Decorative boards and decorative board series

Abstract

To easily provide a decorative board having excellent design and a decorative board series consisting of a plurality of decorative boards each having a different surface pattern. [Solution] The surface 11 of the base material 10 of the decorative plate A is divided into a plurality of surface portions 11a, 11b by vertical grooves 14, a long side chamfered surface 16 is formed between the long side surface 12 and the surface 11 from one end to the other end in the long side direction, a short side chamfered surface 17 is formed only between the first surface portion 11a and the surface 11 on the short side side 13 side, and a horizontal groove 15 is formed on the second surface portion 11b. A pattern D is formed on the surface 11 of the base material 10 by the decorative layer 20, and further, a continuous pattern xy is formed between a first end X at one end side in the long side direction of the second surface portion 11b and a second end Y at the other end side, which connects the first end X and the second end Y when the second end Y is arranged on the short side side of the first end X.

Description

[Technical field]

[0001] The present invention relates to a laminate and a series of laminates. [Background technology]

[0002] Conventionally, decorative boards in which the corners of the four sides and the surface are chamfered so that when multiple decorative boards are arranged and joined together, a groove with a V-shaped cross section is formed at the joint, making gaps and steps that occur at the joint less noticeable, have been used as flooring materials, wall materials, etc. Some of these types of decorative boards have a decorative groove with a V-shaped cross section that is equal in depth to the depth of the groove formed by the chamfered portion at the joint of the decorative board, so that it looks like multiple decorative boards are joined together, even though it is a single decorative board (see, for example, Patent Document 1 below).

[0003] In the decorative board described in Patent Document 1, one vertical groove is formed on the surface of the substrate, and the surface is divided into two surface parts by the vertical groove. At least one horizontal groove is formed on each of the two surface parts. In addition, in the decorative board, a chamfered surface is formed from one end to the other end between the long side surface of the substrate and the surface, while a chamfered surface is formed only on one of the two surface parts between the short side surface of the substrate and the surface, and not on the other, so that at the joint between the two decorative boards joined at the short sides, the grooves parallel to the horizontal grooves formed by each other's chamfered surfaces do not extend to both sides of the vertical groove of each decorative board. With this configuration, the decorative board makes the joint with the other decorative board joined to the short side inconspicuous. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Patent No. 7228437 Summary of the Invention [Problem to be solved by the invention]

[0005] However, in the above decorative board, the decorative layer is made of a decorative sheet, and the decorative sheet covers not only the surface but also the side of the base material. Therefore, when applying a pattern such as wood grain to the above decorative board, the surface parts without chamfers of the two decorative boards joined at the short sides are butted together to make them look continuous, but in the configuration in which the decorative sheet covers not only the surface but also the side of the base material, the patterns formed on the two surface parts cannot be made continuous, so the joints of the decorative boards are exposed, which may impair the aesthetic appearance.

[0006] The present invention has been made in consideration of the above points, and an object of the present invention is to easily provide a decorative board with excellent design and a decorative board series consisting of a plurality of decorative boards each having a different surface pattern. [Means for solving the problem]

[0007] In order to achieve the above-mentioned object, in this invention, when another decorative panel is joined to the short side, a continuous pattern is formed across the two decorative panels in the area where the surfaces are butted together and no chamfered surface is formed.

[0008] Specifically, the first invention comprises a rectangular plate-like substrate and a decorative layer having a pattern formed on a surface of the substrate, the surface of the substrate being partitioned into a plurality of surface portions by at least one longitudinal groove extending in a long side direction on the surface of the substrate, a long side chamfered surface consisting of an inclined surface inclined with respect to the long side side and surface of the substrate is formed between one end of the long side direction of the substrate and the other end of the substrate, and a short side chamfered surface consisting of an inclined surface inclined with respect to the short side side and surface of the substrate is formed between the short side side of the substrate and at least one of the surface portions. At least one horizontal groove extending in the short side direction of the base material is formed in a second surface portion other than the first surface portion on which the short side chamfered surface is formed among the plurality of surface portions, and the plurality of surface portions are configured such that one end side of the short side direction of the base material becomes the second surface portion, and the first surface portion is always adjacent to the second surface portion, and the decorative plate is characterized in that a continuous pattern is formed by the decorative layer at a first end portion at one end side in the long side direction of the second surface portion and a second end portion at the other end side, which connects the first end portion and the second end portion when the second end portion is lined up next to the edge side of the first end portion.

[0009] In the first invention, at least one vertical groove is formed on the surface of the base material, and a long-side chamfered surface is formed between the long-side side surface of the base material and the surface, extending from one end to the other end. Therefore, when multiple decorative panels are arranged vertically and horizontally and joined, a groove parallel to the vertical groove is formed by the long-side chamfered surface at the long-side joint portion of the decorative panel, making gaps and steps less noticeable and improving the design. Meanwhile, between the short-side side surface of the base material and the surface, a short-side chamfered surface is formed only between a first surface portion and the short-side side surface of a part of the multiple surface portions, and a second surface portion without a short-side chamfered surface is always adjacent to the first surface portion. Therefore, when multiple decorative panels are arranged vertically and horizontally and joined, a groove parallel to the horizontal groove is formed by the short-side chamfered surfaces of each other at the short-side joint portion of the decorative panel, and no groove is formed at the portion corresponding to the first surface portion and corresponding to the second surface portion adjacent to the first surface portion, and the second surface portions are butted against each other. In other words, at the short side joints of the decorative panel, grooves parallel to the horizontal grooves are formed without crossing the vertical grooves due to the short side chamfered surface, making gaps and steps less noticeable and improving the design.

