Method for manufacturing wood composite board, and wood composite board

Abstract

To provide a method for manufacturing wood composite boards with a short lead time. [Solution] A method for manufacturing a wood composite board, comprising the steps of: attaching a decorative material 20 to at least one surface of a core material 10; providing an opening 50 in the core material 10 to which the decorative material 20 is attached; cutting out at least a portion of the inner edge of the opening 50, leaving the decorative material 21 attached to one surface of the core material 10, thereby forming a notched portion 30; and attaching a face material 40 to the notched portion 30.

Description

Technical Field

[0001] The present invention relates to a method for manufacturing a wood composite board and a wood composite board.

Background Art

[0002] A wood composite board mainly consists of a core material made of glued laminated timber or the like, a decorative material made of veneer or sliced veneer of natural wood, and a finishing material made of solid wood or sliced veneer. It is used for tables, shelf boards, treads of stairs, countertops of kitchens, etc. By attaching the decorative material and the finishing material to a relatively inexpensive core material, it is possible to achieve an appearance similar to that of solid wood while suppressing costs. Wood composite boards are required to have various shapes and dimensions depending on their applications.

[0003] For example, Patent Document 1 discloses a method for manufacturing a decorative panel, which includes a step of attaching a finishing material to the side surface of a core material and a step of attaching a decorative material to the core material to which the finishing material has been attached. Further, Patent Document 2 discloses a method for manufacturing a flush structure, which includes a step of forming a U-shaped groove in the side surface portion of a core material and a step of inserting a finishing material into the formed groove.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0005] In the invention of Patent Document 1, it is necessary to attach a finishing material to the side surface of the core material as the first step. However, unless the dimensions and shape of the finished product are determined, the dimensions of the finishing material to be attached to the core material will not be determined naturally. That is, it is not possible to prepare work-in-progress products in advance, and it takes time for the work after receiving an order.

[0006] The invention described in Patent Document 2 requires high precision in the process of forming a U-shaped groove. Furthermore, while adhesive is usually used to attach the facing material, when the facing material is inserted into the groove, the adhesive inside the groove is scraped off by the facing material, which can lead to poor adhesion between the core material and the facing material.

[0007] When using wood composite boards in kitchens, bathrooms, etc., it is necessary to provide openings for installing sinks, stoves, etc., as well as openings for wiring and piping. Furthermore, if it is required that the core material not be exposed on the inner edge of the opening, it is necessary to attach a facing material to the inner edge of the opening as well. In this case, the inventions of Patent Documents 1 and 2 have the same problems as described above.

[0008] Therefore, one of the objectives of the present invention is to provide a method for manufacturing wood composite boards with a short lead time, and to provide wood composite boards. [Means for solving the problem]

[0009] The present invention relates to the following method for manufacturing a wood composite board and the wood composite board itself.

[0010] A step of attaching a decorative material to at least one side of the core material, A step of providing an opening in the core material to which the decorative material has been attached, The process of forming a notch in at least a portion of the inner edge of the opening, leaving the decorative material attached to one side of the core material intact, The process involves attaching a decorative material to the aforementioned cutout, A method for manufacturing a wood composite board, comprising the features described above.

[0011] Core material and The first decorative material is attached to one side of the aforementioned core material, A second decorative material is attached to the other side of the aforementioned core material, An opening is provided in the core material to which the first decorative material and the second decorative material are attached, It has a finder material attached to the inner edge of at least a part of the opening, The finder material is a wood composite board having a part where its upper surface is covered by the first decorative material and its lower surface is exposed.

Advantages of the Invention

[0012] According to the present invention, a method for manufacturing a wood composite board with a short lead time and a wood composite board can be obtained.

