Decorative member and method for producing the same

Abstract

To provide a decorative member capable of imparting a natural texture to the surface of a printing layer, and its manufacturing method.SOLUTION: In the preparing step S1, as the base material 10A, there is prepared a base material which is a base material 10A in which a convex portion 11b and a concave portion 11a having irregular shapes are formed by a fiber group of the wood fibers 12 bonded by an adhesive on the front face of the front layer 11, and in which the surfaces of the convex portion 11b and the concave portion are surfaces derived from the fiber shapes of the wood fibers 12 constituting the fiber group and randomly disposed. 11a. In the base layer forming step S2 and the printed layer forming step S3, the base layer 13 and the printed layer 14 are formed so as to leave at least a part of the fiber shape while leaving the shape of the convex portion 11a and the concave portion 11b.SELECTED DRAWING: Figure 4

Description

[Technical Field]

[0001] The present invention relates to a decorative member and a method for producing the same. [Background technology]

[0002] As an example of this type of technology, Patent Document 1 discloses a method for manufacturing a composite member for floorboards, in which a base board such as lauan plywood is attached to both sides of a wood fiberboard, the wood fiberboard is then divided in half in the thickness direction using a dividing blade to create half-boards, and a surface decorative layer is formed on the divided surfaces of the half-boards by coating.

[0003] In addition, Patent Documents 2 and 3 disclose methods for manufacturing decorative parts in which the amount of ink applied by inkjet printing is adjusted to form convex and concave portions on the surface of a smooth substrate, depending on the thickness of the ink layer. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2011-25563 [Patent Document 2] Patent No. 7225636 [Patent Document 3] Japanese Patent Application Laid-Open No. 7444203 Summary of the Invention [Problem to be solved by the invention]

[0005] However, in the components manufactured by the manufacturing method described in Patent Document 1, a base board such as lauan plywood is attached to both sides of a wood fiber board, and then the wood fiber board is divided into two pieces with a dividing blade, resulting in smooth surfaces in the halves. Even if a surface decorative layer (printed layer) is provided on such a halved surface by coating, the surface of the printed layer will be smooth. When viewed, the surface of such a printed layer appears monotonous, lacking a natural texture.

[0006] Therefore, even if the thickness of the printing layer is changed using the methods shown in Patent Documents 2 and 3, the change in thickness is not so large that it affects the texture to the extent that it casts shadows on the surface of the printing layer.

[0007] The present invention has been made in consideration of these points, and its object is to provide a decorative component that can impart a natural texture to the surface of a printed layer, and a method for manufacturing the same. [Means for solving the problem]

[0008] In view of the above-described problems, the present invention provides a method for manufacturing a decorative member, which includes at least a preparation step of preparing a substrate having, at least on its surface, a wood layer formed by compressing accumulated wood fibers in the thickness direction with an adhesive; a base layer formation step of applying a primer coating to the surface of the surface layer to form a base layer for printing; and a print layer formation step of applying a decorative printing coating to the surface of the substrate to form a print layer. In the preparation step, the substrate is prepared such that the surface of the surface layer has irregularly shaped protrusions and recesses formed by the wood fiber clusters bonded with the adhesive, and the surfaces of the protrusions and recesses are derived from the fiber shapes of the randomly arranged wood fibers that make up the fiber clusters. In the base layer formation step and the print layer formation step, the base layer and the print layer are formed so as to retain the shapes of the protrusions and recesses and at least a portion of the fiber shapes.

[0009] According to the present invention, irregularly shaped convex and concave portions are formed on the surface of the prepared substrate by the fiber groups of the wood fibers bonded with an adhesive, and the concave and convex surfaces are surfaces derived from the fiber shapes of the randomly arranged wood fibers that make up the fiber groups. In the base layer forming process and the printing layer forming process, the shapes of the convex and concave portions on the surface of the substrate are retained while at least a portion of the fiber shape is left intact, so that the surface of the printing layer is given not only the shapes of the convex and concave portions but also a fiber shape that is even finer than these shapes. As a result, it is possible to impart a natural, irregular shading to the surface of the printing layer, imparting a natural, unartificial texture.

[0010] In a more preferred embodiment, in the preparation step, a substrate is prepared in which the wood fibers constituting the surface layer further have unconstrained portions on the surface of the surface layer.

[0011] According to this aspect, the unconstrained portions of the wood fibers that make up the surface layer are embedded in the base layer while retaining their fiber shape on the surface of the printed layer, so that the fiber shape can be reflected on the surface of the printed layer more clearly than the shape of the wood fibers on the surfaces of the convex and concave portions, thereby imparting a more natural texture to the surface of the printed layer.