[0010] In the first invention, the decorative layer forms a pattern on the surface of the base material, and the first end at one end of the long side direction of the second surface portion and the second end at the other end of the long side direction of the second surface portion form a continuous pattern that connects the first end and the second end when the second end is arranged on the short side of the first end. By forming such a continuous pattern, when another decorative board is joined to one end of the long side direction, the second surface portions are butted together at the short side joint portion, and the pattern at the first end of the second surface portion of one decorative board and the pattern at the second end of the second surface portion of the other decorative board are connected to form a continuous pattern. In other words, according to the first invention, when another decorative board is joined to the short side, a groove parallel to the transverse groove is formed in the part of the short side joint corresponding to the first surface portion, and no groove is formed in the part corresponding to the second surface portion adjacent to the first surface portion, and the second surface portions are butted together, and a continuous pattern is formed across the butted second surface portions. Therefore, according to the first aspect of the present invention, it is possible to provide a decorative board having excellent design properties in which the joints are not noticeable when multiple pieces are joined together vertically and horizontally.

[0011] A second invention is characterized in that, in the first invention, the continuous pattern is a linear pattern extending in the direction of the longer side of the base material.

[0012] In the second invention, when another decorative board is joined to the short side, the linear pattern continues across the two decorative boards in the portion where there is no chamfered surface and the second surface portion continues. Therefore, according to the second invention, it is possible to provide a decorative board with excellent design in which the joint portion is not noticeable due to the linear pattern that spans the two decorative boards at the joint portion of the short side.

[0013] A third invention is characterized in that in the second invention, the linear pattern is a part of a wood grain pattern.

[0014] In the third invention, when another decorative board is joined to the short side, the wood grain pattern continues across the two decorative boards in the area where there is no chamfered surface and the second surface portion continues. Therefore, according to the third invention, the wood grain pattern is formed across the two decorative boards at the short side joining portion, so that a decorative board with excellent design and an inconspicuous joining portion can be provided.

[0015] A fourth invention is a decorative board series comprising a plurality of decorative boards according to any one of the first to third inventions, characterized in that the patterns on the entire surface of the base material of the plurality of decorative boards are different from one another, while the same continuous pattern is formed on the second surface portion in the same position.

[0016] In the fourth invention, the patterns of the entire surface of the multiple decorative panels are different from each other, while the same continuous pattern is formed on the second surface portion at the same position. By configuring the multiple decorative panels in this way, it is possible to easily provide a series of decorative panels consisting of multiple decorative panels each having a different surface pattern but with inconspicuous seams when joined vertically and horizontally. In addition, by forming floors, walls, etc. using this series of decorative panels, it is possible to construct floors, walls, etc. with excellent design in which the same pattern is not repeated many times and the seams are not noticeable.

[0017] The fifth invention is characterized in that, in the fourth invention, the surface of the base material of each of the decorative panels is divided into a plurality of second surface portions, and the plurality of second surface portions of each of the decorative panels are formed with the continuous patterns that are different from each other.

[0018] In the fifth invention, when each decorative board has a plurality of second surface sections, different continuous patterns can be formed on each of the plurality of second surface sections, thereby preventing the design of the short side joints of the decorative boards from becoming monotonous. Therefore, according to the fifth invention, it is possible to construct floors, walls, etc. with superior design. Effect of the Invention

[0019] As described above, according to the present invention, when another decorative panel is joined to the short side, a continuous pattern is formed across the two decorative panels in the area where no chamfer is formed and the surfaces are butted together, making it easy to provide decorative panels with excellent design and a decorative panel series consisting of multiple decorative panels each with a different surface pattern. [Brief description of the drawings]

[0020] [Figure 1] FIG. 1 is a perspective view of a decorative board according to a first embodiment of the present invention. [Diagram 2] FIG. 2 is a plan view of the decorative board of FIG. [Diagram 3] FIG. 3 is a view taken along line III-III in FIG. [Figure 4] FIG. 4 is a view taken along line IV-IV in FIG. [Diagram 5] FIG. 5 is a cross-sectional view taken along line VV in FIG. [Figure 6] FIG. 6 is an explanatory diagram of the surface pattern of the decorative board of FIG. [Figure 7] FIG. 7 is a diagram showing a schematic configuration of the decorative board series. [Figure 8] FIG. 8 is a perspective view showing a state in which a plurality of decorative boards according to the first embodiment of the present invention are joined lengthwise and crosswise and used as a decorative material for a floor. [Figure 9] FIG. 9 is a plan view of the decorative board according to the second embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0021] Hereinafter, the embodiments of the present invention will be described in detail with reference to the drawings. The following embodiments are essentially preferred examples, and are not intended to limit the scope of the present invention, its applications, or its uses.

[0022] First Embodiment of the Invention 1 shows a decorative board A according to a first embodiment of the present invention, which is used, for example, as a flooring material, etc. In order to make the decorative board A look like a combination of multiple joined decorative boards, a decorative groove B is formed on the surface of the decorative board A at the joint portion, the depth of which is equal to the vertical groove 31 and horizontal groove 32 formed by the chamfered surfaces 16, 17.

