Grooved decorative panel and method of manufacturing same

Abstract

To provide a grooved decorative plate having a uniform thickness of a coated film even in a groove, and a method for manufacturing the same.SOLUTION: A grooved decorative plate is manufactured by bonding a decorative material 2 onto a surface of a wooden base material 1, cutting a part of the decorative material from above it and forming a groove 3, forming a plurality of micropores 6 extending from a groove bottom surface 3b toward a back surface of the wooden base material until a depth not reaching the back surface, and then applying a coating material 4 onto the surface including the groove and forming a coated film 5. Even when the coating material applied onto groove side faces 3a and 3b has fallen down to the groove bottom surface, an excess coating material enters into the micropores, and accordingly a coated film having a substantially uniform thickness as a whole is formed. The coating material having entered into the micropores is cured, is converted into an in-hole curable part 7 and is integrated with the coating film, and accordingly the coated film is hardly peeled by an anchor effect.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a grooved decorative board having a coating film formed on a surface having grooves, and a method for producing the same. [Background technology]

[0002] For the purpose of improving the appearance and surface properties, grooved decorative boards are known in which the surface of a wood base material is formed with vertical grooves parallel to the length of the wood base material, horizontal grooves parallel to the width of the wood base material (for example, "horizontal groove 16" in Patent Document 1), lattice-shaped grooves, block-shaped grooves that appear alternately in the length and / or width of the wood base material, etc., and the surface including the grooves is painted, and these boards are widely used as flooring materials for buildings, etc.

[0003] For example, as shown in Fig. 5, such a grooved decorative board is manufactured by attaching a decorative material 2 such as veneer, single board, decorative paper, or a resin-based sheet such as olefin to a surface 1a (Fig. 5(a)) of a wooden base material 1 such as MDF or plywood (Fig. 5(b)), then cutting the decorative material 2 at a predetermined location from the surface 2a to form a groove 3 (in this example, a groove with an inverted trapezoidal cross section) that penetrates into the wooden base material 1 (Fig. 5(c)), applying a paint 4 such as a UV-curable urethane paint or a water-soluble paint to the entire surface including the groove 3 using a coating device such as a flow coater (Fig. 5(d)), scraping off excess paint 4 with a sponge roll or the like, and drying and curing the paint to form a continuous coating film 5 from the surface 2a of the decorative material 2 to the side surfaces 3a, 3a and bottom surface 3b of the groove 3 (Fig. 5(e)). Such a manufacturing method is described in the following Patent Document 2 (paragraphs 0018 and 0021), etc. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2016-186180 A [Patent Document 2] JP 2003-286768 A Summary of the Invention [Problem to be solved by the invention]

[0005] However, the above method had a problem in that the thickness of the coating film 5 in the groove 3 was not uniform, being thin on the groove side surfaces 3a, 3a and thick on the groove bottom surface 3b. This phenomenon is more likely to be evident when the groove side surfaces 3a, 3a have a steep inclination or when the viscosity of the coating material 4 is relatively low.

[0006] This state is shown in Fig. 5(e), where some of the paint 4 applied to the groove side surfaces 3a, 3a runs down the groove side surfaces 3a, 3a and accumulates on the groove bottom surface 3b, so that the coating film 5 on the groove bottom surface 3b is formed thicker than other locations. If the thickness of the coating film 5 differs at various locations in the groove 3, a difference in color shade (color unevenness) occurs in the width direction and length direction in the groove 3, degrading the appearance. In particular, the amount of paint 4 attached near the upper end of the groove 3, including the cut surface of the decorative material 2 divided by the groove 3, becomes insufficient, exposing the cut surface of the decorative material 2 or making the coating film 5 more likely to peel off, resulting in lifting or tearing.

