JP4007246B2 - Decorative plate manufacturing method - Google Patents

Description

[0001]
BACKGROUND OF THE INVENTION
The present invention relates to a method for manufacturing a decorative board used as a flooring material in a building such as a house, a wall material such as a siding board, a ceiling material, or the like.
[0002]
[Prior art]
Conventionally, for the various uses described above, a thin leaf-like surface decorative material such as a veneer, decorative paper, and decorative sheet is pasted on the surface of a wood substrate such as a substantially rectangular plywood, and the two opposite edges of the substrate Or the decorative board which gave the male-female real process for the fitting fixation between decorative boards in the surrounding 4 edge is widely utilized.
[0003]
In the production of such a decorative board, a wood substrate having substantially the same dimensions as the decorative board to be manufactured in advance is prepared, and it is manufactured by applying the above-mentioned surface decorative material, male or female actual processing, etc. There is also. However, for the purpose of rationalizing the manufacturing process and other purposes, first, a large-sized decorative board is made by attaching a surface decorative material to a wooden board several times the area of the decorative board to be manufactured, and then this is applied to the surface decorative board. A method of manufacturing a decorative board of a desired predetermined size by cutting a whole material and dividing it into several pieces (split) to produce a cut decorative board and then subjecting the edge to male and female real processing. Sometimes used.
[0004]
[Patent Document 1]
Japanese Patent Laid-Open No. 10-325233 [Patent Document 2]
Japanese Patent Laid-Open No. 2000-87543
By the way, when a thin leaf-like surface decorative material is attached to the surface of a substantially rectangular wooden substrate, the adhesion between the wooden substrate and the surface decorative material is unstable in the vicinity of the four peripheral edges (approximately several mm in width). Therefore, troubles that partly peel (drown) due to external force or the like are likely to occur. This is due to the sanding process in the finishing process of the wooden substrate, and the corners of the edges are slightly rounded and the thickness is thinner than that inside the surface. The pressure due to rolls etc. tends to be insufficient, and because of discontinuous parts in the laminating process of discontinuous sheets, the laminating pressure tends to become unstable, and the side surface is open, so the adhesive This is thought to be due to the fact that drying is fast and it is difficult to obtain sufficient adhesion between the wooden substrate and the surface decorative material. Especially, a decorative sheet made of synthetic resin, which is a different material from the wooden substrate, was used as the surface decorative material. It is remarkable in the case.
[0006]
In particular, both ends in the longitudinal direction of the substantially rectangular wooden substrate (both ends parallel to the short direction) are generally edges in which at least the surface layer portion of the wooden substrate is cut in a direction perpendicular to the fiber direction. Because there are many, the cut surface is rough or a scissors-like scratch is generated, and adhesion is hindered in the laminating process of the surface decorative material, and the solvent of the adhesive used for laminating the surface decorative material Since the portion and the like are likely to diffuse along the fiber direction of the wood, the above troubles are particularly likely to occur due to the fact that the above-described adhesive failure is liable to occur due to the drying of the adhesive too fast.
[0007]
Therefore, in the process of male / female real processing after splitting the decorative board, it is good if the unstable part is removed by applying male / female processing to the end edge. When female processing is applied to the body, the unstable part of the adhesive remains as the edge of the product, so it can be used as a building material such as flooring during use after construction. Due to the contact and friction, there has been a problem that a wrinkle phenomenon in which the surface decorative material is partially peeled off from the wooden substrate at the location is likely to occur.
[0008]
In order to solve such a problem, after applying a surface decorative material to a large wooden substrate to produce a large decorative substrate, the adhesive unstable portion of the peripheral edge is cut and removed, and then a small cutting process and A method of performing male and female processing is also conceivable. However, in this method, there is a problem that the size of the decorative plate obtained is reduced by the amount by which the unstable adhesive portion is cut and removed. This problem can be solved by using a large-sized wood substrate that has been cut and removed in advance. In reality, however, the size of a plywood or the like available in the market is, for example, 3 × 6 (920 mm × 1820 mm), and it is extremely difficult to obtain materials with free dimensions.
