Method for manufacturing multi-stacked wood plate

Abstract

This method for manufacturing a multi-stacked wood plate includes: a step for forming a stack by stacking a plurality of single plates 11 to 15 upon a base plate 2 by pressing the stack each time one plate is attached with an adhesive 3, the single plates each having a thickness of 0.8 mm or less, the base plate being long in a first direction; and a step for separating the stacked plurality of single plates from the base plate to obtain a multi-stacked wood plate 1.

Description

Manufacturing method of wood laminate

[0001] The present disclosure relates to a method for manufacturing a wood laminate.

[0002] Wood laminated boards have been known for use as flooring materials, wall materials, ceiling materials, furniture materials, etc. For example, Patent Document 1 listed below discloses a manufacturing method for plywood in which adhesive is spread and applied with a spreader to both sides of a middle board and one side of a front and back board that constitute the plywood, and these veneers are combined to form the plywood.

[0003] Japanese Patent Application Laid-Open No. 2022-188506

[0004] However, in the manufacturing method described in Patent Document 1, adhesive is applied to both sides of the middle plate, which raises concerns that the surrounding environment may be easily soiled during transportation. Furthermore, the veneers that make up conventional plywood generally have a thickness of about 1 mm to 3 mm, making them less likely to get caught in the spreader rolls, but there is also concern that thinner veneers may become more susceptible to getting caught.

[0005] The present disclosure has been made in consideration of the above-described circumstances, and aims to provide a method for manufacturing a wood laminated board that can efficiently produce a thin wood laminated board.

[0006] In order to achieve the above-mentioned object, the manufacturing method of the wood laminate board according to the present disclosure is characterized by comprising a veneer lamination process in which a plurality of veneers, each having a thickness of 0.8 mm or less, are pressed and laminated onto a base plate that is long in a first direction, with each veneer being adhered to the base plate with adhesive, and a separation process in which the stacked veneers are separated from the base plate to obtain a wood laminate board.

[0007] The method for manufacturing a wood laminated board according to the present disclosure has the above-described configuration, making it possible to efficiently manufacture a thin wood laminated board.

[0008] 1A and 1B are schematic perspective views showing an example of a method for manufacturing a wood laminate board according to an embodiment of the present disclosure. 1A and 1B are schematic perspective views showing the example of the manufacturing method. 1A to 1E are schematic side views, partially cut away, showing the example of the manufacturing method. 1A to 1E are schematic perspective views showing the example of the manufacturing method. 1A is a schematic perspective view showing the example of the manufacturing method, and 1B and 1C are schematic side views, partially cut away, showing a modified example of the manufacturing method.

[0009] The following describes embodiments of the present disclosure with reference to the drawings. In some drawings, some of the detailed reference numerals used in other drawings are omitted. Figures 1 to 5 are schematic diagrams illustrating an example and a modified example of a method for manufacturing a wood laminate board according to this embodiment, and an example of a wood laminate board manufactured using this manufacturing method.

[0010] As shown in Figures 1(b) and 2(a) and 2(b), the manufacturing method for a wood laminated board according to this embodiment includes a veneer lamination step in which multiple veneers 11-15, each with a thickness of 0.8 mm or less, are pressed onto a base plate 2 elongated in a first direction after each veneer is bonded with adhesive 3. This configuration allows the adhesive 3 to be applied to the base plate 2. As a result, even when applying the adhesive using a general adhesive application device such as a roll coater 4, the thin veneers 11-15 do not become entrapped, and the surrounding environment is less likely to be soiled, allowing for efficient production. Furthermore, because the veneers 11-15 are pressed after each veneer is bonded, problems such as entrapment during application and poor adhesion on the back layer (lower layer) that faces the base plate 2 are less likely to occur compared to a configuration in which multiple veneers are laminated without being pressed through adhesive 3 and then pressed.

[0011] As shown in Figures 3(d) and 3(e), this manufacturing method includes a separation step in which the laminated veneers 11-15 are separated from the base plate 2 to obtain the wood laminate board 1. This configuration allows the base plate 2 to be reused by separating the wood laminate board 1 from the base plate 2. Furthermore, because the thickness of each of the veneers 11-15 constituting the wood laminate board 1 is 0.8 mm or less, the wood laminate board 1 can be made thinner. Furthermore, the multiple layers of veneers 11-15 can suppress the occurrence of warping, twisting, and other defects, allowing for efficient production of a thin wood laminate board 1. In this manufacturing method, a sheet 10 may be attached to the base plate 2, and the veneers 11-15 may be separated from the base plate 2 at the sheet 10 in the separation step. This configuration allows the wood laminate board 1 to be easily separated from the base plate 2 at the sheet 10.

