JPH0768717A - Grooved decorative board and method for manufacturing the same - Google Patents

Abstract

(57) [Summary] [Purpose] A grooved board that can be manufactured by a simple manufacturing process using a resin board as a base material, and that has the same excellent texture and aesthetics as those using natural wood veneer. Provide a veneer. [Structure] A substrate 4 is manufactured by adhering a semitransparent sheet material 8 to the surface of a resin board 6 with an adhesive 10. A pattern 14 formed by embossing e1, a groove 16 formed by embossing e2, and a groove 18 formed by embossing e3 are simultaneously formed on the sheet material bonding surface 12 of the substrate 4 by embossing. Then, the surface coating layer 22 is formed on the sheet material bonding surface 12 of the substrate 4 to obtain the grooved decorative plate 2.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative board using a resin board as a base material, and more specifically, it has a grooved decorative board which can be suitably used as a board material for floor boards and a method for producing the same. Regarding

[0002]

2. Description of the Related Art Conventionally, a grooved decorative board using a veneer of natural wood as a surface material has been used as a board material for a floorboard in a Western-style room.

The grooved decorative plate is, for example, one shown in FIG. The grooved decorative plate 52 shown in FIG. 3 is formed by laminating a plurality of single plates 54 (e.g., five in this example) such as lauan, which is a lower grade wood, with a length of about 1800 mm (6 scales) and a width of about 300 mm (1
A standard wooden veneer 56 having a thickness of about 12 mm is bonded to the surface of a natural wood veneer 58, grooves 60, 60 are formed by grooving, and a surface coating 62 is finally applied.

The veneer 58 is made by slicing an excellent natural wood board into a thin slice having a thickness of about 0.2 mm to 0.3 mm, and has a good woodgrain pattern 64 such as grain and board which brings a texture and aesthetics peculiar to wood. , And its hue is almost the same throughout. Therefore, the grooved decorative plate 52 using the natural wood veneer 58 looks good and has a high commercial value.

[0005]

In recent years, there is a growing shortage of excellent natural trees. In addition, there is a global trend to effectively use and save natural trees. Against this background, the stable supply of excellent natural wood veneer and the maintenance of appropriate prices are becoming difficult. For this reason,
The grooved decorative board using the veneer of natural wood as shown in FIG. 3 has become very expensive.

Further, the grooved decorative board using the veneer of natural wood shown in FIG. 3 is obtained by normally bonding the plywood and the veneer, and then
Further, there is a problem that a groove process must be performed, and the manufacturing process is complicated. Further, when there is a joint portion 66 of the veneer plate on the surface as shown in FIG. There is a drawback that 66 deteriorates and a gap is generated between the adjacent protruding plates.

On the other hand, the resin board made of hard resin, soft resin, foamed resin or the like has stable quality and can be obtained at a relatively low cost. Therefore, if a grooved decorative board having an excellent appearance can be manufactured using a resin board, it is extremely effective in industrial and resource protection.

However, unlike the wood, the resin board does not have a grain pattern such as a grain or a grain on the surface. Therefore, when a grooved decorative plate is manufactured using a resin board as a base material, only a bad-looking decorative plate can be obtained, and it is difficult to obtain a high-quality grooved decorative plate.

Further, particularly in the foamed resin board, a large number of fine holes due to air bubbles are present on the surface thereof. For this reason, even if the surface is polished before the cosmetic finish such as surface coating, there is a problem that it is difficult to satisfactorily perform the finish coating because of the small irregularities due to the fine holes.

The present invention has been made in view of the above circumstances, and can be manufactured inexpensively and easily using a resin board as a base material, and has the same excellent texture and quality as those using a natural wood veneer. An object is to provide a grooved decorative plate having an aesthetic appearance.

[0011]

Means for Solving the Problems In order to achieve the above-mentioned object, the present inventor has a grooved decorative board having an excellent appearance similar to the case where a veneer board of excellent natural wood is used with a resin board. As a result of earnest research on manufacturing
The following items (1) to (5) were found.

(1) By bonding a semi-transparent sheet material to the surface of the resin board, only desired desired portions can be selectively selected from the appearance elements such as colors and patterns that the resin board has in advance. Being able to show on the surface of the sheet material by seeing through.

(2) By adhering a semi-transparent sheet material to the surface of the resin board, fine holes and the like of the foamed resin board are hidden by the sheet material, and good finish coating can be performed on the surface of the sheet material. .