[0009]
And, for example, a decorative board manufactured by dividing the length of the wooden board of the above-mentioned 3 × 6 scale into two in the longitudinal direction by the above method has a longitudinal length of, for example, a standard length (in the Japanese building industry). The length is shorter than the standard length, such as 900 to 905 mm with respect to the three lengths (about 909 mm) which are effective in terms of the conventional shank penetration method. Therefore, there is a problem that it becomes impossible to perform construction without gaps while aligning the position with the base material such as joists and trunk edges constructed at regular intervals according to the standard. On the other hand, after cutting and removing the adhesive unstable portion, it is not practical to use the material plate only by taking only a portion that can be divided into small parts, because the material is wasted.
[0010]
[Problems to be solved by the invention]
The present invention has been made to solve the above-described problems in the prior art, and is a large-sized decorative substrate obtained by sticking a thin leaf-like surface decorative material on the surface of a substantially rectangular wooden substrate. Of the decorative board obtained by subjecting at least two edges of the longitudinal direction to male / female processing on a cut decorative board obtained by dividing the board into a plurality of parts in the longitudinal direction. An object of the present invention is to provide a method for manufacturing a decorative board capable of efficiently obtaining a fixed-size decorative board without waste of material without leaving a portion where the adhesion between the wooden substrate and the surface decorative material is unstable at the edge. It is.
[0011]
[Means for Solving the Problems]
The method for producing a decorative board according to the present invention includes a large-sized decorative board obtained by sticking a thin leaf-like decorative material on the surface of a substantially rectangular wooden board, by cutting at least in a direction parallel to the short direction. Dividing into a plurality of pieces in the longitudinal direction to obtain a cut decorative board, and then, to the two opposite edges including at least the edges formed by the division in the longitudinal direction, In the manufacturing method of a decorative board in which male and female real processing is performed on at least two opposing edges by performing male and female processing on the other side, in the male and female actual processing of the split decorative substrate, If one of the two edges is not an edge formed by the division in the longitudinal direction, the edge is subjected to male processing, and the edge formed by the division in the longitudinal direction opposite to the edge is formed. Is characterized by subjecting female seeds to processing.
[0012]
DETAILED DESCRIPTION OF THE INVENTION
Hereinafter, the manufacturing method of the decorative board of this invention is demonstrated in detail, referring drawings. FIG.1 and FIG.2 is the top view and side sectional drawing which showed embodiment of the manufacturing method of the decorative board of this invention in order of the process.
[0013]
First, as shown in FIG. 2 (a), a large-sized decorative substrate 1 is produced by sticking a thin leaf-like surface decorative material 12 such as a veneer, a decorative paper, or a decorative sheet to the surface of a wooden substrate 11 such as plywood. To do. The planar outer shape of the large-sized decorative substrate 1 is substantially rectangular as shown in FIG. 1 (a). Then, as already described in the section of the prior art, the wood substrate 11 and the surface decorative material 12 are provided at a location of about several millimeters in width in the vicinity of both longitudinal edges (both edges parallel to the short direction). There is an unstable bonding portion 2 (a fine hatched portion in each figure) that is not sufficiently bonded and is easy to bend.
[0014]
Next, as shown in FIGS. 1 (b) and 2 (b), the obtained large-sized decorative substrate 1 is divided into a plurality in the longitudinal direction by cutting in a direction parallel to the short direction, A small decorative substrate 3 is obtained. At this time, along with the division in the longitudinal direction, it may be divided into a plurality in the lateral direction by cutting in a direction parallel to the longitudinal direction. In the example shown in FIG. 1 (b), two sheets in the longitudinal direction and three sheets in the short direction are combined and divided into six sheets, but the present invention is not limited to this.
[0015]
Next, both ends of the longitudinal direction of the obtained small decorative substrate 3 (the direction corresponding to the longitudinal direction of the large decorative substrate 1; the same applies hereinafter), that is, the short direction (corresponding to the short direction of the large decorative substrate 1). In the same way, both ends are provided with male processing 5 on one side and female processing 6 on the other, with the ends formed by dividing the large-sized decorative substrate 1 in the longitudinal direction. An edge other than the edge, that is, an edge that was originally a longitudinal edge (an edge parallel to the short-side direction) of the large-sized decorative substrate 1 is not subjected to the female processing 6, and must always be the male processing 5. It is important in the present invention to determine the orientation of the small decorative substrate 3 so that
[0016]
In addition, when the large-sized decorative substrate 1 is divided into three or more in the longitudinal direction, both end edges in the longitudinal direction of the small-sized decorative substrate 3 in the middle portion in the longitudinal direction are both divided by the longitudinal direction of the large-sized decorative substrate 1. Since it is formed, it may be arbitrarily determined which of the male processing 5 or the female processing 6 is to be performed.