[0012] In a more preferred embodiment, the surface of the surface layer is a torn surface obtained by torn the wood fiber board in the thickness direction.

[0013] According to this embodiment, the surface of the surface layer is a torn surface obtained by torn the wood fiber board in the thickness direction, so the shapes of the convex and concave portions on the surface of the base material are more natural, and their arrangement is also more natural. Furthermore, the wood fibers that make up the surface layer can be obtained on a surface of the base material that has unconstrained portions on the surface of the fuzzy surface layer. As a result, it is possible to impart a natural, irregular shading to the surface of the printed layer, imparting a natural, unartificial texture.

[0014] In a further preferred embodiment, in the base layer forming step, a sponge roll that has absorbed the base paint is pressed against the surface of the surface layer, while the non-constrained portion is made to conform to the surface of the surface layer, and the base layer is formed in which the non-constrained portion is covered with the base paint.

[0015] According to this aspect, in the base layer forming step, a sponge roll absorbed with base coating material can be used to form a base layer in which the unconstrained portions are coated with the base coating material while conforming the unconstrained portions to the surface of the surface layer in random directions, thereby allowing the fibrous shape of the unconstrained portions to be more clearly imparted to the surface of the printing layer.

[0016] In a more preferred embodiment, the printed pattern formed on the print layer is a surface pattern made of an inorganic material.

[0017] According to this embodiment, by making the printed pattern of the printed layer a surface pattern made of an inorganic material, the surface of the decorative member can acquire the natural texture of an inorganic material, even if the surface layer is an accumulation of wood fibers, which are organic matter. For example, examples of "surface patterns made of an inorganic material" include the surface of cement, concrete, gypsum board, bisque-fired clay (e.g., terracotta pattern), brick, stone, or rock, and by providing these surface patterns as a printed layer, the surface of the decorative member can acquire the natural texture of an inorganic material.

[0018] The decorative member according to the present invention comprises at least a substrate having, at least on its surface, a wood layer formed by compressing accumulated wood fibers in the thickness direction with an adhesive, a base layer for printing formed on the surface of the surface layer, and a printed layer formed on the surface of the base layer. The surface of the surface layer is formed with irregularly shaped protrusions and recesses due to the fiber shapes of the randomly arranged wood fibers that make up the fiber groups, and the base layer and the printed layer are formed so as to retain the shapes of the protrusions and recesses while preserving at least a portion of the fiber shapes.

[0019] According to the present invention, since the shapes of the protrusions and recesses on the surface of the substrate are retained while at least a portion of the fiber shape is retained, the surface of the printed layer is imparted with not only the shapes of the protrusions and recesses but also a fiber shape that is finer than these shapes. As a result, it is possible to impart a natural, irregular shadow to the surface of the printed layer, and to impart a natural, unartificial texture.

[0020] In a more preferred embodiment, the wood fiber portion constituting the surface layer is embedded in the base layer while retaining the shape of the wood fiber portion on the surface of the print layer.

[0021] Because the wood fiber portion of the surface layer is embedded in the base layer while retaining its fiber shape on the surface of the printed layer, the fiber shape can be reflected on the surface of the printed layer more clearly than the shape of the wood fiber on the surface of the convex and concave portions, which gives the surface of the printed layer a more natural texture.

[0022] In a more preferred embodiment, the surface of the surface layer is a torn surface obtained by torn the wood fiber board in the thickness direction.

[0023] According to this aspect, the surface of the surface layer is a torn surface of the wood fiber board torn in the thickness direction, so the shapes of the convex and concave portions on the surface of the base material are more natural, and their arrangement is also more natural. As a result, it is possible to impart a natural, irregular shading to the surface of the printing layer, and to impart a natural, unartificial texture.

[0024] In a more preferred embodiment, the printed pattern formed on the print layer is a surface pattern made of an inorganic material.

[0025] According to this embodiment, by making the printed pattern of the printed layer a surface pattern made of an inorganic material, even if the surface layer is made of accumulated wood fibers, which are organic matter, the surface of the decorative member can have the natural texture of an inorganic material. For example, examples of "surface patterns made of an inorganic material" include the surface of cement, concrete, gypsum board, bisque-fired clay (e.g., terracotta pattern), brick, stone, or rock, and by providing these surface patterns as a printed layer, the surface of the decorative member can have the natural texture of an inorganic material. [Effects of the Invention]

[0026] According to the present invention, a natural texture can be imparted to the surface of the printing layer. [Brief explanation of the drawings]