[0012] In this manufacturing method, a decorative veneer 15 with a fiber direction aligned in the first direction may be used as the outermost veneer among the multiple veneers 11-15. This configuration allows the decorative veneer 15, whose fiber direction is aligned in the longitudinal direction, to be the outermost layer, thereby producing a wood laminated board 1 with a good appearance. In this manufacturing method, the other veneers 11-14 among the multiple veneers 11-15 may be cross-laminated veneers 12, 14 formed from a laminated lumber (cross-laminated lumber 22 (see FIG. 4(c))) in which multiple pieces of wood, each with their fiber direction aligned in a second direction perpendicular to the first direction, are assembled in parallel in the first direction, and long veneers 11, 13 formed from a laminated lumber (long laminated lumber 21 (see FIG. 4(b))) in which multiple pieces of wood, each with their fiber direction aligned in the first direction, are assembled. This configuration more effectively suppresses warping, twisting, and other defects, allowing for more efficient production of a thin wood laminated board 1. Furthermore, by using such laminated cross veneers 12, 14 and laminated long veneers 11, 13, it is possible to achieve uniformity compared to a laminated structure of non-laminated veneers, and it is possible to reduce deformation of the veneers themselves when the environment changes, etc. Furthermore, it is possible to effectively utilize scrap wood, thereby reducing the environmental burden.

[0013] Specifically, in the example shown in FIG. 3( e), the wood laminate board 1 is constructed by laminating five veneers 11-15. The wood laminate board 1 includes a first laminated long veneer 11 as the bottom layer, a first laminated cross veneer 12 laminated on the surface side of the first laminated long veneer, a second laminated long veneer 13 laminated on the surface side of the first laminated cross veneer, a second laminated cross veneer 14 laminated on the surface side of the first laminated long veneer, and a decorative veneer 15 as the top layer laminated on the surface side of the first laminated long veneer. The thickness of the wood laminate board 1 including these multiple veneers 11-15 may be 3 mm or less, 2.5 mm or less, 1 mm or more, or 1.2 mm or more. This wood laminate board 1 has a substantially rectangular shape when viewed from above (thickness direction). This wood laminate board 1 may be used as flooring, wall material, ceiling material, furniture surface material, etc. This wood laminate board 1 can be installed not only in residential buildings but also on non-residential subfloors. This wood laminate board 1 can be installed on a construction substrate such as a subfloor using appropriate fasteners, adhesives, or glue. Furthermore, an appropriate soundproofing base material or a sheet material with various functions can be further laminated on the back side of this wood laminate board 1.

[0014] The dimension of this wood laminate board 1 along a first direction (length dimension) and the dimension along a second direction (width dimension), which is perpendicular to the first direction and the thickness direction, may be appropriately determined depending on the intended use of the wood laminate board 1. The length of the wood laminate board 1 may be, for example, approximately 600 mm to 2000 mm, and the width of the wood laminate board 1 may be approximately 100 mm to 400 mm. Chamfered portions 16 are provided on the four peripheral edges of the surface side of the wood laminate board 1. An appropriate coating layer 17 is formed on the surface of the wood laminate board 1, including the chamfered portions 16, by painting or the like. Solid portions 18, 19 are provided at one or both of the ends of the wood laminate board 1 in the first direction and the second direction. In the illustrated example, one of the solid portions 18, 19 is a first solid portion 18 that protrudes from the back surface side so as to form a recessed step on the front surface side, and the other is a second solid portion 19 that protrudes from the front surface side so as to form a recessed step on the back surface side. In other words, the first solid portion 18 and the second solid portion 19 are convoluted solid portions. However, the present invention is not limited to this example, and a configuration in which solid portions of this solid shape are provided may also be used.

[0015] The decorative veneer 15 may be a sliced ​​veneer (veneer) formed by thinly slicing various natural woods (precious woods). The raw wood material for the decorative veneer 15 may be, for example, hardwoods such as oak, birch, beech, ash, maple, or walnut, or various other softwoods. The decorative veneer 15 before the veneer lamination process may be a so-called wet veneer formed from moisture-containing wood using a slicer, or a dried veneer obtained by naturally or artificially drying a wet veneer. The thickness of the decorative veneer 15 may be 0.1 mm or more, 0.6 mm or less, or approximately 0.2 mm to 0.5 mm. The fiber direction of the decorative veneer 15 in the first direction, i.e., the longitudinal direction of the wood laminate 1, may be roughly the first direction because the wood is natural wood. It also includes veneers with partial portions in the second direction due to knots or the like. As shown in Fig. 2(b), this decorative veneer 15 is a non-laminated veneer, unlike the other veneers 11 to 14 described later. Alternatively, the decorative veneer 15 may be a laminated veneer similar to the laminated long veneers 11 and 13 described later.

