Decorative plate and method for manufacturing decorative plate

Abstract

To provide a decorative plate in which the sizes of top surfaces of projecting handle parts are easily made uniform.SOLUTION: A decorative plate 1 includes a plurality of projecting handle parts 2 having a top surface 4 and an inclined surface 3 connected to the top surface 4 on a surface 5, and the plurality of projecting handle parts 2 include at least one polished projecting handle part 21 having a polished top surface 41.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a decorative board and a method for manufacturing a decorative board. [Background technology]

[0002] Patent Document 1 discloses a method for producing a molded plate, which comprises: molding a molding material using a single mold and curing the molding material to produce multiple molded substrates with the same uneven pattern on their surfaces; cutting convex portions of the uneven pattern that are above a predetermined height to form the tops of these convex portions into cut surfaces; leaving convex portions that are lower than that height uncut; and varying the predetermined height for each molded substrate to produce multiple molded plates with different cut surface heights. It is disclosed that the molded plates produced by this method can provide molded plates with a wide variety of uneven patterns. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent No. 5537066 Summary of the Invention [Problem to be solved by the invention]

[0004] When molding a molded substrate having a convex portion, it is necessary to release the mold from the molded substrate after pressure molding the molding material. Therefore, the peripheral wall of the convex portion needs a draft angle, resulting in an inclined surface at a predetermined angle or more. When the top of the convex portion thus molded is cut, the area of ​​the cut surface becomes larger than the area of ​​the top before cutting.

[0005] Furthermore, if the dimensions of each molded substrate are all the same, the area of ​​the top of the cut convex portion at a predetermined location on each molded substrate will be the same regardless of the cutting process of a predetermined convex portion on any molded substrate. However, the dimensions of each molded substrate are usually subject to molding errors, and warping may also occur. Therefore, if cutting is performed at a predetermined height from the bottom surface of the mold, the area of ​​the top of the cut convex portion at a predetermined location on each molded substrate will vary, which may impair the appearance of the decorative sheet.

[0006] An object of the present invention is to provide a decorative board in which the size of the top surface of the convex pattern portion is easily uniform, and a method for manufacturing the decorative board. [Means for solving the problem]

[0007] The decorative board of the present invention is a decorative board having a plurality of convex pattern portions on its surface, each having a top surface and an inclined surface connected to the top surface, wherein the plurality of convex pattern portions includes at least one polished convex pattern portion having a polished top surface, and the angle formed between the first inclined surface of the polished convex pattern portion and the surface is greater than the average value of the angles formed between the inclined surfaces of all the convex pattern portions of the decorative board and the surface.

[0008] The decorative board of the present invention is a decorative board having a plurality of convex pattern portions on its surface, each having a top surface and an inclined surface connected to the top surface, wherein the plurality of convex pattern portions includes at least one polished convex pattern portion having a polished top surface, the polished convex pattern portion having a second inclined surface and a third inclined surface interposed between the second inclined surface and the surface, the angle formed between the second inclined surface and the surface being larger than the angle formed between the third inclined surface and the surface, and the angle formed between the second inclined surface and the surface being larger than the average value of the angles formed between the inclined surfaces of all the convex pattern portions provided on the decorative board and the surface.

[0009] The decorative board of the present invention is a decorative board having a plurality of convex pattern portions on its surface, each having a top surface and an inclined surface connected to the top surface, wherein the plurality of convex pattern portions include polished convex pattern portions having a polished top surface and unpolished convex pattern portions having an unpolished top surface, and the angle formed between the first inclined surface of the polished convex pattern portion and the surface is greater than the angle formed between the inclined surface of the unpolished convex pattern portion and the surface.

[0010] The decorative board of the present invention is a decorative board having a plurality of convex pattern portions on its surface, each having a top surface and an inclined surface connected to the top surface, wherein the plurality of convex pattern portions include a polished convex pattern portion having a polished top surface and an unpolished convex pattern portion having an unpolished top surface, wherein the polished convex pattern portion has a second inclined surface and a third inclined surface interposed between the second inclined surface and the surface, and the angle formed between the second inclined surface of the polished convex pattern portion and the surface is larger than the angle formed between the third inclined surface and the surface, and the angle formed between the second inclined surface of the polished convex pattern portion and the surface is larger than the angle formed between the inclined surface of the unpolished convex pattern portion and the surface.

[0011] The method for manufacturing a decorative panel of the present invention is a method for manufacturing the decorative panel, and includes preparing an original plate having a plurality of convex portions on its surface, all of which have an unpolished top surface and an inclined surface connecting to the unpolished top surface, and polishing the unpolished top surface of at least one of the plurality of convex portions on the original plate, which has the first inclined surface, to form the polished convex pattern portion having a polished top surface.

[0012] The method for manufacturing a decorative board of the present invention is a method for manufacturing the decorative board, and includes preparing an original plate having a plurality of convex portions on its surface, all of which have an unpolished top surface and an inclined surface connecting to the unpolished top surface; and polishing the unpolished top surface of at least one of the plurality of convex portions on the original plate, which has the second inclined surface and the third inclined surface, within the range of the second inclined surface, to form the polished convex pattern portion having a polished top surface. [Effects of the Invention]

[0013] According to the present invention, the sizes of the top surfaces of the convex pattern portions of the decorative board can be easily made uniform, which means that a decorative board with reduced appearance defects can be provided. [Brief explanation of the drawings]

[0014] [Figure 1] FIG. 1 is a perspective view of a decorative board according to an embodiment of the present invention. [Figure 2] FIG. 2 is a schematic cross-sectional view of the cross section taken along the X1-X1 cutting line in FIG. 1 as viewed from the direction of arrow D1. [Figure 3] FIG. 3 is a cross-sectional view of the original plate according to the embodiment of the present invention. [Figure 4] FIG. 4 is a cross-sectional view of a decorative board according to a modified example of the present invention. [Figure 5] FIG. 5 is a cross-sectional view of an original plate according to a modified example of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0015] Hereinafter, a decorative board and a method for manufacturing a decorative board according to an embodiment will be described with reference to the drawings. However, the following embodiment is merely one of various embodiments of the present invention. The following embodiment can be modified in various ways depending on the design, etc., as long as the object of the present invention can be achieved. Furthermore, each figure described in the following embodiment is a schematic diagram, and the ratios of the sizes and thicknesses of each component in the figure do not necessarily reflect the actual dimensional ratios.

