JP5820996B2 - Manufacturing method for flooring - Google Patents

Description

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

  2. Description of the Related Art Conventionally, floor materials are known in which corner portions between the surface and side surfaces of a wooden decorative board provided with a decorative sheet on the surface of a wooden base material are chamfered to give a paint finish (for example, Patent Document 1). reference). In this floor material, when a plurality of floor materials are joined to each other and laid, a groove having a V-shaped cross section is formed in the joint portion so that a gap or a step generated in the joint portion is not conspicuous. . Moreover, by forming a decorative groove having substantially the same shape as the V-shaped groove of the joint portion on the surface of the flooring, the position of the joint portion is made inconspicuous and the decorative effect is improved. Yes.

  As another flooring material, a decorative layer consisting of an olefin resin base material, a decorative sheet, and a coating layer is provided on the surface of the wooden base material, and chamfering is applied to the upper edge of the four circumferences so that the depth of the chamfered portion is the decorative layer. A flooring formed to a depth substantially equal to or less than the thickness of the sheet is also known (for example, see Patent Document 2). This floor material has a beautiful chamfered surface because the wooden base material is not exposed on the chamfered surface, and a rough surface derived from a conduit of the wooden base material or fluffing of the wooden fiber does not appear.

Japanese Patent Laid-Open No. 2004-300758 Japanese Patent Laid-Open No. 2005-9140

  In the flooring of Patent Document 1, the finish of painting is done by simultaneously coloring the surface of the flooring and the chamfered surface with a paint by a coating means such as a sponge roll coater or a flow coater, and then scraping unnecessary paint on the surface of the flooring. It is done by taking. For this reason, a large amount of paint is required, resulting in high costs. Further, the surface of the flooring may be washed with a solvent or the like, and there are concerns about problems such as deterioration of the working environment and cost required for the washing.

The flooring of Patent Document 2 does not have to be painted because the chamfered surface is beautiful, but when a plurality of flooring materials are joined together and laid, In order to improve the decorative effect, it is required to form a chamfered portion having a certain depth or more. For this purpose, it is necessary to increase the thickness of the base material made of olefin resin, the decorative sheet, or the coating layer to increase the thickness of the decorative layer, resulting in high costs.
In addition, it is also considered to chamfer the corners of the wooden base material before attaching the decorative sheet, and to apply the decorative sheet continuously to the surface of the wooden base material and the chamfered surface. It was difficult to paste both directions.

  The present invention has been made in view of the above circumstances, and when a plurality of flooring materials are joined and laid, the gaps and steps generated in the joined portion are made inconspicuous, and the decorative effect is improved. It is an object of the present invention to provide a method for manufacturing a floor material that can manufacture a floor material that can be manufactured at low cost.

In order to solve the above-described problems, the floor material manufacturing method of the present invention reaches the wooden base material at the corner between the surface and the side surface of the wooden decorative board provided with a decorative sheet on the surface of the wooden base material. Chamfering to form a chamfered surface where the wooden substrate is exposed between the surface and the side of the wooden decorative board; and applying a paint to the chamfered surface to color-apply the chamfered surface; In the step of coloring and painting the chamfered surface, the decorative sheet side surface of the wooden decorative board is directed downward, and the coating roll is in a non-contact state with respect to the surface of the decorative sheet. And, the portion located on the upper side of the paint roll is brought into contact with the ridge between the chamfered surface and the side surface of the wooden decorative board from below , and the roll surface of the paint roll and the wooden decorative board The chamfered surface is in a non-contact state except for the ridge. Thus, a gap is formed between the roll surface of the coating roll and the chamfered surface of the wooden decorative board, and the portion located below the coating roll is immersed in the paint in the paint storage tank and is, paint the whole circumference the roll surface of the coating roll by rotating the coating roll spreads, paint the chamfered surface paint is supplied to the gap is characterized Rukoto applied.

In this flooring manufacturing method, the chamfering is performed by arranging the coating roll so that a contact angle between a contact surface of the coating roll with the wooden decorative plate and a chamfered surface of the wooden decorative plate is within 20 °. It is preferable to apply a paint to the surface.

  According to the present invention, when a plurality of floor materials are joined and laid, a floor material that can make a gap or a step generated in a joint portion inconspicuous or improve a decorative effect can be manufactured at low cost. can do.