[0017]
In the example shown in FIG. 1 and FIG. 2, in the male and female real processing of the split decorative substrate 3, the male processing 5 is applied to the lower edge and the female processing 6 is applied to the upper edge toward the paper surface. Assuming this, first, the upper three of the six divided decorative boards 3 were turned 180 degrees in the horizontal plane, and originally the upper edge of the large-sized decorative board 1 was the upper edge. Furthermore, the three sheets are rearranged so that the upper edges are on the lower side (FIG. 1 (b) → FIG. 1 (c), FIG. 2 (b) → FIG. 2 (c)).
[0018]
After this, if the lower edge of each cut decorative substrate 3 is subjected to male processing 5 and the upper edge is subjected to female processing 6 (FIG. 1 (d)), the wooden substrate 11 and the surface decoration are applied. Since the interface between both in the unstable bonding portion 2 with the material 12 is cut and removed by the male processing 5, the unstable bonding portion 2 does not remain on the obtained decorative board 4 (FIG. 2 (d)). ). In addition, since substantially the entire area of the large-sized decorative substrate 1 is used for the decorative board 4 that is the final product, there is no waste of material and the dimensions of the decorative board 4 are not significantly shorter than the standard size.
[0019]
If necessary, as shown in FIG. 1 (d), the male and female real processing 5 is also applied to both lateral edges (both edges parallel to the longitudinal direction) of each of the small decorative substrates 3. Of course, it is possible to apply 6. In this case, the large size is determined depending on the lamination direction of the surface decorative material 12 and the grain direction of the surface layer portion of the wooden substrate 11 (both are generally the same as the longitudinal direction of the large size decorative substrate 1). There are many cases where the problem of adhesion instability as much as both ends in the longitudinal direction does not occur at both ends in the short direction of the decorative substrate 1, and the bonding that causes a problem in product quality also at both ends in the short direction. Even if an unstable part has occurred, even if the size in the short direction of the decorative plate 4 is slightly deviated from the standard size, there is often no problem in construction. In many cases, the size of the plate 4 in the short direction can be sufficiently reduced by making it shorter than a standard size.
[0020]
When the large-sized decorative board 1 is divided into a plurality of parts in both the longitudinal direction and the short-side direction, as shown in FIG. 1, a small piece having a size corresponding to the decorative board 4 to be obtained by dividing all the parts in both directions in advance. After the decorative board 3 is obtained, the order of the male and female real processing 5, 6 is applied to each edge of each of the small decorative boards 3, and the order of each division and male and female real processing is arbitrarily changed. It is also possible to implement.
[0021]
For example, as shown in FIG. 3, the large-sized decorative substrate 1 (FIG. 3A) is first divided into two pieces in the longitudinal direction (FIG. 3B). The state after the conversion is shown), and the male and female real processings 5 and 6 are performed on the four peripheral edges (FIG. 3 (c)), and then each of the small decorative boards 3 is further divided into three pieces in the lateral direction. Then, a new cut decorative substrate is formed, and the male and female seeds 5 and 6 are applied to the unprocessed edges of the male and female seeds to obtain the target decorative board 4 (FIG. 3D).
[0022]
Also, as shown in FIG. 4, the large-sized decorative substrate 1 (FIG. 4A) is first divided into four pieces, including two in the longitudinal direction and two in the lateral direction (FIG. 4B). The two upper decorative substrates 3 show the state after the vertical direction change), and after the male and female are processed on the four peripheral edges (FIG. 4C), each of the small decorative substrates 3 Is further divided into two pieces each in the short direction to form a new cut decorative board, and the male and female real processed edges 5 and 6 are applied to the unprocessed edges of the male and female real to make eight large-sized decorative boards 1 It is also possible to obtain a decorative plate 4 having a divided dimension (FIG. 4D).
[0023]
Furthermore, in the manufacturing process shown in FIG. 4 described above, in the four-divided state shown in FIG. Both ends in the short direction are left unprocessed, and each split decorative board 3 is further divided into two parts each in the short direction to form a new split decorative board. Male and female real processing 5, 6 may be applied to both end edges. In addition, the process sequence can be variously changed according to the process convenience.