[0016] Furthermore, the arrows indicating each direction in each figure are not intended to define the direction when the decorative board 1 is in use, but are merely shown to make the explanation easier to understand and have no substance. The first direction D1, second direction D2, and third direction D3 are mutually perpendicular. The first direction D1 is, for example, the vertical direction when the decorative board 1 is installed. If the first direction D1 is the vertical direction, the second direction D2 is the horizontal direction when the decorative board 1 is installed. If the first direction D1 is the horizontal direction when the decorative board 1 is installed, the second direction D2 is the vertical direction when the decorative board 1 is installed. The third direction D3 is the thickness direction of the decorative board 1. Viewing along the third direction D3 is called a planar view.

[0017] [First embodiment] (overview) The decorative board 1 according to this embodiment comprises a plurality of convex pattern portions 2 on a surface 5, each having a top surface 4 and an inclined surface 3 connecting to the top surface 4. The plurality of convex pattern portions 2 includes at least one convex pattern portion with a polished top surface 41 (hereinafter, referred to as a polished convex pattern portion 21). The decorative board 1 according to this embodiment can easily make the top surfaces 4 of the convex pattern portions 2 of the decorative board 1 uniform in size by designing the value of the angle α1 between the first inclined surface 31 of the polished convex pattern portion 21 and the surface 5. Specifically, by making the angle α1 between the first inclined surface 31 of the polished convex pattern portion 21 and the surface 5 larger than the average angle between the inclined surfaces 3 of all the convex pattern portions 2 of the decorative board 1 and the surface 5, or by making the angle α2 larger than the angle α2 between the inclined surface 3 of a convex pattern portion 2 whose top surface 4 is not polished (hereinafter, also referred to as an unpolished convex pattern portion 22) and the surface 5. This can reduce defects in the appearance of the decorative board 1.

[0018] The average value of the angle between the inclined surface 3 of the convex pattern portion 2 and the surface 5 refers to the sum of the angles between the inclined surface 3 of all the convex pattern portions 2 of the decorative board 1 and the surface 5, divided by the number of inclined surfaces 3 of all the convex pattern portions 2 of the decorative board 1. This average value can also be said to be the sum of the angles α1 between the first inclined surface 31 of all the polished convex pattern portions 21 of the decorative board 1 and the surface 5, and the angle α2 between the inclined surface 32 of all the non-polished convex pattern portions 22 of the decorative board 1 and the surface 5, divided by the number of inclined surfaces 3 of all the convex pattern portions 2 of the decorative board 1. The size of the top surface 4 refers to the area of ​​the top surface 4 when the decorative board 1 is viewed in a plane.

[0019] (decorative panels) The decorative board 1 according to this embodiment is used as a wall panel for forming the walls of a building. The decorative board 1 is, for example, a ceramic siding. The ceramic siding is an inorganic board containing hardened cement. The decorative board 1 is formed in a rectangular shape when viewed from above. The thickness of the decorative board 1 is not particularly limited, but is, for example, about 16 mm. The thickness of the decorative board 1 refers to the maximum value of the length from the surface opposite to the surface 5 of the decorative board 1 to the top surface 4 of the convex pattern portion 2 provided on the decorative board 1. The surface 5 is perpendicular to the thickness direction.

[0020] The decorative board 1 has a plurality of convex pattern portions 2. Therefore, unevenness is observed on the surface 5. In the embodiment, the plurality of convex pattern portions 2 are formed in a line along the edge of the decorative board 1 (see FIG. 1). For example, the plurality of convex pattern portions 2 are lined up at regular intervals in the vertical direction. Also, the plurality of convex pattern portions 2 are lined up at regular intervals in the horizontal direction. Furthermore, the vertical dimensions of the plurality of convex pattern portions 2 are approximately constant. Also, the horizontal dimensions of the plurality of convex pattern portions 2 are approximately constant.

[0021] The convex pattern portion 2 has a top surface 4 and an inclined surface 3 connected to the top surface 4. In this embodiment, the convex pattern portion 2 rises on all four sides of the surface 5 (see Figure 1). That is, in this embodiment, the convex pattern portion 2 has four inclined surfaces 3. Of the four inclined surfaces 3, two inclined surfaces 3 face each other along the vertical direction, and two inclined surfaces 3 face each other along the horizontal direction. The shapes of the surfaces included in the inclined surfaces 3 are quadrilaterals such as squares, rectangles, and trapezoids. The two inclined surfaces 3 facing each other along the vertical direction have the same shape and size. Furthermore, the two inclined surfaces 3 facing each other along the horizontal direction have the same shape and size.

[0022] The inclined surface 3 of the convex pattern portion 2 is inclined with respect to the surface 5. The angle formed between the inclined surface 3 of the convex pattern portion 2 and the surface 5 is, for example, 45° or more and 80° or less. If this angle is 45° or more, there is an advantage that the decorative board 1 is easy to manufacture. If this angle is 80° or less, a decorative board 1 with few chipped or cracked parts can be obtained.

[0023] In this embodiment, the top surface 4 is a flat surface. The top surface 4 is perpendicular to the thickness direction. A textured pattern may be formed on the top surface 4. Examples of the textured pattern include a matte finish, a grained finish, a stone finish, and a rock finish.

