back surface is fed into a roll coater and a coating material is applied to the surface of the decorative material, the plate-like body rolls the backside skewed grooves. The sheet passes through the roll coater while always intersecting the axial direction of the upper and lower rolls of the coater. Therefore, the plate-shaped body portion pressed by the roll coater has a plurality of skewed grooves intersecting with the axis of the roll coater, and a plate thickness portion between the adjacent skewed grooves is present. There is no possibility that the sloping groove is opened and closed even by the pressing force of the roll coater because the plate thickness portion exhibits a large bending strength, and there is no possibility that the plate-like body is wavy.
Therefore, the paint is uniformly applied to the entire surface of the plate-shaped decorative material, and a beautiful flexible decorative plate can be obtained.

Further, even when a buffer sheet is adhered to the back surface of the plate, the thickness of the plate exists in any portion in the width direction of the plate. So
Due to this thickness, the plate-shaped body is provided with uniform bending rigidity over the entire surface and concentrated bending stress is not generated at a part, so that bending and waving between rolls can be eliminated, and the center in the length direction can be eliminated. The bending strength is also high at the part, so that breakage can be prevented, and handleability is improved.

[0009]

BRIEF DESCRIPTION OF THE DRAWINGS FIG.
FIG. 1 is a plan view of a rectangular decorative board 1 used as a floorboard manufactured by the method of the present invention. The decorative board 1 is formed into a long board having a width of 10 cm or more and a length of 180 cm or more. On the surface thereof, a linear long groove 1a is engraved over the entire length so as to be equally divided into four in the width direction, and between the long grooves 1a adjacent to the long edges 1b and 1c on both sides, and adjacent to the long grooves 1a. Slot 1
On the surface of the elongated plate portion between a and 1a, grooves 1d in the width direction perpendicular to the long groove are engraved at desired intervals in the length direction, as if a plurality of small-sized rectangular floor pieces were combined vertically and horizontally. It has a good appearance. Note that a structure in which a plurality of small-sized rectangular plate pieces are combined and stuck on the surface of the decorative plate base material without forming the long groove 1a or the concave groove 1d may be employed.

Further, as shown in FIG. 2, a decorative coating layer 2 is applied to the front surface of the decorative board 1, and a desired angle is raised to the right with respect to one side, as shown in FIG. The slanting grooves 3 inclined in this manner are engraved in parallel with each other at small intervals, and the bending rigidity of the decorative board 1 is reduced by the slanting grooves 3 to provide flexibility and adaptability to a construction surface. . In addition, as shown in FIG.
May be formed in parallel with each other at a small interval. Reference numerals 5a and 5b denote male and female real portions formed on the four end faces of the decorative board 1.

In order to manufacture such a decorative board 1, first, as shown in FIG. 5 and FIG.
In FIG. 5, diagonal grooves 3 extending obliquely upward to the right at a desired angle with respect to one side are formed at small intervals (every 40 mm to 50 mm) on the back surface of a rectangular plate material A having a large size of 180 cm and 180 cm. In FIG. 6, a plurality of downward-sloping sloping grooves 4 inclined in a direction intersecting the right-sloping sloping grooves 3 are formed in parallel with each other at the same intervals as the right-sloping sloping grooves 2. After engraving, the rectangular plate material A is cut X at a portion indicated by a two-dot chain line that divides the rectangular plate material A into three in the width direction, and the width is 30 cm,
Three flexible long plate-shaped bodies B having a length of 180 cm are obtained.

A rectangular plate A for obtaining the plate B
Plywood, LVL, MDF, wood fiber board such as particle board, inorganic board such as rock wool board and gypsum board, or composite board of these such as laminating MDF on 3-5 ply plywood Can be used, for example,
In FIG. 2, the decorative material 6 is applied to the surface of the 5-ply plywood.
Are used. The decorative material 6 is formed by sticking a decorative veneer or a decorative sheet such as WPC, melamine, polyester, or PVC.

The oblique grooves 3 and 4 as described above are formed in the rectangular plate material A.
As shown in FIG. 7, the rectangular plate material A is circularly cut at regular intervals on the rotating shaft 21 in a state where the rectangular plate material A is obliquely oriented according to the inclination angle of the oblique grooves 3 and 4 to be engraved. One skew groove 3 is engraved by feeding into a cutting device equipped with a blade 22. When the other oblique groove 4 intersecting the oblique groove 3 is engraved, the oblique groove 3 is engraved, and then the rectangular plate material A is inclined in the opposite direction. It can be formed by sending it to a cutting device. In addition, as shown in FIG. 4, there may be a portion where the oblique groove 3 is not provided at a corner of the rectangular plate material A.

The depth of these skewed grooves 3 and 4 is the same as that of FIG.
As shown in (1), it is engraved from the back surface of the rectangular plate material A to a depth reaching the central portion of the thickness of the wooden veneer 11 on the surface layer side. That is, the core plate 12 made of a wooden veneer disposed in the center of the rectangular plate material A has its fiber direction oriented parallel to the length direction of the rectangular plate material A, and is divided into small pieces by the core plate 12. In this case, since the long plate-shaped body B has a large bending rigidity, the core plate 12 is cut and the oblique grooves 3 and 4 are engraved so as to reach the inside of the above-mentioned wooden veneer 11. In this way, the bending rigidity is weakened, and flexibility and adaptability to a construction surface are imparted.

