Manufacturing methods for building materials

Abstract

To provide a method for manufacturing a building material capable of suppressing silvering caused by entrapment of air even when a laminate film is stuck on the surface of a wooden board.SOLUTION: A base sheet 22A for printing made of a first thermoplastic resin is attached to the surface of a wooden board 21 via an adhesive to form a base layer 22 on the surface of the wooden board 21. A predetermined printed pattern 24A is imparted to the base layer 22 by attaching an ultraviolet curable resin ink. A laminate film 26 made of a second thermoplastic resin is applied to the base layer 22 having the printed pattern 24A through an adhesive layer 25 formed of an adhesive so as to cover the surface having the printed pattern 24A at a temperature below the softening point of the second thermoplastic resin while heat-pressing the base layer 22 with the printed pattern.SELECTED DRAWING: Figure 5

Description

Technical Field

[0001] The present invention relates to a method for manufacturing building materials.

Background Art

[0002] As a conventional technique, for example, Patent Document 1 discloses a method for manufacturing building materials as follows. In this manufacturing method, first, an ink layer made of a first resin cured by ultraviolet rays is formed so that a part of the surface of the wooden board is exposed. Next, a surface protection layer that transmits visible light and uses a second resin different from the first resin as a main component is thermally press-molded so as to cover the surface of the wooden board on which the ink layer is formed.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, when trying to attach a laminate film to the surface of a wooden board that is the base material of a building material and has a printed pattern on it using the manufacturing method of the building material shown in Patent Document 1, there is a risk that air will be trapped between the laminate film and the wooden board. Due to this entrapment of air, silvering (whitening phenomenon) may occur on the surface of the building material, and the appearance of the building material may be impaired.

[0005] The present invention has been made in view of such points, and an object thereof is to provide a method for manufacturing a building material that can suppress silvering caused by air entrapment even when a laminate film is attached to the surface of a wooden board.

Means for Solving the Problems

[0006] In view of the above-mentioned problems, the present invention provides a method for manufacturing building materials, a method for manufacturing building materials with a printed pattern, comprising: a base layer formation step of forming a base layer on the surface of a wood-based board that serves as a base material for the building material by attaching a printing base sheet made of a first thermoplastic resin to the surface of the wood-based board via an adhesive; a printing step of applying a predetermined printed pattern to the base layer by attaching an ultraviolet-curable resin ink to the base layer; and a lamination step of attaching a laminate film made of a second thermoplastic resin to the base layer with the printed pattern by applying heat and pressure to the base layer with the printed pattern via an adhesive layer formed by an adhesive, at a temperature lower than the softening point of the second thermoplastic resin.

[0007] According to the present invention, in the lamination process, a laminate film is heat-pressed onto a printed substrate layer at a temperature lower than the softening point of the second thermoplastic resin. This allows lamination to be performed on the surface of a wood-based board while maintaining the surface condition (such as texture or smoothness) formed on the laminate film and increasing the flexibility of the laminate film. As a result, it is possible to suppress the trapping of air between the substrate layer (or printed layer) and the laminate film during lamination, thereby suppressing silvering of the building material surface.

[0008] Furthermore, in the present invention, since a base sheet made of a first thermoplastic resin is attached during the base layer formation process, heat from the laminate film heated by a hot-press roll or the like is less likely to be transferred to the surface of the wood-based board by the base layer. In addition, the base sheet (base layer) can block the movement of air contained in the wood-based board toward the laminate film, so that the laminate film can be indirectly attached to the surface of the wood-based board and silvering caused by trapped air can be suppressed.

[0009] Here, the back surface of the wood fiberboard, that is, the surface of the wood fiberboard opposite to the surface on which the base sheet is formed, may be exposed. However, in a more preferred embodiment, a moisture-proof sheet is attached to the back surface of the wood fiberboard before the lamination process.