Brief Description of the Drawings

[0013] [Figure 1] FIG. 1 is a diagram showing an overview of a wood composite board, (a) is a top view, and (b) is a cross-sectional view taken along line A-A. [Figure 2] FIG. 2 is a diagram showing the state after the first step of the wood composite board, (a) is a top view, and (b) is a cross-sectional view taken along line B-B. [Figure 3] FIG. 3 is a diagram showing the state after the second step of the wood composite board, (a) is a top view, and (b) is a cross-sectional view taken along line C-C. [Figure 4] FIG. 4 is a diagram showing the state after the third step of the wood composite board, (a) is a top view, and (b) is a cross-sectional view taken along line D-D. [Figure 5] FIG. 5 is a perspective view showing an example of an assembled finder material. [Figure 6] FIG. 6 is a partially enlarged cross-sectional view of the wood composite board. [Figure 7] FIG. 7 is a perspective view showing another example of an assembled finder material. [Figure 8] FIG. 8 is a partially enlarged cross-sectional view showing an example of the manufacturing process of the wood composite board, (a) shows the state after attaching the finder material 40, and (b) shows the state after providing the mounting space.

Modes for Carrying Out the Invention

[0014] [1. Wood Composite Board According to the Present Embodiment] FIG. 1 is a diagram showing an outline of a wood composite board, (a) is a top view, and (b) is a cross-sectional view taken along line A-A. As shown in FIG. 1, the wood composite board 1 includes a core material 10, a first decorative material 21 attached to one surface (front surface) of the core material 10, a second decorative material 22 attached to the other surface (back surface) of the core material 10, an opening 50 provided in the core material 10 to which the first decorative material 21 and the second decorative material 22 are attached, and a finder material 40 attached to at least a part of the inner edge of the opening 50. Hereinafter, the first decorative material 21 and the second decorative material 22 are also collectively referred to as the decorative material 20.

[0015] In this embodiment, the core material 10 is a rectangular parallelepiped plate. The dimensions and shape of the core material 10 are not particularly limited. For example, typical dimensions when the core material is a rectangular parallelepiped are a length of 500 to 3000 mm, a width of 50 to 1000 mm, and a thickness of 10 to 40 mm. Also, the material of the core material 10 is not particularly limited, and existing materials such as laminated wood, wood, wood board, gypsum board, and resin board can be used. It is preferable that the material of the core material 10 has a lower density than the material of the decorative material 20. By reducing the weight of the entire wood composite board 1, the transportation cost is reduced and handling during construction becomes easier. Also, the core material 10 does not have to be a single board, and a plurality of materials may be laminated and used.

[0016] In this embodiment, the decorative material 20 is a rectangular parallelepiped plate. The material of the decorative material 20 is not particularly limited, and existing materials such as a sawn board, veneer, or fiberboard of natural wood with a veneer or the like attached to the base material can be used. Also, the material of the decorative material 20 may be a plurality of sawn boards or veneers stacked. Also, the thickness of the decorative material 20 is not particularly limited, but if it is too thin, the decorative material 20 is likely to be damaged during the manufacturing process. Therefore, the thickness of the decorative material 20 is preferably 0.5 mm or more, and more preferably 1.5 mm or more. Also, if the decorative material 20 is too thick, it will lead to an increase in cost and weight. Therefore, the thickness dimension of the decorative material is preferably 3.0 mm or less.

[0017] In this embodiment, the wood composite board 1 has decorative materials 20 attached to the front and back surfaces of the core material 10. Hereinafter, the decorative material 20 attached to the front surface of the core material 10 will be referred to as the first decorative material 21, and the decorative material 20 attached to the back surface of the core material 10 will be referred to as the second decorative material 22. The wood composite board 1 only needs to have at least the first decorative material 21, and does not need to have the second decorative material 22. In addition, multiple layers of the first decorative material 21 and the second decorative material 22 may be attached to the core material 10.

[0018] The materials for the first decorative material 21 and the second decorative material 22 are preferably the same tree species, but they may be different tree species. If the first decorative material 21 and the second decorative material 22 are different tree species, they are preferably of the same color, but they may be of different colors.