[0024] As described above, the convex handle portion 2 includes a polished convex handle portion 21 and a non-polished convex handle portion 22 (see FIG. 1). The top of the polished convex handle portion 21 is polished. In other words, the polished convex handle portion 21 has a polished top surface 41. The top of the non-polished convex handle portion 22 is not polished. In other words, the non-polished convex handle portion 22 has an unpolished top surface 42.

[0025] The thickness direction length of the convex pattern portion 2 can be designed appropriately depending on the usage mode. That is, the thickness direction length of the convex pattern portion 2 may be uniform or may vary. Furthermore, the thickness direction length of the polishing convex pattern portion 21 and the thickness direction length of the non-polishing convex pattern portion 22 may be the same length or may be different lengths.

[0026] Top surface 41 has different properties from top surface 42. When at least the upper part of the convex pattern portion is dense, top surface 41 is polished to make it more flat than top surface 42. As a result, top surface 41 is more likely to have a higher gloss than top surface 42. In particular, when top surface 42 has an uneven pattern formed thereon, the difference in flatness between top surface 41 and top surface 42 tends to be large. Furthermore, when there are many voids at least in the upper part of the convex pattern portion, top surface 41 is polished to expose the many voids, making it more uneven than top surface 42.

[0027] The order in which the polishing convex pattern portion 21 and the non-polishing convex pattern portion 22 are arranged along the edge is not particularly limited, and the polishing convex pattern portion 21 and the non-polishing convex pattern portion 22 may be arranged regularly or randomly. In other words, the polishing convex pattern portion 21 and the non-polishing convex pattern portion 22 may be adjacent to each other, or convex pattern portions 2 of the same type may be arranged consecutively.

[0028] The polishing convex pattern portion 21 has a first inclined surface 31. The first inclined surface 31 is included in the inclined surface 3. In this embodiment, the angle α1 between the first inclined surface 31 of the polishing convex pattern portion 21 and the surface 5 is larger than the average angle between the inclined surfaces 3 and the surface 5 of all the convex pattern portions 2 included in the decorative board 1 (see FIG. 2 ). In this case, the size of the top surface 41 and the size of the top surface 42 in one decorative board 1 are likely to be uniform. Furthermore, there is less variation in the size of the top surface 41 between different decorative boards 1. As a result, the decorative board 1 is one in which the size of the top surface 4 of the convex pattern portion 2 is likely to be uniform. Note that the angle α1 is preferably 60° or more and 80° or less. If the angle α1 is 60° or more, there is more likely to be a uniform size of the top surface 41 and the size of the top surface 42 in one decorative board 1. Furthermore, there is less variation in the size of the top surface 41 between different decorative boards 1. As a result, the decorative board 1 is more likely to have uniform sizes for the top surfaces 4 of the convex pattern portions 2. If the angle α1 is 80° or less, the decorative board 1 will have fewer chipped or cracked areas.

[0029] Furthermore, if angle α1 is 60° or more and 80° or less, the average angle between the inclined surfaces 3 of all the convex pattern portions 2 of the decorative board 1 and the surface 5 is preferably 45° or more and less than 60°. If this average angle is 45° or more, there is an advantage that the irregularities seen on the surface 5 of the decorative board 1 are easily visible. If this average angle is less than 60°, there is an advantage that the decorative board 1 is easily manufactured. Note that the average angle may be 60°, but in that case, angle α1 should be greater than 60°.

[0030] Furthermore, in this embodiment, the angle α1 between the first inclined surface 31 of the polished convex pattern portion 21 and the surface 5 is larger than the angle α2 between the inclined surface 32 of the non-polished convex pattern portion 22 and the surface 5 (see FIG. 2 ). In this case, the size of the top surface 41 and the size of the top surface 42 within a single decorative board 1 are likely to be uniform. Furthermore, there is less variation in the size of the top surface 41 between different decorative boards 1. As a result, the decorative board 1 is one in which the size of the top surface 4 of the convex pattern portion 2 is more likely to be uniform. Note that the angle α1 is preferably 60° or greater and 80° or less. When the angle α1 is 60° or greater, the size of the top surface 41 and the size of the top surface 42 are more likely to be uniform. Furthermore, there is less variation in the size of the top surface 41 between different decorative boards 1. As a result, the decorative board 1 is one in which the size of the top surface 4 of the convex pattern portion 2 is more likely to be uniform. If angle α1 is 60° or more and 80° or less, angle α2 is preferably 45° or more and less than 60°. An angle α2 of 45° or more has the advantage that the irregularities seen on surface 5 of decorative board 1 are more easily visible. An angle α2 of less than 60° has the advantage that decorative board 1 is easier to manufacture. Note that angle α2 may be 60°, but in that case, angle α1 should be greater than 60°.

[0031] (Manufacturing method) A method for manufacturing the decorative board 1 according to the embodiment will be described.

[0032] The manufacturing method of the decorative panel 1 of this embodiment includes preparing an original plate 10 having a plurality of convex portions 20 on its surface 50, all of which have an unpolished top surface 40 and an inclined surface 30 connecting to the unpolished top surface 40 (preparation process), and polishing the unpolished top surface 40 of at least one convex portion 20 having a first inclined surface 301 among the plurality of convex portions 20 provided on the original plate 10 to form a polished convex pattern portion 21 having a polished top surface 41 (polishing process).

[0033] <Preparation process> The base plate 10 is manufactured from a molding material. In this embodiment, a cement-based hydraulic material is used as the molding material.

[0034] The convex portions 20 include polishing convex portions 201 and non-polishing convex portions 202. The polishing convex portions 201 correspond to the polishing convex pattern portions 21 provided on the decorative board 1, and the non-polishing convex portions 202 correspond to the non-polishing convex pattern portions 22 provided on the decorative board 1.

