JPH04176601A - Manufacture of natural wood overlay board with decorative pattern - Google Patents

Abstract

PURPOSE:To cut off part, which serves as a part of tally pattern, from primcoated overlay veneer sheets and the like by a method wherein the cutting- off is performed with a knife or laser beam operated with a cutting plotter. CONSTITUTION:Parts A, which are the same in shape, are cut off out of a plurality of various primcoated overlay veneer sheet 1a and 1b and a non-wood- based sheets 5 with a cutting plotter, to the head part of which a knife or laser emitter is attached. The cut-off part A of one overlay veneer sheet is fitted to the remaining part B excluding the cut-off part A of the other overlay veneer sheet so as to exchange the parts A and B between the kinds of sheets with each other in order to make a sheet having tally pattern, the kind of wood of which is different from that of matrix. Next, the resultant overlay veneer sheet 1 having the exchanged tally pattern is pasted with an adhesive 3 on wood-based material and hot-pressed. After the hot-pressing is completed, the surface of the overlay veneer sheet 1 is polished mechanically and then finish-coated so as to be finished to natural wood overlay board 10. As various overlay veneer sheet, sheets varied in resin, grain and surface coloring of veneer are exemplified.

Description

DETAILED DESCRIPTION OF THE INVENTION (Industrial Field of Application) The present invention relates to a method for manufacturing a natural wood decorative board having a decorative pattern.

The present invention is particularly advantageously applied to the production of decorative wood products with interlocking patterns made of different materials.

(Conventional technology) Products called inlaid decorative boards have been known for a long time.

This product is made by cutting out a part of the surface of a lotion plate using a scroll saw or the like, and then inserting decorative materials such as glass beads or metal pieces into the cut-out recesses. Decorative wood boards have usually been made by pasting thick decorative veneers with a thickness of 0.50 to 0.60 m or more onto the surface of a base material such as plywood. In some cases, solid wood boards were used instead of such decorative wood boards.

However, since the above-mentioned cutting process has conventionally been performed manually, it requires a lot of effort and time to complete, resulting in high manufacturing costs.

A technique that has been proposed so far to solve this problem is the technique described in Japanese Patent Application Laid-Open No. 2-1140 [1]. This involves cutting the surface of decorative plywood etc. using an NC router to form recesses in a predetermined pattern, then creating a veneer sheet with a release paper attached, and then peeling off the release paper from the veneer sheet. , discloses a pattern making method in which the pattern is pasted onto the recessed portion.

(Problems to be Solved by the Invention) However, the above-mentioned pattern making method has the following drawbacks and problems.

■First, the decorative laminate obtained by this method is a veneer sheet embedded in a part of the surface of a base material such as plywood, and the pattern that can be formed is limited to the surface of the veneer and the base material. It is limited to combinations, and the freedom of design expression is limited.

■Also, it is necessary that the depth of the recesses on the surface of the base material formed by cutting with the NC router completely match the thickness of the veneer sheet to be embedded.If they do not match, the surface of the resulting product will be uneven. If unevenness occurs, a post-process of pressing or mechanical polishing is required.The surface of the product may be damaged during the pressing or polishing process.

Therefore, in order to ensure such consistency, the NC router
It would be necessary to adjust the cutting condition every time the veneer sheet is changed. Therefore, when embedding various types of veneer sheets into plywood, the above-mentioned pattern making method is not suitable.

(1) The shape and dimension stability of the veneer sheet embedded in the plywood surface is required to be extremely good. If the shape and dimensions are not stable, changes in surrounding temperature and humidity conditions may cause deformation such as cracking, warping, or gaps. The veneer sheet described in the above-mentioned publication was unpainted and no particular measures were taken to stabilize the shape, etc., and there was a need for further improvement.

■Furthermore, in the above pattern making method, an NC router is used to cut the concave portions that are the parts of the irregular pattern, so the cut surfaces at the corners of the periphery of the concave portions are rounded surfaces. It was not possible to cut at a perfect acute angle, and therefore there were certain limitations on the outer shape of the pattern that could be produced.