(3) A semi-transparent sheet material is adhered to the surface of the resin board, and an embossed pattern is formed on the adhered surface of the sheet material by embossing to selectively watermark the surface of the resin board. A decorative board having an excellent appearance can be obtained by combining the appearance elements such as colors and patterns and the embossed pattern on the surface of the sheet material.

(4) When embossing is directly formed on the resin board, the embossing may deform with time due to the resilience of the resin board. However, a sheet material, especially a thin paper, should be adhered to the resin board. Therefore, it is possible to suppress the restoring force of the resin board and prevent the emboss from deforming with time.

(5) In the embossing process, by forming the pattern by embossing and forming the groove by embossing, the groove can be formed without requiring the groove processing process, and the manufacturing process can be simplified.

By adopting the means of adhering the translucent sheet material to the resin board and forming patterns and grooves by embossing, the resin board can be formed without using a veneer of natural wood. The inventors have found that it is possible to easily and inexpensively manufacture a grooved decorative plate having an excellent texture and aesthetics while utilizing external elements such as colors and patterns that are provided in advance, and have completed the present invention.

Therefore, according to the present invention, the embossed pattern and grooves are formed on the sheet material bonding surface of the substrate formed by bonding the translucent sheet material to the surface of the resin board, and the sheet material bonding of the substrate is performed. Provided is a grooved decorative plate characterized in that the surface is surface-painted.

Further, according to the present invention, a substrate is manufactured by adhering a semitransparent sheet material to the surface of a resin board, and then a pattern and a groove by embossing are simultaneously formed by embossing on the sheet material adhering surface of the substrate. After forming
Provided is a method for manufacturing a grooved decorative plate, characterized in that a surface coating is applied to a sheet material bonding surface of a substrate.

The present invention will be described in more detail below. The grooved decorative board of the present invention uses a substrate in which a semitransparent sheet material is bonded to the surface of a resin board.

Here, the resin board is not particularly limited, but examples thereof include a hard resin board, a soft resin board and a foamed resin board made of various synthetic resins. Further, when a resin board having special properties such as noncombustibility, flame retardancy, heat insulation, sound absorption, sound insulation, and cushioning is used, it is possible to obtain a grooved decorative board that makes full use of each characteristic. .

When the grooved decorative board of the present invention is used as a floor board, it is preferable that the resin board has a thickness of about 10 to 18 mm.

The translucent sheet material is not necessarily limited, but it is required to have a translucent property that allows the preferred color or pattern on the surface of the resin board to pass through while hiding the undesirable color or pattern. preferable. By using a sheet material having such a degree of semi-transparency, it is possible to select and display only the preferable portion from the external appearance elements that the surface of the resin board has in advance. The degree of translucency of the sheet material may be substantially constant over the entire surface or may be partially different.

As the translucent sheet material, specifically,
For example, thin paper (indian paper made from hemp fibers, rice paper, etc.) weighing 20 to 50 g / m ² , glassine paper, paraffin paper, Japanese paper,
Examples of the resin sheet include, but are not limited to:

The translucent sheet material may be colored in an arbitrary color or provided with a pattern of an arbitrary shape, whereby a more varied appearance and texture can be obtained. it can.

Particularly preferred among these is thin paper. By using thin paper, it is possible to effectively suppress the restoring force of the resin board and reliably prevent the emboss from deforming with time.

Further, when the grooved decorative board of the present invention is manufactured, the difference in color between the resin board and the semitransparent sheet material is small in the case of coloring or surface coating the semitransparent sheet material. This is preferable from the viewpoint of ease of selection of the coating color and the like. From such a point of view, in the present invention, it is preferable to use a light brown resin board as the resin board and a thin paper as the translucent sheet material, especially a thin paper containing unbleached pulp. Thin paper containing unbleached pulp has a light brown hue, so when this thin paper is bonded to a light brown resin board, the difference between the hue of the resin board and that of the thin paper is small, so it is translucent. Coloring and surface coating on flexible sheet materials become easy.

Furthermore, when Japanese paper is used as the sheet material, since the Japanese paper has a dense fiber portion and a sparse fiber portion, the degree of translucency differs between the portions, which causes a change. You can get a rich appearance.