[0010] In the invention described above, during the lamination process, the laminate film is applied to the printed base layer while applying heat and pressure to it. As a result, moisture contained in the wood fiberboard evaporates and easily escapes from the wood fiberboard, which may cause the wood fiberboard to warp. However, in this embodiment, even if the wood fiberboard is heated during the lamination process, the moisture-proof sheet prevents moisture from escaping from the back side of the wood fiberboard, and the moisture content of the wood fiberboard is easily maintained. As a result, warping of the wood fiberboard can be suppressed.

[0011] Here, the first thermoplastic resin and the second thermoplastic resin may be different types of resins, but in a more preferred embodiment, the first thermoplastic resin and the second thermoplastic resin are made of the same type of resin.

[0012] Since both the base sheet (base layer) and the laminate film are made of the same type of resin, the heat generated during lamination causes both the base sheet and the laminate film to expand to roughly the same extent. This prevents air from becoming trapped between them due to differences in thermal expansion during lamination. In this way, even when a laminate film is applied to a base layer with a printed pattern, silvering caused by trapped air can be suppressed.

[0013] In a more preferred embodiment, in the printing step, the printing pattern is applied using the resin ink such that a plurality of raised ridges are formed along one direction, and in the laminating step, the laminating film is applied while applying heat and pressure to the laminate film along the direction in which the raised ridges with the printing pattern extend, from one end of the base layer to the other end of the base layer.

[0014] In this embodiment, during the lamination process, adhesive is pressed between the raised ridges via the laminating film, and the laminating film is heat-pressed from one end of the base layer toward the other end of the base layer. This allows the air trapped between the raised ridges to escape to the outside from between the laminating film and the base layer along the ridges. As a result, the laminating film can be applied to cover the printed pattern while suppressing air trapped inside.

[0015] In a more preferred embodiment, in the lamination process, the thickness of the adhesive layer formed on the laminate film is greater than the thickness of the printed layer.

[0016] According to this embodiment, by making the thickness of the adhesive layer before lamination greater than the thickness of the printed layer, the printed layer can be embedded in the adhesive layer, and the trapping of air between the laminate film and the printed layer can be suppressed. Furthermore, even if the temperature of the laminate film decreases after heat pressing, the adhesive layer is uniformly formed on the laminate film, so it can absorb the shrinkage of the laminate film caused by the adhesive layer. [Effects of the Invention]

[0017] According to the present invention, even if a laminate film is applied to the surface of a wood-based board, silvering caused by trapped air can be suppressed. [Brief explanation of the drawing]

[0018] [Figure 1] (a) is a schematic perspective view of a building material manufactured by the manufacturing method according to an embodiment of the present invention, (b) is a perspective view seen from the back side, and (c) is a cross-sectional view of the main part of the building material in (a). [Figure 2] This is a flowchart illustrating a method for manufacturing building materials according to an embodiment of the present invention. [Figure 3]It is a principal part diagram for explaining the base layer forming process shown in FIG. 2. (a) is a perspective view thereof, and (b) is a cross-sectional view of the wooden board after the base layer forming process. [Figure 4] It is a principal part diagram for explaining the printing process shown in FIG. 2. (a) is a perspective view thereof, and (b) is a cross-sectional view of the wooden board after the printing process. [Figure 5] It is a perspective view for explaining the laminating process shown in FIG. 2. (a) is a schematic perspective view of the wooden board during the laminating process, and (b) is an enlarged perspective view of the principal part of (a). [Figure 6] (a) is a cross-sectional view for explaining the state before the laminating process, and (b) is a cross-sectional view for explaining the state after the laminating process.

Embodiments for Carrying Out the Invention

[0019] Hereinafter, an embodiment of a building material manufactured by the manufacturing method according to the present embodiment will be described in detail based on the drawings. FIG. 1(a) is a schematic perspective view of a building material manufactured by the manufacturing method according to the embodiment of the present invention, FIG. 1(b) is a perspective view seen from the back side, and FIG. 1(c) is a cross-sectional view of the principal part of the building material in FIG. 1(a). In FIG. 1(c) and the like, for the sake of convenience, the thickness of the laminate film 26 is drawn thinner than the thickness of the printing layer 24 and the thickness of the adhesive layer 25, but the thickness of the laminate film 26 is thicker than these thicknesses.