Therefore, an object of the present invention is to eliminate such drawbacks, to form a pattern of different materials on a natural wood decorative board with a very high degree of freedom, and to prevent unevenness from occurring between the different materials on the surface of the decorative board. To reliably and mass-produce a decorative patterned natural wood decorative board having excellent smoothness and having high shape and dimensional stability against changes in ambient temperature and humidity conditions without causing inconveniences such as cracking and deformation. The objective is to provide a manufacturing method that can be used.

(Means for Solving the Problems) The method for manufacturing a natural wood decorative board according to the present invention includes: (A) attaching a knife or a laser projector to the head of a cutting plotter, and using the plotter to produce a plurality of different kinds (B) Cutting out portions of the same shape from each decorative veneer sheet; (B) transferring the cut portions of each decorative veneer sheet to the cut portions of another decorative veneer sheet; (C) Attaching the replaced decorative veneer sheet onto the wood base material with adhesive and then heat-pressing it, and (D) Completing the heat-pressing. After that, the surface of the decorative veneer sheet is mechanically polished and then painted with a top coat.

The different types of decorative veneer sheets used in this method include those classified by type with respect to wood species, grain, or surface coloration of the veneers.

Another method of manufacturing a natural wood decorative board according to the present invention is as follows: (A) A knife or a laser projector is attached to the head of a cutting plotter, and using the plotter, a decorative veneer sheet coated with an undercoat and a non-wood sheet are cut. (B) Refitting the cut-out portion of the decorative veneer sheet to the cut-out portion of the non-wood sheet, or cutting out the cut-out portion of the non-wood sheet to the decorative veneer sheet. (C) pasting the refitted sheet onto a wood base material with an adhesive and then heat-pressing it; and (D) after completion of heat-pressing. , mechanically polishing the surface of the sheet,
Thereafter, it consists of a step of painting with a top coat.

The non-woody sheet used in this method consists of, for example, metal foil, resin sheet, paper or woven fabric.

In the method of the present invention, a portion that will become a part of a mating pattern is cut out of a decorative veneer sheet or the like coated with a primer using a knife or a laser that follows the operation of a cutting plotter. Therefore, the corner of the periphery of the cut-out portion can be formed into an acute angle without creating a rounded surface.

Furthermore, in the method of the present invention, a mating pattern of different sheet materials is formed before the decorative veneer sheet is attached to the base material, and after the mating pattern is formed, the sheets made of different materials are heat-pressed. . Therefore, on the surface of the produced natural wood decorative board, no unevenness occurs between the sheets of different materials that make up the mating pattern, and high smoothness can be obtained.

Furthermore, the method of the present invention uses a decorative veneer sheet on whose surface an undercoat film such as a sump ink sealer has been formed in advance. Therefore, in mechanical polishing before topcoating, it is possible to polish only the basecoat film and not polish the decorative veneer sheet itself underneath. Therefore, on the surface of the natural wood decorative board to be produced, wood powder, fine pieces, and traces of sheet materials of different types do not mix or remain on each type of sheet portion.

Further, the present invention is a method of forming a negative pattern by butting together a plurality of decorative veneer sheets of different types. Therefore, the decorative veneer sheet used in the present invention does not suffer from inconveniences such as warping, deformation, and peeling due to changes in ambient temperature, humidity, etc., and has excellent shape retention and high dimensional stability. It is required that the sheet has the characteristics of

Examples of decorative veneer sheets that meet these requirements are Japanese paper, kraft paper, tissue paper, impregnated paper, or nonwoven fabric.

Ethylene copolymer resin film.

Aluminum foil or iron foil; Ethylene copolymer resin film; Japanese paper, kraft paper, tissue paper, impregnated paper, or nonwoven fabric: in this order, and if necessary, an adhesive, preferably EAA/
Lamination is performed using an EVA adhesive, and then a decorative veneer is further laminated on the surface of the laminate using a cold-curing, thermosetting or thermoplastic adhesive, preferably an EAA/EVA adhesive. Then, there are decorative veneer sheets made by heat pressing, or dry pressing followed by cold pressing.