[0007] Therefore, an object of the present invention is to provide a grooved decorative board in which a coating film having a uniform thickness is formed even in the grooves, and a method for manufacturing the same. [Means for solving the problem]

[0008] In order to solve this problem, the invention according to claim 1 of the present application is a grooved decorative board in which grooves are formed on the surface of a wood base material and a coating film is formed on the surface including the grooves, and at least the bottom of the grooves from the bottom of the wood substrate to a depth not reaching the bottom of the wood substrate. A plurality of micropores are formed, and the paint that has entered the micropores hardens to form hardened portions within the micropores, which are continuous with the coating film that covers the inner surface of the groove.

[0009] The invention according to claim 2 of the present application is characterized in that in the grooved decorative board according to claim 1, the micropores are formed to extend in a direction approximately perpendicular to the surface of the wood base material.

[0010] The invention of claim 3 of the present application is characterized in that, in the grooved decorative board described in claim 1 or 2, a groove is formed on the surface of the wood base material, having a pair of side surfaces inclined relative to the surface and a bottom surface approximately parallel to the surface, and having an approximately inverted trapezoidal cross-sectional shape, and the microholes are formed in at least the bottom surface of this groove.

[0011] The invention according to claim 4 of the present application is characterized in that in the grooved decorative board according to claim 3, the micropores are formed over the entire area of ​​the inner surface of the groove including the side surface of the groove.

[0012] The invention according to claim 5 of the present application is a grooved decorative board according to any one of claims 1 to 4, wherein a decorative material is provided on a surface of a wood base material, The groove extends from the surface of the decorative material toward the inside of the wood base material. It is characterized in that it is formed.

[0013] The invention according to claim 6 of the present application is a method for forming a groove on the surface of a wood substrate, and forming a groove at least at the bottom of the groove. from the bottom of the wood substrate to a depth not reaching the bottom of the wood substrate. This method for producing a grooved decorative panel is characterized in that after forming a plurality of microscopic holes, a paint is applied to the surface including the grooves to form a coating film.

[0014] The invention of claim 7 of the present application is characterized in that, in the manufacturing method for a grooved decorative board described in claim 6, a decorative material is attached to the surface of a wood base material, a part of the decorative material is removed from above it to form the groove, and paint is applied to the removed end of the decorative material that is exposed in the groove to form a coating. Effect of the Invention

[0015] According to the invention, at least the bottom of the groove from the bottom of the wood substrate to a depth not reaching the bottom of the wood substrate. Since multiple micropores are formed, it is possible to prevent some of the paint applied to the bottom of the groove from entering the micropores and forming paint pools. This makes the thickness of the coating film uniform, preventing or reducing color unevenness in the groove. In addition, the hardened parts in the holes formed by the paint that has entered the micropores and hardened are formed continuously in the coating film that covers the inner surface of the groove, so the peel strength of the coating film is increased by the anchor effect, and peeling of the coating film can be prevented.

[0016] In addition, a decorative material is provided on the surface of the wood base material, and the decorative material From the surface towards the inside of the wood substrate Even in grooved decorative panels in which grooves are formed, a substantially uniform coating film is continuously formed on the cut surfaces of the decorative material exposed near the open ends of the grooves, thereby preventing a loss of appearance due to exposure of the cut surfaces and peeling of the coating film. [Brief description of the drawings]

[0017] [Figure 1] FIG. 1 is a process diagram showing a method for producing a grooved decorative board according to one embodiment of the present invention (Example 1). [Diagram 2] 5 is a process diagram showing a method for producing a grooved decorative board according to another embodiment (Example 2) of the present invention. FIG. [Diagram 3] 5 is a process diagram showing a method for producing a grooved decorative board according to another embodiment (Example 3) of the present invention. [Figure 4] 5 is a process diagram showing a method for producing a grooved decorative board according to another embodiment (Example 4) of the present invention. [Diagram 5] 1A to 1C are process diagrams showing a method for manufacturing a grooved decorative board according to the prior art. BEST MODE FOR CARRYING OUT THEINVENTION

[0018] The present invention will be described in detail below with reference to examples. Example 1

[0019] A method for manufacturing a grooved decorative panel according to one embodiment of the present invention will be described with reference to the process diagram of Figure 1. To clearly compare with the prior art (Figure 5), the same or corresponding parts and elements are given the same reference numerals as in Figure 5.