[0023] -composition- As shown in FIGS. 1 to 6, the decorative board A includes a rectangular plate-like base material 10 and a decorative layer 20 formed on the surface of this base material 10.

[0024] <Base material composition> The substrate 10 is made of a wood board such as plywood having a thickness of about 3 mm to 25 mm, a wood fiber board such as insulation board (IB) or medium density fiberboard (MDF), oriented strand board (OSB), particle board (PB), or a single or composite of these. The substrate 10 may be made of other wood boards or inorganic boards such as "Dailite" manufactured by Daiken Kogyo Co., Ltd., or other boards that are commonly used as building materials. The substrate 10 is made of a rectangular board having a thickness of 15 mm, a width of 303 mm, and a length of 1818 mm.

[0025] At least one vertical groove 14 (one in the present embodiment 1) extending in the long side direction of the substrate 10 and multiple horizontal grooves 15 (three in the present embodiment 1) extending in the short side direction of the substrate 10 are formed on the surface 11 of the substrate 10. A decorative layer 20, which will be described later, is formed on the inner surface of the vertical groove 14 and the horizontal groove 15, constituting the decorative groove B of the decorative board A.

[0026] The vertical groove 14 is formed in the vertical direction from one end to the other end in the long side direction at the center of the short side direction of the substrate 10 so as to divide the surface 11 of the substrate 10 in half. The surface 11 of the substrate 10 is divided into two surface parts 11a and 11b by such vertical groove 14. In this embodiment, the vertical groove 14 has two groove side surfaces inclined at a predetermined inclination angle (for example, 30° to 60°) with respect to the surface 11 of the substrate 10, and has a V-shaped cross section. The depth of the vertical groove 14 is 0.3 mm to 2.0 mm, and the groove width is, for example, 0.3 mm to 4.0 mm. The inclination angle of the groove side surface of the vertical groove 14 is approximately the same as the inclination of the long side chamfered surface 16 described later. The cross section of the vertical groove 14 is not limited to a V-shape.

[0027] The lateral grooves 15 are formed on each of the two surface portions 11a and 11b of the substrate 10. One lateral groove 15 is formed on the first surface portion 11a of the two surface portions 11a and 11b, and two lateral grooves 15 are formed on the second surface portion 11b. In this embodiment, the lateral grooves 15 are formed so that their cross-sectional shape is equal to that of the longitudinal grooves 14. That is, the lateral grooves 15 have two groove side surfaces inclined at a predetermined inclination angle (for example, 30° or more and 60° or less) with respect to the surface 11 of the substrate 10, and their cross-sectional shape is formed in a V-shape. The depth of the lateral grooves 15 is equal to the depth of the longitudinal grooves 14, being 0.3 mm or more and 2.0 mm or less, and the groove width is equal to the groove width of the longitudinal grooves 14, being 0.3 mm or more and 4.0 mm or less, for example. The inclination angle of the groove side surface of the lateral grooves 15 is approximately the same as the inclination of the short side chamfered surface 17 described later. The cross-sectional shape of the lateral groove 15 is not limited to a V-shape.

[0028] The lateral grooves 15 are formed at different positions between the first surface portion 11a and the second surface portion 11b. In this embodiment 1, the lateral groove 15 is formed in the first surface portion 11a at the center position in the long side direction of the substrate 10. On the other hand, the lateral grooves 15 are formed in the second surface portion 11b at the positions of the first and third line segments of three line segments that divide the substrate 10 into four equal parts in the long side direction. By forming the lateral grooves 15 at different positions between the adjacent first surface portion 11a and second surface portion 11b in this way, the design of the decorative board A is improved. In addition, in this embodiment 1, the lateral grooves 15 are formed so that the interval between the lateral grooves 15 aligned in the long side direction of the substrate 10 and the short side chamfered surface 17 described later in the first surface portion 11a is equal to the interval between the two lateral grooves 15 aligned in the long side direction of the substrate 10 in the second surface portion 11b.

[0029] 1 to 4, a long side chamfered surface 16 is formed between the surface 11 of the substrate 10 and each long side surface 12 by cutting out a corner at an angle (or in an arc shape). In this embodiment, the long side chamfered surface 16 is formed as an inclined surface made of a flat surface, and as described above, the inclination angle is formed to be approximately the same as the inclination angle of the groove side surface of the longitudinal groove 14.

[0030] Between the surface 11 of the substrate 10 and each short side surface 13, a short side chamfered surface 17 is formed by cutting out a corner obliquely (or in an arc shape) only between the first surface portion 11a and each short side surface 13. In this embodiment, the short side chamfered surface 17 is formed as an inclined surface made of a flat surface, and as described above, the inclination angle is formed to be approximately the same as the inclination angle of the groove side surface of the lateral groove 15. Note that, as shown in FIG. 4, the short side chamfered surface 17 is not formed between the second surface portion 11b and each short side surface 13, and the second surface portion 11b and each short side surface 13 are continuous at approximately a right angle.

[0031] A female indentation 18 or a male indentation 19 is formed on each of the four peripheral side surfaces 12, 12, 13, 13 of the base material 10. Specifically, a female indentation 18 is formed on one of the long side surfaces 12, 12 facing the short side direction of the base material 10, and a male indentation 19 that can fit into the female indentation 18 is formed on the other. Also, a female indentation 18 is formed on one of the short side surfaces 13, 13 facing the long side direction of the base material 10, and a male indentation 19 that can fit into the female indentation 18 is formed on the other, and the male indentation 19 of the adjacent decorative board A (base material 10) is fitted into the female indentation 18, so that both decorative boards A, A are installed side by side.