Another example of a decorative veneer sheet includes the following steps: (a) impregnating a fibrous sheet with a resin solution and drying it to produce a resin-impregnated fibrous sheet; (b) applying the resin-impregnated fibrous sheet to the board surface. The step of placing the plate on a smooth fixing plate coated with a resin and fixing it by heating, for example, using a hot roll or a hot press.

(c) applying an adhesive onto the resin-impregnated fibrous sheet of the fixing plate; (d) subsequently placing a decorative thin plate on the adhesive of the fixing plate; and placing the fixing plate in a hot press. (e) Next, the process of stacking and curing a plurality of heat-pressed fixing plates; (f) After curing, the decorative veneer sheets on the fixing plates are (g) Then, the process of painting the surface of the polished decorative veneer sheet with paint; and (h) Finally, the process of peeling off the painted decorative veneer sheet from the fixed plate. There are decorative veneer sheets manufactured by the method of

In the latter method, the fixing plate is passed through the final steps (b) to (h) of manufacturing the decorative veneer sheet, and each material of the decorative veneer sheet, especially the sheet base material (resin-impregnated fibrous sheet), is fixed. The decorative veneer sheet is manufactured on a fixed plate without being fixed on the plate.

Therefore, during the manufacturing process, the decorative veneer is held in its flat form on the fixed plate, which prevents the occurrence of cracks, etc.
It can also reduce and alleviate internal stress. Moreover, joint work for decorative veneers becomes easier.

Furthermore, since the fixing plate is separated from the decorative veneer sheet in the final step (h), it can be reused for subsequent manufacturing of the decorative veneer sheet by returning it to step (b).

The fixing plate is preferably one coated with a polyester resin or a wood base material such as general plywood or MDF. The method for resin coating is to apply a resin solution onto the substrate, or to adhere a resin film onto the substrate using an adhesive, preferably with a nonwoven fabric interposed.

Preferred resin-impregnated fibrous sheets are prepared by impregnating fibrous sheets such as Japanese paper, paperboard, woven fabrics and preferably non-woven fabrics with polyurethane resin or styrene-phtadiene rubber latex and drying the impregnated fibrous sheets.

In addition, the amount of resin to be impregnated is set to 5 solids to obtain the required adhesion strength between the fixed plate and the resin-impregnated fibrous sheet.
Is it necessary to set it to g/112 or more? An appropriate amount of resin impregnated is, for example, in the case of a fibrous sheet (polyester/valve nonwoven fabric) with a basis weight of 20 to 30 g/s2, a solid amount of 7 to 15
An impregnation amount of g/m2 is appropriate.

In addition, the adhesion strength between the decorative veneer sheet and the fixing plate is preferably 3.
The range is 0 to 200g/25m. Therefore, it is necessary to take this point into consideration when hot pressing the fixing plate in step (d).

Also, during the curing (e), the moisture in the decorative veneer and adhesive gradually transfers to the wood base material of the fixing plate and the decorative veneer, etc. dries, while the decorative veneer, etc. The laminate remains completely fixed to the upper surface of the fixed plate. Therefore, due to the dry ink set effect or the like, the dimensions of the laminate are stabilized while maintaining the form of a flat sheet.

The stacking and curing is preferably carried out by stacking usually about 10 fixed plates while still hot and continuing at room temperature until the moisture content of the decorative veneer becomes equal to or lower than the equilibrium moisture content.

The vine decorative veneer used in the present invention is made of various precious woods, for example, with a thickness of 0.10 to 3.011 mm, preferably thin < (0.15 to 0.4 mm thickness), and cut. Examples include carved sawn boards and wedge boards. The grain of the decorative veneer does not matter, and it can be straight-grained, continuous-grained, board-grained, or heathered. Furthermore, the wood species of the veneer is not particularly limited. Examples of preferred tree species include cypress, oak, zelkova, cherry tree, elm, black persimmon, horse chestnut, katsura,
Enju, maple, camphor tree, rosewood, teak, mahogany, ebony, rosewood, bird's eye maple, American black walnut J renatt, clarow all nut, Latin walnut, Quincelan tau J lenut, zebra wood, mangashiro, Brazilian rose, Carisi, Hershimon, Silhar Rose, Redout, Purple Wood, Silky Oak, Parma, Formosan, Chessie, Macnolya, Black Leo, White Leo, Saberi, Fuhinka, Makore, Matroner, Myrtle, Maple, Arasin, and Intuiya. .

