JP5135198B2 - Manufacturing method for flooring - Google Patents

Description

  The present invention relates to a method for manufacturing a flooring.

  The floor material that forms the floor surface of a residential room is a wooden floor material in which a decorative material such as a veneer or a decorative sheet is attached to the surface of a base material such as plywood or medium density fiberboard (MDF). Widely known. Conventionally, various studies have been made on such flooring to improve functionality, and the present applicant has also proposed a method for manufacturing a flooring described in Patent Document 1 below.

  The manufacturing method of a flooring described in Patent Document 1 realizes prevention of intrusion of water, ammonia, and the like from the side of the flooring and suppressing the swelling of the flooring. That is, in the above flooring manufacturing method, a paint reservoir groove is formed at the end of the surface of the base material for flooring in which a surface decorative plate is bonded to the surface of the base material, and the flooring material is formed on both sides of the paint reservoir groove. The side farthest from the end of the base plate where the paint reservoir groove is provided is the vertical surface, and then water-resistant paint is applied to the surface of the floor base plate and paint is applied to the paint reservoir groove. After the paint has hardened, the paint applied in the paint reservoir groove is cut from the top to the bottom of the vertical face along the vertical face so that the paint remains on the vertical face. By cutting, a convex portion protruding outward from the vertical surface or a concave portion recessed inward is formed.

By such a flooring manufacturing method, it is possible to manufacture a flooring in which a water-resistant paint is applied to the side surface on the convex side or the concave side of the flooring, and from the side on the convex side or the concave side. Water and ammonia can be prevented from entering the flooring.
JP 2003-245908 A

  By the way, the performance required for the floor surface of a house room or the like varies depending on the age and preference of the person using the room. For example, in a house where small children live, it is easy to spill drinks from the cup etc. on the floor, so it is particularly required to prevent the intrusion of drinks from the side of the flooring and to suppress the swelling of the flooring. . The floor material manufacturing method can manufacture a floor material that satisfies such requirements.

  On the other hand, when the floor surface is not so much concerned and the smooth appearance that the floor surface is formed by a continuous flat surface is regarded as important, it may be difficult to cope with the above floor material manufacturing method. .

  For coated products with a relatively large amount of paint to be applied to the surface, it is formed on the periphery of the male and female berries formed at the ends for bonding between flooring materials, and on the end surface side to be bonded. The chamfered portion that forms the groove portion by joining has been painted so as not to cause a discomfort to the painted color of the floor material surface.

  However, as shown in FIG. 8, the vertical surface 33 and the female seed 34 that are located above the male fruit 32 at the end of the flooring 31 when the surface of the flooring 31 is painted or the periphery of the male fruit 32 is painted. In some cases, a paint pool may be formed on the vertical surface 35 located on the upper side. When the paint reservoir is cured as it is, the thickness of the coating film 36 formed on the vertical surfaces 33 and 35 tends to increase. When the thick coating film 36 is formed on the vertical surfaces 33 and 35 in this way, the male fruit 32 cannot completely enter the female fruit 34 when the floor material 31 is constructed, and a gap is formed at the ends of the two adjacent floor materials 31. A phenomenon known as “mekuki” occurs.

  On the other hand, since the chamfered portion 37 is inclined obliquely downward, no paint pool is generated. Therefore, the degree of adhesion of the paint differs between the chamfered portion 37 and the surface portion 38 of the flooring 31, and 2 A phenomenon occurs in which the color of the coating film 39 in the groove portion formed by combining the two chamfered portions 37 is different from that of the coating film 40 formed on the surface portion 38.

  These phenomena cause the end of the floor material 31 to be recognized, and must be eliminated in order to form a smooth and excellent floor surface.

  The present invention has been made in view of the circumstances as described above, and suppresses the occurrence of a gap phenomenon when joining two adjacent flooring materials, and a groove portion formed by combining two chamfered portions. It is an object of the present invention to provide a method for manufacturing a flooring material that can realize a floor surface having a good appearance without causing a sense of incongruity by making the color tone of the same as that of the surface portion.