[0019] The second decorative material 22 may be made of a material with an inferior appearance to the first decorative material 21. For example, when the wood composite board 1 is used as a table top, the manufacturing cost can be reduced by using a material with a superior appearance for the first decorative material 21 and a material with an inferior appearance for the second decorative material 22, which is not easily visible to the user. The material with an inferior appearance may include, for example, materials with many cracks, knots, and discoloration.

[0020] At least a portion of the inner edge of the opening 50 is provided with a housing portion 30 on the back side of the first decorative material 21, and the visible material 40 is housed in the housing portion 30. That is, the core material 10 may be exposed in a portion of the inner edge of the housing portion 30. The housing portion 30 is, for example, a notch formed by cutting out while leaving the first decorative material 21 intact. Furthermore, when providing the housing portion 30, its position and number are not limited. Also, the shape of the housing portion 30 is not limited and may be formed in the shape of a rectangular parallelepiped, or in the shape of a step or inclined shape, etc. This is to facilitate the installation of covers, sinks, stoves, etc. Note that the core material 10 may remain on the back side of the first decorative material 21 in the housing portion 30. In addition, although Figure 1 shows a rectangular opening 50, the shape of the opening is not limited to this shape and may include curved shapes.

[0021] The fascia material 40 is housed and attached to the housing section 30. The fascia material 40 is attached within the housing section 30, which is composed of the back surface of the first decorative material 21, the side surface of the core material 10, and the side surface of the second decorative material 22. As a result, the upper surface of the fascia material 40 has a portion that is covered by the first decorative material 21. For example, if the side surface (inner edge) of the opening 50 is a vertical surface, the entire upper surface of the fascia material 40 will be covered by the first decorative material 21. On the other hand, if the side surface (inner edge) of the opening 50 has a slope that widens upward, a portion of the upper surface of the fascia material 40 will be covered by the first decorative material 21. In other words, it is preferable that the upper surface of the fascia material 40 has a portion that is covered by the first decorative material 21 so that the core material 10 is not visible from above. The material of the fascia material 40 is not particularly limited, and existing materials such as solid wood can be used. The thickness of the visible material 40 is not particularly limited, but it is preferably the sum of the thickness of the core material 10 and the second decorative material 22. By making the back surface of the second decorative material 22 and the back surface of the visible material 40 flush, the sides of the second decorative material 22 are not exposed, resulting in an appearance closer to solid wood. If the wood composite board 1 does not have a second decorative material 22, it is preferable that the thickness of the visible material 40 is about the same as that of the core material 10.

[0022] The visible material 40 is preferably of a length such that the end of the core material 10 to which the visible material 40 is attached is not exposed. Furthermore, the visible material 40 may be formed by combining multiple visible materials 40 with butt joints, scarf joints, or the like.

[0023] The material of the visible timber 40 is preferably the same tree species as the decorative timber 20, but it may be a different tree species. If it is a different tree species, it is preferable that the color and grain are similar. By using the same tree species or similar tree species for the visible timber 40 and decorative timber 20, an appearance closer to solid wood can be achieved.

[0024] When the facing material 40 is attached to a side surface of the decorative material that extends in the direction of the fibers, it is preferable that the facing material 40 is long such that its longitudinal direction is in the direction of the fibers. Also, when the facing material 40 is attached to a side surface of the decorative material that extends in a direction perpendicular to the direction of the fibers, it is preferable that the facing material 40 is attached so that its end grain is exposed.

[0025] The means by which the core material 10, the decorative material 20, and the visible material 40 are attached are not particularly limited. For example, they may be attached using an existing adhesive.

[0026] [2. Method for manufacturing wood composite board according to this embodiment] Next, the manufacturing method of the wood composite board 1 according to this embodiment will be described with reference to Figures 2 to 6. Figure 2 shows the state of the wood composite board after the first process, where (a) is a top view and (b) is a cross-sectional view BB. Figure 3 shows the state of the wood composite board after the second process, where (a) is a top view and (b) is a cross-sectional view CC. Figure 4 shows the state of the wood composite board after the third process, where (a) is a top view and (b) is a cross-sectional view DD. Figure 5 is a perspective view showing an example of assembled visible material. Figure 6 is a partially enlarged cross-sectional view of the wood composite board.