[0020] A decorative material 2 such as veneer, single board, decorative paper, or a resin-based sheet such as olefin is attached (FIG. 1(b)) to the surface 1a (FIG. 1(a)) of a wooden base material 1 such as MDF or plywood, and then the decorative material 2 is cut away at a predetermined location from the surface 2a to form a groove 3 (a groove with an inverted trapezoidal cross section in this example) toward the inside of the wooden base material 1 (FIG. 1(c)). The process from FIG. 1(a) to FIG. 1(c) is substantially the same as the process from FIG. 5(a) to FIG. 5(c) according to the conventional technology.

[0021] Next, a plurality of microholes 6 are formed from the groove side surfaces 3a, 3a and the groove bottom surface 3b toward the inside of the wood substrate 1 (FIG. 1(d)). The diameter, depth, number, etc. of the microholes 6 are appropriately determined so as to obtain the effects described below, but generally, the diameter is 30 to 80 μm, preferably 40 to 70 μm, the depth is 0.1 to 1.5 mm, preferably 0.2 to 0.8 mm, and the number is 50 to 1000 / cm. 2 The cross-sectional shape of the micropores 6 is not particularly limited, but a circular shape is preferable. The means for forming the micropores 6 is not particularly limited, but for example, a laser light irradiation device that irradiates laser light such as a UV laser, a carbon dioxide laser, or a YAG laser can be used. In this embodiment, laser light is vertically irradiated from the UV laser light irradiation device to form 500 micropores 6 per cm, each having a depth of 0.7 mm and a diameter of 50 μm. 2 In this embodiment, a plurality of microholes 6 were formed at equal intervals in the groove width direction on the groove side surfaces 3a, 3a and the groove bottom surface 3b, and a large number of microholes 6 were further formed at equal intervals in the groove length direction at the same groove width direction positions to achieve the above density.

[0022] After forming a large number of micropores 6 on the inner surface of the groove 3 in this manner, a coating device such as a flow coater is used to coat the entire surface, including the groove 3, with a coating material 4 such as a UV-curable urethane coating or a water-soluble coating material (Fig. 1(e)). This coating material coating process itself is substantially the same as the coating material coating process of the prior art (Fig. 5(d)). However, because the micropores 6 are formed from the inner surface of the groove 3 toward the wood substrate 1, the coating or adhesion state of the coating material 4 on the groove side surfaces 3a, 3a and the groove bottom surface 3b is different.

[0023] Explaining in more detail, Figure 1(e) shows the state immediately after the paint 4 has been applied, and the paint 4 applied to the groove side surfaces 3a, 3a and groove bottom surface 3b has not yet penetrated into the micropores 6, but some of the paint 4 applied to the decorative sheet surface 2a around the groove 3 flows into the groove 3, so that at this point, the paint 4 is relatively thin on the decorative sheet surface 2a and relatively thick on the inner surface of the groove 3 (groove side surfaces 3a, 3a and groove bottom surface 3b).

[0024] As time passes, some of the paint 4 adhering to the groove side surfaces 3a, 3a and the groove bottom surface 3b gradually enters the micropores 6, so the amount (thickness) of paint 4 adhering thereto gradually decreases. Some of the paint 4 applied to the groove side surfaces 3a, 3a flows down along the groove side surfaces 3a, 3a to the groove bottom surface 3b, but since a large number of micropores 6 are formed on the groove bottom surface 3b, the paint 4 that flows down along the groove side surfaces 3a, 3a to the groove bottom surface 3b also enters the micropores 6 from the groove bottom surface 3b, so the amount of paint 4 remaining on the groove bottom surface 3b does not increase excessively. Due to these synergistic effects, the amounts of paint 4 adhering to the groove side surfaces 3a, 3a and the groove bottom surface 3b are leveled out to approximately the same thickness (FIG. 1(f)).