[0020] 1. Regarding the building material 10 As shown in FIGS. 1(a) to (c), the building material 10 has a printed pattern 24A and includes a wooden board 21 that serves as the main body of the building material 10. The wooden board 21 is made of, for example, a wood fiber board or the like as will be described later. A base layer 22 is formed on one surface of the wooden board 21, and a moisture-proof sheet 23 is adhered to the other surface. The base layer 22 is made of a first thermoplastic resin described later.

[0021] The base layer 22 is a layer formed on the wood board 21 via an adhesive, and as shown in Figure 1(c), a portion of the adhesive 29 may be impregnated into the surface layer 21a of the wood board 21. The moisture barrier sheet 23 is not particularly limited, as long as it ensures waterproofing, and can be a resin moisture barrier sheet or a generally known waterproof paper. The adhesive 29 is fluid when applied but hardens with heat and drying.

[0022] A printed pattern 24A is applied to the surface of the base layer 22 by a resin hardened by ultraviolet light. Specifically, the printed pattern 24A is formed by a printed layer 24 made of the ultraviolet-curable resin described above. As shown in Figure 1(c), the printed layer 24 is formed by spraying resin ink using inkjet printing. The printed layer 24 may be a layer in which ultraviolet-cured resin particles 24a are deposited to cover the entire surface of the base layer 22, or it may be a layer that covers a part of the base layer 22 by applying a printed pattern such as a character. In this embodiment, a wood grain-like printed pattern 24A is applied, and multiple raised ridges 24b, described later, are formed by the resin particles 24a along one direction (along the wood grain pattern) (see, for example, Figure 5(b)). The raised ridges 24b may be, for example, parts where the thickness of the printed layer 24 is partially increased to give the texture of wood, or parts where the thickness of the printed layer 24 is partially increased in anticipation of the anchoring effect of the adhesive layer 25, described later.

[0023] A laminate film 26 is attached to the base layer 22 on which the printed layer 24 is formed, via an adhesive layer 25 made of an adhesive. Specifically, when the printed layer 24 covers a part of the base layer 22, the laminate film 26 is attached to the surface of both the printed layer 24 and the base layer 22 via the adhesive layer 25. On the other hand, when the printed layer 24 covers the entire base layer 22, the laminate film 26 is attached to the surface of the printed layer 24 via the adhesive layer 25. The laminate film 26 is made of a second thermoplastic resin, which will be described later, and both the laminate film 26 and the adhesive layer 25 are made of a resin material that can transmit visible light.

[0024] In this embodiment, it is preferable that the laminate film 26 is rigid relative to the base layer 22. Here, "rigid" means that the hardness (Shore hardness or Vickers hardness) of its surface is high. More preferably, the Young's modulus (longitudinal elastic modulus) of the second thermoplastic resin constituting the laminate film 26 is greater than the Young's modulus (longitudinal elastic modulus) of the first thermoplastic resin constituting the base layer 22. This prevents dents or scratches from occurring on the surface of the building material 10, and allows the soft base layer 22 and adhesive layer 25 to act as a cushioning material against impacts acting from the surface of the building material 10.

[0025] 2. Regarding the manufacturing method of building material 10 The manufacturing method of the building material 10 described in Figure 1, etc., will be explained below with reference to Figures 2 to 6. Figure 2 is a flowchart illustrating the manufacturing method of the building material 10 according to an embodiment of the present invention. Figure 3 is a diagram of the main parts illustrating the base layer formation process shown in Figure 2, where (a) is a perspective view thereof and (b) is a cross-sectional view of the wood-based board after the base layer formation process.

[0026] 2-1. Board preparation process S1 First, in this embodiment, as shown in Figure 3(a), a wood-based board 21 to which a moisture-proof sheet 23 is attached is prepared via an adhesive or bonding agent described later. The thickness of the wood-based board 21 is not particularly limited as long as it acts as a base material for the building material 10, but it is preferably 1.0 mm to 30 mm, and more preferably 2.5 mm to 5.5 mm.