[0027] [Figure 1] FIG. 2 is a flow chart illustrating a method for manufacturing a decorative member according to an embodiment of the present invention. [Figure 2] 2A and 2B are diagrams for explaining the preparation process shown in FIG. 1, where (a) and (b) are schematic diagrams for explaining the manufacturing process of the half-cut product, (c) is an enlarged cross-sectional view of the surface of the half-cut product, (d) is an enlarged cross-sectional view of the surface of the concave portion of part A shown in (c), (e) is an enlarged cross-sectional view of the surface of the convex portion of part B shown in (c), and (f) is a schematic diagram for explaining the bonding process. [Figure 3]2A and 2B are diagrams for explaining the base layer forming step shown in FIG. 1, where (a) is a diagram for explaining the step of forming a white paint layer as the base layer, (b) is an enlarged cross-sectional view of a substrate on which a base layer has been formed, and (c) is a schematic enlarged cross-sectional view of part C shown in (b). [Figure 4] (a) is a diagram for explaining the printing layer formation process shown in Figure 1, (b) is an enlarged cross-sectional view after the printing layer has been formed, corresponding to Figure 3(c), and (c) is an enlarged cross-sectional view after the clear coating layer has been formed. [Figure 5A] This is a photograph of the surface of the substrate (half-cut product) prepared in the preparation process. [Figure 5B] This is a photo of the surface of a white paint layer that was applied once during the primer layer formation process. [Figure 5C] This is a photograph of the surface of multiple white paint layers applied during the primer layer formation process. [Figure 5D] This is a photograph of the surface of a printing layer on which a stone pattern was printed during the printing layer formation process. [Figure 6] (a) is a three-dimensional profile of the surface of the substrate (semi-cut product) prepared in the preparation step, and (b) is a three-dimensional profile of the surface of the printing layer after the printing layer formation step. [Figure 7] (a) Surface roughness profile of the semi-cut product, (b) Surface roughness profile of the white paint layer after one coat, (c) Surface roughness profile of the white paint layer after multiple coats (5 coats), (d) Surface roughness profile of the receiving layer (primer layer), (e) Surface roughness profile of the printing layer, (f) Surface roughness profile of the clear paint layer. DETAILED DESCRIPTION OF THE INVENTION

[0028] A decorative member 10 according to an embodiment of the present invention and a method for producing the same will be described below with reference to FIGS.

[0029] 1. Manufacturing method of decorative member 10 1, this manufacturing method includes a preparation step S1, a base layer forming step S2, a print layer forming step S3, and a clear coating layer forming step S4. Note that the clear coating layer forming step S4 may be omitted depending on the application location of the decorative member 10.

[0030] 1-1. Preparation process S1 First, in this embodiment, a base material 10A of the decorative member 10 is prepared. Specifically, in the preparation step, the base material 10A is prepared, which has, at least on the surface layer 11, a wood layer in which accumulated wood fibers 12 are compressed in the thickness direction with an adhesive.

[0031] In this embodiment, the preparation step S1 includes, for example, a manufacturing step S11 of the semi-cut product 11B and a bonding (kneading) step S12. First, in the manufacturing step S11 of the semi-cut product 11B, a wood fiber board 11A is prepared in which accumulated wood fibers 12 are compressed in the thickness direction using an adhesive.

[0032] To manufacture the wood fiber board 11A, wood fibers are prepared by opening wood chips made from softwood such as cedar, pine, or cypress, or hardwood such as chestnut, oak, teak, or red lauan. These wood fibers are then aggregated using, for example, a thermosetting resin adhesive and thermocompressed into a board shape. This process yields the substrate 10A. Examples of such wood fiber boards 11A include MDF, HDF, and hardboard.

[0033] Next, as shown in Figure 2(a), the wood fiber board 11A is torn in the thickness direction using a half-cutting device 4 to produce half-cut products 11B. Specifically, the wood fiber board 11A is passed between a pair of spike rolls 40A, 40B, each having needle-like protrusions 43 spaced apart on the circumferential surface 42 of a cylindrical roll body 41. The leading edge of the wood fiber board 11A that has passed through the spike rolls 40A, 40B is brought into contact with a splitting blade 45, which forms a starting point at the leading edge of the wood fiber board 11A for splitting the wood fiber board 11A in the thickness direction. In this state, when the wood fiber board 11A is further fed between the spike rolls 40A and 40B, as shown in Figure 2(b), both sides of the wood fiber board 11A are constrained by the multiple needle-like protrusions 43, and the rotational force of the spike rolls 40A and 40B acts on the wood fiber board 11A, tearing the wood fiber board 11A in the thickness direction without relying on the splitting blade 45. This makes it possible to produce half-cut products 11B whose split surfaces (surfaces 11f) have a unique surface shape.