As the adhesive agent for adhering the sheet material to the resin board, any one-component adhesive agent, two-component adhesive agent or the like can be used. When a resin board having fine pores on the surface is used, it is preferable to use, as the adhesive, one in which a masking agent such as abrasive powder is dispersed.
When an adhesive in which a masking agent is dispersed is used, the masking agent masks fine pores on the surface of the resin board, improving the appearance of the product. A colorant may be mixed with the adhesive.

A light brown resin board,
When using thin paper containing unbleached pulp as the sheet material, and when using a dispersion of abrasive powder as an adhesive, the abrasive powder is the same as unbleached pulp and resin board that is a part of the raw material of the thin paper. Since it has a hue, the hue of the resin board, the abrasive powder and the hue of the thin paper are synchronized on the surface of the thin paper.

In the grooved decorative plate of the present invention, the embossed pattern and the groove are formed on the surface of the above substrate to which the sheet material is bonded. The emboss means a concave portion formed by embossing. The embossing is performed by using an embossing machine equipped with a forming roll having a convex portion corresponding to the embossing.

In this case, the embossed pattern can be formed by arranging an arbitrary small number of closely-spaced embossed groups on the sheet material adhering surface of the substrate in a desired pattern. Examples of embossed patterns include grain patterns, wood grain patterns such as plank patterns, or arabesque patterns,
A checkerboard pattern, a net pattern, etc. may be mentioned, but the pattern is not limited to these.

The groove by embossing can be formed by providing a groove-like embossing on the surface of the substrate on which the sheet material is adhered.

There is no particular limitation on the cross-sectional shape, the plane shape, etc. of the embossing forming the pattern and the groove, and it may be any shape depending on the purpose.

Further, the convex portion for forming the pattern of the molding roll of the embossing machine is set in an arbitrary height range (for example, 100 to 400).
μ) to have various heights, or to add a fine uneven pattern (for example, a satin pattern) to any place on the surface of the molding roll, for example, the upper surface of the convex portion or the bottom surface of the concave portion formed between the convex portions. As a result, it is possible to obtain a grooved decorative plate having a more varied appearance.

In the grooved decorative board of the present invention, the surface of the base material to which the sheet material is adhered is surface-coated. Examples of the coating agent include colorless transparent or colored transparent lacquer and urethane coating, but are not limited thereto. Further, before the surface coating, a coloring coating may be applied to the surface of the substrate on which the sheet material is adhered with a dye or a pigment.

[0037]

EXAMPLES Next, the present invention will be illustrated concretely by examples, but the present invention is not limited to the following examples.

Embodiment FIG. 1 and FIG. 2 show a grooved decorative board according to an embodiment of the present invention. This decorative board 2 is used as a board material for a floor board. In the figure, 4 indicates a substrate. The base 4 is formed by adhering a semitransparent sheet material 8 to the surface of a light brown resin board 6 with an adhesive 10.

The sheet material 8 is a thin paper containing unbleached pulp having a basis weight of 40 g / m ² or less, and its front surface side is smoother than the back surface side (resin board 6 side). .

The adhesive 10 is a one-component or two-component adhesive and is applied over the entire surface of the resin board 6. Further, abrasive powder is uniformly dispersed in the adhesive 10.

On the sheet material adhering surface 12 of the substrate 4, an embossing group E1 consisting of an arbitrary number of small embosses e1 densely packed with each other is arranged in a woodgrain pattern, and a woodgrain pattern 14 is formed by this embossing group E1. . Small embossed e1
Has a quadrangular vertical cross-sectional shape, and its planar shape is a cloud shape, an elliptical shape, a spindle shape, or the like. The size of the small embossing e1 is about 0.1 to 0.2 mm in depth and about 0.3 to width.
The length is 1.8 mm and the length is about 1.3 to 8.0 mm.

On the sheet material adhering surface 12 of the substrate 4, two long groove-shaped embosses e2 continuous along the length direction are arranged in parallel at equal intervals, and the groove 16 is formed by the long groove-shaped embosses e2. Are formed. Long groove embossed e2
The vertical cross-sectional shape is quadrangular. Long groove embossing e
The size of 2 is about 0.5-2 mm in depth and about 0.5-width.
At 2 mm, the length is the same as the length of the substrate 4.

Further, the sheet material bonding surface 12 of the substrate 4 is
Between the one side portion of the base 4 and the one groove 16, between the one groove 16 and the other groove 16, and between the other groove 16 and the other side portion of the base 4 along the width direction, respectively. Shallow groove embossed e3
The shallow groove-shaped embossing e3 forms the groove 18 that represents the seam of the projecting plate. The shallow groove-shaped embossment e3 has a quadrangular vertical cross section. The groove-like embossment e3 has a depth of about 0.1 to 1 mm and a width of about 0.3 to 1.8 mm.