[0025] Furthermore, after that, the excess paint 4 on the decorative sheet surface 2a and the inner surface of the groove 3 is scraped off with a sponge roll or the like, and at this time, the paint 4 is pressed against the groove side surfaces 3a, 3a and the groove bottom surface 3b inside the groove 3, so that the excess paint enters the micropores 6. As a result, when the paint 4 is dried and hardened, a thin coating film 5 having a substantially uniform thickness is formed continuously from the surface 2a of the decorative material 2 to the inner surface of the groove 3 (the groove side surfaces 3a, 3a and the groove bottom surface 3b) (FIG. 1(g)). In the grooved decorative board manufactured in this manner, the coating film 5 having a substantially uniform thickness is formed, so that color unevenness in the groove 3 is prevented or reduced, and the appearance is good. In addition, the hardened portion 7 in the hole formed by hardening the paint 4 that entered the micropores 6 is formed continuously with the coating film 5 covering the inner surface of the groove 3 (the groove side surfaces 3a, 3a and the groove bottom surface 3b), so that the coating film 5 is difficult to peel off due to the anchor effect. Example 2

[0026] In this example, except that the depth of the microholes 6 was set to 0.2 mm, a grooved decorative panel was manufactured in the same manner as in Example 1, through steps (a) to (g) shown in Fig. 2. Each step is substantially the same as in Example 1, and therefore a description thereof will be omitted. In this example, the microholes 6 are shallow, and therefore the amount of paint 4 entering is small, but when the inclination of the groove side surfaces 3a, 3a is relatively gentle or when the viscosity of the paint 4 is relatively high, the amount of paint 4 entering the microholes 6 from the groove side surfaces 3a, 3a and the amount of paint 4 flowing down the groove side surfaces 3a, 3a are also small, so that the same effect can be obtained even when shallow microholes 6 are formed in this way. Example 3

[0027] In this embodiment, in the step of FIG. 3(d), the diameter and depth of the microholes 6 were 50 μm and 0.7 mm, the same as in the first embodiment, but one microhole 6 was formed at approximately the center in the groove width direction on each of the groove side surfaces 3a, 3a and the groove bottom surface 3b, and many microholes 6 were formed at equal intervals in the groove length direction at the same width direction position, at a density of 100 pcs / cm. 2 A grooved decorative panel was manufactured by forming the grooved decorative panel so that the density of the grooved decorative panel was 100 μm and the grooved decorative panel was manufactured by steps (a) to (g) shown in Fig. 3. Each step other than Fig. 3(d) is substantially the same as that of Example 1, and therefore the explanation is omitted. In this example, the number of microholes 6 is small, and therefore the amount of paint 4 entering the groove is also small, but if the inclination of the groove side surfaces 3a, 3a is relatively gentle or if the viscosity of the paint 4 is relatively high, the amount of paint 4 entering the microholes 6 from the groove side surfaces 3a, 3a and the amount of paint 4 flowing down the groove side surfaces 3a, 3a are also small, so that the same effect can be obtained even when a small number of microholes 6 are formed. Example 4

[0028] In this embodiment, in the step of FIG. 4(d), no micro holes 6 are formed on the groove side surfaces 3a, 3a, but three micro holes 6 are formed at equal intervals in the groove width direction on the groove bottom surface 3b including the corners with the groove side surfaces 3a, 3a, and a large number of micro holes 6 are formed at equal intervals in the groove length direction at the same groove width direction positions at a density of 100 holes / cm. 2The grooved decorative panel was manufactured by forming the grooved decorative panel so that the density of the grooved decorative panel was 100%. The steps other than that of FIG. 4(d) are substantially the same as those of Example 1, and therefore the description will be omitted. In this example, the microholes 6 are formed only on the groove bottom surface 3b, and therefore the paint 4 cannot enter the microholes 6 from the groove side surfaces 3a, 3a. However, the paint 4 applied to the groove side surfaces 3a, 3a can flow down the groove side surfaces 3a, 3a and allow the excess of the paint 4 accumulated on the groove bottom surface 3b to enter the microholes 6 from the groove bottom surface 3b. This has the effect of preventing the coating film 7 formed on the groove bottom surface 3b from becoming excessively thick.