[0016] The first and second laminated cross veneers 12 and 14 are formed by slicing a cross laminated lumber 22 (see FIG. 4(c) ) in which multiple rectangular cross lumber pieces (flitches) are butted together in the first direction, with their longitudinal directions aligned in the second direction. The cross lumber fibers in the second direction, as described above, may be generally aligned in the second direction, and may also have portions aligned in the first direction due to knots or other factors. These cross lumber pieces may be of the same or different species as the raw wood materials that make up the decorative veneer 15. Furthermore, the cross lumber pieces may be broad-leaved trees, as described above, or various coniferous trees, or a mixture of multiple species. The first and second laminated cross veneers 12 and 14 formed from the cross laminated lumber 22 are composed of multiple cross pieces corresponding to each cross lumber piece, as shown in FIG. 2(a) . The first and second laminated cross veneers 12 and 14 before the veneer lamination process may be wet veneers formed from moisture-containing wood using a slicer, as described above, or may be dry veneers obtained by naturally or artificially drying wet veneers. The thickness of the first and second laminated cross veneers 12 and 14 may be 0.1 mm or more, 0.6 mm or less, or approximately 0.2 mm to 0.5 mm. The first and second laminated cross veneers 12 and 14 may be the same thickness or different thicknesses.

[0017] The first and second laminated long veneer panels 11 and 13 are formed by slicing a long laminated lumber 21 (see FIG. 4( b) ) in which multiple rectangular column-shaped long lumber pieces (flitches) are butted together in the first and second directions, with the longitudinal direction of each piece aligned in the first direction. The long laminated lumber 21 may be formed, for example, by butting multiple long lumber pieces together in two rows in the width direction (second direction) of the first and second laminated long veneer panels 11 and 13, or by assembling the long lumber pieces in each row with a longitudinal offset so that they appear randomly aligned when viewed in the thickness direction of the first and second laminated long veneer panels 11 and 13. The long laminated lumber 21 may be assembled in three rows, for example, or in various other ways. The term "first direction" as used herein means that the fiber direction of these long lumber pieces is generally in the first direction, as described above, and also includes pieces with partial portions in the second direction due to knots or the like. These long pieces of wood may be of the same species as or different from the raw wood materials that make up the decorative veneer 15. Furthermore, the long pieces of wood may be broad-leaved wood as described above, or may be various types of coniferous wood, or a mixture of multiple species.

[0018] The first and second laminated long veneer panels 11 and 13 formed from the above-described long laminated lumber 21 are composed of multiple long pieces corresponding to each long piece of wood, as shown in FIG. 1(b). The first and second laminated long veneer panels 11 and 13 before the veneer lamination process may be so-called wet veneers formed from moisture-containing wood using a slicer, as described above, or may be dried veneers obtained by naturally or artificially drying wet veneers. The thickness of the first and second laminated long veneer panels 11 and 13 may be 0.1 mm or more, 0.6 mm or less, or approximately 0.2 mm to 0.5 mm. The first and second laminated long veneer panels 11 and 13 may be the same thickness or different thicknesses.

[0019] At least one of the plurality of veneers 11-15 may be impregnated with a dimensional stabilizing resin. This configuration allows the veneer impregnated with the dimensional stabilizing resin to suppress dimensional changes due to moisture absorption and desorption, making the wood laminate 1 less susceptible to warping and twisting. The veneer located toward the center of the thickness of the wood laminate 1 may be impregnated with the dimensional stabilizing resin. For example, in a wood laminate 1 having five veneers 11-15 stacked together as described above, the three veneers 12-14, excluding the rearmost veneer (first long laminated veneer 11) and the frontmost veneer (decorative veneer 15), may be impregnated with the dimensional stabilizing resin.