Further, the sheet material bonding surface 12 of the substrate 4 is
Although not shown, by using a molding roll of the embossing machine, which has fine concave and convex patterns on the bottom surface of the concave portion formed between the convex portions, the base portion (pattern by embossing e1, e2, e3) (A part where no groove or groove is formed and which is indicated by reference numeral 20 in FIG. 1)
Has a satin finish.

A surface coating layer 22 for a cosmetic finish is formed on the entire surface of the base material 4 on which the sheet material is adhered. The surface coating layer 22 is made of clear lacquer which is a transparent paint.

The grooved decorative board 2 of this embodiment is manufactured as follows. First, if necessary, the surface of the resin board 6 is polished by a polishing machine such as a scraper or a belt sander.

Next, the adhesive 10 is applied to the entire surface of the resin board 6, and the thin paper 8 is adhered to the surface of the resin board 6 by this adhesive 10 to manufacture the base 4.

At this time, the adhesive 10 is thin paper (sheet material).
8 is impregnated, but the thin paper 8 is not thereby completely clarified and its translucency is maintained under a light brown hue.

After the substrate 4 is dried, the embossing machine is used to simultaneously form the embosses e1, e2 and e3 on the sheet material bonding surface 12 from above the thin paper 8.

In this case, as the forming roll of the embossing machine, one having protrusions corresponding to the embossing e1 forming the pattern 14, the embossing e2 forming the groove 16 and the embossing e3 forming the groove 18 is used. This convex portion is provided on the surface of the forming roll by etching or the like. In addition, the forming roll is provided with small concaves and convexes for forming a satin finish by etching or the like on all or part of the concaves formed between the convexes corresponding to the embosses e1, e2, and e3. Then, the substrate 4 is placed between the forming roll of the embossing machine and the carrier,
By pressing the molding roll against the sheet material bonding surface 12 of the base body 4 and rotating the molding roll, the embossing e
Formed satin with 1, e2 and e3. If the groove 16 formed by the embossing e2 or the groove 18 formed by the embossing e3 is made deeper, a normal groove processing may be performed along the embossing e2 or e3 in the post-processing.

Next, if necessary, the sheet material adhering surface 12 of the substrate 4 is colored with a dye before forming the surface coating layer 22. The dye stains the inner peripheral wall and the bottom of the embosses e1, e2 and e3. A pigment may be used for this coloring.

Finally, a clear lacquer is applied on the entire surface of the base material 4 on which the sheet material is adhered 12 to protect the surface and polish the surface, thereby forming a surface coating layer 22. As a result, the grooved decorative plate 2 of this embodiment is completed. The surface coating layer may be formed by a plurality of coatings such as polishing the coating layer after the first coating and then performing the second coating.

The operation and effect of this embodiment are as described below. (1) In this embodiment, the thin paper 8 is attached to the surface of the resin board 6. Therefore, the thin paper 8
Due to the semi-transparency, the color or pattern that the resin board 6 is provided in advance is displayed on the surface thereof only within a certain range.

(2) In this embodiment, a thin brown paper 8 containing unbleached pulp and having a hue similar to that of the resin board 6 is attached to the surface of the light brown resin board 6. Therefore, when performing color coating or surface coating on the sheet material bonding surface 12 of the substrate 4, it becomes easy to select a coating color or the like.

(3) Since the abrasive powder 38 is uniformly dispersed in the adhesive 10 for adhering the thin paper 8 to the resin board 6, even if the surface of the resin board 6 has fine holes, the abrasive powder 38 is It works to hide the fine pores. Moreover, since the abrasive powder 38 has a hue similar to that of the unbleached pulp and the resin board 6 which are a part of the raw material of the thin paper 8, the hue appearing on the surface of the thin paper 8 is the resin board 6 and the abrasive powder 38. And the hue of the thin paper 8 is synchronized.

(4) Even if there are fine holes on the surface of the resin board 6, the fine holes are hidden by the thin paper 8, and the surface 22 of the thin paper 8 can be easily coated with a uniform surface. You can get a makeup finish.

