JP5166748B2 - Decorative plate manufacturing method - Google Patents

Description

  The present invention relates to a method for manufacturing a decorative board used for a housing interior material such as a door panel, a door panel, a flooring material, a ceiling material, or a wall material, and in particular, a wooden surface of a decorative substrate using a general water-based colorant. The present invention relates to a method of manufacturing a decorative board that is to be painted.

  In the conventional “decorative board manufacturing method”, (a) a decorative board is constructed by sticking a wooden thin veneer on the surface of a board such as plywood or MDF (medium fiber board); The surface of the substrate is ground evenly using a grinding device such as a belt sander, (c) a colorant is applied to the surface of the decorative substrate, (d) the colorant is dried, and then (e) the decorative substrate is Resin paint was applied to the surface.

  In such “decorative plate manufacturing method”, it is common to use organic solvent-based colorants, but in recent years, the problem of health damage caused by volatile organic compounds (VOC) has become a social problem. For this reason, it is desired to use a safer water-based colorant in consideration of the residential environment. However, if the colorant used in the step (c) is simply made water-based, the surface of the decorative board (hereinafter referred to as “decorative surface”) generates “scratching”. There was a problem that the design of the decorative surface was worse than when using.

  That is, when the surface of the decorative substrate is uniformly ground with a grinding device in the step (b), a water-based colorant is applied in the step (c), and then dried in the step (d), the fine particles generated by grinding The wood slice rises due to a sudden change in the moisture content, and “spotting” occurs on the surface of the decorative substrate. Therefore, even if the resin paint is applied in the subsequent step (e), the “scratching” of the decorative surface cannot be suppressed, and the design is remarkably inferior to the case where the organic solvent colorant is used.

As a means for solving this problem, Patent Document 1 discloses that a brush (made of brass is coated with moisture and made to have needles and blisters on the surface of the decorative substrate and has needles implanted therein. A method of removing the surface from the surface with a hand brush, etc., removing “blurring” or “blurs”, drying the surface, polishing it with sandpaper, etc., and painting with water-based paint Is disclosed.
Japanese Patent Laid-Open No. 2001-198907

  In the painting method of Patent Document 1, since the surface of the decorative substrate is cut out with a brush to remove “blurring” and “blurred eyes”, a large “ It is thought that there will be no “offspring”.

  However, in this painting method, “brush scratches” occur when the surface of the decorative substrate is cut out with a brush, and thus there is a problem that the design properties of the decorative surface are impaired by the “brush scratches”. Further, since a minute tree piece is generated when the surface of the decorative substrate is polished with sandpaper or the like, there is a problem that the design of the decorative surface is impaired by a small “offset” caused by the minute tree piece.

  Therefore, the main problem of the present invention is that it is possible to prevent the occurrence of “brush scratches” and “scratching” in spite of the use of the water-based colorant, which is equivalent to the case where the organic solvent-based colorant is used. It is providing the manufacturing method of a decorative board which can acquire the designability.

According to the first aspect of the present invention, “(a) a decorative substrate 12 having at least a surface formed of a wood material is prepared, (b) the surface of the decorative substrate 12 is ground uniformly, and (c) grinding. (D) applying a water-based colorant to the surface of the decorative substrate, (e) drying the water-based colorant, and (f) applying a transparent resin paint on the surface of the decorative substrate. In the manufacturing method of a decorative board to be applied, (g) after the step (b) and before the step (c), (g1) after water-coating the surface of the decorative substrate, (g2) A method for producing a decorative board, wherein the surface of the decorative substrate is dried at once and the surface of the decorative substrate is uniformly blasted in the step (c) . "

  In the present invention, since the water-based colorant is applied to the surface of the decorative substrate 12 after removing the fine tree section, even if the water-based colorant is subsequently dried, “standing up of the small tree section” occurs. In other words, no “offset” occurs on the surface of the decorative substrate 12.