[0027] (Step 1: Applying decorative material) The manufacturing method of the wood composite board 1 according to this embodiment first includes the step of attaching a decorative material 20 to a core material 10, as shown in Figure 2. In this embodiment, the first decorative material 21 is attached to the surface of the core material 10 and the second decorative material 22 is attached to the back surface, but the decorative material 20 only needs to be attached to at least one of the front or back surfaces of the core material 10, for example, only the first decorative material 21 may be attached to the core material 10. It is preferable to use the same tree species for the first decorative material 21 and the second decorative material 22, but different tree species may be used. Also, when different tree species are used for the first decorative material 21 and the second decorative material 22, it is preferable to use tree species of the same color, but different tree species may be used. By using the same tree species or tree species with similar color and grain for the first decorative material 21 and the second decorative material 22, an appearance closer to solid wood can be achieved.

[0028] The method for attaching the decorative material 20 to the core material 10 is not particularly limited, and existing techniques can be used. For example, the decorative material 20 can be attached to the core material 10 by applying an adhesive, overlapping the core material 10 and the decorative material 20, and then applying a pressing treatment. The adhesive may be applied to the core material 10, to the decorative material 20, or to both the core material 10 and the decorative material 20. Existing adhesives such as vinyl acetate type, water-based vinyl urethane type, melamine resin type, and SBR type can be used. The first decorative material 21 and the second decorative material 22 may be attached at the same time, or the second decorative material 22 may be attached first and then the first decorative material 21, or the first decorative material 21 may be attached first and then the second decorative material 22.

[0029] (Second process: opening forming process) Next, as shown in Figure 3, the manufacturing method of the wood composite board 1 according to this embodiment includes the step of providing an opening 50 in the core material 10 to which the decorative material 20 is attached. The opening 50 provided in the second step is preferably made slightly smaller in dimensions than the final shape of the opening (for example, an opening formed to fit a sink, stove, etc.), and then processed to the dimensions of the final shape of the opening after the facing material is attached. There are no particular restrictions on the processing method for providing the opening 50, but examples include cutting using an NC processing machine.

[0030] (Step 3: Notching process) Next, as shown in Figure 4, the manufacturing method of the wood composite board 1 according to this embodiment includes a step of forming a notch 30 by cutting out at least a portion of the inner edge 50a of the opening 50, leaving the first decorative material 21 attached to one side of the core material 10 intact. In this embodiment, as shown in Figure 4, notches 30 are formed in all four inner edge portions 50a of the opening 50, but the position and number of notches 30 are not limited, and notches 30 can be formed at any end. There are no particular restrictions on the processing method for providing the notches 30, but for example, cutting using an NC processing machine can be used. In addition, the notching process can be performed simultaneously with the opening formation process.

[0031] When forming the notch 30, it is preferable to cut from the back side of the core material 10 to which the decorative material 20 is attached, up to the boundary between the first decorative material 21 and the core material 10. This processing can be done using a router or saw or other cutting tool from the inner edge and back side of the opening 50. Alternatively, when forming the notch 30, the back side of the first decorative material 21 may be partially cut beyond the boundary between the first decorative material 21 and the core material 10. Also, some of the core material 10 may remain on the back side of the first decorative material 21. If a thick layer of core material 10 remains, the cross-section of the core material will be exposed between the decorative material and the visible material, impairing the solid appearance of the finished product. Therefore, it is preferable that the thickness of the core material 10 remaining on the back side of the first decorative material 21 be 2 mm or less. Furthermore, to achieve an excellent appearance, it is more preferable that the thickness of the core material 10 remaining on the back side of the first decorative material 21 be 1.0 mm or less, and even more preferable that it be 0.5 mm or less.