[0035] In the original plate 10 according to the embodiment, the angle β1 formed between the first inclined surface 301 of the polishing convex portion 201 and the surface 50 can be designed to be larger than the average angle formed between the inclined surfaces 30 of all the convex portions 20 on the original plate 10 and the surface 50, or larger than the angle β2 formed between the inclined surface 302 of the non-polishing convex portion 202 and the surface 50, thereby making it easier to make the sizes of the top surfaces 4 of the convex pattern portions 2 of the decorative board 1 manufactured from the original plate 10 uniform. This makes it possible to prevent defects in the appearance of the decorative board 1.

[0036] In the embodiment, the average value of the angles between the inclined surfaces 30 of the convex portions 20 and the surface 50 is the sum of the angles between the inclined surfaces 30 of all the convex portions 20 on the original plate 10 and the surface 50, divided by the number of inclined surfaces 30 of all the convex portions 20 on the original plate 10. This average value may also be the sum of the angles β1 between the inclined surfaces 30 of all the polishing convex portions 201 on the original plate 10 and the surface 50, as described later, and the angle β2 between the inclined surfaces 302 of all the non-polishing convex portions 202 on the original plate 10 and the surface 50, as described later, divided by the number of inclined surfaces 30 of all the convex portions 20 on the original plate 10.

[0037] In this embodiment, the angle β1 between the first inclined surface 301 of the polishing convex portion 201 and the surface 50 is larger than the average value of the angles between the inclined surfaces 30 of all the convex portions 20 of the decorative board 1 and the surface 50 (see FIG. 3 ). In this case, the size of the top surfaces 4 of the convex pattern portions 2 of the decorative boards 1 manufactured from the original sheet 10 can be more uniform. Note that the angle β1 is preferably 60° or more and 80° or less. If the angle β1 is 60° or more, the size of the top surfaces 4 of the convex pattern portions 2 of the manufactured decorative boards 1 can be more uniform. If the angle β1 is 80° or less, chipping or cracking of the convex portions 20 is less likely to occur during the manufacturing process of the original sheet 10. Therefore, a decorative board 1 with fewer chipped or cracked portions can be obtained. Furthermore, in this case, the average value of the average values ​​of the angles between the inclined surfaces 30 of the convex portions 20 and the surface 50 is preferably 45° or more and less than 60°. The average value of this angle may be 60°, but in that case, the angle β1 is set to be greater than 60°.

[0038] Furthermore, the angle β1 between the first inclined surface 301 of the polishing convex portion 201 and the surface 50 is larger than the angle β2 between the inclined surface 302 of the non-polishing convex portion 202 and the surface 50 (see FIG. 3). In this case, it is easier to make the size of the top surface 4 of the convex pattern portion 2 of the decorative board 1 manufactured from the original sheet 10 uniform. If the angle β1 is 60° or more and 80° or less, the angle β2 is preferably 45° or more and less than 60°. Note that the angle β2 may be 60°, but in that case, the angle β1 should be greater than 60°.

[0039] The base plate 10 can be manufactured as follows. First, a molding die is placed on a molding material that has been produced by papermaking or extrusion molding and supplied onto a conveyor or the like, and the molding material is press-molded by the molding die. The molding die is then released to obtain the base plate 10. Recesses are provided on the surface of the molding die. The recesses include recesses corresponding to the polishing convex portions 201 for forming the polishing convex pattern portion 21 and recesses corresponding to the non-polishing convex portions 202 for forming the non-polishing convex pattern portion 22. The base plate 10 may be manufactured by curing and hardening using moist heat curing, autoclave curing, or the like.

[0040] <Polishing process> Next, the top surface 401 of at least one of the protrusions 20 of the original plate 10 is polished to form a polishing protrusion pattern portion 21 having a polished top surface 41. In other words, the top surface 401 of the polishing protrusion 201 of the protrusions 20 of the original plate 10 is polished to form the polishing protrusion pattern portion 21. There is no particular method for polishing the top surface 401, but examples include a method using a belt sander. Note that the top surface 402 of the non-polishing protrusions 202 is not polished.

[0041] When polishing top surface 401 to form polishing convex pattern portion 21, top surface 401 is polished while polishing convex portion 201 is cut in the thickness direction until the thickness of the resulting decorative board 1 reaches a predetermined thickness. As described above, first inclined surface 301 and surface 50 form an incline. Therefore, the deeper the depth to which polishing convex portion 201 is cut (cutting distance H), the larger the size of top surface 41 can be.

[0042] Therefore, if the thickness of the resulting base plate 10 varies, the cutting distance H may vary for each base plate 10 to obtain a decorative board 1 of a consistent thickness. In this case, if the angle β1 between the first inclined surface 301 of the polishing convex portion 201 and the surface 50 is equal to or smaller than the average angle between the inclined surfaces 30 and the surface 50 of all the convex portions 20 on the base plate 10, the larger the cutting distance H, the larger the area of ​​the cut surface compared to the area of ​​the top portion before cutting. In other words, the size of the top surface 41 of the polishing handle convex portion 21 after polishing is larger than the size of the top surface 401 of the polishing convex portion 201 before polishing. In this case, it becomes difficult to ensure that the size of the top surface 41 of the decorative board 1 is uniform. Furthermore, individual differences in the dimensions of the base plate 10 may occur due to molding errors, warping, and the like. Therefore, even if the polishing convex portions 201 are cut in the same way for each base plate 10, the size of the top surface 41 will vary among the manufactured decorative boards 1. As a result, there is a risk that the decorative board 1 will be manufactured in which the top surfaces 4 of the convex pattern portions 2 will not be uniform in size.