Further, when the surface of the decorative substrate 12 is dried after the surface of the decorative substrate 12 is dipped in water, the fine wood slices generated in the grinding step (b) rise up. Therefore, in the step (c), the raised minute tree slice can be efficiently removed.

And, since “in the step (c), the surface of the decorative substrate 12 is uniformly blasted ”, a new small tree section is not generated in the tree section removing step (c). It is possible to more reliably prevent the occurrence of “standing”.

According to the second aspect of the present invention, “(a) preparing a decorative substrate 12 having at least a surface formed of a wood material, (b) grinding the surface of the decorative substrate 12 uniformly, (c) grinding” (D) applying a water-based colorant to the surface of the decorative substrate, (e) drying the water-based colorant, and (f) applying a transparent resin paint on the surface of the decorative substrate. In the manufacturing method of a decorative board to be applied, (g) after the step (b) and before the step (c), (g1) after water-coating the surface of the decorative substrate, (g2) A method for producing a decorative board in which the surface of the decorative substrate is dried at once, and in the step (c), the fine wood piece is entangled using a removing material made of a fiber assembly. " .

In the present invention, in the step (c), “the above-mentioned minute tree piece is entangled with the removal material made of the fiber aggregate”, so that the tree piece removal is performed in the same manner as in the invention according to claim 1 described above. In the step (c), a new minute tree section is not generated, and the occurrence of “offset” can be more reliably prevented.

According to the invention described in claim 1 or 2 , since the water-based colorant is used, the problem of health damage caused by the volatile organic compound (VOC) can be solved.

  Moreover, since the water-based colorant is applied to the surface of the decorative substrate after removing the fine tree slices generated on the surface of the decorative substrate, “offset” caused by the fine tree slices does not occur. . In addition, since “brushing out with a brush” as in the prior art is not performed, “brush scratches” do not occur. Therefore, the designability of the decorative surface can be dramatically improved, and the same excellent designability as when an organic solvent colorant is used can be obtained.

In particular, after the step (b) and before the step (c), the water content is suddenly changed to erect the minute tree section, and the minute tree section is removed in that state. The section can be removed efficiently and reliably.

In the present invention , the minute tree slices generated in the grinding step (b) are removed by “blasting” or “entanglement with fiber aggregates”. Small tree slices do not occur, and the occurrence of “offset” can be more reliably prevented.

  Hereinafter, the “method for producing a decorative board” to which the present invention is applied will be described with reference to FIG.

  This “decorative board manufacturing method” is used for manufacturing a decorative board used as a housing interior material such as a door panel, a door panel, a flooring material, a ceiling material, or a wall material, and a decorative board preparing step (a) , Grinding step (b), wood slice removing step (c), colorant applying step (d), drying step (e) and resin coating step (f).

  The decorative substrate preparation step (a) is a step of preparing a decorative substrate 12 having at least a surface formed of a wood material.

  The decorative substrate 12 in this embodiment is composed of a “core material” and a wooden “decorative material” adhered to the surface of the “core material”.

  The “core material” secures the strength of the decorative substrate 12 and is formed in a plate shape having a predetermined thickness (about 10 to 15 mm in this embodiment). The material of the “core material” is not particularly limited, and in addition to woody materials such as plywood, MDF (medium fiberboard), particle board, laminated wood, gypsum board, wood wool cement board, volcanic glassy An inorganic material such as a multilayer plate or a composite material obtained by combining these materials can be used.

  On the other hand, the “decorative material” secures the design of the decorative substrate 12 and is formed in a thin plate shape having a predetermined thickness (in this embodiment, about 0.2 to 3 mm). There are no particular restrictions on the type of wooden material that constitutes the “decorative material”, but from the viewpoint of ensuring excellent design properties, “spreading materials” such as hippo, “ring holes” such as oak and tamo, etc. It is desirable to use wood, color tone, luster or the like such as “wood”, “conifer” such as pine and cypress.