[0024]
【Example】
Example 1
A decorative sheet made of polypropylene resin with a wood grain design applied to the surface of a commercially available 3 x 6 (approx. 920 mm x approx. 1820 mm) external plywood and 12 mm thick laminated plywood with a modified vinyl acetate emulsion adhesive A large-sized decorative substrate was obtained. Thereafter, the large-sized decorative board is first divided into three in the short direction to obtain three small decorative boards having an outer dimension of 1 × 6 (about 303 mm × about 1820 mm). By dividing, 6 new cut decorative substrates having an outer dimension of 1 × 3 (about 303 mm × about 909 mm) were obtained.
[0025]
Of the six pieces of the small decorative boards, of the two longitudinal edges, the edge derived from the two longitudinal edges of the large-sized decorative board before division is male and the other is female. In addition to the processing, one end of both lateral edges in the short direction was subjected to male processing, and the other was subjected to female processing. Thereafter, each of the small decorative boards is further divided into two in the lateral direction to obtain 12 new small decorative boards having an outer dimension of 5 × 3 (about 151.5 mm × about 909 mm). The male and female real unprocessed edges of both ends in the hand direction are respectively subjected to male processing or female processing, and the final dimension is 5 × 3 (about 151.5 mm × about 15 mm). 909 mm), 12 sheets of flooring, which is a decorative board in which male and female real processing was applied to the four peripheral edges, were obtained.
[0026]
The obtained flooring is derived from both longitudinal edges of the large-sized decorative board, and the unstable parts of adhesion between the laminated plywood and the decorative sheet are all removed by male processing. The laminated plywood and the decorative sheet are in intimate contact with each other at both edges. There was no occurrence of curling of the decorative sheet even when the test was performed.
[0027]
Comparative Example 1
In Example 1 described above, in the male and female actual processing of both ends in the longitudinal direction of the split decorative substrate at the time of dividing into six, by dividing the direction of the split decorative substrate from the large decorative substrate, the division is not considered. A flooring material was obtained that contained half of the front edges of the large-sized decorative substrate that were derived from the longitudinal edges of the large decorative substrate. A lot of this flooring was mated with males and females to spread the floor, and the floor surface was constructed. The occurrence of drowning was observed.
[0028]
【The invention's effect】
As described above in detail, according to the method of manufacturing a decorative board of the present invention, a large-sized wooden board is effectively used to save a small-sized decorative board while eliminating waste of materials. It can be manufactured efficiently, and all the unstable parts of the adhesion caused by the laminating process between the large wood substrate and the surface decoration material are all removed by the male processing after the split division. It has an excellent practical advantage that the surface cosmetic material will not be wrinkled later.
[Brief description of the drawings]
FIG. 1 is a plan view showing an embodiment of a method for producing a decorative board according to the present invention in the order of steps.
FIG. 2 is a sectional side view showing an embodiment of a method for manufacturing a decorative board according to the present invention in the order of steps.
FIG. 3 is a plan view showing another embodiment of the method of manufacturing a decorative board according to the present invention in the order of steps.
FIG. 4 is a plan view showing another embodiment of the method for manufacturing a decorative board according to the present invention in the order of steps.
[Explanation of symbols]
DESCRIPTION OF SYMBOLS 1 Large format decorative substrate 11 Woody substrate 12 Surface decorative material 2 Adhesive unstable part 3 Small decorative substrate 4 Decorative plate 5 Male processing 6 Female actual processing

Claims (1)

A large-sized decorative substrate obtained by sticking a thin leaf-like surface decorative material on the surface of a substantially rectangular wooden substrate is divided into a plurality of pieces in the longitudinal direction by cutting in a direction parallel to at least the lateral direction. A decorative substrate is obtained, and then, at the two opposite edges including at least the edge formed by the division in the longitudinal direction, male processing is applied to one and female processing is applied to the other. In the manufacturing method of a decorative board in which male and female real processing is performed on at least two opposing edges by processing, one of the two edges is the longitudinal direction in the male and female real processing of the split decorative substrate. If the edge is not an edge formed by the division, the edge is subjected to male processing, and the edge formed by the division in the longitudinal direction opposite thereto is subjected to female processing. A method for manufacturing a decorative board.

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