[0032] As shown in Figure 4, the notch 30 may be formed in a shape (rectangular parallelepiped) having a surface parallel to and perpendicular to the first decorative material 21, or it may be formed in a stepped or inclined shape, etc.

[0033] (Step 4: Applied trim) Next, the manufacturing method of the wood composite board 1 according to this embodiment includes a step of attaching a face material 40 to the notched portion 30. After attaching the face material 40, the wood composite board 1 will have a shape as shown in Figure 1 above, for example. The means of attaching the face material 40 are not particularly limited. For example, the face material 40 can be attached to the notched portion 30 by applying an adhesive and pressing the face material 40 onto the notched portion 30. The adhesive may be applied to the side surface of the core material 10 facing the notched portion 30 and the back surface of the first decorative material 21, or it may be applied to the face material 40, or it may be applied to both. Furthermore, existing adhesives such as vinyl acetate-based, water-based vinyl urethane-based, melamine resin-based, and SBR-based adhesives can be used.

[0034] Furthermore, after attaching the facing material 40 to the notch 30, the back surface of the second decorative material 22 and the back surface of the facing material 40 may be adjusted using a sander or grinder as needed so that they are on the same plane. Alternatively, the first decorative material 21 and the facing material 40 may be cut at the end where the facing material 40 is attached so that the core material 10 is not exposed, thereby shaping the opening 50. For example, an opening (temporary opening) with an inner edge shape smaller than the dimensions of the opening specified by the customer may be provided, and after attaching the facing material 40 in the fourth step, the shape of the opening 50 may be adjusted by cutting, sanding, etc.

[0035] Furthermore, the core material 10, the first decorative material 21, the second decorative material 22, and the visible material 40 may be painted as needed. The type of paint is not particularly limited and may be water-based or solvent-based. The material may be colored using a coloring agent before painting, or it may be colored using a paint containing pigments.

[0036] According to the manufacturing method of the wood composite board 1 of this embodiment, the work can be carried out up to the first step before the dimensions of the opening are determined. Therefore, by providing the opening 50 in the core material 10 to which the decorative material 20 has been attached after receiving the order, the lead time can be shortened.

[0037] In the fourth step, a step may be included in which multiple facing materials 40a, 40b, 40c, and 40d are assembled in advance (assembled in a square shape) to form a shape that follows the notch 30, thereby obtaining the assembled facing material 41 shown in Figure 5, and the assembled facing material 41 may be attached to the notch 30. This method makes it easier to attach to the notch 30 compared to attaching the facing materials 40a, 40b, 40c, and 40d individually. In this case, adhesive will be applied to the assembled facing material 41 or the notch before attachment.

[0038] However, since it is difficult to accurately machine the dimensions of the assembly face material 41, when using the assembly face material 41, it is preferable to provide an inclined portion 31 on the core material 10 (or further, the second decorative material 22) that constitutes the wall surface of the notch 30, as shown in Figure 7. In this inclined portion 31, the width of the front side of the wood composite board (i.e., the side with the first decorative material 21) is smaller than the width of the back side. The width of the front side at this time is set to a length corresponding to the outer shape of the assembly face material 41. Without such an inclination, there are problems such as the assembly face material 41 not being able to be accommodated in the notch 30, or a large gap being created between the assembly face material 41 and the notch 30. With the inclined portion 31, even if the dimensions of the assembly face material 41 are slightly larger than the notch 30, it is possible to accommodate it without gaps by pushing it in. Furthermore, when both the core material 10 and the assembly facing material 41 are provided with inclinations (in the same direction), pressing the assembly facing material 41 causes the inclined portions to press against each other, thus ensuring more reliable adhesion between the core material 10 and the assembly facing material 41. Although there may be some gaps on the back side, these do not adversely affect the strength of the wood composite board 1 like gaps on the front side, and are therefore acceptable. Regarding the external dimensions of the assembly facing material 41, for the same reasons as above, it is preferable that the width of the front side (i.e., the side with the first decorative material 21) is smaller than the width of the back side.