  In this embodiment, a “composite material” in which a “core material” and a “decorative material” are bonded is used as the decorative substrate 12. A single wood board may be used as the decorative substrate 12 as it is.

  The grinding step (b) is a step of grinding the surface of the decorative substrate 12 uniformly.

  The surface of the decorative substrate 12 prepared in the decorative substrate preparation step (a) is usually not smooth. Accordingly, in the grinding step (b), the surface of the decorative substrate 12 is uniformly ground using an abrasive such as an abrasive sheet, sandpaper, iron file, or buff containing abrasive.

  As a grinding method, a method using a grinding device such as a belt sander or a buff sander, or a manual method can be arbitrarily selected. When a method using a belt sander is selected, a belt sander 14 is disposed at a position facing the surface of the decorative substrate 12 as shown in FIG. The abrasive sheet 14a is attached to the belt. Then, the polishing sheet 14a is brought into contact with the surface of the decorative substrate 12 conveyed by a conveying belt or the like, and the polishing sheet 14a is rotated together with the drive belt to grind the surface of the decorative substrate 12.

  The “grinding roughness” and “grinding amount” are not particularly limited, but in this example, about 0.03 to 0.05 mm of grinding is performed using about 240 to 320 count abrasive sheets. Grind with quantity.

  The tree piece removing step (c) is a step of removing a minute tree piece generated by grinding.

  When the surface of the decorative substrate 12 is ground in the grinding step (b), the surface is scraped with a polishing sheet or the like, so that a fine tree piece is generated. The following steps (d) to (f) are performed while leaving the fine tree piece. When “” is executed, “spotting” occurs on the makeup surface. Therefore, in the tree section removing step (c), the surface of the decorative substrate 12 is uniformly “blasted” to remove the minute tree sections.

  “Blasting” is a polishing method in which the surface of the decorative substrate 12 is polished by colliding a fine granular blasting abrasive with the surface of the decorative substrate 12, and generally, as in “floating process” It is used when roughening the surface of a wooden material. The “blasting process” in the present embodiment is not “an object to be subjected to uneven processing” but “an object that removes a small tree piece”, but the same blasting apparatus and blasting abrasive (hereinafter referred to as “blasting process”) , Simply referred to as “abrasive”).

  As shown in FIG. 1C, the blast device 16 includes a plurality of nozzles 16a that discharge the abrasive 18, and a pressurization device (not shown) that applies discharge pressure to the abrasive 18 discharged from the nozzle 16a. It has. When removing a small tree piece using the blasting device 16, a plurality of nozzles 16 a are arranged in a direction orthogonal to the conveying direction (arrow direction) of the decorative substrate 12 at a position facing the surface of the decorative substrate 12. It arrange | positions and the said surface is grind | polished by spraying the abrasive 18 from the nozzle 16a to the surface of the decorative substrate 12. FIG.

  The abrasive 18 is hard fine particles. Specifically, “inorganic particles” such as glass beads, glass powder, and silicon, “metal particles” such as alumina, and “hard organic particles such as walnuts and peach seeds”. "Dry ice particles" obtained by finely pulverizing dry ice. The particle size of the abrasive 18 is not particularly limited, but it is preferably about 90 to 150 μm in consideration of “smoothness of finish”, “polishing efficiency”, and the like.

  When aligning the particle size of the abrasive 18 to about 90 to 150 μm, the so-called “sieving method” is used to select the abrasive 18 stepwise. For example, first, the “sieving” having an opening diameter of 180 μm is used to remove the abrasive 18 having a particle diameter larger than 180 μm from a predetermined amount of the abrasive 18 (first stage). Next, the abrasive 18 having a particle diameter larger than 150 μm is removed from the remaining abrasive 18 using a “sieving” having an opening diameter of 150 μm (second stage). Then, an abrasive having a particle size smaller than 90 μm is removed from the remaining abrasive 18 using a “sieving” having an opening diameter of 90 μm (third stage). Thereby, the particle size ratio of the abrasive 18 subjected to the “blasting process” is adjusted so that the abrasive 18 having a particle size of 90 μm or more and 150 μm or less is contained by about 70% or more. The remaining approximately 30% of the abrasive is either a flat shape or a sharp shape, or one that cannot be sieved by “sieving” having an opening diameter of 90 μm.