[0043] In contrast, in the original plate 10 according to this embodiment, the angle β1 between the first inclined surface 301 of the polishing convex portion 201 and the surface 50 is greater than the average angle between the inclined surfaces 30 and the surface 50 of all the convex portions 20 on the original plate 10. Therefore, regardless of the cutting distance H, the size of the top surface 401 before polishing and the size of the top surface 41 after polishing are unlikely to change. This makes it easier to make the size of the top surface 41 of a single decorative board 1 uniform. Furthermore, even if there are individual differences in the dimensions of the original plate 10 due to molding errors, warping, etc., the change in the top area caused by cutting the polishing convex portion 201 is likely to be small. This makes it easier to make the size of the top surface 41 of different decorative boards 1 uniform. As a result, decorative boards 1 can be manufactured in which the size of the top surface 4 of the convex pattern portion 2 is likely to be uniform.

[0044] Similarly, if the angle β1 between the first inclined surface 301 of the polishing convex portion 201 and the surface 50 is the same as or smaller than the angle β2 between the inclined surface 302 of the non-polishing convex portion 202 and the surface 50, the larger the cutting distance H, the larger the top surface 41 of the polishing convex pattern portion 21 after polishing becomes compared to the top surface 401 of the polishing convex portion 201 before polishing. This makes it difficult to ensure uniformity in the size of the top surface 41. Furthermore, individual differences in the dimensions of the base plate 10 may occur due to molding errors, warping, and the like. Therefore, even if the polishing convex portion 201 is cut in the same way for each decorative panel 1, the size of the top surface 41 will vary between different decorative panels 1. As a result, there is a risk that only decorative panels 1 will be obtained in which the top surfaces 4 of the convex pattern portions 2 are unlikely to be uniform in size.

[0045] In contrast, in the original plate 10 according to the embodiment, the angle β1 between the first inclined surface 301 of the polishing convex portion 201 and the surface 50 is larger than the angle β2 between the inclined surface 302 of the non-polishing convex portion 202 and the surface 50. Therefore, regardless of the cutting distance H, the size of the top surface 401 before polishing and the size of the top surface 41 after polishing are unlikely to change. This makes it easier to make the size of the top surface 41 of a single decorative board 1 uniform. Furthermore, even if there are individual differences in the dimensions of the original plate 10 due to molding errors, warping, etc., the change in the top area caused by cutting the polishing convex portion 201 is likely to be small. This makes it easier to make the size of the top surface 41 of different decorative boards 1 uniform. As a result, it is possible to manufacture decorative boards 1 in which the size of the top surface 4 of the convex pattern portion 2 is likely to be uniform.

[0046] In this way, the decorative board 1 can be manufactured from the original board 10 through the preparation step and the polishing step.

[0047] [Second embodiment] A second embodiment of the present invention will be described below. Note that the same description as that of the second embodiment may be omitted.

[0048] (decorative panels) In the first embodiment, the first inclined surface 31 of the polishing convex pattern portion 21 rises on all four sides of the surface 5, but the present invention is not limited to this. In the second embodiment, the polishing convex pattern portion 21 has a second inclined surface 33 and a third inclined surface 34 instead of the first inclined surface 31. The second inclined surface 33 and the third inclined surface 34 are included in the inclined surface 3. Therefore, when calculating the average value of the angle between the inclined surfaces 3 of all the convex pattern portions 2 provided in the decorative board 1 and the surface 5, the angle between the inclined surface 3 of the polishing convex pattern portion 21 and the surface 5 is calculated by dividing the sum of the angles between the second inclined surface 33 and the third inclined surface 34 and the surface 5 by the total number of second inclined surfaces 33 and third inclined surfaces 34. Furthermore, in the decorative board 1 according to this embodiment, the second inclined surface 33 is not directly connected to the surface 5. Therefore, the angle α4 formed between the second inclined surface 33 of the polishing convex pattern portion 21 and the surface 5 is the angle formed between the surface 5 and a plane extending from the second inclined surface 33 of the polishing convex pattern portion 21 (see FIG. 4). The second inclined surface 33 is not directly connected to the surface 5, so a third inclined surface 34 is interposed between the second inclined surface 33 and the surface 5. A bending point 71 is interposed between the second inclined surface 33 and the third inclined surface 34. The non-polishing convex pattern portion 22 may have the same configuration as in the above embodiment, and specifically, the inclined surface 3 of the non-polishing convex pattern portion 22 may be directly connected to the surface 5 (see FIG. 4).

[0049] In the second embodiment, the angle α4 between the second inclined surface 33 of the polishing convex pattern portion 21 and the surface 5 is larger than the average value of the angles between the inclined surfaces 3 and the surface 5 of all the convex pattern portions 2 of the decorative board 1. In this case, the size of the top surface 41 of one decorative board 1 is more likely to be uniform. Furthermore, the size of the top surface 41 is less likely to vary between different decorative boards 1. As a result, the decorative board 1 is one in which the size of the top surfaces 4 of the convex pattern portions 2 is more likely to be uniform. Note that the angle α4 is preferably between 60° and 80°. If the angle α4 is 60° or more, the size of the top surfaces 41 is more likely to be uniform. Furthermore, the size of the top surfaces 41 is less likely to vary between different decorative boards 1. As a result, the decorative board 1 is one in which the size of the top surfaces 4 of the convex pattern portions 2 is more likely to be uniform. If the angle α4 is 80° or less, the decorative board 1 is one in which there are fewer chipped or cracked portions.

[0050] If angle α4 is 60° or more and 80° or less, the average angle between the inclined surfaces 3 of all the convex pattern portions 2 of the decorative board 1 and the surface 5 is preferably 45° or more and less than 60°. If this average angle is 45° or more, there is an advantage that the irregularities seen on the surface 5 of the decorative board 1 are easily visible. If this average angle is less than 60°, there is an advantage that the decorative board 1 is easily manufactured. Note that the average angle may be 60°, but in that case, angle α4 should be greater than 60°.