[0027] Here, the wood-based board 21 can be a variety of wood-based board materials such as particleboard (PB), wood fiberboard (MDF, hardboard, etc.), insulation board, oriented strand board (OSB), LVL, laminated timber, plywood, or solid wood, and may also be a composite board made from some of these board materials. Furthermore, a veneer or sawn veneer may be attached to the surface of the wood-based board 21. In particular, wood fiberboard is porous and readily absorbs or evaporates moisture into the wood fibers, making it effective in the following manufacturing method.

[0028] Examples of the moisture barrier sheet 23 include roofing materials used as underlayment for roofs, commonly known waterproof paper or moisture barrier paper, or resin sheets such as polyolefin resin. The material composition of the moisture barrier sheet 23 is not particularly limited, as long as it can block moisture attempting to pass through in the thickness direction of the moisture barrier sheet 23, or reduce the amount of moisture that passes through.

[0029] Here, if a moisture-proof sheet 23 is to be attached to the back of the wood-based board 21 before the lamination process S4 described later, then, for example, the moisture-proof sheet 23 may be attached to the back of the wood-based board 21 between the start of the base layer formation process S2 described later and the start of the lamination process S4.

[0030] 2-2. Regarding the subsoil formation process S2 The base layer formation process S2 is performed on the wood-based board 21 prepared in the board preparation process S1. Specifically, as shown in Figures 3(a) and 3(b), a printing base sheet 22A made of a first thermoplastic resin is attached to the surface of the wood-based board 21, which will be the base material of the building material 10, via an adhesive 29, thereby forming a base layer 22 on the surface of the wood-based board 21.

[0031] Examples of adhesives 29 include, for example, water-based adhesives such as urea-melamine resin adhesives or ethylene vinyl acetate cocondensation resin adhesives such as modified vinyl acetate adhesives; adhesives that have the function of curing by chemical reaction with moisture, such as one-component polyurethane adhesives and silicone adhesives; hot-melt adhesives such as polyamide adhesives and EVA adhesives; and others such as urea resin adhesives, epoxy resin adhesives, phenolic resin adhesives, and isocyanate resin adhesives. In addition, adhesives in which the resin to be used as the bonding material is dissolved in a hydrocarbon-based organic solvent may also be used.

[0032] In this manner, a portion of the adhesive 29 is impregnated into the surface layer 21a of the wood-based board 21. This reliably prevents moisture contained in the wood-based board 21 from moving towards the substrate layer 22. Therefore, after applying the adhesive 29 to the surface of the wood-based board 21, a portion of the adhesive 29 may be impregnated into the surface layer 21a of the wood-based board 21, and then the substrate sheet 22A may be attached to the surface of the wood-based board 21.

[0033] The base sheet 22A is not limited in color or material, as long as it can be coated with UV-curable resin ink and a printed pattern 24A can be applied in a subsequent process. The base sheet 22A may be, for example, a sheet made of thermoplastic resin containing a coloring agent such as a white dye or pigment, or a sheet made of brown-colored thermoplastic resin. The thickness of the base sheet 22A is not particularly limited, but is preferably thinner than the thickness of the wood board 21, for example, about 0.05 to 1.0 mm.

[0034] Examples of the first thermoplastic resin constituting the base sheet 22A (base layer 22) include melamine resin, polyvinyl chloride, polyurethane, polyolefin resins (polyethylene, polypropylene, polyethylene vinyl acetate, polyvinyl alcohol, etc.), polyethylene terephthalate (PET), and other resins.

[0035] 2-3. Printing Process S3 Next, the printing process S3 performed on the base sheet 22A will be explained with reference to Figure 4. Figure 4 is a diagram illustrating the main parts of the printing process shown in Figure 2, where Figure 4(a) is a perspective view and Figure 4(b) is a cross-sectional view of the wood fiberboard after the printing process S3.