[0020] At least one of the plurality of veneers 11-15 may be formed from wood that has been heat-treated with high-pressure steam. This configuration reduces the dimensional changes due to moisture absorption and desorption, resulting in altered wood fibers in the veneers formed from the heat-treated wood. This, as described above, also reduces warping and twisting in the wood laminate 1. Furthermore, when forming laminated cross veneers (first laminated cross veneer 12 and second laminated cross veneer 14) from the above-described cross laminated lumber 22, depending on the type of slicer, the sliced ​​laminated cross veneer tends to curl. However, the heat treatment alters and softens the wood fibers, making the sliced ​​laminated cross veneer less likely to curl. This allows the use of a general-purpose slicer. Among the plurality of veneers 11-15, the veneer located toward the center of the thickness of the wood laminate 1 may be formed from wood that has been heat-treated with high-pressure steam. That is, as described above, the three veneers 12-14 at the center of the thickness of the wood laminate 1 may be formed from wood that has been heat-treated with high-pressure steam. Alternatively, at least one of the veneers 11-15 may be formed from wood that has been heat-treated with high-pressure steam, and this veneer may be impregnated with a dimensionally stabilizing resin. This configuration makes the wood laminate 1 less susceptible to warping and twisting. In this case, as described above, the three veneers 12-14 at the center of the thickness of the wood laminate 1 may be formed from wood that has been heat-treated with high-pressure steam, and these veneers may be impregnated with a dimensionally stabilizing resin.

[0021] Specifically, the heat treatment of wood with high-pressure steam and the impregnation with dimensionally stabilizing resin may be performed using a heat treatment device or resin impregnation device having a tank 20 for storing wood (dried wood), as shown in FIG. 4( a). The wood to be heat-treated and resin-impregnated may be a rectangular prism-shaped piece of wood (flitch) that forms the long laminated lumber 21 or cross laminated lumber 22 described above. Alternatively, a device may be used that heat-treats wood in the same tank 20 and impregnates the heat-treated wood with dimensionally stabilizing resin. For example, the tank 20 may be connected to a steam supply pipe for supplying high-pressure steam from a high-pressure steam source, a pressurized air pipe for supplying pressurized air from a pressurized air source, a drain pipe for discharging liquefied steam, etc. The temperature for the heat treatment of wood with high-pressure steam may be approximately 105°C to 160°C.

[0022] The tank 20 may also be connected to an aqueous solution supply pipe for supplying an aqueous solution containing a dimensional stabilizing resin (an aqueous solution in which a dimensional stabilizing component is dissolved), a pump for pressurizing the tank 20, a decompression pipe for decompressing the tank 20, and the like. For example, the wood heat-treated in the tank 20 may be left or cooled until its temperature reaches approximately 100°C, and then the tank 20 may be decompressed, filled with an aqueous solution, and pressurized to impregnate the wood with the dimensional stabilizing resin. This liquid pressurization method is not limited to this, and a method of impregnation by supplying pressurized air may also be used. The dimensional stabilizing resin may also be polyethylene glycol or glyoxal. When polyethylene glycol is used, it may have a relatively large molecular weight, for example, a molecular weight of 600 or more, preferably 1000 or more. The concentration (mass % concentration) of the aqueous solution containing the dimensional stabilizing resin may be approximately 5% to 60%, and preferably approximately 20% to 40%. In the case of an aqueous solution containing polyethylene glycol and glyoxal, the blending ratio of polyethylene glycol to glyoxal (polyethylene glycol:glyoxal) may be about 8:1 to 5:5, and preferably about 8:2 to 6:4. The wood (flitch) that has been heat-treated and resin-impregnated as described above may be assembled to form the long laminated lumber 21 and cross laminated lumber 22.

[0023] In this manufacturing method, the adhesive 3 may be a high-solids adhesive, e.g., 100% solids, or an aqueous (water-based) adhesive. Using an aqueous adhesive as the adhesive 3 allows application using a roll coater 4. This allows for more uniform application and lower costs compared to the bead-like application of a high-solids adhesive. In this manufacturing method, a moisture-permeable sheet 10 and a moisture-absorbent base plate 2 may be used. With this configuration, even when at least one of the veneers 11-15 is a wet-laid veneer, as described above, moisture in the veneer can be transferred to the base plate 2 through the sheet 10 during pressing, thereby reducing the impact of moisture in the veneer on the adhesive 3. This eliminates the need to dry the veneers in advance, improving manufacturing efficiency. Furthermore, pressing such wet-laid veneers can be prone to shrinkage, especially in the width direction. However, the base plate 2 essentially restrains the veneer, suppressing shrinkage and improving yield. Furthermore, if any of the plurality of veneers 11 to 15 is impregnated with the dimensional stabilizing component as described above, shrinkage, etc. can be more effectively suppressed. Furthermore, if the adhesive 3 is a water-based adhesive as described above, the moisture in the adhesive 3 can also be transferred to the base plate 2 side via the sheet 10, and the hardening time of the adhesive 3 can be shortened compared to, for example, a configuration in which only a plurality of veneers are laminated with the adhesive 3 interposed therebetween and pressed.