Oblique grooves 3 and 4 with respect to the long side of rectangular plate material A
The cutting angle is 20 to 70 °, preferably 30 to 60 °. In short, the fiber direction is the width direction of the rectangular plate material A, that is,
The core plate 12 arranged so that the fiber direction is orthogonal to the core plate 12
What is necessary is just to carve so that it may cross | intersect with the fiber direction of the said wooden veneer 11 above. Therefore, even if the fiber direction of the wooden veneer 11 is oriented in the length direction of the rectangular composite plate-like body 1, if the skew grooves 3 and 4 are carved at the above angle, they will intersect with the fiber direction. be able to.

After the oblique grooves 3 inclined in one direction or the oblique grooves 3 and 4 intersecting with each other are engraved on the back surface of the rectangular plate material A, a large number of the grooves are engraved. Is cut in parallel with its long side by a suitable cutting blade or saw or the like at regular intervals to obtain a plurality of (three in the figure) flexible long plate-like bodies B. In the case of a rectangular plate material A in which oblique grooves 3 and 4 intersecting each other are engraved on the back surface, cutting is performed along a cutting line X passing through the intersection of the oblique grooves 3 and 4.

When the intersection of the two oblique grooves 3 and 4 is cut in this way, the plate-shaped body B that has been divided into small pieces, as shown in FIGS. Triangular portion 7a surrounded by row grooves 3, 4 and cutting line X or long side edge
Has a maximum width obtained by dividing the parallelogram portion 7 surrounded by the oblique grooves 3 and 4 into two, and the triangular portion 7a is less likely to be missing during handling and actual machining.

As shown in FIG. 8, when obtaining a decorative plate 1 having a buffer sheet 8 adhered to the back surface, the oblique grooves 3 and 4 are covered over the entire back surface of the rectangular plate material A. Then, one sheet-like material 8 is stuck and then cut into the plate-like body B as described above. At the time of this cutting, since the sheet-like material 8 is attached to the back surface in advance, the occurrence of chipping or the like at the cut end surface can be prevented by the sheet-like material 8. As such a sheet-like material 8, a resin sheet having flexibility and conformability to a fine uneven surface,
Paper or a sheet of rubber, urethane foam, foamed polyethylene, foamed rubber, nonwoven fabric, woven fabric, or the like, which has soundproofness as well as flexibility and familiarity, is used.

The long groove 1a or the concave groove 1d is engraved on the surface of the plate-like body B thus obtained, or a small-sized plate is combined and adhered to give an appearance composed of a plurality of floor plate pieces. After forming the applied decorative material 6 and performing the actual processing 5a and 5b on the four end faces of the plate-shaped body B, the plate-shaped body B is fed into a roll coater C as shown in FIG. A decorative coating layer 2 is formed by applying a paint on the surface to obtain a flexible long decorative board 1 suitable as a floorboard.

As is well known, the roll coater C has a distributor roll C2 and a doctor roll C3 which are rotatable in the direction of the arrow before and after the coating roll C1 with the coating roll C1 at the center. A backup roll C4 is rotatably arranged in the direction of the arrow with an interval, and a paint reservoir 10 is supplied between the upper peripheral surfaces of the coating roll C1 and the distributor roll C2, which are opposed to each other. The paint is adhered to the surface of the coating roll C1 through the gap, and the plate B is fed between the coating roll C1 and the backup roll C4 to be applied to the surface of the plate B. C5 is a scraper for scraping off paint that is in sliding contact with the surface of the doctor roll C3.

The plate B is fed into the roll coater C with its long side perpendicular to the axial direction of the coating roll C1, and the surface of the plate B is coated with paint while being sandwiched between the coating roll C1 and the backup roll C4. Thereafter, the rolls are fed forward by the rotation of these rolls. The oblique grooves 3 and 4 engraved on the back surface of the plate-like body B are, as shown in FIG. Pass over the backup roll C4 in a state crossing the axis of each roll of the roll coater C.

Accordingly, the widthwise portion of the plate B sandwiched between the coating roll C1 and the backup roll C4 crosses the axis of the roll coater C at any portion in the length direction of the plate B. There are a plurality of skewed grooves 3 and 4 and a plate thickness portion b1 between the skewed grooves adjacent in the width direction, and the bottoms of the skewed grooves 3 and 4 and the surface of the plate-like body B are present. The rigidity of the plate thickness portion b prevents the thin portion b2 between the two portions from bending downward while opening the oblique grooves 3 and 4 due to the pressing force of the coating roll C1. The coating is uniformly applied by the coating roll C1 while maintaining the entire surface flat.

Even when the elastic sheet 8 having a cushioning property is adhered to the back surface of the plate-like body B, the coating roll C1 and the backup roll
Although the sheet-like material 8 is compressed by the sandwiching pressure with C4, the plate-like body B itself is not deformed due to the presence of the plate-thick portion b as described above.