[0032] The female indentations 18, 18 of the long side surface 12 and the short side surface 13 are configured in the same manner. The female indentations 18, 18 are formed by cutting out the middle portions of the long side surface 12 and the short side surface 13 of the base material 10 in the thickness direction, that is, the front-back direction, so that the middle portions form recessed grooves 18a.

[0033] The male inseminations 19, 19 of the long side surface 12 and the short side surface 13 are configured in the same manner. The male inseminations 19, 19 are formed by cutting out the front and back sides of the intermediate portions of the long side surface 12 and the short side surface 13 of the base material 10 in the front-back direction, respectively, so that the intermediate portions become protruding portions 19a.

[0034] In this manner, in this embodiment, the base material 10 is subjected to a so-called main joint processing in which a female joint 18 and a male joint 19 are formed so that the end faces of adjacent decorative panels A can be fitted together. However, the structure for fitting the end faces of adjacent decorative panels A is not limited to this. For example, a so-called mating structure may be formed by cutting out the front side portion in the thickness direction of the base material 10 on one of the long side surface 12 and the short side surface 13 of the base material 10 and cutting out the back side portion in the thickness direction of the base material 10 on the other side.

[0035] <Composition of cosmetic layer> 5, the decorative layer 20 is formed on the surface of the substrate 10. The decorative layer 20 includes an undercoat layer 21, an ink-receiving layer 22, an inkjet printed layer 23, and a protective layer 24. The undercoat layer 21, the ink-receiving layer 22, the inkjet printed layer 23, and the protective layer 24 are coated on the surface of the substrate 10 in this order.

[0036] The undercoat layer 21 is formed by applying an undercoat paint to the surface 11 of the substrate 10. The undercoat layer 21 is a filling layer that fills fine holes in the surface 11 of the substrate 10 to smooth the surface 11 and prevents other layers 22 to 24 from penetrating into the substrate 10. The components of the undercoat paint are not particularly limited, but for example, various synthetic resins such as acrylic resin, urethane resin, epoxy resin, vinyl chloride resin, silicone resin, etc., mixtures arbitrarily selected from these, coating film adjusters such as dispersants and thickeners, and mixtures of water, etc. as a main agent mixed with an isocyanate curing agent can be used as the undercoat paint.

[0037] The ink receiving layer 22 is formed by applying a white paint for the receiving layer to the surface 11 of the substrate 10 on which the undercoat layer 21 is formed. The ink receiving layer 22 is provided to quickly fix the ink sprayed from the inkjet printer to the surface to form the inkjet printing layer 23. The components of the white paint for the receiving layer are not particularly limited, but for example, various synthetic resins such as acrylic resin, urethane resin, epoxy resin, vinyl chloride resin, silicone resin, etc., or mixtures arbitrarily selected from these, inorganic particles such as amorphous silica, aluminum oxide, titanium oxide, etc., coating film adjusters such as dispersants and thickeners, and a mixture of an isocyanate curing agent with water as the main agent can be used as the white paint for the receiving layer. The ink receiving layer 22 is formed to a thickness of about 10 μm.

[0038] The inkjet printed layer 23 is formed by spraying ink from an inkjet printer onto the surface 11 of the substrate 10 on which the undercoat layer 21 and the ink receiving layer 22 are formed. The inkjet printed layer 23 forms a pattern D on the white ink receiving layer 22 with ink. The ink is not particularly limited as long as it can be sprayed from an inkjet printer, and various inks such as water-based, solvent-based, and UV (ultraviolet) curing inks can be used. The ink components include, for example, a pigment and a dispersant as a coloring agent, or a dye as a coloring agent, and the pigment or dye can be used according to the color of the ink used. The inkjet printed layer 23 is formed to a thickness of about 5 μm to 10 μm.

[0039] The inkjet printed layer 23 may form any pattern D on the white ink receiving layer 22, but in this embodiment 1, a wood grain pattern D is formed. The wood grain pattern D is formed over the entire surface 11 of the substrate 10. A plurality of patterns (for example, five patterns) of wood grain patterns D are prepared. The pattern configuration of the wood grain pattern D will be described later.

[0040] In addition, in this embodiment 1, when another decorative panel A is joined to the short side, the pattern D (wood grain pattern D) formed on the second surface portion 11b where the two decorative panels A, A are butted together is configured to appear connected.

[0041] Specifically, at least one linear pattern x, y indicating a portion of the wood grain extending to the end edge is formed on a first end X at one end side of the long side of the second surface portion 11b of the decorative panel A and a second end Y at the other end side, and the linear patterns x, y are configured to connect when the second end Y is lined up next to the end edge side of the first end X (upper side in Figure 6).

[0042] Here, the first end X refers to a range of a predetermined distance h (5 mm to 20 mm) from an end side (upper end side in FIG. 6) on one side in the long side direction of the second surface portion 11b. Similarly, the second end Y refers to a range of a predetermined distance h (5 mm to 20 mm) from an end side (lower end side in FIG. 6) on the other side in the long side direction of the second surface portion 11b.