[0024] Specifically, as shown in FIG. 1( a), in this manufacturing method, adhesive 3 is applied to the surface (top surface) of base plate 2 using a roll coater 4. The hygroscopic base plate 2 may be a wood board such as plywood, LVL, or MDF, or other board material. The dimensions of the base plate 2 along the first direction (length) and the dimensions along the second direction (width) may be appropriately determined depending on the length and width of the wood laminate 1. The thickness of the base plate 2 may be appropriately determined so as to prevent it from getting caught in the roll coater 4 and from the viewpoint of reusability, for example, 3 mm or more, or 5 mm or more. The adhesive 3 may be an aqueous adhesive appropriate for application properties and initial adhesion, such as an aqueous adhesive containing vinyl acetate resin, polylactic acid, starch, acrylic resin, or the like. For example, a vinyl acetate resin-based adhesive may be used. The roll coater 4 may be configured to include an applicator roll 5 that applies the adhesive 3 and a transport roller 6 that transports the object to be coated (a base plate 2 in the illustrated example). In this case, an appropriate supply unit that supplies the adhesive 3 to the applicator roll 5 may be provided. The roll coater 4 is not limited to the configuration shown in the illustrated example, and various other configurations may be used.

[0025] Next, the sheet 10 is laminated on the base plate 2, and the laminate is introduced into a press (hot press) 7 having upper and lower press dies and pressed (hot pressed) so that the adhesive 3 hardens. The moisture-permeable sheet 10 may be a paper sheet. This sheet 10 may be an appropriate paper sheet so that the laminated veneer body 1A can be easily separated from the base plate 2 in the separation step described below. The sheet 10 may also be laminated (supplied) onto the base plate 2 using an appropriate sheet supplying device. Instead of the above-described method of bonding the base plate 2 and the sheet 10 entirely using the roll coater 4, the adhesive 3 may be applied to the base plate 2 in a bead (line) or dot pattern, and the sheet 10 may be partially bonded to the base plate 2. This configuration makes it easier to separate the laminated veneer body 1A from the base plate 2 in the separation step described below. The adhesive strength (fixing strength) between the base plate 2 and the sheet 10 may be an appropriate adhesive strength (fixing strength) that allows separation in the separation process described below and prevents deformation or shifting due to drying shrinkage of each laminated veneer, or shifting or peeling during coating roll or transport.

[0026] 1(b), adhesive 3 is applied to the surface of sheet 10 using roll coater 4, as described above, and then a first assembled long veneer 11, which constitutes the bottommost veneer, is laminated thereon, introduced into press 7, and pressed to harden the adhesive 3. Also, as shown in FIG. 2(a), adhesive 3 is applied to the surface of first assembled long veneer 11 using roll coater 4, as described above, and then a first assembled cross veneer 12 is laminated thereon, introduced into press 7, and pressed to harden the adhesive 3. Also, adhesive 3 is applied to the surface of first assembled cross veneer 12 using roll coater 4, as described above, and then a second assembled long veneer 13 is laminated thereon, introduced into press 7, and pressed to harden the adhesive 3 (see FIG. 1(b)). As described above, adhesive 3 is applied to the surface of the second laminated long veneer 13 using a roll coater 4, and the second laminated cross veneer 14 is laminated on top of it. The laminate is then introduced into a press 7 and pressed so that the adhesive 3 hardens (see FIG. 2(a)).

[0027] As shown in FIG. 2(b), adhesive 3 is applied to the surface of the second laminated cross veneer 14 using a roll coater 4, as described above, and the decorative veneer 15 constituting the outermost layer of veneer is then laminated. The laminate is then introduced into a press 7 and pressed to harden the adhesive 3. By carrying out the lamination process, including the sheet lamination process and each veneer lamination process, as described above, a laminate is formed, as shown in FIG. 3(a), in which multiple veneers 11-15 (five in the illustrated example) are laminated on a base plate 2 via a sheet 10. The lamination (supply) of each veneer 11-15 may be performed using an appropriate veneer supply device. The pressing conditions in the press 7 during each lamination process may be set as appropriate depending on the type of adhesive 3, the configuration of the veneers 11-15, and other factors. For example, a pressing temperature of approximately 90°C to 120°C and a pressing pressure of 5 kgf / cm are used. ２ (approx. 0.49MPa) ~ 15kgf / cm ２ (about 1.47 MPa) for a pressing time of about 30 to 120 seconds. When each of the veneers 11 to 15 is a wet veneer as described above, they may be pressurized and dried by pressing in each lamination step.