  In this embodiment, the abrasive 18 is vigorously jetted from the nozzle 16a onto the surface of the decorative substrate 12. However, the abrasive may be naturally dropped from the nozzle. In any case, the polishing depth is preferably suppressed to less than 0.05 mm from the viewpoint of ensuring the smoothness of the decorative surface.

  The colorant application step (d) is a step of applying an aqueous colorant to the surface of the decorative substrate 12.

  Colorants are roughly classified into “organic solvent-based colorants” using organic solvents such as lacquer thinner and urethane thinner for diluents and cleaning liquids, and “water-based colorants” using water as a diluent. In the present invention, a “water-based colorant” is used in order to avoid problems caused by volatile organic compounds (VOC). The type of the water-based colorant is not particularly limited, and a colorant based on a water-soluble urethane resin, a urethane resin emulsion, an epoxy resin emulsion, or the like can be arbitrarily selected. In order to stabilize the water-based colorant, a stabilizer such as a dispersant or an antifreezing agent may be added to the diluent (water).

  As a method for applying the water-based colorant, a spray method, a roll coater method, an electrostatic coating method, or the like can be arbitrarily selected. When the roll coater method is used, as shown in FIG. 1D, an application roller 20 is disposed at a position facing the surface of the decorative substrate 12, and an aqueous colorant is supplied to the surface of the application roller. Then, the application roller 20 is rotatably brought into contact with the surface of the decorative substrate 12 conveyed by a conveyance belt or the like, and the aqueous colorant adhered to the surface of the application roller 20 is applied to the surface of the decorative substrate 12.

  The drying step (e) is a step of drying the aqueous colorant.

  In the drying step (e), a drying device 22 such as a hot air dryer or an infrared heater is disposed at a position facing the surface of the decorative substrate 12. Then, the surface of the decorative substrate 12 conveyed by the conveyance belt or the like is dried by the drying device 22. That is, the water colorant applied to the surface of the decorative substrate 12 is evaporated by hot air or hot wire. When a hot air dryer is used as the drying device 22, it is desirable to set the “hot air temperature” to about 60 to 100 ° C. and the “spraying time” to about 30 to 90 seconds.

  The resin paint application step (f) is a step of applying a transparent resin paint to the surface of the decorative substrate 12.

  The transparent resin paint forms a transparent protective layer that protects the surface of the decorative substrate 12. The type of transparent resin paint is not particularly limited, but it is desirable to use a “solvent-free transparent resin paint” in order to avoid problems caused by volatile organic compounds (VOC).

  As a method for applying the transparent resin paint, a spray method, a roll coater method, an electrostatic coating method, or the like can be arbitrarily selected. When the roll coater method is used, as shown in FIG. 1 (f), an application roller 24 is disposed at a position facing the surface of the decorative substrate 12, and a transparent resin paint is supplied to the surface of the application roller 24. Then, the application roller 24 is rotatably brought into contact with the surface of the decorative substrate 12 conveyed by a conveyance belt or the like, and the transparent resin paint adhered to the surface of the application roller 24 is applied to the surface of the decorative substrate 12. In addition, since the surface temperature of the decorative substrate 12 has increased in the previous drying step (e), in order to stabilize the coating quality, the resin coating application step is performed after the surface temperature has decreased to about 35 to 40 ° C. It is desirable to start (f).