[0034] As a result, irregularly shaped protrusions 11a and recesses 11b are formed on the surface 11f of the semi-cut product 11B, which corresponds to the surface layer 11 of the base material 10A, due to the fiber clusters of wood fibers 12 bonded by the adhesive. This is because, during tearing, cracks propagate from the starting points formed by the dividing blade 45 to areas where the adhesive strength between the wood fibers 12 and the adhesive is low and the fiber density of the wood fibers 12 is relatively low, resulting in this shape of the surface 11f of the semi-cut product 11B. In addition, the surfaces of the protrusions 11a and recesses 11b on this surface are derived from the fiber shapes of the randomly arranged wood fibers 12 that form these fiber clusters, as shown in Figure 2(c).

[0035] That is, on a macroscopic level, the surface of the obtained semi-cut product 11B has a plurality of irregularly shaped convex portions 11a and concave portions 11b formed randomly. The convex portions 11a and concave portions 11b on the surface 11f of the semi-cut product 11B have more natural shapes, and their arrangement is also more natural. Specifically, the height difference from concave portion 11b to convex portion 11a is in the range of approximately 100 μm to 500 μm, resulting in an undulating surface in which convex portions 11a are island-shaped and concave portions 11b are pockmarked. The size of convex portions 11a and concave portions 11b is in the range of approximately 10 mm to 30 mm in width in cross section. In addition, on a microscopic level, the wood fibers 12 of the fiber groups forming convex portions 11a and concave portions 11b form fine irregularities randomly due to the fibrous shape of these wood fibers 12. Here, as an example, it is preferable that the length of the wood fibers 12 is in the range of 1.0 mm to 2.0 mm, and the fiber diameter of the wood fibers 12 is in the range of 10 μm to 50 μm. With such a fiber diameter, fine irregularities in the range of about 10 μm to 50 μm are generated on the surfaces of the convex portions 11a and the concave portions 11b.

[0036] Furthermore, most of the wood fibers 12 are embedded in the semi-cut product 11B (surface layer 11), and on the surface 11f of the semi-cut product 11B (surface layer 11) there are constrained portions 12a where some of the wood fibers 12 are constrained, and the remaining portions are unconstrained portions 12b that look fluffy (see Figures 2(d) and 2(e)). If printing is done so that the shapes of these unconstrained portions 12b are preserved, it is possible to create a natural, irregular shadow on the surface 14a of the printing layer 14 (described later), and to impart a natural, unartificial texture.

[0037] In the bonding (kneading) step S12, a flat base plate 18 is bonded with an adhesive to the surface (back surface) opposite to the front surface 11f of the semi-cut product 11B. This makes it possible to prepare a flat substrate 10A while suppressing warping of the semi-cut product 11B. Here, the base plate 18 may be made of a wood fiber board such as MDF, plywood, particle board, gypsum board, resin board, or metal board, and is not particularly limited as long as it can suppress warping of the semi-cut product 11B.

[0038] In this way, the substrate 10A has irregularly shaped protrusions 11a and recesses 11b formed on the surface 11f of the surface layer 11 by the fiber clusters of wood fibers 12 bonded with an adhesive. Furthermore, the surfaces of the protrusions 11a and recesses 11b of the substrate 10A have fine irregularities resulting from the fiber shapes of the randomly arranged wood fibers 12 that make up the fiber clusters (see FIG. 5A). Furthermore, the wood fibers 12 that make up the surface layer 11 of the substrate 10A have a fluffy surface with additional unconstrained portions 12b on the surface 11f of the surface layer 11.

[0039] 1-2. Undercoat layer formation process S2 Next, a base layer forming step S2 is performed. In this step, a base coating P is applied to the surface 11f of the surface layer 11 of the substrate 10A (the surface in its original state after being cut in half and not smoothed by a grinder or the like), thereby forming a base layer 13 for printing. The formation of the base layer 13 is not particularly limited to spray coating, brush coating, etc., but in this embodiment, the base layer 13 is formed using a coating device 5 shown in FIG. 3(a).

[0040] In this embodiment, the base layer forming step S2 includes a white coating layer forming step S21 and a receiving layer forming step S22. The receiving layer forming step S22, which will be described later, is a coating that improves the fixability of the ink (paint) that forms the printing layer 14, and if the ink fixability is high, the receiving layer forming step S22 may be omitted.