(Example) Embodiments of the present invention will be described below with reference to the drawings.

In addition to the cutting plotter, using the manufacturing apparatus shown in FIG. 1, natural wood decorative boards 10a to 10c made of different materials and having a laminated pattern as shown in FIG. 3 were manufactured.

First, a knife or a laser projector is attached to the head of a cutting plotter (not shown), and using the plotter, as shown in FIG. 5, portions A of the same shape were cut out.

Then, the cutout part A of the decorative veneer sheet 1b is fitted into the cutout part B of the veneer sheet lb (Fig. 3(a)), while the cutout part A of the veneer sheet 1b is inserted into the cutout part B of the veneer sheet lb. )-1a (FIG. 3(b)) to produce a sheet having a combination pattern of different tree species.

Also, for the non-woody sheet 5 made of metal (A1) foil, a cutout portion A of the same shape is cut out using an NC laser or the like.
This was inserted into the cutout part B of the decorative veneer sheet la (FIG. 3(c)) to produce a sheet having a pattern of a decorative veneer and a metal plate.

Other types of sheets were also made, which will not be described in further detail, or which form one-piece patterns by interchanging sheet types in the same manner as described above.

Next, as shown in FIG. 1, a predetermined amount of a thermosetting water-soluble adhesive 3 is applied onto the wood base material 2 using a coating device 6 such as an applicator roll (step (A)). ).

Subsequently, the decorative veneer sheet 1 with the laminated pattern made above was further placed on the adhesive 3 of the base material 2 and stacked (step (B)).
.

Then, the fixed plate 2 on which the veneer sheet 1 is placed is placed in a hot press machine 7 at, for example, 105°C x 90 seconds x 6 kg/c.
Heat compaction was carried out under the conditions of "m" (step (C)).

After hot pressing, the laminate of the decorative veneer sheet 1 and the base material 2 was taken out from the hot press machine, and the surface of the decorative veneer sheet etc. was mechanically polished using a sander 8 (step (D)).

Next, using the coating device 9, the surface of the polished decorative veneer sheet etc. l is painted with polyurethane paint to form the top coat 4 (Step (E)), the natural wood decorative board IO.
Finished.

Therefore, the finished decorative board is shown in Figures 3 (a) to (c).
It had a mating pattern as shown in Figure 2, and the surface smoothness was very good.

In addition, all decorative board products have extremely good dimensional stability, and defects such as the outer edge of the cutout part A overlapping the cutout part B, or the gap between the two can be avoided due to the ambient temperature and humidity. It did not occur even if the conditions changed significantly.

Furthermore, the veneer sheet on the surface of the decorative board was highly unlikely to undergo deformation such as cracking or warping.

Two decorative veneer sheets that could be effectively used in the method of the above-described example are shown in FIGS. 4 and 5.

The decorative veneer sheet 11 shown in FIG.

Japanese paper, kraft paper, tissue paper, impregnated paper or non-woven fabric 15: Polyethylene film 19: EAA resin film 16° Aluminum foil 17° EAA resin film 16° Polyethylene film 19. Then, Japanese paper, kraft paper, tissue paper, impregnated paper, or nonwoven fabric 15 are laminated in this order according to a method similar to the melt extrusion lamination method, and then pasted, and then on the surface of the formed laminate 14, Decorative veneers 13 are laminated with a vinyl acetate/acrylic copolymer adhesive 18 interposed therebetween, and then this is heat-pressed, or heat-pressed and cold-pressed.

After pressing, the surface of the decorative veneer sheet is coated with an undercoat to form an undercoat film 12 of sump ink sealer.