[0028] The surface of at least one of the multiple veneers 11-15 stacked on the base plate 2 as described above may be polished, as shown in FIG. 5(a). This configuration allows polishing while the veneers are still stacked on the base plate 2, allowing for stable polishing of the surface of the veneer to be polished, improving surface smoothness (reducing unevenness). In particular, when forming laminated cross veneers (the first laminated cross veneer 12 and the second laminated cross veneer 14) from the above-described cross laminated lumber 22, thickness variations (unevenness on the front and back surfaces) tend to occur depending on the type of slicer. Therefore, the surface of at least the laminated cross veneer (the second laminated cross veneer 14) directly below the decorative veneer 15 constituting the outermost veneer may be polished using an appropriate polishing device 23. This configuration can reduce the unevenness of the laminated cloth veneer (second laminated cloth veneer 14) and reduce the effect of the unevenness (unevenness transfer) on the surface of the decorative veneer 15. The surfaces of each laminated cloth veneer (first laminated cloth veneer 12 and second laminated cloth veneer 14) may be polished using an appropriate polishing device 23. In the illustrated example, a belt sander with abrasive paper wound around a belt is used as the polishing device 23, but this is not a limitation. Furthermore, the thickness of the veneer to be polished (laminated cloth veneer) may be adjusted to take polishing into account. In other words, the thickness of the veneer (laminated cloth veneer) before lamination may be greater than the thickness described above so that the thickness after polishing is as described above.

[0029] Alternatively, after the sheet 10 is stacked on the base plate 2, the adhesive 3 may be applied to the sheet 10 without pressing, and then the bottommost veneer (first assembled long veneer 11) may be stacked. In other words, the sheet 10 and the first assembled long veneer 11 may be stacked on the base plate 2 via the adhesive 3, and then simultaneously pressed to harden the adhesive 3. Even in this configuration, if the sheet 10 is a paper sheet as described above, it is less likely to get caught and adhesion problems may be less likely to occur. Furthermore, to facilitate separation in the separation process described below, the adhesive 3 used to stack and bond the sheet 10 may be different from the adhesive 3 used to stack and bond the individual veneers 11-15. For example, the adhesive 3 used to stack and bond the sheet 10 may not contain the additives added to the adhesive 3 used to stack and bond the individual veneers 11-15, and the amount of adhesive applied may be smaller than the amount of adhesive 3 used to stack and bond the individual veneers 11-15.

[0030] As shown in Figure 3(b), the manufacturing method may include a groove forming step between the veneer lamination step and the separation step described below, in which grooves 8 are formed on the surface side. This configuration, compared to a configuration in which grooves 8 are formed after separation from the base plate 2, allows each veneer 11-15 to be constrained by the base plate 2, improving surface smoothness and facilitating the formation of grooves 8. Furthermore, compared to a configuration in which only veneers are laminated, the thickness of the target for groove formation is greater, making it easier to transport the target in the processing machine that forms the grooves 8, thereby enabling improved processing accuracy and increased processing speed. The grooves 8 may be formed using an appropriate cutting machine, such as a tenoner or a router. While the illustrated example shows an example in which grooves 8 are formed in a substantially V-shape when viewed in the longitudinal direction, this is not a limitation. The grooves 8 may also be formed on the surface side of the laminate so as not to reach the sheet 10 or the base plate 2. In the illustrated example, the bottom of the groove 8 is located in the second layer of veneer from the front surface (second laminated cross veneer 14), but this is not a limitation. The groove 8 may also be a groove in which one inner wall in the groove width direction forms a chamfered portion 16. In this case, the groove 8 may be formed on all four periphery edges on the front surface side, taking into account the solid portions 18, 19 and dimensional adjustment margins. Furthermore, the groove 8 is not limited to a groove that forms a chamfered portion 16, but may also be a decorative groove that extends longitudinally in a widthwise intermediate portion of the wood laminate 1.

[0031] As shown in Figure 3(c), the manufacturing method may also include a coating step for forming a coating layer 17 on the surface of the laminate between the veneer lamination step and the separation step described below. This configuration, compared to a configuration in which the coating layer 17 is formed after separation from the base plate 2, allows each veneer 11-15 to be constrained by the base plate 2, improving surface smoothness and facilitating the formation of the coating layer 17. Furthermore, compared to a configuration in which only veneers are laminated, the thickness of the object to be coated is greater, making it easier to transport in the coating device, improving coating accuracy, and increasing the coating speed. In this example, the coating step is performed after the groove formation step. Furthermore, the coating layer 17 is also formed on the inner surface of the groove 8. This coating layer 17 may be a transparent or translucent protective layer (top coat layer), and an appropriate decorative layer may also be formed in addition to this. Alternatively, the coating layer 17 may be formed by applying a suitable stain paint, resin-based clear paint, or the like to the surface of the laminate using a suitable coating device such as a roll coater. Before forming the coating layer 17, the surface of the laminate may be subjected to a raised finish.