[0041] In the white coating layer forming step S21, a white base paint P is prepared. Here, it is desirable that the color of the surface 11f of the surface layer 11 of the substrate 10A is not reflected in the base paint P, and that the color of the base paint P is not reflected in the printed layer 14. In this embodiment, the base paint P is white, but is not particularly limited as long as it is a single color, and may be, for example, yellow, or a color between white and yellow (e.g., cream). The base paint P may be a water-based or oil-based paint in which a white pigment or colorant is added to water or a solvent, or may be a white paint made of resin to which a pigment or colorant is added.

[0042] In this embodiment, the surface layer of the sponge roll 51 of the coating device 5 has a sponge layer 52 that absorbs the white primer coating P, and a pressure roll 53 is in contact with the sponge roll 51 at a position where it contacts the sponge roll 51. The primer coating P is supplied between the pressure roll 53 and the sponge roll 51. In the white coating layer forming step S21, the sponge roll 51 that has absorbed the white primer coating P is pressed against the surface 11f of the surface layer 11 of the substrate 10A, while the transport roll 54 transports the substrate 10A, and the unconstrained portions 12b are made to conform to the surface of the surface layer 11, thereby forming a primer layer 13 in which the unconstrained portions 12b are coated with the primer coating P.

[0043] The base layer 13 may be formed by multiple coatings, such as by passing the substrate 10A through the sponge roll 51 multiple times. Because multiple coatings slightly smooth the surface of the base layer 13, the number of coatings may be determined, for example, according to the printing pattern of the printing layer 14 (i.e., the texture resulting from the printing pattern), as described below. In particular, by using a resin paint containing a pigment or colorant as the base paint P, the base paint P is formed as a thin film. Therefore, when forming the base layer 13, it is preferable to determine the number of coatings of the base paint P (resin paint) according to the printing pattern of the printing layer 14. This allows for the deposition of thin films of the base paint P according to the number of coatings, thereby achieving a surface profile of the printing layer 14 with the desired texture according to the number of layers (number of coatings). In this embodiment, a receiving layer (not shown) is further formed in the receiving layer formation step S22. In the receiving layer formation step S22, a transparent or white paint made of an ultraviolet-curable resin is applied using the method described above. In this way, the undercoat layer 13 can be formed by only the white coating layer or by the white coating layer and the receiving layer.

[0044] Here, in this embodiment, in the base layer formation process S2, the base layer 13 is formed on the surface 13a of the base layer 13 so as to retain the shapes of the convex portions 11a and concave portions 11b of the substrate 10A (see Figure 3(b)), and to retain at least a portion of the fibrous shape (see Figure 3(c)).

[0045] In this way, in the base layer forming step S2, the sponge roll 51 absorbed with the base coating P causes the unconstrained portions 12b of the wood fibers 12 to follow the surface 11f of the surface layer 11 of the substrate 10A in a random direction, while forming the base layer 13 in which the unconstrained portions 12b are coated with the base coating P. This allows the fiber shape of the unconstrained portions 12b to be more clearly imparted to the surface of the printing layer 14, which will be described later.

[0046] Fig. 5B is a photograph of the surface 13a of the base layer 13 to which white paint has been applied only once, and Fig. 5C is a photograph of the surface 13a of the base layer 13 to which white paint has been applied multiple times (twice). As is clear from both Fig. 5B and Fig. 5C, a fiber pattern (unevenness) derived from the wood fibers 12 is formed on the surface 13a of the base layer 13. Furthermore, as shown in Fig. 5C, by repeatedly applying the white paint, the unconstrained portions 12b of the wood fibers 12 more closely conform to the surface 11f of the surface layer 11 of the substrate 10A, and the convex portions derived from the unconstrained portions 12b are more clearly visible.

[0047] 1-3. Printing layer formation process S3 Next, the printing layer formation step S3 is performed. In this step, a decorative printing paint J is applied to the surface of the base layer 13 to form a printing layer 14. In this embodiment, as shown in Figures 4(a) and 4(b), in the printing layer formation step S3, the printing layer 14 is formed so as to leave the shapes of the convex portions 11a and concave portions 11b and at least a part of the fibrous shape.

[0048] In this embodiment, as shown in Figure 4(a), the printing layer 14 is formed using an inkjet printer 6. In this embodiment, the printing paint (ink) J of the inkjet printer is composed of four colors, for example, yellow, magenta, cyan, and black, and printing is performed using these inks. If the printing paint is an ultraviolet-curing paint, after the printing layer 14 is formed, the surface of the printing layer 14 may be irradiated with ultraviolet light to cure the paint of the printing layer 14.