Further, another decorative thin veneer sheet 21 shown in FIG. 5 is made by applying a thermosetting water-soluble adhesive (
For example, a styrene-butadiene rubber latex 24, a decorative veneer 23 having a thickness of 0.10 to 0.40 mm, and an undercoat film 22 of polyurethane resin paint are laminated in this order.

This decorative thin veneer sheet 21 was manufactured according to the procedure shown in FIG. The procedure will be explained below.

First, fibrous sheet (polyester/pulp nonwoven fabric) 2
6 from the raw roll and polyurethane resin 27
Step (1) of immersing and passing through the impregnating tank 31 containing
), followed by passing it through a drying oven 32 and drying it to produce a resin-impregnated fibrous sheet 25 (step (2)).

Next, the produced resin-impregnated fibrous sheet 25 is attached to a fixing plate 30.
Step (a)) of fixing the sheet 25 on the fixing plate 30 by heating and suppressing the heat roll 33;
Subsequently, it was cut into the size of the plate 30 using a cutter 34 (
Step (b)).

Note that the fixing plate 30 is formed by pasting a polyester film on a wood base material (for example, MDF, plywood) with an adhesive and covering it with a polyester resin.

Next, a predetermined amount of the thermosetting water-soluble adhesive 24 was applied to the resin-impregnated fibrous sheet 25 on the fixed plate 30 using a coating device 35 such as an applicator roll (step (C)).

Subsequently, the decorative veneer 23 was further placed on the adhesive 24 of the fixing plate 30 (step (d)).

Then, the fixed plate 30 with the veneer 23 placed thereon is pressed in a hot press machine 36 using, for example, iosoCx 90 seconds x 6 kg/c.
■ Heat compaction was carried out under the conditions of 2 (step (e)).

In this step, the adhesion strength between the decorative veneer sheet 21 and the fixing plate 30 or the limit strength in a 90° peeler was determined to be in the range of 30 to 200 g/25 mm width.

Next, the laminate 2 of the fixing plate 30 and the veneer plate etc.
8... are taken out from the hot press machine and stacked again while still hot, and the stacked body 29 is left at room temperature for about 24 hours until the moisture content of the decorative veneer sheet reaches about 6 to 15%. Intermediate deposition curing (stage 11! f (f)
).

Thus, the decorative veneer 2 integrated by such heat pressing
3. The laminate 28 of the adhesive 24 and the resin-impregnated fibrous sheet 25 was maintained in a stable planar form on the fixed plate 30 upon completion of curing (step (g)).

Thereafter, the surface of the veneer of the laminate 28 on the fixing plate 30 was mechanically polished using a sander 37 (step (h)).

Next, using the coating device 38, the polished decorative veneer 2
Paint the surface of 3 with polyurethane paint and top coat!
After forming I22 (step (i)), the decorative veneer sheet 21 was finished on the fixing plate 30 (step (j)).

Thereafter, when the finished decorative veneer sheet 21 is used for producing the above-mentioned combined pattern, it is peeled off from the fixing plate 30 (step (k)), while the remaining fixing plate 30 is stored and removed in step (1). )'), and it was decided to reuse it by going to step (a). It should be noted that the fixed plate 30 could be reused in several thousand or several directions without any problem.

(Effects of the Invention) As described above, according to the manufacturing method of the present invention, it is possible to reliably and continuously produce natural wood decorative boards having a pattern of interlocking different materials having the following excellent characteristics. I have something to do.

(a) Multiple types of decorative veneer sheets together (at the same time)
Using this method, a natural wood decorative board with a - pattern can be produced, and the combination of decorative veneer sheets to be used is completely free without any restrictions.

Therefore, it is possible to form a combination pattern of different materials on a natural wood decorative board with a very high degree of freedom.

In addition, the corners of the boundary lines of the laminated pattern can be formed at acute angles, so that a natural wood decorative board with a clearer laminated pattern can be obtained.

(b) With respect to the surface of the natural wood decorative board, no unevenness occurs between the sheets of different materials that make up the mating pattern, and therefore a natural wood decorative board with very high surface smoothness can be obtained.

Therefore, there is no need for post-treatment processes such as polishing or compaction to obtain the desired smoothness.