The coating material applied to the surface of the plate-like body B includes
Although not particularly limited, for example, a resin paint such as amino alkyd, polyurethane, acrylic urethane, acrylic emulsion, or the like can be used.
It is appropriate to apply at a rate of 100100 g / m ² =. As the roll coater C, a device in which the coating roll C1 rotates in the direction in which the plate-shaped body B is sent out is used, but the coating roll rotates in the opposite direction to rub the paint on the surface of the plate-shaped body. A reverse coater may be used.

The surface treatment for the plate-like body B includes:
The one-coating treatment, the intermediate coating, and the top coating are repeatedly performed one or more times, but all of these treatments may be performed by a roll coater. Also, the surface coating treatment is performed by combining the roll coater C with a spray means or a flow coater. May go.

[0026]

As described above, according to the method for producing a flexible decorative board of the present invention, the decorative material is integrally laminated on the front surface of the plate-like body, and the back surface of the plate-like body is After forming a large number of diagonal grooves in the diagonal direction and engraving them in parallel with each other, this plate is directed to the length direction and fed to a roll coater to apply a paint to the decorative material surface of the plate. Since it is a feature, the sloping grooves engraved on the back of the plate are inclined in the oblique direction with respect to the sides of the plate, so this plate is fed into a roll coater, When applying the paint on the surface of the decorative material, the oblique grooves on the back of the plate-shaped body are always in a state of intersecting with the axial direction of the roll coater, and accordingly, the plate-shaped body pressed by the roll coater has: There are a plurality of sloping grooves intersecting the axis of the roll coater and a thick portion between the adjacent sloping grooves. The skewed groove part can be reinforced by the bending strength of the plate thickness part, eliminating the occurrence of wavy due to the skewed groove part displacing downward due to the pressing force of the roll coater, making the surface of the plate-like body always flat The coating can be uniformly applied while being maintained, and a beautiful flexible decorative plate can be obtained.

Further, even when a buffer sheet is adhered to the back surface of the plate, the thickness of the plate exists in any portion in the width direction of the plate. So
Due to this thickness, the plate-shaped body is provided with uniform bending rigidity over the entire surface and concentrated bending stress is not generated at a part, so that bending and waving between rolls can be eliminated, and the center in the length direction can be eliminated. The bending strength is also high at the part, so that breakage can be prevented, and handleability is improved.

Further, as described in claim 2, the oblique grooves and the oblique grooves intersecting with the oblique grooves are engraved on the back surface of the plate-shaped body, so that the entirety is uniform. A well-balanced decorative board exhibiting flexibility and familiarity can be obtained, and furthermore, as described in claim 3, by attaching a sheet-like material to the back surface of the plate-like body The end portion is reinforced by the sheet-like material, thereby preventing the cut end surface from being chipped or falling off from the oblique groove at the time of actual processing or the like.

[Brief description of the drawings]

FIG. 1 is a simplified plan view of a flexible decorative board,

FIG. 2 is a partially enlarged longitudinal sectional view thereof,

FIG. 3 is a bottom view of a flexible decorative board provided with a skew groove in one direction;

FIG. 4 is a bottom view of a flexible decorative board provided with crossed oblique grooves;

FIG. 5 is a rear view of a rectangular plate material provided with a diagonal groove in only one direction on the back surface;

FIG. 6 is a back view of a rectangular plate member provided with oblique grooves in directions intersecting with each other on the back surface;

FIG. 7 is a simplified plan view showing a method for processing a skew groove,

FIG. 8 is a partially omitted enlarged vertical cross-sectional view of a decorative plate having a sheet-like material adhered to the back surface;

FIG. 9 is a simplified side view showing a state in which the surface of the plate-shaped body is being painted;

FIG. 10 is a simplified plan view thereof.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Flexible decorative board 2 Decorative coating layer 3, 4 Slanting groove 6 Decorative material 8 Sheet material A Rectangular plate material B Plate material C Roll coater

Continuation of the front page (56) References JP-A-63-107649 (JP, A) JP-B-51-2494 (JP, B1) (58) Fields investigated (Int. Cl. ⁷ , DB name) E04F 15 / 04 B32B 3/30 B32B 21/08

Claims (3)

(57) [Claims] 1. A plurality of oblique grooves oblique to the sides of the plate-shaped body are engraved in parallel with each other on the back surface of the plate-shaped body having a decorative material integrally laminated on the surface. A method for producing a flexible decorative board, comprising feeding the plate-shaped body in a length direction to a roll coater and applying a paint to the surface of a decorative material of the plate-shaped body. 2. The method for manufacturing a flexible decorative board according to claim 1, wherein a plurality of skewed grooves intersecting with the skewed grooves are formed on the back surface of the plate-shaped body in parallel with each other. 3. After the oblique groove is cut in the back surface of the plate, a sheet is adhered to the back of the plate, and thereafter, the surface of the plate is coated with a roll coater. The method for producing a flexible decorative board according to claim 1 or 2, wherein a paint is applied.