[0043] In the present embodiment 1, the linear patterns x and y are formed in pairs. As shown in FIG. 6, the two linear patterns x extend in the long side direction of the substrate 10 at the first end X to points P1 and P2 on the edge of one end side (upper edge in FIG. 6), and the two linear patterns y extend from points Q1 and Q2 on the edge of the other end side of the second end Y (lower edge in FIG. 6) in the long side direction of the substrate 10. The points Q1 and Q2 are points on the edge of the other end side of the second end Y (lower edge in FIG. 6) corresponding to the points P1 and P2 when the second end Y is arranged on the edge side (upper side in FIG. 6) of the first end X. With this configuration, the linear patterns x and y form a continuous pattern xy that connects the first end X and the second end Y when the second end Y is arranged on the edge side of the first end X.

[0044] Furthermore, by forming the linear patterns x, y configured in this manner in the decorative panel A, when multiple decorative panels A are joined on their short sides, at the butt joint portion (part of the short side joint portion) where the second surface portions 11b of each decorative panel A are butted together, the linear pattern x formed at the first end portion X of one decorative panel A and the linear pattern y formed at the second end portion Y of the other decorative panel A butted against the first end portion X are connected, forming a continuous pattern xy that extends across both decorative panels A.

[0045] The protective layer 24 is formed by applying a transparent protective coating to the surface 11 of the substrate 10 on which the undercoat layer 21, the ink receiving layer 22, and the inkjet printing layer 23 are formed. The protective layer 24 is provided to protect the inkjet printing layer 23. The components of the protective coating are not particularly limited, but for example, a thermosetting resin coating such as DAP (diallyl phthalate) resin, melamine resin, or unsaturated polyester resin can be used as the protective coating. The protective layer 24 is formed to a thickness of about 30 μm.

[0046] -Pattern composition- 7, in the present embodiment 1, five patterns of wood grain patterns D1 to D5 are prepared as the wood grain pattern D formed by the inkjet printed layer 23. The wood grain patterns D1 to D5 are different from each other, but each has two linear patterns x and y. In other words, the wood grain patterns D1 to D5 each have two linear patterns x and y, and the patterns d1 to d5 other than the linear patterns x and y are different from each other.

[0047] The wood grain patterns D1 to D5 may be created by any method, but may also be created using AI (Artificial Intelligence). Using AI, a huge number of patterns can be created instantly, even for complex patterns. The patterns may be created by an operator inputting the pattern, or may be created using data extracted from a photograph or the like of a wood grain or other pattern. The created patterns are digitized and sent to the inkjet printer.

[0048] -Manufacturing method- Next, a description will be given of a method for producing the decorative board A. This method includes (1) a cutting process, (2) an undercoat layer forming process, (3) a receiving layer forming process, (4) a printing process, and (5) a protective layer forming process.

[0049] (1)Cutting process First, cutting is performed on the substrate 10. The cutting includes actual cutting, chamfering, and groove cutting. The actual cutting and chamfering may be performed simultaneously or sequentially.

[0050] [Actual processing process] In the seed processing step, the four peripheral sides of the base material 10 are cut out, and female seeds 18 and male seeds 19 are processed on the long side sides 12, 12 and the short side sides 13, 13, respectively.

[0051] [Chamfering process] In the chamfering process, corners between the surface 11 of the base material 10 and each long side surface 12 are cut out obliquely (or in an arc shape) to form long side chamfered surfaces 16. The long side chamfered surfaces 16 are formed by cutting out the corners between the surface 11 of the base material 10 and each long side surface 12 from one end to the other end in the long side direction of the base material 10.

[0052] In the chamfering process, the corners between the surface 11 of the base material 10 and each short side surface 13 are cut out obliquely (or in an arc shape) to form short side chamfered surfaces 17. The short side chamfered surfaces 17 formed between the surface 11 of the base material 10 and each short side surface 13 are formed only between the first surface portion 11a and each short side surface 13, and are not formed between the second surface portion 11b and each short side surface 13. Note that short side chamfered surfaces 17 that form lateral grooves 32 described later are not formed between the second surface portion 11b and each short side surface 13, but fine chamfered surfaces (so-called thread chamfers) associated with processing such as deburring may be formed.

[0053] [Groove machining process] In the groove processing step, a vertical groove 14 with a V-shaped cross section is formed in the center of the short side direction of the surface 11 of the substrate 10, extending in the long side direction from one end (one short side surface 13) to the other end (the other short side surface 13). The vertical groove 14 is formed by cutting the center of the short side direction of the surface 11 of the substrate 10 from one end to the other end in the long side direction of the substrate 10 into a V-shaped cross section.

[0054] In the groove processing step, a lateral groove 15 having a V-shaped cross section is formed in each of the two surface portions 11a and 11b of the surface 11 of the substrate 10, the lateral groove 15 extending in the short side direction from one end (long side surface 12) to the other end (longitudinal groove 14). The single lateral groove 15 formed in the first surface portion 11a is formed by cutting the central portion in the long side direction of the substrate 10 into a V-shaped cross section from the long side surface 12 of the substrate 10 to the longitudinal groove 14. The two lateral grooves 15 formed in the second surface portion 11b are formed by cutting the positions of the first and third line segments of three line segments that divide the substrate 10 into four equal parts in the long side direction into a V-shaped cross section from the long side surface 12 of the substrate 10 to the longitudinal groove 14.