[0039] There are no particular restrictions on the shape of the assembled facing material. That is, for example, in the fourth step, a step may be included in which multiple facing materials 40a, 40b, 40c, and 40d are assembled around the plate material 40e in advance so as to conform to the shape of the notch 30, thereby obtaining the assembled facing material 42 shown in Figure 6, and the assembled facing material 42 may be attached to the notch 30. Alternatively, a plate material such as solid wood shaped to correspond to the opening may be used as the facing material.

[0040] The visible material 40 can be larger or smaller than the notch 40, as long as it can be accommodated in the notch 40. Furthermore, the boundary between the first decorative material 21 and the visible material 40 may or may not have a step (a state where the first decorative material 21 or the visible material 40 protrudes in a direction perpendicular to its thickness). There are no restrictions on the shape of each end face. For example, they may be flat or curved, and if flat, they may be inclined.

[0041] Figure 8 is a partially enlarged cross-sectional view showing an example of the manufacturing process of a wood composite board, where (a) shows the state after the face material 40 has been attached, and (b) shows the state after the mounting space has been created. Although not shown in the illustration, an opening is provided on the right side of the face material 40. As shown in Figure 8(a), the face material 40 attached to the notch 30 protrudes from the first decorative material 21 in a direction perpendicular to the thickness. In this wood composite board, as shown in Figure 8(b), the first decorative material 21, face material 40, core material 10, and second decorative material 22 are cut into predetermined shapes to provide a mounting space 60. Next, although not shown in the illustration, a sink, stove, etc., are attached to the back surfaces of the core material 10 and face material 40 in the mounting space 60. In this way, if there is a step between the back surface of the face material 40 and the back surface of the second decorative material 22 in the thickness direction of the wood composite board, the appearance is not compromised and the installation of sinks, stoves, etc., becomes easy. [Industrial applicability]

[0042] According to the present invention, a method for manufacturing wood composite boards with a short lead time, and wood composite boards can be obtained. [Explanation of Symbols]

[0043] 1. Wood composite board 10 Core material 20 Decorative materials 22 First Decorative Materials 24 Second decorative material 30 Notch 31 Slope 40, 40a, 40b, 40c, 40d visible material 41,42 Assembly material 50 openings 60 mounting space

Claims

1. A step of attaching a decorative material to at least one side of the core material, A step of providing an opening in the core material to which the decorative material has been attached, The process of forming a notch in at least a portion of the inner edge of the opening, leaving the decorative material attached to one side of the core material intact, The process involves attaching a decorative material to the aforementioned cutout, A method for manufacturing a wood composite board, comprising the features described above.

2. Furthermore, the process includes a step of assembling multiple facing members so as to form a shape along the notch, A method for manufacturing a wood composite board according to claim 1, wherein the assembled facing material is attached to the notched portion.

3. The method for manufacturing a wood composite board according to claim 1, wherein the step of attaching the decorative material involves attaching the decorative material to both sides.

4. A method for manufacturing a wood composite board according to any one of claims 1 to 3, wherein the notched portion includes an inclined portion such that the width of one side is smaller than the width of the other side.

5. Core material and The first decorative material is attached to one side of the aforementioned core material, A second decorative material is attached to the other side of the aforementioned core material, An opening is provided in the core material to which the first decorative material and the second decorative material are attached, The opening has a facing material attached to at least a portion of its inner edge, The aforementioned visible material is a wood composite board having a portion of its upper surface covered by the first decorative material and an exposed lower surface.

6. The wood composite board according to claim 5, wherein the back surface of the visible material and the back surface of the second decorative material are flush.

7. The wood composite board according to claim 5, wherein in the thickness direction of the wood composite board, there is a step between the back surface of the visible material and the back surface of the second decorative material.

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