[0029] Although several embodiments of the present invention have been described in detail above with reference to the drawings, the present invention is not limited to these, and can be implemented with a wide variety of modifications and alterations within the scope of the invention defined by the claims.

[0030] For example, in the embodiment described above, a groove 3 having an inverted trapezoidal cross section is shown, but the groove shape is not limited to this and may be a V-groove having a triangular cross section, or a round groove whose inner surface is formed in an arc shape.

[0031] In the above-mentioned embodiment, (f) of Fig. 1 to Fig. 3 shows a state in which the paint 4 has penetrated deep into all the micropores 6, and (g) of Fig. 1 to Fig. 3 shows a state in which the in-pore hardened portion 7 has been formed over the entire depth of all the micropores 6 when they have dried and hardened, but this is not always the case. Depending on the inclination angle of the groove side surfaces 3a, 3a and the viscosity of the paint 4, for example, the in-pore hardened portion 7 may be formed only in a shallow region of the micropores 6 formed on the groove side surfaces 3a, 3a, and the in-pore hardened portion 7 may be formed over the entire depth of the micropores 6 formed on the groove bottom surface 3b.

[0032] In the above-described embodiment, all the microholes 6 are formed to the same depth, but the depth of the microholes 6 may be different between the groove side surfaces 3a and the groove bottom surface 3b. For example, the microholes 6 on the groove side surfaces 3a may be formed to be small and the microholes 6 on the groove bottom surface 3b may be formed to be deep, or the microholes 6 may be formed to be gradually deeper from the upper ends of the groove side surfaces 3a toward the groove bottom surface 3b. [Explanation of symbols]

[0033] 1 Wood base material 2. Cosmetic materials 3 grooves 4 Paint 5. Coating 6 Micropore 7 Hardened part inside the hole

Claims

1. This grooved decorative board has grooves formed on the surface of a wood substrate and a coating film formed on the surface including the grooves, and is characterized in that a plurality of microholes are formed extending from at least the bottom of the groove toward the back surface of the wood substrate to a depth not reaching said back surface, and the hardened portions within the holes formed by the hardening of the paint that has entered the microholes are continuous with the coating film that covers the inner surface of the groove.

2. 2. The grooved decorative board according to claim 1, wherein the micropores are formed so as to extend in a direction substantially perpendicular to the surface of the wood substrate.

3. A grooved decorative board as described in either claim 1 or 2, characterized in that a groove having a cross-sectional shape of an approximately inverted trapezoid is formed on the surface of the wood base material, the groove having a pair of side surfaces inclined relative to the surface and a bottom surface approximately parallel to the surface, and the microholes are formed on at least the bottom surface of the groove.

4. 4. The grooved decorative board according to claim 3, wherein the micropores are formed over the entire area of ​​the inner surface of the groove including the side surfaces of the groove.

5. 5. The grooved decorative board according to claim 1, wherein a decorative material is provided on a surface of the wooden base material, and the grooves are formed from the surface of the decorative material toward the inside of the wooden base material.

6. This method for producing a grooved decorative board is characterized in that a groove is formed on the surface of a wooden substrate, a plurality of minute holes are formed extending from at least the bottom of the groove toward the back surface of the wooden substrate to a depth not reaching said back surface, and then a paint is applied to the surface including the groove to form a coating film.

7. 7. The method for manufacturing a grooved decorative board according to claim 6, characterized in that a decorative material is attached to the surface of a wood base material, a part of the decorative material is cut away from the surface to form the groove, and paint is applied to the cut-away end of the decorative material exposed in the groove to form a coating film.

Images