  The present invention has the following features in order to solve the above problems.

According to a first aspect of the present invention, there is provided a vertical surface located near the edge of the floor material along two opposing sides of the floor material on the surface portion of the floor material having a substantially rectangular shape in plan view. Forming a groove portion having an inclined surface inclined obliquely downward from the upper end portion located farther from the edge of the floor material than the upper end portion toward the lower end portion of the vertical surface, and then the groove portion and the inner floor from the groove portion After painting the surface of the material, on the inclined surface of the groove, cut downward and perpendicular to the surface of the floor material, and cut off the cut portion to the edge of the floor material to form the real part The vertical surface located above the real part is formed on the surface on which the coating film thinner than the coating surface formed on the uncoated cutting surface or the surface portion of the flooring is formed. It is said.

  The second invention is characterized in that, in the above-described feature of the first invention, a paint reservoir is formed in the groove when painting, and a vertical surface located above the real part is formed on an unpainted cutting surface. .

  According to a third invention, in the feature of the first invention, the groove portion has a smooth bottom surface portion between the vertical surface and the inclined surface, and is cut downward from the bottom surface portion on the vertical surface side after painting. The surface is formed by forming the male part with the upper surface coated as a real part, and the vertical surface located on the upper side of the male part is formed with a coating film thinner than the coating film formed on the surface part of the flooring. It is characterized by forming.

According to the first aspect of the present invention, by cutting on the inclined surface after painting of the groove portion, the vertical surface positioned above the real portion is more than the coating surface formed on the unpainted cutting surface or the surface portion of the flooring material. Since it forms on the surface in which the thin coating film was formed, a thick coating film is not formed in the vertical surface formed above the real part in the edge part of a flooring. Therefore, when the flooring is successful, the male and the fruit penetrate almost completely into the female, and it becomes difficult to form a gap at the end portions of the two adjacent flooring materials, thereby suppressing the gap phenomenon.

  Further, since the groove portion is painted together with the surface portion, a coating film having a sufficient thickness is formed on the inclined surface, and the inclined surface thus coated forms a chamfered portion, and the two adjacent floor materials are joined. At the time, the two are combined to form a groove. Therefore, the color of the groove is equivalent to the color of the surface.

  The floor material manufactured in this way realizes a floor surface having a good appearance without a sense of incongruity.

According to the second aspect of the invention, in addition to the effect of the first aspect of the invention, the inclined surface of the groove part can be easily applied by the paint reservoir formed in the groove part, and the inclination after the application of the groove part is achieved. By cutting on the surface , it is possible to reliably form an uncoated cutting surface on the vertical surface located above the real part.

  According to the third aspect of the invention, in addition to the effect of the first aspect of the invention, the upper surface of the male fruit is painted. Even if it is not suppressed, it is difficult to be recognized as a gap, and the uncomfortable feeling can be alleviated. The vertical surface located on the upper side of the male is not thin enough to be formed on the surface of the flooring material even when the groove is painted. Can be kept as low as possible.

  FIGS. 1A and 1B are a plan view and an AA enlarged cross-sectional view, respectively, showing the formation of a groove in the first embodiment of the flooring manufacturing method of the present invention. FIG. 2 is a perspective view showing the floor material after forming the groove.

  The flooring 1 in which the grooves are formed is made by adhering a decorative material 3 such as a veneer or a decorative sheet to the surface of a single layer of plywood or MDF or a plate-like substrate 2 formed by laminating them. And has a substantially rectangular shape in plan view. The groove part 4 is formed in the surface part of the flooring 1 with the cutting machine, such as a router, along the two long side parts 5 which oppose in the flooring 1.