[0051] Furthermore, in this embodiment, the angle α4 between the second inclined surface 33 of the polished convex pattern portion 21 and the surface 5 is larger than the angle α2 between the inclined surface 32 of the non-polished convex pattern portion 22 and the surface 5 (see FIG. 4 ). In this case, the size of the top surface 41 of a single decorative board 1 is likely to be uniform. Furthermore, the size of the top surface 41 is less likely to vary between different decorative boards 1. As a result, the decorative board 1 is one in which the size of the top surface 4 of the convex pattern portion 2 is likely to be uniform. If the angle α4 is 60° or greater and 80° or less, the angle α2 is preferably 45° or greater and less than 60°. An angle α2 of 45° or greater has the advantage that the irregularities seen on the surface 5 of the decorative board 1 are more likely to be clear. An angle α2 of less than 60° has the advantage that the decorative board 1 is more easily obtained. Note that the angle α2 may be 60°, but in that case, the angle α4 should be greater than 60°.

[0052] Furthermore, in this embodiment, the angle α4 between the second inclined surface 33 of the polishing convex pattern portion 21 and the surface 5 is larger than the angle α3 between the third inclined surface 34 of the polishing convex pattern portion 21 and the surface 5 (see FIG. 4). In this case, the size of the top surface 4 of the convex pattern portion 2 is more likely to be uniform, and the decorative board 1 is easier to manufacture. If the angle α4 is 60° or more and 80° or less, the angle α3 is preferably 45° or more and less than 60°. If the angle α3 is 45° or more, the unevenness seen on the surface 5 of the decorative board 1 is more likely to be clear. If the angle α3 is less than 60°, the decorative board 1 is easier to obtain. Note that the angle α3 may be 60°, but in that case, the angle α4 should be greater than 60°.

[0053] In the second embodiment, the average value of the angle between the inclined surface 3 and the surface 5 of all the convex pattern portions 2 of the decorative panel 1, the angle α2 between the inclined surface 32 of the non-polished convex pattern portion 22 and the surface 5, and the angle α3 between the third inclined surface 34 of the polished convex pattern portion 21 and the surface 5 may be the same or different.

[0054] (Manufacturing method) The manufacturing method of the decorative board 1 according to this embodiment includes a preparation step and a polishing step, as in the first embodiment. More specifically, the manufacturing method of the decorative board 1 according to the second embodiment includes preparing an original plate 10 having a plurality of protrusions 20 on its surface 50, all of which have an unpolished top surface 40 and an inclined surface 30 connecting to the unpolished top surface 40, and polishing the unpolished top surface 40 of at least one protrusion 20 of the plurality of protrusions 20 on the original plate 10, the protrusion 20 having a second inclined surface 303 and a third inclined surface 304, within the range of the second inclined surface 303, to form a polished protrusion pattern portion 21 having a polished top surface 41.

[0055] The decorative board 1 can be manufactured from an original plate 10 having polishing convex portions 201 each having a second inclined surface 303 and a third inclined surface 304. The second inclined surface 303 and the third inclined surface 304 are included in the inclined surface 30. Therefore, when calculating the average value of the angles formed between the inclined surfaces 30 of all the convex portions 20 of the original plate 10 and the surface 50, the angle formed between the inclined surface 30 of the polishing convex portion 201 and the surface 50 is a value calculated by dividing the sum of the angles formed between the second inclined surface 303 and the third inclined surface 304 and the surface 50 by the total number of second inclined surfaces 303 and third inclined surfaces 304. Preferably, the value calculated by dividing the sum of the angles formed between the second inclined surface 303 and the surface 50 by the total number of second inclined surfaces 303.

[0056] The manufacturing method of the original plate 10 in this embodiment may be the same as that in the first embodiment, but at the time of manufacturing the original plate 10, the shape of the recess provided on the surface of the mold is designed in advance so that a polishing convex portion 201 having a second inclined surface 303 and a third inclined surface 304 can be formed.

[0057] The polishing convex portion 201 has a second inclined surface 303 and a third inclined surface 304 interposed between the second inclined surface 303 and the surface 50. A bending point 701 is interposed between the second inclined surface 303 and the third inclined surface 304. The cutting distance H of the polishing convex portion 201 is within the range from the top surface 401 before polishing to the bending point 701. In other words, the polishing convex portion 201 is polished within the range of the second inclined surface 303. In other words, a part or all of the second inclined surface 303 is cut, but the third inclined surface 304 is not cut. The non-polishing convex portion 202 may have the same configuration as in the first embodiment. Specifically, the inclined surface 30 of the non-polishing convex portion 202 may be directly connected to the surface 50. In the original plate 10 according to this embodiment, the second inclined surface 303 is not directly connected to the surface 50. Therefore, the angle β4 formed between the second inclined surface 303 of the polishing convex portion 201 and the surface 50 is the angle formed between the surface 50 and the plane extending from the second inclined surface 303 of the polishing convex portion 201 (see Figure 5).

[0058] In this embodiment, the angle β4 between the second inclined surface 303 of the polishing convex portion 201 and the surface 50 is greater than the average angle between the inclined surfaces 30 and the surface 50 of all the convex portions 20 of the original plate 10 (see FIG. 5 ). In this case, regardless of the cutting distance H, the size of the top surface 401 before polishing and the size of the top surface 41 after polishing are unlikely to change. This makes it easier to make the size of the top surface 41 of a single decorative board 1 uniform. Furthermore, even if there are individual differences in the dimensions of the original plate 10 due to molding errors, warping, etc., the change in the top area caused by cutting the polishing convex portion 201 is likely to be small. Therefore, it is possible to make it less likely that the size of the top surface 41 will vary between different decorative boards 1. As a result, it is possible to manufacture decorative boards 1 in which the size of the top surface 4 of the convex pattern portion 2 is likely to be uniform. Note that the angle β4 is preferably between 60° and 80°. If angle β4 is 60° or more, the size of the top surface 4 of the convex pattern portion 2 of the decorative board 1 manufactured from the original sheet 10 can be more uniform. If angle β4 is 80° or less, chipping or cracking is less likely to occur in the convex portion 20 during the process of manufacturing the original sheet 10. Therefore, a decorative board 1 with fewer chipped or cracked areas can be obtained. In this case, the average value of the average value of the angle between the inclined surface 30 of the convex portion 20 and the surface 50 is preferably 45° or more and less than 60°. Note that the average value of this angle may be 60°, but in that case, angle β4 should be greater than 60°.