[0036] In the printing process S3, a predetermined print pattern 24A is applied to the base layer 22 by adhering an ultraviolet-curable resin ink. In this embodiment, in the printing process S3, a print pattern 24A is applied using resin ink, in which multiple raised ridges 24b are formed along one direction. In this embodiment, a print layer 24 consisting of the print pattern 24A is formed by inkjet printing so as to be exposed from the surface of the base layer 22. The print pattern 24A may be a wood grain pattern as shown below, as well as a pattern of the surface of a stone, a pattern of the surface of a gypsum board, a pattern of the surface of a fabric, or a geometric pattern such as a checkerboard pattern, or a print pattern in which characters, letters, logos, etc. are partially printed, or a print pattern which is a combination of these.

[0037] In this embodiment, a wood grain patterned printing layer 24 is formed as the printed pattern 24A. When forming such a wood grain patterned printing layer 24, if streaky protrusions (i.e., raised ridges 24b) are formed on the surface including the printing layer 24 along the pattern of the wood's pores, a wood grain texture can be obtained. Here, if multiple raised ridges 24b are oriented in the printing layer 24 that forms the printed pattern 24A, more resin particles 24a should be deposited in that area. Such printing is carried out as follows.

[0038] Specifically, the wood grain pattern of the printed layer 24 can be obtained by taking an image of the surface of wood, such as straight grain, and printing a pattern (wood surface pattern) corresponding to the captured image. The printing of the wood grain pattern is performed using an inkjet printer. In this embodiment, the resin ink of the inkjet printer contains at least an ultraviolet-curable resin in which a photopolymerization initiator is added to a reactive oligomer or reactive monomer, and a colorant. For example, four types of resin inks are prepared, each containing a different colorant of four colors: yellow, magenta, cyan, and black, in an ultraviolet-curable resin. The wood grain pattern is printed by forming the printed layer 24 on the surface of the base layer 22 using these resin inks.

[0039] As shown in Figure 4(a), the inkjet printer 40 includes a head 41 and an irradiation device 42, and further includes a transport device (not shown) for transporting the wood board 21 in the transport direction L.

[0040] In this embodiment, the head 41 contains resin ink used in general printing and individually sprays each resin ink (resin particle) according to the wood grain pattern to be printed based on the image described above. The irradiation device 42 irradiates ultraviolet light to harden the resin particles attached to the base layer 22. The head 41 and the irradiation device 42 reciprocate in a direction S perpendicular to the transport direction L.

[0041] This allows a predetermined printing pattern 24A to be printed onto the base layer 22 of the transported wood-based board 21, and the ultraviolet-curable resin that forms the printing pattern 24A to be cured. In this embodiment, the head 41 and the irradiation device 42 are provided separately, but they may be configured as an integrated unit, for example.

[0042] 2-4. Regarding the lamination process S4 Next, the lamination process S4 will be explained with reference to Figures 5 and 6. Figure 5 is a perspective view illustrating the lamination process S4 shown in Figure 2, Figure 5(a) is a schematic perspective view of the wood fiberboard during lamination, and Figure 5(b) is a perspective view of the main part of Figure 5(a). Figure 6(a) is a cross-sectional view illustrating the state before the lamination process, and Figure 6(b) is a cross-sectional view illustrating the state after the lamination process.

[0043] In the lamination process S4, a laminate film 26 is attached to the base layer 22 on which the printed pattern 24A is applied, via an adhesive layer 25 formed by an adhesive, so as to cover the surface on which the printed pattern 24A is applied.

[0044] The laminating film 26 is a film made of a second thermoplastic resin and is a film that can transmit visible light. During lamination, the laminating film 26 is attached to the base layer 22 with the printed pattern 24A by applying heat and pressure at a temperature lower than the softening point of the second thermoplastic resin. For example, if the second thermoplastic resin of the laminating film 26 is polyvinyl chloride, the softening point of polyvinyl chloride is about 65°C to 85°C, so the temperature at which the laminating film 26 is applied by heat and pressure is still low, about 40°C.

[0045] In this way, during the lamination process S4, the laminate film 26 is heat-pressed onto the base layer 22 with the printed pattern 24A at a temperature lower than the softening point of the second thermoplastic resin. Therefore, the laminate film 26 can be attached while maintaining the surface condition (texture, smooth surface, etc.) formed on the laminate film 26, and while increasing the flexibility of the laminate film 26. As a result, it is possible to suppress the trapping of air between the base layer 22 (or printed layer 24) and the laminate film 26 during lamination, and to suppress silvering of the surface of the building material 10.