[0049] The inkjet printer 6 contains inks used in general printing and includes at least a head 61 that individually ejects each ink in a pattern to be printed (print pattern) according to a previously prepared image, and a feeder 63 that feeds the substrate 10A. During printing, the head 61 ejects ink from a direction substantially perpendicular to the substrate 10A (for example, from above), while the feeder 63 feeds the substrate 10A, and the print pattern is printed on the surface 13a of the base layer 13 formed on the surface layer 11 of the substrate 10A.

[0050] The printed pattern formed on the printing layer 14 may be a single color or a geometric pattern, but is more preferably a surface pattern made of an inorganic material. The printed pattern is a pattern in which an image of the inorganic material is acquired in advance and printed. Even if the surface layer 11 is made of accumulated organic wood fibers, the surface of the decorative member 10 can have the natural texture of an inorganic material. For example, examples of "surfaces made of an inorganic material" include cement surfaces, bisque-fired clay surfaces (e.g., terracotta patterns), concrete surfaces, gypsum board surfaces, brick surfaces, stone surfaces, and rock surfaces. By providing patterns of these surfaces as a printing layer, the surface of the decorative member can have the natural texture of an inorganic material. In particular, by using a motif of a cement surface, bisque-fired clay surfaces (e.g., terracotta patterns), stone surfaces, or rock surfaces, these natural textures can be obtained. Note that FIG. 5D is a perspective view of the surface of the printing layer 14 in which a stone pattern is printed on the surface 13a of the base layer 13, which has been repeatedly coated with white paint three times. As is clear from the photograph in Figure 5D, a fiber pattern (unevenness) derived from the wood fibers 12 is formed on the surface 14a of the printed layer 14, but the surface of the printed layer 14 has a natural texture like the surface of stone.

[0051] 1-4. Clear coating layer formation process S4 Next, the clear coating layer forming step S4 is performed. In this step, as shown in FIG. 4(c), the surface 14a of the printing layer 14 is painted with a transparent resin paint to form a clear coating layer 15. As in the white coating layer forming step S21, the clear coating layer 15 may be formed by roll coating, or by spray coating or brush coating. In this step, the clear coating layer 15 is formed so as to retain the shapes of the convex portions 11a and concave portions 11b and at least a portion of the fibrous shape. The paint used for the clear coating layer 15 is a light-transmitting paint, and may be, for example, a paint made of an acrylic resin.

[0052] According to this embodiment, irregularly shaped protrusions 11a and recesses 11b are formed on the surface 11f of the substrate 10A by groups of wood fibers 12 bonded together with an adhesive. The surfaces of the protrusions 11a and recesses 11b are derived from the fibrous shapes of the randomly arranged wood fibers that make up the fiber groups. In the base layer forming step S2 through the clear coating layer forming step S4, the shapes of the protrusions 11a and recesses 11b on the surface of the substrate 10A are preserved while at least a portion of the fibrous shape of the wood fibers 12 is left intact. Therefore, in addition to the shapes of the protrusions and recesses, the surface of the decorative member 10 is imparted with even finer fibrous shapes than these shapes. As a result, the surface of the printed layer 14 can be given a natural, irregular shading, imparting a natural, unartificial texture.

[0053] 2. Changes in surface profile during manufacturing Changes in surface roughness during manufacturing will be described with reference to Figures 6 and 7. First, surface 11f of substrate 10A prepared in preparation step S1 and surface 13a of printing layer 14 in printing layer formation step S3 were measured using a three-dimensional surface roughness meter. Figures 6(a) and 6(b) show the results of measurements over an area of ​​25 mm x 85 mm.

[0054] As shown in Figure 6(a), the three-dimensional roughness data for the surface 11f of the substrate 10A (semi-cut product 11B) prepared in the preparation step S1 clearly shows the shapes of the convex and concave portions, as well as the fiber shape of the wood fibers 12. Furthermore, as shown in Figure 6(b), as is clear from the three-dimensional roughness data for the surface of the printed layer 14 in the printing layer formation step S3, the surface 14a of the printed layer 14 is smoother than the surface 11f of the semi-cut product 11B due to the base layer 13 and the printed layer 14, but the shapes of the convex portions 11a and concave portions 11b remain, and the fiber shape of the wood fibers 12 is also shown.

[0055] Here, the range of the maximum height difference between the convex portions 11a and the concave portions 11b of the substrate 10A prepared in the preparation step S1 was measured as follows. Specifically, the surface profile was measured at 25 different locations using a surface roughness meter conforming to JIS B0601:2001. From the data of each surface profile, the midpoint between the position of the maximum height and the position of the maximum depth was set as the reference height, and the range of the height (maximum height) of the highest convex portion 11a from the reference height and the depth (maximum depth) of the deepest concave portion 11b from the reference height was measured.