  After applying the transparent resin paint, it is cured using a method according to the type of the transparent resin paint (not shown). In other words, the “thermosetting transparent resin paint” is cured by blowing hot air, the “ultraviolet curable transparent resin paint” is cured by irradiating with ultraviolet rays, and the “electron beam curable transparent resin paint” is an electron beam. Irradiate to cure.

  In addition, from the viewpoint of improving the “durability” and “designability” of the transparent protective layer, the resin coating application step (f) is performed by dividing it into a plurality of steps such as “undercoating”, “intermediate coating”, and “topcoating”. Is desirable. In the case of carrying out by dividing into three steps, first, a transparent resin paint for undercoating is applied to the surface of the decorative substrate 12, and this is cured to form an undercoating layer (undercoating). Next, a transparent resin paint for intermediate coating is applied on the undercoat layer and cured to form an intermediate coating layer (intermediate coating). When the intermediate coating layer is sufficiently cured, the surface of the intermediate coating layer is uniformly polished. Then, a transparent resin paint for overcoating is applied on the intermediate coating layer and cured to form an overcoating layer (overcoating).

  According to the present embodiment, the fine wood slice generated in the grinding step (b) is removed in the wood slice removal step (c), and then the water-based colorant is applied in the colorant application step (d). Therefore, it is possible to suppress the occurrence of “offset” due to the fine wood slice, and to obtain an excellent design property equivalent to the case where the organic solvent colorant is used.

  In the above-described embodiment, the surface of the decorative substrate 12 is “blasted” in the tree piece removing step (c). However, as shown in FIG. A small tree piece may be entangled by using.

  The removal material 26 is a fiber assembly such as kraft paper or a nonwoven fabric, and has a function of entwining a minute tree piece with fine constituent fibers. When removing the minute tree piece using the removing material 26, as shown in FIG. 2, the sheet-like removing material 26 is attached to an annular driving belt constituting a general belt sander 28, and the decorative substrate 12 is attached. A belt sander 28 is disposed at a position facing the surface of the belt. Then, the removing material 26 is brought into contact with the surface of the decorative substrate 12 conveyed by a conveying belt or the like, and the removing material 26 is rotated together with the driving belt, thereby entwining a minute tree piece generated on the surface of the decorative substrate 12.

  The number of belt sanders 28 to be used at the same time is not particularly limited. As shown in FIG. 2, two belt sanders 28 are arranged side by side in the same direction as the conveyance direction (arrow direction) of the decorative substrate 12. You may make it do. In this case, one belt sander 28 may be rotationally driven in the same direction as the conveying direction, and the other belt sander 28 may be rotationally driven in a direction opposite to the conveying direction. As described above, when the two belt sanders 28 are rotationally driven in opposite directions, the minute tree pieces can be entangled from the two directions and efficiently removed.

  Moreover, as shown in FIG. 3, you may make it perform a wood-section standing-up process (g) after a grinding process (b) and before a wood-section removal process (c). The wood piece standing step (g) is a step of standing a minute wood piece by watering the surface of the decorative substrate 12 and then drying the surface of the decorative substrate 12, and the water-dropping step (g1) and the drying step ( g2).

When performing the water-cooking step (g1), a water supply device (spray in this embodiment) 30 such as a spray or a sponge roll coater is disposed at a position facing the surface of the decorative substrate 12. Then, water is supplied from the water supply device 30 to the surface of the decorative substrate 12 conveyed by a conveyance belt or the like, and water is uniformly included on the surface with a water content of about 10 to 50 g / m ² as a guide.

  Here, when the amount of water supply is too small, it is not possible to obtain a sufficient standing effect, and it becomes impossible to efficiently remove the minute tree piece in the subsequent tree piece removal step (c). On the other hand, when there is too much water supply, the burden of a dryer will increase in a subsequent drying process (g2), and since a large sized dryer will be needed, efficiency will worsen. In addition, when a large dryer is used, the overall temperature of the decorative substrate 12 rises undesirably, so that “coloring is not stable” or “water-based colorant is applied to the application roller in the subsequent colorant application step (d). May cause problems such as “curing on the surface of the surface”. Therefore, the amount of water supply needs to be adjusted optimally according to the tree type of the decorative substrate 12, the environmental conditions (such as temperature and humidity), and the like.