[0055] (2) Undercoat layer formation process In the undercoat layer forming step, an undercoat paint is applied to the surface 11 of the substrate 10 on which the grooves 14, 15 have been formed in the cutting step and to the inner surfaces of the grooves 14, 15 to form the undercoat layer 21. Specifically, the undercoat paint is applied to the surface 11 of the substrate 10 using a coating device such as a die coater, a knife coater, or a comma coater, and then dried to harden the coating film and form the undercoat layer 21.

[0056] (3) Receptive layer formation process In the receiving layer forming step, a white paint for the white receiving layer is applied onto the undercoat layer 21 formed in the undercoat layer forming step to form the ink receiving layer 22. Specifically, the white paint for the white receiving layer is applied to the entire surface 11 of the substrate 10 on which the undercoat layer 21 has been formed and the entire inner surfaces of the grooves 14 and 15 using a coating device such as a die coater, knife coater, or comma coater, and then dried to harden the coating film and form the ink receiving layer 22.

[0057] (4)Printing process In the printing step, ink is sprayed by an inkjet printer onto the white ink-receiving layer 22 formed in the receiving layer forming step, to form an inkjet printed layer 23. Specifically, as described above, the inkjet printer sprays ink onto the surface 11 of the substrate 10 on which the white ink-receiving layer 22 has been formed, based on data of the patterns of the wood grain patterns D1 to D5 created in advance by AI or the like, to print one of the wood grain patterns D1 to D5 onto the white ink-receiving layer 22. After printing, the sprayed ink is dried and cured or UV-cured to form the inkjet printed layer 23.

[0058] (5) Protective layer formation process In the protective layer forming step, a transparent protective coating is applied onto the inkjet printed layer 23 formed in the printing step to form the protective layer 24. Specifically, a transparent protective coating is applied to the entire surface 11 of the substrate 10 on which the inkjet printed layer 23 is formed and the entire inner surfaces of the grooves 14 and 15 using a coating device such as a die coater, knife coater, or comma coater, and then dried to harden the coating film and form the protective layer 24.

[0059] By going through the above steps, the decorative board A is obtained.

[0060] -Installation of decorative panels- Next, a description will be given of an installation mode of the decorative board A. In the present embodiment 1, as an example, a case will be described in which a plurality of decorative boards A are installed on a floor base material to serve as a decorative material for the floor.

[0061] As shown in Fig. 8, when the decorative board A is used as a floor decorative material, multiple decorative boards A are installed on the floor base material. The multiple decorative boards A are lined up in the same direction in the long side direction and the short side direction, and are joined together.

[0062] Specifically, two decorative boards A (substrates 10) whose long sides are joined together are joined by fitting the male rib 19 on the long side surface 12 of one decorative board A into the female rib 18 on the long side surface 12 of the other decorative board A. Also, two decorative boards A (substrates 10) whose short sides are joined together are joined by fitting the male rib 19 on the short side surface 13 of the other decorative board A into the female rib 18 on the short side surface 13 of one decorative board A.

[0063] 8, at the joint portion of two decorative boards A where the long sides are joined together (hereinafter referred to as the long side joint portion of the decorative boards A), a V-shaped vertical groove 31 having a cross-sectional shape and length approximately equal to that of the vertical groove 14 is formed by the long side chamfered surfaces 16. In this way, by forming the vertical groove 31 that looks the same as the vertical groove 14 formed in each decorative board A at the joint portion of the long sides of the decorative boards A, the joint portion becomes less noticeable.

[0064] In addition, in the joint portion of the two decorative boards A where the short sides are joined together (hereinafter referred to as the short side joint portion of the decorative board A), a V-shaped lateral groove 32 having a cross-sectional shape and length substantially equal to that of the lateral groove 15 is formed by the short side chamfered surfaces 17 in the portion corresponding to the first surface portion 11a. On the other hand, in the short side joint portion of the decorative board A, the short side chamfered surface 17 is not formed in the portion corresponding to the second surface portion 11b, and the second surface portions 11b, 11b are butted together. Therefore, in the short side joint portion of the decorative board A, the butt portion 33 where the second surface portions 11b are butted together is connected flatly without any gaps so that the second surface portions 11b of the two decorative boards A are continuous.

[0065] In this way, at the joint portion of the short sides of the decorative board A, V-shaped lateral grooves 32 having approximately the same cross-sectional shape and length as the lateral grooves 15 are formed only on the first surface portion 11a side so as not to be aligned in the same positions between the first and second surface portions 11a, 11b, similar to the lateral grooves 15 formed at different positions between the first and second surface portions 11a, 11b. As a result, at the joint portion of the short sides of the decorative board A, lateral grooves 32 are formed which appear to be the same shape and arranged in the same manner as the lateral grooves 15 formed on each of the decorative boards A, making the joint portion less noticeable.