[0056] The maximum height difference between the recesses 11b and the protrusions 11a (i.e., the sum of the maximum height and the maximum depth) was calculated from these maximum heights and maximum depths, and it was confirmed that the maximum height difference between the recesses 11b and the protrusions 11a was within the range of 100μm to 500μm (calculated results: 166μm to 469μm) for all surface profiles. Similarly, the height difference between the recesses and the protrusions formed in the printing layer 14 printed in the printing layer formation step S3 was calculated from the surface profiles at 42 locations, and it was confirmed that the maximum height difference between the recesses 11b and the protrusions 11a was within the range of 100μm to 400μm (calculated results: 125μm to 343μm).

[0057] Furthermore, the surface roughness of the substrate or decorative component at each stage was measured at multiple locations using a surface roughness meter conforming to JIS B0601:2001. An example is shown in Figure 7. Figure 7 shows (a) the surface roughness profile of the substrate 10A (semi-cut product 11B), (b) the surface roughness profile of the white coating layer (primer layer 13) after one coat, (c) the surface roughness profile of the white coating layer (primer layer 13) after multiple coats (five coats), (d) the surface roughness profile of the receiving layer (primer layer 13), (e) the surface roughness profile of the printing layer 14, and (f) the surface roughness profile of the clear coating layer 15. Figure 7(a) shows the surface waviness caused by the protrusions 11a and recesses 11b of the substrate 10A (semi-cut product 11B) and the surface fuzz caused by the wood fibers. As we move from (b) to (f) in Figure 7, we can see that the surface becomes smoother, and while the shapes of the convex and concave portions remain, some of the fibrous shape of the wood fibers also remains.

[0058] As a result, it was found that the center line average roughness Ra of the substrate 10A (semi-cut product 11B), measured in accordance with JIS B0601:2001, was in the range of 15 to 45 μm, the center line average roughness Ra of the printed layer 14 was in the range of 15 to 40 μm, and the center line average roughness Ra of the clear coating layer 15 was in the range of 10 to 35 μm. It was also found that the maximum height Rz of the surface roughness of the semi-cut product was in the range of 130 to 250 μm, the center line average roughness Ra of the printed layer 14 was in the range of 85 to 200 μm, and the center line average roughness Ra of the clear coating layer 15 was in the range of 70 to 185 μm.

[0059] 3. About the decorative member 10 The decorative member 10 thus obtained comprises at least a substrate 10A having, at least on a surface layer 11, a wood layer formed by compressing accumulated wood fibers 12 in the thickness direction with an adhesive, a base layer 13 for printing formed on the surface of the surface layer 11, and a printed layer 14 formed on the surface of the base layer 13. Furthermore, a clear coating layer (protective layer) 15 may be formed on a surface 14a of the printed layer 14.

[0060] Irregularly shaped protrusions 11a and recesses 11b are formed on the surface 11f of the surface layer 11 of the substrate 10A by groups of wood fibers 12 bonded with an adhesive, and the surfaces of the protrusions 11a and recesses 11b are derived from the fiber shapes of the randomly arranged wood fibers that make up the fiber groups of the wood fibers 12. Furthermore, the base layer 13 and the printed layer 14 are formed so as to retain the shapes of the protrusions 11a and recesses 11b and at least a portion of the fiber shape of the wood fibers 12 (see FIG. 4(b)). If a clear coating layer 15 is formed, this clear coating layer 15 is also formed so as to retain the shapes of the protrusions 11a and recesses 11b and at least a portion of the fiber shape of the wood fibers 12 (see FIG. 4(c)).

[0061] In this way, the shapes of the protrusions 11a and depressions 11b of the surface layer 11 of the substrate 10A are retained while at least a portion of the fiber shape is retained, so that in addition to the shapes of the protrusions 11a and depressions 11b, a fiber shape that is even finer than these shapes is imparted to the surface of the printed layer 14. As a result, it is possible to impart a natural, irregular shadow to the surface of the printed layer 14, and to impart a natural, unartificial texture.

[0062] 4(c), the portions of the wood fibers 12 (unconstrained portions 12b) that make up the surface layer 11 of the substrate 10A are embedded in the base layer 13, while the shapes of the portions of the wood fibers 12 remain on the surface of the printed layer 14. This allows the portions of the wood fibers embedded in the base layer (unconstrained portions 12b) to reflect on the surface of the printed layer 14 a fiber shape that is even clearer than the shape of the wood fibers that form the surfaces of the convex portions 11a and concave portions 11b. As a result, a more natural texture can be imparted to the surface of the printed layer 14.