  The depth of the groove portion 4 can be adjusted as appropriate, and can be, for example, the depth until the surface portion of the substrate 2 is reached. The groove portion 4 can have, for example, a substantially V-shaped cross section, and has a vertical surface 6 and an inclined surface 7. The vertical surface 6 is located near the edge of the long side portion 5 of the flooring 1 in the groove portion 4. On the other hand, the inclined surface 7 is positioned away from the edge of the long side portion 5 of the flooring 1, and the upper end thereof is farther from the edge of the long side portion 5 of the flooring 1 than the upper end portion of the vertical surface 6. Is located. The inclined surface 7 is inclined obliquely downward from the upper end portion toward the lower end portion of the vertical surface 6, and the lower end thereof coincides with the lower end of the vertical surface 6. Therefore, the two groove parts 4 are symmetrically arranged on the surface part of the flooring 1 with respect to the center line in the direction of the long side part 5.

  The flooring 1 on which the grooves 4 are formed is then painted.

  As shown in FIG. 3A, the coating is performed on the inner area from the groove 4 in the surface portion of the flooring 1. That is, the paint is applied to the groove portion 4 and the surface portion of the flooring 1 inside the groove portion 4. The reason why the long side part 5 of the flooring 1 located outside the groove part 4 is not painted is that part of the long side part 5 of the flooring 1 located outside the groove part 4 where the real part is formed later by cutting. This is for economically reducing the amount of paint used.

  By coating the groove 4, a coating film 8 having a sufficient thickness is formed on the inclined surface 7.

  As the kind of paint to be applied, an appropriate one can be selected according to the material and color of the decorative material 3, and the number of times of painting can be adjusted as appropriate. The coating can be performed in the same manner as before by a coating machine such as a roll coater.

  In addition, when painting, in order to improve the quality and efficiency of the painting of the groove portion 4, as shown in FIG. 3B, the groove portion 4 can be filled with a paint to form a paint reservoir 9. The paint is more sufficiently applied to the inclined surface 7 of the groove portion 4 by the paint reservoir 9, and the coating film 8 having a sufficient thickness is easily formed on the inclined surface 7 as shown in FIG. The coating film 8 is obtained as being inferior to the coating film 10 formed on the surface portion of the flooring 1 located inside the groove portion 4.

  In addition, even if the coating film formed in the groove part 4 by coating is formed not only on the inclined surface 7 but also partially or entirely on the vertical surface 6, it does not affect coating quality and actual processing performed later.

  The flooring 1 thus coated is then subjected to actual processing as shown in FIG. The flooring 1 after actual processing is shown in FIG.

  Actual processing is performed at the edge of the long side portion 5 of the flooring 1. For actual machining, a cutting machine such as a router can be used in the same way as in actual machining. In the present embodiment, the edge of the long side portion 5 of the flooring 1 is cut perpendicularly to the surface portion of the flooring 1 from the inclined surface 7 of the groove 4 downward.

  One of the edge portions of the long side portion 5, that is, the left edge portion in FIG. 4 is cut downward as described above, and then the floor at a position above the middle in the thickness direction of the flooring 1. Cutting toward the outside of the material 1 forms a vertical surface 11. Further, the base material 2 is cut vertically from the back surface side of the flooring material 1 at the same position as the vertical surface 11, and the flooring material 1 is cut at a position below the middle in the thickness direction of the flooring material 1. Cut towards the outside. Cut from the cut location to the edge of the flooring 1. By such cutting, a male solid 12 is formed as a real part 13 of the flooring 1 at one end edge of the long side portion 5 of the flooring 1.

  In the other end edge of the long side portion 5, that is, the right end edge in FIG. 4, the floor 4 faces downward from the inclined surface 7 side portion of the groove 4 in the same manner as the left end edge. A vertical surface 11 is formed by cutting perpendicularly to the surface portion of the material 1. Thereafter, cutting is performed toward the inside of the flooring 1 at a position above the middle in the thickness direction of the flooring 1. Next, cutting is performed again downward, and cutting is performed toward the outside of the flooring 1 at a position below the middle in the thickness direction of the flooring 1. Then, cutting is performed again downward, and the portion from the cut location to the edge of the flooring 1 is discarded. By such cutting, a female fruit 14 is formed as a real part 13 of the flooring 1 at the other end edge of the long side part 5 of the flooring 1. The size and shape of the female fruit 14 correspond to the male fruit 12, and in the construction of the flooring 1, in the two flooring materials 1 arranged adjacent to each other, the convex male fruit 12 is concave. It fits into the female fruit 14 and the floor materials 1 are joined at the real part 13.