[0066] Furthermore, in each decorative panel A, linear patterns x, y are formed at a first end X at one end in the longitudinal direction of the second surface portion 11b and at a second end Y at the other end, which form a continuous pattern xy connecting the first end X and the second end Y when the second end Y is arranged on the edge side of the first end X. Therefore, when multiple decorative panels A are joined on their short sides, at the butt joint portion 33 (part of the short side joint portion) where the second surface portions 11b of the decorative panels A are butted against each other, the linear pattern x formed at the first end X of one decorative panel A and the linear pattern y formed at the second end Y of the other decorative panel A butted against the first end X are connected to each other, forming a continuous pattern xy connecting both decorative panels A. In this manner, at the butt joint portion 33 where the second surface portions 11b of the short side joint portions of each decorative panel A are butted together, the second surface portions 11b of the two decorative panels A are connected flatly and without any gaps as if they were continuous, and the decorative layer 20 (specifically, the inkjet printed layer 23) forms a continuous pattern xy across both decorative panels A, making the joint portion less noticeable.

[0067] -Effects of embodiment 1- In the decorative board A of the above-mentioned embodiment 1, at least one vertical groove 14 is formed on the surface 11 of the base material 10, and a long side chamfered surface 16 is formed between the long side surface 12 and the surface 11 of the base material 10, extending from one end to the other end. Therefore, when a plurality of decorative boards A are arranged vertically and horizontally and joined, a groove parallel to the vertical groove 14 is formed by the long side chamfered surface 16 at the long side joint portion of the decorative board A, so that gaps and steps are not noticeable, and the design is improved. On the other hand, between the short side surface 13 and the surface 11 of the base material 10, a short side chamfered surface 17 is formed only between a part of the first surface portion 11a and the short side surface 13 of the plurality of surface portions 11a, 11b, and the second surface portion 11b without the short side chamfered surface 17 is always adjacent to the first surface portion 11a. Therefore, when multiple decorative boards A are lined up lengthwise and widthwise and joined, grooves 32 parallel to the horizontal grooves 15 are formed by the short side chamfered surfaces 17 at the short side joining portions of the decorative boards A corresponding to the first surface portions 11a, and no grooves are formed at the portions corresponding to the second surface portions 11b adjacent to the first surface portions 11a, and the second surface portions 11b are butted together. In other words, at the short side joining portions of the decorative boards A, grooves 32 parallel to the horizontal grooves 15 are formed by the short side chamfered surfaces 17 without crossing the vertical grooves 14, making gaps and steps less noticeable and improving the design.

[0068] Furthermore, in the decorative board A of the above-mentioned embodiment 1, when a first end X at one end in the long side direction of the second surface portion 11b is arranged on the short side side of a second end Y at the other end, a continuous pattern xy is formed that connects the first end X and the second end Y. By forming such a continuous pattern xy, when another decorative board A is joined to one end in the long side direction, the second surface portions 11b are butted against each other at the short side joint portion, and the pattern x at the first end X of the second surface portion 11b of one decorative board A and the pattern y at the second end Y of the second surface portion 11b of the other decorative board A are connected to form the continuous pattern xy. That is, according to the decorative board A of the present embodiment 1, when another decorative board A is joined to the short side, a groove 32 parallel to the horizontal groove 15 is formed in the part of the short side joint corresponding to the first surface portion 11a, and no groove is formed in the part corresponding to the second surface portion 11b adjacent to the first surface portion 11a, and the second surface portions 11b are butted together, and a continuous pattern xy is formed across the butted second surface portions 11b. Therefore, according to the present embodiment 1, it is possible to provide a decorative board A with excellent design in which the joints are not noticeable when multiple decorative boards are joined vertically and horizontally.

[0069] In the decorative board A of the first embodiment, the continuous pattern xy is composed of a linear pattern extending in the long side direction of the base material 10. Therefore, when another decorative board A is joined to the short side of the decorative board A, the linear patterns x, y continue across the two decorative boards A at the butt joint where there is no chamfered surface and the second surface portion 11b is continuous. Therefore, according to the first embodiment, a decorative board A with excellent design can be provided in which the joint is not noticeable due to the linear pattern xy that spans the two decorative boards A at the short side joint.

[0070] Furthermore, in the decorative board A of the above embodiment 1, the linear pattern (continuous pattern) xy constitutes a part of the wood grain pattern D. Therefore, when another decorative board A is joined to the short side of the above decorative board A, the continuous patterns x, y cause the wood grain pattern D to continue across the two decorative boards A at the butt joint where there is no chamfered surface and the second surface portion 11b is continuous. Therefore, according to this embodiment 1, the wood grain pattern D is formed across the two decorative boards A at the short side joint portion, thereby making it possible to provide a decorative board A with excellent design in which the joint portion is not noticeable.

[0071] In addition, in the above-mentioned embodiment 1, a series of decorative boards A is configured. The multiple decorative boards A in the series of decorative boards have different patterns D on the entire surface 11 of the base material 10, while the same continuous pattern xy is formed on the second surface portion 11b at the same position. In this way, the patterns D on the entire surface 11 are different between the multiple decorative boards A, while the same continuous pattern xy is formed on the second surface portion 11b at the same position. By configuring the multiple decorative boards A in this way, it is possible to easily provide a series of decorative boards A consisting of multiple decorative boards A each having a different surface pattern D (wood grain patterns D1 to D5), but with inconspicuous seams when joined vertically and horizontally. In addition, by forming floors, walls, etc. using this series of decorative boards, it is possible to construct floors, walls, etc. with excellent design in which the same pattern is not repeated many times and the seams are inconspicuous.

[0072] Second Embodiment of the Invention In the second embodiment, the surface configuration of the base material 10 of the decorative board A of the first embodiment is changed so that a plurality of second surface portions 11b are formed.