[0032] 3(d), a separation step is performed in which the laminated veneer body 1A, which includes the multiple veneers 11-15 stacked together as described above, is separated from the base plate 2 at the sheet 10. This separation step may be performed using a separator 9 such as a slicer or scraper. Alternatively, the laminated veneer body 1A may be peeled off from the base plate 2 without using such a separator 9. To facilitate this separation step, at least one of the four peripheral edges of the laminated veneer body 1A may be configured to extend outward beyond one edge of the base plate 2, and the laminated veneer body 1A may be peeled off by grasping this extended portion. By performing this separation step, the sheet 10 is divided in the thickness direction so as to cause interlayer (inter-sheet) peeling, and a portion of the sheet 10 may remain on the back side of the laminated veneer body 1A as sheet layer 10A, and a portion of the sheet 10 may remain on the front side of the base plate 2 as sheet layer 10B.

[0033] The configuration is not limited to the above-described configuration in which portions of the sheet 10 remain on both sides; the entire sheet 10 may remain on either side. For example, as shown in Figures 5(b) and (c), the sheet 10 may not remain on the base plate 2A side. In this case, the surface of the base plate 2A may have releasability, and multiple veneers 11-15 (laminated veneer body 1B) may be separated from the surface of the base plate 2A during the separation process. This configuration allows for easy separation of the laminated veneer body 1B from the base plate 2A. Furthermore, since the entire sheet 10 remains on the laminated veneer body 1B side, i.e., the sheet 10 also constitutes the laminated veneer body 1B, the back-side layer of the laminated veneer body 1B (wood laminate board 1) becomes more uniform than in the above-described configuration in which only a portion of the sheet 10 remains on the base plate 2 side, improving the appearance and smoothness of the back surface.

[0034] The base plate 2A having a release surface need only have adequate release properties against the adhesive 3. As described above, the release properties are sufficient to allow separation during the separation process and prevent deformation or shifting due to drying shrinkage of the laminated veneers, or to prevent shifting or peeling during coating or transport. For example, the base plate 2A itself, or at least the surface layer of the base plate 2A, may be formed from PET (polyethylene terephthalate) or the like. In other words, in this example, the base plate 2A does not need to be hygroscopic. While the illustrated example shows an example in which the dimension of the base plate 2A in one direction (at least one of the longitudinal and width directions) is larger than the dimension of the laminate in the same direction, this is not a limitation. Alternatively, instead of using a base plate 2A having a release surface, the sheet 10 may be attached to the base plate 2 using a highly releasable adhesive, such as a peel-up bond. That is, instead of the configuration in which the laminated veneer structure 1B including the adhesive 3 and the sheet 10 is separated from the surface of the base plate 2A as described above, a configuration in which the laminated veneer structure including the sheet 10 is separated from the adhesive on the base plate 2 may be used. Furthermore, when the entire sheet 10 constitutes the laminated veneer structure 1B as described above, the sheet 10 may be, for example, so-called moisture-proof paper including a polyethylene sheet layer. That is, in this example, the sheet 10 does not need to be moisture-permeable. Furthermore, when the sheet 10 is not separated from the base plate by interlayer (interpaper) peeling, the sheet may not be used.

[0035] As shown in FIG. 3( e), the manufacturing method may also include a solid portion forming step for forming solid portions 18 and 19. This results in the wood laminate board 1 described above. While this solid portion forming step may be performed before the separation step, in the illustrated example it is performed after the separation step. This configuration allows the base plate 2 (2A) to be reused. In this case, if the sheet layer 10B remains on the surface side of the base plate 2, the sheet layer 10B may be polished and removed using an appropriate grinding machine or the like. This solid portion forming step may also be performed using an appropriate cutting machine such as a tenoner. Note that, when using a base plate 2A with a releasable surface as described above, polishing the surface of the base plate 2A after the separation step is not necessary; foreign matter (such as residual adhesive) may be removed as needed. Furthermore, double-sided tape or the like may be attached to the back surface of the wood laminate board 1 manufactured as described above. The above-described manufacturing method for the wood laminate board 1 is merely an example, and various other modifications are possible. For example, the manufacturing method may be configured to not include at least one of the solid portion forming step, the painting step, and the groove forming step.