It is the schematic diagram which showed one Embodiment of the manufacturing method of the flooring of this invention in process order. It is a perspective view which shows one Embodiment of the flooring manufactured with the manufacturing method of the flooring of this invention.

  Hereinafter, an embodiment of a flooring manufacturing method of the present invention will be described with reference to the drawings.

  FIG. 1 is a schematic diagram showing an embodiment of a flooring manufacturing method of the present invention in the order of steps, and FIG. 2 shows an embodiment of a flooring manufactured by the flooring manufacturing method of the present invention. It is a perspective view. In the following embodiments, the longitudinal direction is the paper surface penetrating direction in FIGS. 1A and 1B, the paper surface left and right directions in FIGS. 1C and 1D, and the short direction is FIG. In FIGS. 1 (a) and 1 (b), the description will be made in the left-right direction of the paper, and in FIGS.

  A wooden base material 1 shown in FIG. 1 (a) has a convex male fruit 2 formed on one of a pair of side surfaces 1b, 1b along the longitudinal direction among four surrounding side surfaces, and a concave female fruit 3 on the other side. Is formed. Each of the male fruit 2 and the female fruit 3 is a male between two floor materials 40 arranged adjacent to each other when a plurality of floor materials 40 shown in FIG. The fruit 2 has a shape that can be fitted to the female fruit 3. Specifically, the outer peripheral shape of the male fruit 2 and the inner peripheral shape of the female fruit 3 are substantially the same. Such male fruit 2 and female fruit 3 are the same not only for the pair of side surfaces 1b and 1b along the longitudinal direction of the wooden substrate 1, but also for the pair of side surfaces 1c and 1c along the short direction of the wooden substrate 1. (See FIGS. 1C, 1D, and 2).

  A chamfered surface 4 is formed along the longitudinal direction at the boundary between the surface 1a of the wooden substrate 1 and the side surface 1b along the longitudinal direction. The chamfered surface 4 is formed, for example, by chamfering the corner between the surface 1a and the side surface 1b of the wooden substrate 1 using a cutting tool such as a saw or a router. In the present embodiment, the chamfered surface 4 is formed in a flat shape (C chamfer), but may be formed in a curved surface (R chamfer) having an arcuate cross section.

  When the chamfered surface 4 is a C chamfer, when a plurality of floor materials 40 are joined and laid, a groove having a V-shaped cross section is formed as a joint or the like in the joint. This groove prevents a gap or a step generated in the joint from being noticeable. In addition, the decorative effect is improved by, for example, making a three-dimensional appearance appear on the floor surface formed by laying the flooring 40. When the chamfered surface 4 is an R chamfer, a U-shaped groove is formed in the joint.

  The wood substrate 1 has a decorative groove 5 formed in the longitudinal direction in the surface 1a and having substantially the same shape as the groove of the joint. In the present embodiment, since the chamfered surface 4 is a C chamfer, a decorative groove 5 having a V-shaped cross section is formed. When the chamfered surface 4 is an R chamfer, a decorative groove 5 having a U-shaped cross section is formed. The decorative groove 5 is formed by, for example, cutting the surface 1a of the wooden substrate 1 using a cutting tool as described above. This decorative groove 5 also has a decorative effect such that a three-dimensional effect appears on the floor surface when a plurality of floor materials 40 are joined and laid. Moreover, it has the effect of making the position of the joint portion inconspicuous.

  The wood substrate 1 includes plywood, particle board, medium density fiberboard (MDF), and a mixed board formed by molding a mixture of wood powder and resin into a plate shape (Wood Plastic). Board: WPB), orientated strand board (OSB), and the like. Or what combined these can also be used as the wooden base material 1. FIG. For example, a composite material obtained by bonding MDF or WPB to the surface of a plywood can be used as the wood substrate 1.

Next, as shown in FIG. 1B, a decorative sheet 6 is laminated on the surface 1 a of the wooden substrate 1 to obtain a wooden decorative board 10.
Examples of the decorative sheet 6 include a single layer structure in which a pattern layer is provided on the front and back surfaces of a thermoplastic resin sheet, and a multilayer structure in which a pattern layer and a thermoplastic resin layer are laminated.