(C) The shape of the natural wood decorative board, especially the decorative veneer sheet as the surface material, in response to changes in conditions such as temperature and humidity of the wall,
Dimensional stability is high, even if there are large changes in temperature, humidity, etc.
cracks, warping, peeling and other deformation of the top sheet;
In addition, there are no inconveniences such as the occurrence of gaps at the border lines of the mating patterns.

(d) In the mechanical polishing process before topcoat painting, only the undercoat film is polished and the underlying decorative veneer sheet itself is not damaged, so a mating pattern is formed on the surface of the natural wood decorative veneer that is produced. Each veneer sheet part must not contain traces or traces of fine particles of different types of veneer sheet material. Therefore, a natural wood decorative board with high commercial value can be obtained.

Moreover, the decorative board produced by topcoating has very little directionality and very high homogeneity.

The natural wood decorative board provided by the present invention can generally be used in the following applications. : Building interior materials such as wall materials.

Surface materials such as ceiling surface materials, column covering materials, and movable partitions;
Surface materials for interior products of automobiles and ships, exterior decorative materials for furniture such as chests of drawers, exterior decorative materials for general wooden products such as fixtures, and exterior decorative materials for electronic devices and musical instruments.

[Brief explanation of the drawing]

FIG. 1 is an overall view showing the manufacturing process of natural wood decorative board according to the method of the embodiment of the present invention, and FIGS. 2(a) to C) and 3(a) to c) are FIG. 3 is a diagram illustrating the process of forming a pattern of different materials on a natural wood decorative board according to the method. Figures 4 and 5 are cross-sectional views showing two types of decorative veneer sheets suitable for use in the method of the present invention, and Figure 6 is a diagram showing the manufacturing process of the decorative veneer sheet shown in Figure 5. be. In the figure, 1, la, lb... Decorative veneer sheet coated with an undercoat 2... Wood base material 3... Adhesive 4... Top coat film 5... Non-wood sheet 10...・Natural wood decorative board lOa~10c...Natural wood decorative board with a pattern of combining different materials 11.2
1... Decorative veneer sheet 12.22... Undercoat coating film 13.23... Decorative veneer A... Cutout portion of the decorative veneer sheet B... Excision of the cut-out decorative veneer sheet Part 1 rl! J (C) CB) (A)↓ Figure 2 (Q) (b) (c) Figure 3 (a) (b) (c)
WI4 Figure 5 Honto Press Single "Antonym Isu ↑Children 11 yen 4 Shigo (9) (h) (i) (
'J Zuguchi=Ko'ri

Claims (4)

[Claims] (1) (A) A step of attaching a knife or a laser projector to the head of a cutting plotter and using the plotter to cut out parts of the same shape from a plurality of undercoated decorative veneer sheets of different types, (B ) a step of replacing the cut-out portion of each decorative veneer sheet with the cut-out portion of another decorative veneer sheet so that the sheet types are interchanged; (C) the replaced decorative veneer sheet; (D) After the heat pressing is completed, the surface of the decorative veneer sheet is mechanically polished, and then a top coat is applied. A method for producing a natural wood decorative board comprising the step of painting. (2) The manufacturing method according to claim 1, wherein the decorative veneer sheets of different types to be used are classified according to the wood species, grain, or surface coloring of the veneers. (3) (A) A step of attaching a knife or a laser projector to the head of a cutting plotter and using the plotter to cut out parts of the same shape from the primed decorative veneer sheet and the non-wood sheet. (B) Refitting the cut-out portion of the decorative veneer sheet to the cut-out portion of the non-wood sheet, or replacing the cut-out portion of the non-wood sheet to the cut-out portion of the decorative veneer sheet; ( C) adhering the refitted sheet onto a wood base material with an adhesive and then heat-pressing it; and (D) mechanically polishing the surface of the sheet after completing the heat-pressing;
A method for producing a natural wood decorative board, which comprises the step of subsequently painting with a top coat. (4) The manufacturing method according to claim 3, wherein the non-wood sheet used is made of metal foil, resin sheet, paper, or knitted fabric.