  At the end portion on the long side portion 5 side of the floor material 1 after actual processing, the base material 2 and the makeup are positioned on the upper side in both the male fruit 12 and the female fruit 14 formed as the real part 13. The vertical surface 11 formed on the material 3 is a cutting surface. That is, the vertical surface 11 is a non-coating surface to which no paint is applied, and no coating film is formed. Further, the inclined surface 7 remaining after cutting forms a chamfered portion 15, and the chamfered portion 15 is sufficiently coated, and a coating film 8 having a sufficient thickness is formed.

  As shown in FIG. 6, the floor material 1 manufactured as described above is fitted with the male fruit 12 on the female fruit 14 in the two flooring materials 1 disposed adjacent to each other as described above. The floor materials 1 are joined at the real part 13. At the end on the long side 5 side of the flooring 1, the vertical formed on the base material 2 and the decorative material 3 located on the upper side in both the male fruit 12 and the female fruit 14 formed as the real part 13. The surface 11 is a cut surface that is not painted, and a coating film is not formed at all. Accordingly, the male fruit 12 almost completely enters the female fruit 14, and it is difficult to form a gap at the end portions of the two adjacent flooring materials 1, thereby suppressing the gap phenomenon.

  Moreover, in the two flooring materials 1 arrange | positioned adjacently by construction, each one chamfering part 15 joins together and forms the groove part 16 used as the joint for cosmetics. A coating 8 having a sufficient thickness is formed on the inclined surface 7 forming the chamfered portion 15 in the flooring 1. Therefore, the color of the groove part 16 is equivalent to the color of the surface part of the flooring 1, and it is possible to suppress a sense of discomfort based on the difference in the degree of adhesion of the paint.

  Such a flooring 1 makes it possible to realize a floor surface having a good appearance without a sense of incongruity.

  FIGS. 7 (a) and 7 (b) are cross-sectional views showing the main part of a second embodiment of the method for manufacturing a flooring material according to the present invention, and FIG. 7 (c) shows a construction state of the manufactured flooring material. FIG.

  7 (a), (b), and (c), the same reference numerals are given to portions common to the first embodiment, and description thereof will be omitted below.

  This embodiment is different from the first embodiment regarding the formation of the male seed 12.

  As shown in FIG. 7A, the groove portion 41 for forming the male fruit 12 is formed not in a substantially V-shaped cross section but in a shape close to a U-shape. That is, the groove portion 41 has a smooth bottom surface portion 17 between the vertical surface 6 and the inclined surface 7 together with the vertical surface 6 and the inclined surface 7, and is formed wider than the groove portion 4. A vertical surface 19 is formed between the lower end of the inclined surface 7 and one end of the bottom surface portion 17. Therefore, after coating, a coating film 18 having a sufficient thickness is formed on the upper surface of the bottom surface portion 17. On the other hand, although the vertical surface 19 is also painted, it is not painted as much as the inclined surface 7 because it is standing upright. Therefore, after painting, the vertical surface 19 is formed on a surface on which a coating film having a sufficiently smaller thickness than the coating film 10 formed on the surface portion of the flooring 1 is formed.

  In actual machining, as shown in FIG. 7B, in the groove portion 41, cutting is performed downward from the bottom surface portion 17 on the vertical surface 6 side (for example, the lower end of the vertical surface 6 or a position close thereto). Done. After cutting, the male part 121 whose upper surface is painted is formed as the real part 13.