(5) In this embodiment, since the woodgrain pattern 14 of the embossing group E1 is provided, the appearance elements on the surface of the resin board 6 appearing on the surface of the thin paper 8 and the embossing group E1.
It is possible to obtain the grooved decorative board 2 which has the same texture and aesthetics as those using the veneer of natural wood and has a visually excellent appearance by being combined with the wood grain pattern 14 according to 1.

(6) In this embodiment, in the embossing process, the pattern 14 composed of the embosses e1, e2 and e3 and the groove 1 are formed.
Since the groove 6 and the groove 18 are simultaneously formed, the manufacturing process can be simplified and the manufacturing cost can be reduced.

(7) Since the thin paper 8 is adhered to the resin board 6 in this embodiment, the restoring force of the resin board 6 can be suppressed by the action of the thin paper 8 and the embossed shape changes with time. It is possible to prevent the pattern and the groove from changing and deteriorating.

In the above embodiment, the embossing e
Although the vertical cross-sectional shapes of 1, e2 and e3 are quadrangular, for example, by making the vertical cross-sectional shape a V-shape, embosses e1, e2
Alternatively, the areas of the inner peripheral wall portions of e3 and e3 may be increased, and the reflected light from the inner peripheral wall portion may be diffusely reflected to change the appearance of the embosses e1, e2, and e3. Further, other configurations may be variously modified without departing from the scope of the present invention.

[0061]

As described above, the present invention has the following features.
Produce the effect of.

A semi-transparent sheet material is adhered to the surface of the resin board, and a pattern by embossing is further provided on this sheet material adhering surface. The pattern is compounded,
A grooved decorative board having an excellent appearance can be obtained.

Since the sheet material is adhered to the resin board, the restoring force of the resin board against embossing is suppressed, and the embossed shape is prevented from deteriorating with time.

Even if there are fine holes on the surface of the resin board, the fine holes are hidden by the sheet material, and the finish coating can be satisfactorily performed on the surface of the sheet material.

Unlike the grooved decorative board using the natural wood veneer, there is no problem that a gap is formed due to deterioration of the joint portion of the veneer with time.

According to the manufacturing method of the present invention, both the pattern and the groove are formed at the same time in the embossing process, so that there is no need for the conventional bonding process between the substrate and the projecting plate and the subsequent groove processing process. Moreover, since the sheet material is laminated on the resin board, the finish coating is easy, so that the manufacturing process can be simplified and the grooved decorative board of the present invention can be efficiently manufactured.

Therefore, according to the present invention, the resin board is used as a base material without using an expensive veneer, and the appearance elements such as colors and patterns which the resin board has in advance are prepared by a simple manufacturing process. While utilizing the above, it is possible to provide an inexpensive grooved decorative sheet having an excellent appearance and a good makeup finish.

[Brief description of drawings]

FIG. 1 is a partially omitted plan view showing a grooved decorative plate according to an embodiment of the present invention.

FIG. 2 is a schematic enlarged cross-sectional view showing a grooved decorative plate of the same example.

3A and 3B show a conventional grooved decorative board using a veneer of natural wood, in which FIG. 3A is a partially omitted plan view and FIG. 3B is a sectional view.

[Description of symbols] 2 grooved decorative plate 4 substrate 6 resin board 8 semi-transparent sheet material 10 adhesive 12 sheet material adhesive surface 14 pattern 16 groove 18 groove 22 surface coating layer e1 small embossing e2 long groove embossing e3 Shallow groove embossing

Claims (6)

[Claims] 1. A pattern and grooves made of embossing are formed on a sheet material adhering surface of a substrate formed by adhering a semitransparent sheet material on the surface of a resin board, and surface coating is applied on the sheet material adhering surface of the substrate. Veneered veneer with a groove. 2. The grooved decorative sheet according to claim 1, wherein the translucent sheet material is thin paper. 3. The grooved decorative plate according to claim 1, wherein the translucent sheet material is colored. 4. A substrate is manufactured by adhering a semitransparent sheet material to the surface of a resin board, and then a pattern and a groove by embossing are simultaneously formed by embossing on the sheet material adhering surface of the substrate, A method for producing a grooved decorative board, characterized in that a surface coating is applied to a surface of the substrate on which the sheet material is adhered. 5. The method of manufacturing a grooved decorative sheet according to claim 4, wherein thin paper is used as the semitransparent sheet material. 6. The method for producing a grooved decorative sheet according to claim 4, wherein the translucent sheet material is colored.