[0063] The surface 11f of the surface layer 11 of the substrate 10A is a torn surface obtained by torn the wood fiberboard in the thickness direction. The convex portions 11a and concave portions 11b of the surface layer 11 of the substrate 10A have a more natural shape and are arranged more naturally. As a result, the surface 14a of the printed layer 14 can be given a natural, irregular shading, imparting a natural, unartificial texture.

[0064] Therefore, by forming the printed pattern on the printed layer 14 as a surface pattern made of an inorganic material, even if the surface layer 11 is made up of an accumulation of wood fibers 12, which are organic matter, the surface of the decorative member 10 can acquire the natural texture of an inorganic material. In particular, by printing a pattern resembling the surface of cement, the surface of bisque-fired earth (e.g., a terracotta pattern), the surface of stone, or the surface of rock as the printed pattern, the natural texture of an inorganic material can be acquired on the surface of the decorative member 10. Furthermore, such decorative member 10 can be effectively used as a building material, for example, for interior materials including interior wall materials, exterior wall materials, flooring materials, ceiling materials, and the like.

[0065] Although the embodiments of the present invention have been described in detail above, the present invention is not limited to the above-described embodiments, and various design modifications can be made without departing from the spirit of the present invention as set forth in the claims.

[0066] In this embodiment, a substrate having a half-cut surface of a half-cut product is prepared in the preparation process, but as long as the surface profile of the substrate described above can be obtained, the substrate may be formed, for example, by molding or press-molding a mixture of wood fiber and adhesive. [Explanation of symbols]

[0067] 10: decorative member, 10A: base material, 11: surface layer, 11a: convex portion, 11b: concave portion, 11f: surface, 12: wood fiber, 12b: non-constrained portion, 13: base layer, 14: printed layer, 15: clear coating layer, S1: preparation step, S2: base layer forming step, S3: printed layer forming step

Claims

1. a preparation step of preparing a substrate having, at least on its surface, a wood layer formed by compressing accumulated wood fibers in the thickness direction with an adhesive; a base layer forming step of forming a base layer for printing by applying a base paint to the surface of the surface layer; and a printing layer forming step of applying a decorative printing paint to the surface of the base layer to form a printing layer, In the preparation step, the substrate is prepared such that irregularly shaped convex portions and concave portions are formed on the surface of the surface layer by the fiber groups of the wood fibers bonded by the adhesive, and the surfaces of the convex portions and the concave portions are surfaces derived from the fiber shapes of the randomly arranged wood fibers that make up the fiber groups; A method for manufacturing a decorative member, characterized in that in the base layer forming process and the printing layer forming process, the base layer and the printing layer are formed so as to leave the shapes of the convex portions and the concave portions and at least a portion of the fiber shape.

2. 2. The method for manufacturing a decorative member according to claim 1, wherein in the preparation step, a substrate is prepared in which the wood fibers constituting the surface layer further have unconstrained portions on the surface of the surface layer.

3. 2. The method for manufacturing a decorative member according to claim 1, wherein the surface of the surface layer is a torn surface obtained by torn a wood fiber board in the thickness direction.

4. A method for manufacturing a decorative member as described in claim 2, characterized in that in the base layer forming process, a sponge roll absorbed with the base paint is pressed against the surface of the surface layer, while the non-constrained portion is made to conform to the surface of the surface layer, and the base layer is formed in which the non-constrained portion is covered with the base paint.

5. 2. The method for manufacturing a decorative member according to claim 1, wherein the printed pattern formed on the printed layer is a surface pattern made of an inorganic material.

6. a substrate having, at least on its surface, a wood layer formed by compressing accumulated wood fibers in the thickness direction with an adhesive; a printing base layer formed on the surface of the surface layer; a printing layer formed on the surface of the base layer, On the surface of the surface layer, irregularly shaped convex portions and concave portions are formed by the fiber groups of the wood fibers bonded by the adhesive, and the surfaces of the convex portions and the concave portions are surfaces derived from the fiber shapes of the randomly arranged wood fibers that make up the fiber groups, A decorative member, characterized in that the base layer and the printed layer are formed so as to leave the shapes of the convex portions and the concave portions and at least a part of the fiber shape.

7. A decorative member as described in claim 6, characterized in that the wood fiber portion constituting the surface layer is embedded in the base layer while retaining the shape of the wood fiber portion on the surface of the printed layer.

8. 7. The decorative member according to claim 6, wherein the surface of the surface layer is a torn surface obtained by torn a wood fiber board in the thickness direction.

9. 7. The decorative member according to claim 6, wherein the printed pattern formed on the print layer is a surface pattern made of an inorganic material.

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