[0046] In the lamination process S4, a laminate film is applied to the base layer 22 with the printed pattern 24A while applying heat and pressure. As a result, moisture contained in the wood fiberboard 21 evaporates and easily escapes from the wood fiberboard 21, which may cause the wood fiberboard to warp. However, in this embodiment, since a wood fiberboard 21 with a moisture-proof sheet 23 is prepared in advance in the board preparation process S1, even if the wood fiberboard 21 is heated in the lamination process S4, the moisture-proof sheet 23 prevents moisture from escaping from the back side of the wood fiberboard 21, and the moisture content of the wood fiberboard 21 is easily maintained. As a result, warping of the wood fiberboard 21 can be suppressed.

[0047] In this embodiment, during the lamination process S4, the hot pressure roller (heated roller) 30 is rolled while pressing along the direction in which the raised ridges 24b with the printed pattern 24A extend, from one end 22a to the other end 22b of the base layer 22. In this way, the laminating film 26 can be attached while being heat-pressed by the hot pressure roller 30.

[0048] In this embodiment, the laminate film 26 can be heat-pressed from one end 22a of the substrate layer 22 toward the other end 22b of the substrate layer 22, while releasing air A along the raised ridges 24b in the direction of the arrow in Figure 5(b). As a result, the laminate film 26 can be attached to the substrate layer 22 while suppressing air trapped inside. In particular, since the raised ridges 24b are porous areas where resin particles 24a are deposited, heat-pressing along the longitudinal direction of the raised ridges 24b allows for efficient removal of air in that direction.

[0049] Here, the second thermoplastic resin constituting the laminate film 26 can be the same material as the material exemplified for the first thermoplastic resin. Here, the first thermoplastic resin constituting the base layer 22 (base sheet 22A) and the second thermoplastic resin constituting the laminate film 26 are made of the same type of resin. For example, if the first thermoplastic resin is polyvinyl chloride, then the second thermoplastic resin is also polyvinyl chloride.

[0050] Examples of adhesives that can constitute the adhesive layer 25 include acrylic resin adhesives, synthetic rubber adhesives, natural rubber adhesives, vinyl ether adhesives, silicone adhesives, and urethane adhesives. Unlike the adhesive 29, the adhesive that constitutes the adhesive layer 25 does not harden but has viscoelastic properties and is a material that is more easily deformed than the adhesive 29.

[0051] Here, the thickness of the laminate film 26 is not particularly limited, but is, for example, in the range of 30 to 350 μm (for example, 100 μm thick), and it is preferable that the thickness of the adhesive layer 25 is greater than the thickness of the printed layer 24. For example, the thickness of the printed layer 24 is 10 to 30 μm, and the thickness of the adhesive layer 25 is 35 μm or more, preferably 100 μm or less.

[0052] In this embodiment, as shown in Figures 6(a) and 6(b), by making the thickness T2 of the adhesive layer 25 before lamination thicker than the thickness T1 of the printed layer 24, the printed layer 24 can be embedded in the adhesive layer 25 after lamination. This makes it possible to suppress air from being trapped between the laminate film 26 and the printed layer 24.

[0053] In addition, even if the temperature of the laminate film 26 decreases after heat pressing, the adhesive layer 25 is uniformly formed on the laminate film 26 without being divided by the raised ridges 24b of the printed layer 24, so the adhesive layer 25 can absorb the shrinkage of the laminate film 26.

[0054] According to this embodiment, in the base layer formation step S2, a base sheet 22A made of the first thermoplastic resin is attached, so that the heat from the hot pressure roller 30 is less likely to be transferred to the surface of the wood fiberboard 21 by the base layer 22. In addition, the base layer 22 can block the movement of air contained in the wood fiberboard 21 toward the laminate film 26.