[0073] Specifically, in embodiment 2, as shown in Figure 9, two vertical grooves 14 are formed on the surface 11 of the base material 10 of the decorative panel A, and the surface 11 of the base material 10 is divided into three surface portions 11a, 11b, 11b by the two vertical grooves 14, one of which is formed as the first surface portion 11a and the remaining two are formed as the second surface portion 11b.

[0074] Even when a plurality of second surface portions 11b are partitioned on the surface 11 of the base material 10 in this manner, the continuous pattern xy is formed on each of the second surface portions 11b. In addition, the continuous patterns xy formed on each of the plurality of second surface portions 11b in each decorative plate A may be the same pattern, but it is preferable to form them so that they are different from each other. In the second embodiment, as shown in FIG. 9, the second surface portion 11b provided in the center of the left and right of the three surface portions has three continuous patterns x1y1 formed by three linear patterns x1 and three linear patterns y1, and the second surface portion 11b provided on the right side of the three surface portions has two continuous patterns x2y2 formed by two linear patterns x2 and two linear patterns y2. That is, in the second embodiment, the continuous patterns xy of the two second surface portions 11b are different from each other.

[0075] In the second embodiment, in a decorative board series consisting of a plurality of decorative boards A each having a different surface pattern D formed thereon, the same continuous pattern xy is formed on the second surface portion 11b at the same position of each of the decorative boards A.

[0076] According to the decorative board A and the decorative board series of the second embodiment, the same effects as those of the decorative board A and the decorative board series of the first embodiment can be achieved.

[0077] In the decorative board series of the second embodiment, a different continuous pattern xy is formed on each of the second surface portions 11b divided into a plurality of portions on the surface 11 of the base material 10 of each decorative board A, so that the design of the short side joint portion of the decorative board A does not become monotonous. Therefore, according to the second embodiment, it is possible to construct floors, walls, etc. with superior design.

[0078] Other Embodiments In the above embodiments 1 and 2, the lateral groove 15 was also formed on the first surface portion 11a, on which the short side chamfered surface 17 of the multiple surface portions 11a, 11b of the base material 10 was formed, but the decorative board A may not have the lateral groove 15 formed on the first surface portion 11a.

[0079] In the above-mentioned first and second embodiments, the pattern D formed on the entire surface 11 of the base material 10 is a wood grain pattern, and the continuous pattern xy consisting of linear patterns constitutes a part of the wood grain pattern D, but the continuous pattern xy is not limited to a linear pattern constituting a part of the wood grain pattern D. The pattern D may be a stone pattern, a geometric pattern, a striped pattern, a lattice pattern, etc., and the continuous pattern xy may be a part of it.

[0080] In addition, in the above-mentioned embodiments 1 to 3, the decorative board A is used as a flooring material, but the application of the decorative board A is not limited to flooring materials. Of course, the decorative board A can also be used as a wall material, for example. [Industrial Applicability]

[0081] The present invention is useful for decorative laminates and decorative laminate series consisting of a plurality of decorative laminates each having a different surface pattern. [Explanation of symbols]

[0082] 10 Base material 11 Surface 11a 1st surface section 11b Second surface section 12 Long side 13 Short side 14 Vertical groove 15 Yokomizo 16 Long side chamfer 17 Short side chamfer 20 Makeup layer 31 Vertical groove 32 Yokomizo D. Wood grain pattern xy continuous pattern

Claims

1. The present invention comprises a rectangular plate-shaped substrate and a decorative layer having a pattern formed on a surface of the substrate, The surface of the substrate is partitioned into a plurality of surface portions by at least one longitudinal groove extending in the long side direction on the surface of the substrate, Between the long side surface of the substrate and the surface of the substrate, a long side chamfered surface is formed, which is an inclined surface inclined with respect to the long side surface and the surface of the substrate from one end to the other end in the long side direction of the substrate, Between the short side surface of the base material and at least one of the surface portions, a short side chamfered surface is formed, the short side chamfered surface being an inclined surface inclined with respect to the short side surface of the base material and the surface portion; At least one lateral groove extending in a short side direction of the base material is formed in a second surface portion other than the first surface portion on which the short side chamfer is formed among the plurality of surface portions, The plurality of surface portions are One end side in a short side direction of the base material becomes the second surface portion, A decorative board configured so that the first surface portion is always adjacent to the second surface portion, A continuous pattern is formed by the decorative layer at a first end portion at one end side in the long side direction of the second surface portion and a second end portion at the other end side, the continuous pattern being connected across the first end portion and the second end portion when the second end portion is arranged on the edge side of the first end portion. A decorative panel characterized by:

2. The decorative board according to claim 1, The continuous pattern is a linear pattern extending in the long side direction of the substrate. A decorative panel characterized by:

3. The decorative board according to claim 2, The linear pattern is a part of the wood grain pattern. A decorative panel characterized by:

4. A decorative board series comprising a plurality of decorative boards according to any one of claims 1 to 3, The plurality of decorative panels are The patterns across the surface of the substrate are different from each other, The same continuous pattern is formed on the second surface portion at the same position. A decorative panel series characterized by its

5. In the decorative laminate series according to claim 4, The second surface portion is divided into a plurality of sections on the surface of the base material of each of the decorative boards, The plurality of second surface portions of each of the decorative panels are formed with the continuous patterns different from one another. A decorative panel series characterized by its

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