  When performing the drying step (g2), a drying device 32 such as a hot air dryer or an infrared heater is disposed at a position facing the surface of the decorative substrate 12. And the surface of the decorative substrate 12 conveyed with a conveyance belt etc. is dried at a stretch with a drying apparatus. That is, the moisture on the surface of the decorative substrate 12 is evaporated at a stretch by hot air or heat rays.

  In this drying step (g2), it is necessary to increase only the surface temperature of the decorative substrate 12 at a stretch in order to reduce the influence on the subsequent colorant application step (d). Therefore, it is desirable to use as the drying device 32 an infrared heater that can be “disposed over a wide area” and can obtain “high temperature”. The infrared heater is preferably disposed at a position about 10 to 20 cm away from the surface of the decorative substrate 12.

  In order to avoid problems such as “coloration is not stable” in the subsequent colorant application step (d), it is necessary to lower the surface temperature of the decorative substrate 12 to 40 ° C. or lower (preferably 30 ° C. or lower). However, when the time interval from the drying step (g2) to the colorant application step (d) is short, the surface temperature cannot be lowered sufficiently. In that case, the surface of the decorative substrate 12 is forcibly cooled by a cooling device such as an electric fan so that the surface temperature is lowered to 40 ° C. or lower (preferably 30 ° C. or lower).

  According to the embodiment of FIG. 3, since the minute tree piece is erected before the tree piece removing step (c), the minute tree piece is efficiently and reliably removed in the tree piece removing step (c). can do. In particular, when the minute tree piece is entangled using the removal material 26 made of the fiber aggregate (FIG. 2), the removal material 26 can be easily entangled with the standing minute tree piece. The removal efficiency can be dramatically increased.

Process chart showing manufacturing steps (a) to (f) of decorative plate Process drawing which shows the modification of a tree slice removal process (c) Process chart showing the wood slice standing process (g)

Explanation of symbols

DESCRIPTION OF SYMBOLS 12 ... Decorative substrate 14, 28 ... Belt sander 14a ... Polishing sheet 16 ... Blasting device 16a ... Nozzle 18 ... Abrasive material 20, 24 ... Application roller 22 ... Drying device 26 ... Removal material 30 ... Water supply device 32 ... Drying device

Claims (2)

(A) preparing a decorative substrate having at least a surface formed of a wood material;
(B) grinding the surface of the decorative substrate uniformly;
(C) removing a small tree section generated by grinding;
(D) applying a water-based colorant to the surface of the decorative substrate;
(E) drying the aqueous colorant;
(F) In the method for manufacturing a decorative board, a transparent resin paint is applied to the surface of the decorative substrate.
(G) After the step (b) and before the step (c), (g1) watering the surface of the decorative substrate, and (g2) drying the surface of the decorative substrate all at once. As well as
In the step (c), a method for manufacturing a decorative board , wherein the surface of the decorative substrate is uniformly blasted . (A) preparing a decorative substrate having at least a surface formed of a wood material;
(B) grinding the surface of the decorative substrate uniformly;
(C) removing a small tree section generated by grinding;
(D) applying a water-based colorant to the surface of the decorative substrate;
(E) drying the aqueous colorant;
(F) In the method for manufacturing a decorative board, a transparent resin paint is applied to the surface of the decorative substrate.
(G) After the step (b) and before the step (c), (g1) watering the surface of the decorative substrate, and (g2) drying the surface of the decorative substrate all at once. As well as
In the step (c), a method of manufacturing a decorative board, wherein the fine wood slice is entangled using a removing material made of a fiber assembly .

Images