[0055] Furthermore, since both the base layer 22 and the laminate film 26 are made of thermoplastic resin, the heat generated during lamination causes both the base sheet 22A and the laminate film 26 to expand due to linear expansion, making it difficult for air to get trapped between them during lamination.

[0056] In this way, the laminate film 26 is indirectly attached to the surface of the wood-based board 21, thereby suppressing silvering caused by trapped air.

[0057] In particular, by using the same type of resin for both the base layer 22 and the laminate film 26, the heat generated during lamination causes both the base sheet 22A and the laminate film 26 to expand to roughly the same extent. This prevents air from being trapped between them during lamination due to differences in linear expansion, and even when the laminate film 26 is applied to the surface of the base layer 22, silvering caused by trapped air can be suppressed.

[0058] Although one embodiment of the present invention has been described in detail above, the present invention is not limited to the above-described embodiment, and various design modifications can be made without departing from the spirit of the invention as described in the claims. The present invention allows for adding the configuration of one embodiment to the configuration of another embodiment, replacing the configuration of one embodiment with that of another embodiment, or deleting a part of the configuration of one embodiment.

[0059] For example, in this embodiment, raised ridges 24b are formed on the printed layer 24, but the printed layer 24 may also be formed by uniformly depositing resin particles 24a on the surface of the base layer 22, for example. Even in such a case, recesses and protrusions are formed on the surface of the printed layer 24, so by making the thickness T2 of the adhesive layer 25 thicker than the thickness T1 of the printed layer 24, air can be suppressed. [Explanation of symbols]

[0060] 10: Building material, 21: Wood fiberboard, 21a: Surface layer, 22: Substrate layer, 22A: Substrate sheet, 23: Moisture barrier sheet, 24: Printed layer, 24A: Printed pattern, 24a: Resin particles, 24b: Raised stripes, 25: Adhesive layer, 26: Laminate film, 29: Adhesive

Claims

1. A method for manufacturing building materials with printed patterns, A base layer formation step is to form a base layer on the surface of a wood-based board that serves as the base material of the building material by attaching a printing base sheet made of a first thermoplastic resin to the surface of the wood-based board via an adhesive, A printing process in which a predetermined printed pattern is applied to the aforementioned base layer by adhering an ultraviolet-curing resin ink, The process includes a lamination step in which a laminate film made of a second thermoplastic resin is attached to the base layer with the printed pattern by applying heat and pressure to the base layer with the printed pattern, via an adhesive layer formed by an adhesive agent so as to cover the surface on which the printed pattern is applied, at a temperature lower than the softening point of the second thermoplastic resin. In the printing process described above, the printing pattern is applied using the resin ink such that a plurality of raised stripes are formed along one direction. A method for manufacturing building materials, characterized in that, in the lamination process, the laminate film is applied to the base layer from one end to the other end of the base layer while applying heat pressure to the laminate film along the direction in which the raised stripes on which the printed pattern is applied extend.

2. A method for manufacturing building materials with printed patterns, A base layer formation step is to form a base layer on the surface of a wood-based board that serves as the base material of the building material by attaching a printing base sheet made of a first thermoplastic resin to the surface of the wood-based board via an adhesive, A printing process in which a predetermined printed pattern is applied to the aforementioned base layer by adhering an ultraviolet-curable resin ink, The process includes a lamination step in which a laminate film made of a second thermoplastic resin is attached to the base layer with the printed pattern by applying heat and pressure to the base layer with the printed pattern, via an adhesive layer formed by an adhesive agent so as to cover the surface on which the printed pattern is applied, at a temperature lower than the softening point of the second thermoplastic resin. A method for manufacturing building materials, characterized in that, in the lamination process, the thickness of the adhesive layer formed on the laminate film is greater than the thickness of the printed layer consisting of the printed pattern.

3. The method for manufacturing building materials according to claim 1 or 2, characterized in that a moisture-proof sheet is attached to the back surface of the wood-based board before the lamination process.

4. A method for manufacturing building materials according to any one of claims 1 to 3, characterized in that the first thermoplastic resin and the second thermoplastic resin are made of the same type of resin.

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