[0059] Furthermore, the angle β4 between the second inclined surface 303 of the polishing convex portion 201 and the surface 50 is larger than the angle β2 between the inclined surface 302 of the non-polishing convex portion 202 and the surface 50 (see FIG. 5). In this case, regardless of the cutting distance H, the size of the top surface 401 before polishing and the size of the top surface 41 after polishing are unlikely to change. This makes it easier to make the size of the top surface 41 of a single decorative board 1 uniform. Furthermore, even if there are individual differences in the dimensions of the original board 10 due to molding errors, warping, etc., the change in the top area caused by cutting the polishing convex portion 201 is likely to be small. Therefore, it is possible to make it less likely that the size of the top surface 41 will vary between different decorative boards 1. As a result, it is possible to manufacture decorative boards 1 in which the size of the top surface 4 of the convex pattern portion 2 is likely to be uniform. If the angle β4 is 60° or greater and 80° or less, the angle β2 is preferably 45° or greater and less than 60°. The angle β2 may be 60°, but in that case, the angle β4 should be greater than 60°.

[0060] Furthermore, in the second embodiment, the angle β4 between the second inclined surface 303 of the polishing convex portion 201 and the surface 50 is larger than the angle β3 between the third inclined surface 304 of the polishing convex portion 201 and the surface 50 (see FIG. 5). In this case, the polishing convex portion 201 of the original plate 10 has the third inclined surface 304 with a relatively shallow angle, which has the advantage of facilitating the mold release from the original plate 10. As a result, the decorative board 1 can be easily manufactured from the original plate 10, with the top surface 4 of the convex pattern portion 2 having a uniform size. If the angle β4 is 60° or more and 80° or less, the angle β3 is preferably 45° or more and less than 60°. Note that the angle β3 may be 60°, but in that case, the angle β4 should be greater than 60°.

[0061] In the second embodiment, the average value of the angle between the inclined surfaces 30 of all the convex portions 20 on the original plate 10 and the surface 50, the angle β2 between the inclined surfaces 302 of the non-polishing convex portions 202 and the surface 50, and the angle β3 between the third inclined surfaces 304 of the polishing convex portions 201 and the surface 50 may be the same or different.

[0062] [summary] As described above, the decorative board 1 of the present invention is likely to have a uniform size of the top surface 4 of the convex pattern portion 2 of the decorative board 1. If the thickness of the resulting decorative board 1 is about 16 mm, the cutting distance H may be greater than 0 mm and not greater than 1.0 mm. Even if the cutting distance H is within the above range, there is an advantage in that it is likely to have a uniform size of the top surface 4 of the convex pattern portion 2 of the decorative board 1.

[0063] Furthermore, the difference between the horizontal extension length of the top surface 41 of the polishing protrusions 21 and the horizontal extension length of the top surface 401 of the polishing protrusions 201 tends to be small. If the thickness of the resulting decorative board 1 is about 16 mm, even if the cutting distance H is 1.0 mm, the difference between the horizontal extension length of the top surface 41 of the polishing protrusions 21 and the horizontal extension length of the top surface 401 of the polishing protrusions 201 can be 0.3 mm or less. Similarly, the difference between the vertical extension length of the top surface 41 of the polishing protrusions 21 and the vertical extension length of the top surface 401 of the polishing protrusions 201 also tends to be small, and even if the cutting distance H is 1.0 mm, the difference between the vertical extension length of the top surface 41 of the polishing protrusions 21 and the vertical extension length of the top surface 401 of the polishing protrusions 201 can be 0.3 mm or less.

[0064] [Aspect] As is apparent from the above embodiment, the present invention includes the following aspects.

[0065] A decorative board 1 according to a first aspect of the present invention is a decorative board comprising a plurality of convex pattern portions 2 on a surface 5, each having a top surface 4 and an inclined surface 3 connected to the top surface 4, and the plurality of convex pattern portions 2 includes at least one polished convex pattern portion 21 having a polished top surface 41. The angle α1 formed between the surface 5 and a first inclined surface 31 of the polished convex pattern portion 21 is greater than the average value of the angles formed between the surface 5 and the inclined surfaces 3 of all the convex pattern portions 2 provided on the decorative board 1.

[0066] A decorative board 1 according to a second aspect of the present invention is a decorative board 1 comprising a plurality of convex pattern portions 2 on a surface 5, each having a top surface 4 and an inclined surface 3 connecting to the top surface 4, wherein the plurality of convex pattern portions 2 includes at least one polished convex pattern portion 21 having a polished top surface 41. The polished convex pattern portion 21 has a second inclined surface 33 and a third inclined surface 34 interposed between the second inclined surface 33 and the surface 5. The angle α4 formed between the second inclined surface 33 and the surface 5 is larger than the angle α3 formed between the third inclined surface 34 and the surface 5. The angle α4 formed between the second inclined surface 33 and the surface 5 is larger than the average value of the angles formed between the inclined surfaces 3 and the surface 5 of all the convex pattern portions 2 provided on the decorative board 1.