  In the flooring 1 manufactured in this way, during construction, as shown in FIG. 7C, the male fruit 121 does not completely enter the female fruit 14, and the occurrence of the gap phenomenon is sufficiently caused. Even if it can no longer be suppressed, the painted upper surface of the male 121 is visible in the groove 16. The coating film 18 formed on the upper surface of the male 121 is comparable to the coating film 8 of the inclined surface 7 forming the chamfered portion 15 and the coating film 10 of the surface portion of the flooring 1, and therefore the groove portion. 16 is not easily recognized as a gap. As described above, the flooring 1 having the male fruit 121 whose upper surface is painted is assumed to sufficiently suppress the gap phenomenon due to an error in the formation of the actual part 13 on the assumption that the gap phenomenon is suppressed. Even if it cannot be suppressed, the uncomfortable feeling can be alleviated by the painted upper surface of the male fruit 121. In the two flooring materials 1 arrange | positioned adjacently, it is suppressed that it is visually recognized that the clearance gap is formed in the groove part 16 formed by two chamfering parts 15 combining. Also in this case, the flooring 1 can realize a floor surface having a good appearance without a sense of incongruity.

  And the vertical surface 19 located on the upper side of the male 121 does not form a coating film that is thick enough to be formed on the surface of the flooring 1 even by the coating of the groove 4, and is sufficiently thin. The influence on the fitting of 121 and the female fruit 14 is suppressed as low as possible. Since the vertical surface 19 is slightly painted, the complete fitting of the male fruit 121 and the female fruit 14 is not hindered. Rather, since the vertical surface 19 is slightly painted, the uncomfortable feeling can be reduced as compared with the case where the substrate is exposed.

  The present invention is not limited by the above embodiment. Various aspects are possible for details such as the size and structure of the flooring, the configuration, shape and size of the real parts, and the type of equipment used for painting and cutting.

(A) (b) is the top view shown about formation of the groove part in 1st Embodiment of the manufacturing method of the flooring of this invention, respectively, and AA expanded sectional drawing. It is the perspective view which showed the flooring after a groove part formation. (A) is the expanded sectional view corresponding to Drawing 1 (b) which showed the flooring after painting, and (b) is an important section sectional view showing one form of painting. It is the expanded sectional view which showed the flooring after the actual process performed to the flooring after coating, and a process. It is the perspective view which showed the flooring after an actual process. It is principal part sectional drawing which showed the construction state of the flooring. (A) (b) is principal part sectional drawing which each showed 2nd Embodiment of the manufacturing method of the flooring of this invention, (c) is principal part sectional drawing which showed the construction state of the manufactured flooring FIG. It is principal part sectional drawing shown about the problem of the conventional flooring.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Floor material 4 Groove part 5 Long side part 6 Vertical surface 7 Inclined surface 9 Paint reservoir 13 Real part 17 Bottom face part 19 Vertical surface 41 Groove part 121 Male

Claims (3)

A vertical surface located near the edge of the floor material along two opposing sides of the floor material on the surface of the substantially rectangular floor material in plan view, and the floor material more than the upper end of this vertical surface Forming a groove portion having an inclined surface inclined obliquely downward from the upper end portion located far from the edge of the vertical direction toward the lower end portion of the vertical surface, and then forming the groove portion and the surface portion of the floor material inside from the groove portion. After painting, on the inclined surface of the groove part, cut downward perpendicularly to the surface part of the flooring material, cut off from the cut part to the edge of the flooring material to form the real part, and above the real part The floor surface is formed on a surface on which a coating film having a thinner film thickness than a coating surface formed on the uncoated cutting surface or the surface portion of the floor material is formed. Method.   2. The method for producing a flooring material according to claim 1, wherein a paint reservoir is formed in the groove when painting, and a vertical surface located above the real part is formed on an unpainted cutting surface.   The groove portion has a smooth bottom surface portion between the vertical surface and the inclined surface, and cuts downward from the bottom surface portion on the vertical surface side after coating to form a male part with the upper surface painted as a real part, The floor according to claim 1, wherein the vertical surface located on the upper side of the male body is formed on a surface on which a coating film thinner than a coating film formed on the surface portion of the flooring material is formed. A method of manufacturing the material.

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