  As the thermoplastic resin constituting the sheet of the decorative sheet 6 and the thermoplastic resin layer, for example, a polyolefin resin, a polyester resin, an acrylic resin, a polystyrene resin, a polyamide resin, a polyvinyl chloride resin, or the like may be used. it can. Among these, it is desirable to use a polyolefin-based resin or a polyester-based resin in consideration of surface properties, processability, economic efficiency, discardability, and the like as a flooring material.

  As for the thickness of the decorative sheet 6, it is desirable to adopt a thin one in consideration of cost and workability.

  The decorative sheet 6 is laminated on the surface 1a of the wooden substrate 1 using an adhesive. As the adhesive, it is desirable to use an adhesive having excellent water resistance after bonding. Specific examples include an ethylene-vinyl acetate copolymer emulsion adhesive, a two-component curable urethane-based adhesive, a one-component moisture-curable urethane-based hot melt adhesive, and the like.

  When laminating the decorative sheet 6 on the surface 1a of the wooden substrate 1, the inner surface of the decorative groove 5 on the surface 1a of the wooden substrate 1 and the chamfered surface 4 formed along the longitudinal direction using a narrow roll or the like. The decorative sheets 6 are laminated along.

  Next, as shown in FIG. 1 (c), the corner portion between the surface 10a of the wooden decorative board 10 and the side surface 10b along the short direction is applied to the wooden substrate 1 using the cutting tool as described above. Chamfering to reach. As a result, a chamfered surface 11 from which the wooden substrate 1 is exposed is formed along the short direction at the boundary between the surface 10a of the wooden decorative board 10 and the side surface 10b along the short direction. In the present embodiment, the chamfered surface 11 is formed in a flat shape (C chamfer), but may be formed in a curved surface (R chamfer) having an arcuate cross section.

  Next, as shown in FIG. 1 (d), the chamfered surface 11 is colored and painted by applying a paint to the chamfered surface 11 using the paint supply member 20.

  As the paint, it is desirable to use a paint having a color tone approximate to the color tone of the surface 6a of the decorative sheet 6. Since the color tone of the surface 6a of the decorative sheet 6 is similar to the color tone of the colored coating film of the chamfered surface 11 described later, a flooring material with better design can be obtained.

  The coating material supply member 20 is not particularly limited, such as a synthetic resin material, a rubber material, or a metal material, but it is preferable to use a material that is inexpensive and easy to process. Moreover, if the shape can also contact the ridge part 12 between the chamfered surface 11 and the side surface 10b of the wooden decorative board 10 in a non-contact state with respect to the surface 6a of the decorative sheet 6, a flat plate shape or a curved plate shape , Columnar, conical, frustoconical, etc. In the present embodiment, a frustoconical coating roll 21 is used as the coating material supply member 20. The coating roll 21 has a roll surface 22 at a portion corresponding to the side surface of the truncated cone.

When the chamfered surface 11 of the wooden decorative board 10 is colored and painted using the coating roll 21, the decorative sheet 6 side of the wooden decorative board 10 is directed downward.
The coating roll 21 is centered on the rotation shaft 23 so that the upper part thereof is in contact with the ridge 12 of the wooden decorative board 10 and the coating roll 21 is not in contact with the surface 6a of the decorative sheet 6. It is pivotally supported so that it can rotate. Further, the roll surface 22 of the coating roll 21 and the chamfered surface 11 of the wooden decorative board 10 are in a non-contact state except for the ridge portion 12, and the roll surface 22 of the coating roll 21 and the chamfered surface 11 of the wooden decorative board 10 are not in contact with each other. A gap Q is formed between them. A coating material storage tank 31 storing the coating material 30 is installed below the coating roll 21. The paint reservoir 31 is arranged so that the lower part of the coating roll 21 is immersed in the paint 30 of the paint reservoir 31. By rotating the coating roll 21, the coating material 30 can be spread over the entire circumference of the roll surface 22 of the coating roll 21 and supplied to the gap Q.