[0067] A decorative board 1 according to a third aspect of the present invention is a decorative board 1 comprising a plurality of convex pattern portions 2 on a surface 5, each having a top surface 4 and an inclined surface 3 connecting to the top surface 4, the plurality of convex pattern portions 2 including a polished convex pattern portion 21 having a polished top surface 41 and an unpolished convex pattern portion 22 having an unpolished top surface 42. An angle α1 formed between a first inclined surface 31 of the polished convex pattern portion 21 and the surface 5 is larger than an angle formed between the inclined surface 3 of the unpolished convex pattern portion 22 and the surface 5.

[0068] A decorative board 1 according to a fourth aspect of the present invention is a decorative board 1 comprising a plurality of convex pattern portions 2 on a surface 5, each having a top surface 4 and an inclined surface 3 connecting to the top surface 4, the plurality of convex pattern portions 2 including a polished convex pattern portion 21 having a polished top surface 41 and an unpolished convex pattern portion 22 having an unpolished top surface 42. The polished convex pattern portion 21 has a second inclined surface 33 and a third inclined surface 34 interposed between the second inclined surface 33 and the surface 5. The angle α4 formed between the second inclined surface 33 and the surface 5 is greater than the angle α3 formed between the third inclined surface 34 and the surface 5. The angle α4 formed between the second inclined surface 33 and the surface 5 is greater than the angle α2 formed between the inclined surface 3 of the unpolished convex pattern portion 22 and the surface 5.

[0069] The manufacturing method of a decorative board 1 according to the fifth aspect of the present invention is a method of manufacturing a decorative board 1 according to either the first or third aspect, and includes preparing an original plate 10 having a plurality of convex portions 20 on its surface 50, all of which have an unpolished top surface 40 and an inclined surface 30 connecting to the unpolished top surface 40, and polishing the unpolished top surface 40 of at least one convex portion 20 having a first inclined surface among the convex portions 20 of the original plate 10, to form a polished convex pattern portion 21 having a polished top surface 41.

[0070] A manufacturing method for a decorative board 1 according to the sixth aspect of the present invention is a method for manufacturing a decorative board 1 according to either the second or fourth aspect, and includes preparing an original plate 10 having a plurality of convex portions 20 on its surface 50, all of which have an unpolished top surface 40 and an inclined surface 30 connecting to the unpolished top surface 40, and polishing the unpolished top surface 40 of at least one convex portion 20 among the plurality of convex portions 20 on the original plate 10, which has a second inclined surface 303 and a third inclined surface 304, within the range of the second inclined surface 303, to form a polished convex pattern portion 21 having a polished top surface 41. [Explanation of symbols]

[0071] 1 decorative panel 2 Convex pattern part 21 Polished convex pattern part 22 Non-polished convex pattern part 20 Convex part 201 Polishing convex part 3,30,32,302 Slope 31,301 1st slope 4,40,41,42,401 Top 5,50 surface 33,303 2nd slope 71,701 bending points 34,304 Third slope

Claims

1. A decorative board having a plurality of convex pattern portions on a surface thereof, each of which has a top surface and an inclined surface connected to the top surface, The plurality of convex handle portions include at least one polishing convex handle portion having a polished top surface, the angle formed between the first inclined surface of the polishing convex pattern portion and the surface is greater than the average value of the angles formed between the inclined surfaces of all the convex pattern portions of the decorative board and the surface; Decorative panel.

2. A decorative board having a plurality of convex pattern portions on a surface thereof, each of which has a top surface and an inclined surface connected to the top surface, The plurality of convex handle portions include at least one polishing convex handle portion having a polished top surface, the abrasive handle portion has a second inclined surface and a third inclined surface interposed between the second inclined surface and the surface; an angle formed between the second inclined surface and the surface is larger than an angle formed between the third inclined surface and the surface; The angle formed between the second inclined surface and the surface is greater than the average value of the angles formed between the inclined surfaces of all the convex pattern portions provided on the decorative board and the surface. Decorative panel.

3. A decorative board having a plurality of convex pattern portions on a surface thereof, each of which has a top surface and an inclined surface connected to the top surface, The plurality of convex handle portions include polished convex handle portions having polished top surfaces and non-polished convex handle portions having non-polished top surfaces, an angle formed between the first inclined surface of the abrasive convex handle portion and the surface is larger than an angle formed between the inclined surface of the non-abrasive convex handle portion and the surface; Decorative panel.

4. A decorative board having a plurality of convex pattern portions on a surface thereof, each of which has a top surface and an inclined surface connected to the top surface, The plurality of convex handle portions include polished convex handle portions having polished top surfaces and non-polished convex handle portions having non-polished top surfaces, the abrasive handle portion has a second inclined surface and a third inclined surface interposed between the second inclined surface and the surface; an angle formed between the second inclined surface and the surface is larger than an angle formed between the third inclined surface and the surface; an angle formed between the second inclined surface and the surface is larger than an angle formed between the inclined surface of the non-abrasive convex handle portion and the surface; Decorative panel.

5. A method for producing the decorative board according to claim 1 or 3, preparing an original plate having a plurality of protrusions on a surface thereof, the protrusions having an unpolished top surface and an inclined surface connecting to the unpolished top surface; and polishing the unpolished top surface of at least one of the plurality of protrusions provided on the original plate, the protrusion having the first inclined surface, to form the polished protrusion pattern portion having a polished top surface. A method for manufacturing decorative panels.

6. A method for producing the decorative board according to claim 2 or 4, preparing an original plate having a plurality of protrusions on a surface thereof, the protrusions having an unpolished top surface and an inclined surface connecting to the unpolished top surface; and polishing the unpolished top surface of at least one of the plurality of convex portions of the original plate, the convex portion having the second inclined surface and the third inclined surface, within the range of the second inclined surface, to form the polished convex pattern portion having a polished top surface. A method for manufacturing decorative panels.

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