  The wooden decorative board 10 is sent out along the short direction, and the paint roll 21 is rotated in the same direction as the feeding direction of the wooden decorative board 10, so that the paint is applied to the chamfered surface 11 of the wooden decorative board 10 over the entire length in the short direction. 30 can be applied and the chamfered surface 11 can be colored. The coated surface is dried as necessary. Since the coating roll 21 and the surface 6a of the decorative sheet 6 are in a non-contact state, only the chamfered surface 11 along the short direction can be colored and coated without coloring the surface 6a of the decorative sheet 6. . Since the wooden base material 1 exposed on the chamfered surface 11 is covered and covered by this colored coating, a sense of incongruity due to the difference between the color tone of the wooden base material 1 and the color tone of the decorative sheet 6 is reduced, and the design is excellent in FIG. Floor material 40 can be obtained.

  The contact angle θ between the contact surface 24 of the painting roll 21 with the wooden decorative board 10 and the chamfered surface 11 of the wooden decorative board 10 (the angle formed between the roll surface 22 of the painting roll 21 and the chamfered face 11 of the wooden decorative board 10). It is preferable to arrange the coating roll 21 so as to be within 20 °. More preferably, it is 3 ° or more and 15 ° or less. If it is within 20 °, the paint 30 can be efficiently supplied from the roll surface 22 of the coating roll 21 to the gap Q, and the paint 30 supplied to the gap Q is effective on the chamfered surface 11 of the wooden decorative board 10. And can be applied to the chamfered surface 11. Furthermore, the wrapping of the paint 30 supplied to the gap Q to the portion other than the chamfered surface 11 of the wooden decorative board 10 such as the surface 6a of the decorative sheet 6 is suppressed, and coloring paint other than the chamfered surface 11 is suppressed. Can do.

When the chamfered surface 11 of the wooden decorative board 10 is colored and coated as described above, a flooring 40 in which the colored coating film 13 is formed on the chamfered surface 11 of the wooden decorative board 10 is obtained as shown in FIG. It is done.
The manufacturing method of the flooring 40 does not require a large amount of paint unlike the conventional flooring manufacturing method shown in the background art. Further, it is not necessary to make the decorative layer thick. For this reason, when a plurality of flooring materials 40 are joined and laid, the flooring 40 capable of making the gaps and steps generated in the joints inconspicuous and improving the decorative effect is manufactured at low cost. be able to.

  In the above embodiment, the decorative sheet 6 is laminated on the chamfered surface 4 formed at the corner in the longitudinal direction of the wooden decorative board 10, and the chamfered surface 4 formed at the corner in the short direction is colored and painted. Although the mode of forming the film 13 is shown, the present invention is not limited to this. The colored coating film 13 is formed on both the chamfered surfaces in the longitudinal direction and the short side direction, the decorative sheet 6 is laminated on the chamfered surface in the short side direction, and the colored coating film 13 is formed on the chamfered surface in the longitudinal direction. You may do it.

DESCRIPTION OF SYMBOLS 1 Woody base material 1a Surface 6 Decorative sheet 6a Surface 10 Wooden decorative board 10a Surface 10b Side surface 11 Chamfered surface 12 Ridge part 20 Paint supply member 21 Coating roll 24 Contact surface 30 Paint 40 Floor material

Claims (2)

A chamfering process that reaches the wooden base material is performed at a corner between the surface and the side surface of the wooden decorative board having a decorative sheet on the surface of the wooden base material, and the wooden material is provided between the surface and the side surface of the wooden decorative board. A step of forming a chamfered surface on which the base material is exposed, and a step of applying a paint to the chamfered surface and coloring the chamfered surface.
In the step of coloring and painting the chamfered surface, the surface of the decorative sheet side of the wooden decorative board is directed downward,
The coating roll is brought into a non-contact state with respect to the surface of the decorative sheet , and the portion positioned on the upper side of the coating roll is brought into contact with the ridge between the chamfered surface and the side surface of the wooden decorative board from the lower side. And, the roll surface of the coating roll and the chamfered surface of the wooden decorative plate by making the roll surface of the coating roll and the chamfered surface of the wooden decorative plate in a non-contact state except for the ridges. A gap is formed between
The portion located on the lower side of the coating roll is immersed in the coating tank, and the coating roll is rotated to spread the coating around the entire roll surface of the coating roll, and the coating is applied to the gap. method for producing a flooring material coating on the chamfered surface is supplied is characterized by Rukoto applied. Characterized by applying a coating material to the chamfered surface contact angle is disposed the coating roll such that within 20 ° and the contact surface and the wood veneer chamfered surface of said wood veneer in the paint roll The method for producing a flooring material according to claim 1.

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