[0036] In the above example, an aqueous adhesive is used as the adhesive 3 and applied using a roll coater 4, but this is not a limitation. In the above example, five veneers 11-15 are stacked as the plurality of veneers 11-15. However, two or more veneers, such as three to seven, may be used. In the above example, long veneers including laminated long veneers 11, 13 and decorative veneer 15 are alternately stacked with cross veneers including laminated cross veneers 12, 14. However, this is not a limitation. Alternatively, the long veneers including decorative veneers and the cross veneers may be stacked in a line-symmetrical arrangement with the center of the thickness direction as the axis of symmetry. The manufacturing method for a wood laminate board according to this embodiment and the configuration of each component and part of the wood laminate board 1 manufactured thereby are merely examples, and various other modifications are possible.

[0037] <Supplementary Notes> The above embodiments disclose the following technologies. <Technology 1> A method for manufacturing a wood laminate board, comprising: a veneer lamination step in which multiple veneers, each 0.8 mm thick or less, are laminated on a base plate that is long in a first direction by pressing each veneer to be adhered with adhesive; and a separation step in which the laminated multiple veneers are separated from the base plate to obtain a wood laminate board. <Technology 2> A method for manufacturing a wood laminate board as described in Technology 1, in which the surface of the base plate has releasability, and the multiple veneers are separated from the surface of the base plate in the separation step. <Technology 3> A method for manufacturing a wood laminate board as described in Technology 1, in which a sheet is adhered to the base plate, and the multiple veneers are separated from the base plate at the sheet in the separation step. <Technology 4> A method for manufacturing a wood laminate board as described in Technology 3, in which the sheet is moisture-permeable and the base plate is moisture-absorbent. <Technology 5> A method for manufacturing a wood laminate board as described in any one of Technology 1 to 4, in which the aqueous adhesive that constitutes the adhesive is applied using a roll coater. <Technology 6> A method for manufacturing a wood laminated board according to any one of Techniques 1 to 5, comprising a groove forming step for forming grooves that open on the surface side between the veneer laminating step and the separating step. <Technology 7> A method for manufacturing a wood laminated board according to any one of Techniques 1 to 6, wherein the outermost veneer of the plurality of veneers is a decorative veneer whose fiber direction is a first direction, and the other veneers of the plurality of veneers include an assembled cross veneer formed from laminated lumber in which multiple pieces of wood, each with their fiber direction in a second direction perpendicular to the first direction, are assembled in parallel in the first direction, and a assembled long veneer formed from laminated lumber in which multiple pieces of wood, each with their fiber direction in the first direction, are assembled. <Technology 8> A method for manufacturing a wood laminated board according to any one of Techniques 1 to 7, wherein at least one veneer of the plurality of veneers is impregnated with a dimensionally stabilizing resin. <Technology 9> A method for manufacturing a wood laminated board according to any one of Technology 1 to Technology 8, wherein at least one of the plurality of veneers is formed from wood that has been heat-treated with high-pressure steam.

[0038] REFERENCE SIGNS LIST 1 Wood laminate 2, 2A Base plate 3 Adhesive 4 Roll coater 8 Groove 10 Sheet 11 First laminated long veneer (laminated long veneer, veneer) 12 First laminated cross veneer (laminated cross veneer, veneer) 13 Second laminated long veneer (laminated long veneer, veneer) 14 Second laminated cross veneer (laminated cross veneer, veneer) 15 Decorative veneer (veneer)

Claims

1. A method for manufacturing a wood laminate comprising: a veneer lamination process in which a plurality of veneers, each having a thickness of 0.8 mm or less, are laminated on a base plate that is long in a first direction, by pressing each veneer after attaching it with adhesive; and a separation process in which the laminated veneers are separated from the base plate to obtain a wood laminate.

2. A method for manufacturing a wood laminate according to claim 1, wherein the surface of the base plate has releasability, and in the separating step, the plurality of veneers are separated from the surface of the base plate.

3. A method for manufacturing a wood laminate according to claim 1, characterized in that a sheet is attached onto the base plate, and in the separating step, the plurality of veneers are separated from the base plate at the portion of the sheet.

4. A method for manufacturing a wood laminate according to claim 3, characterized in that the sheet has moisture permeability and the base plate has moisture absorption properties.

5. A method for manufacturing a wood laminate according to any one of claims 1 to 4, characterized in that the aqueous adhesive constituting the adhesive is applied using a roll coater.

6. A method for manufacturing a wood laminate according to any one of claims 1 to 5, further comprising a groove forming process for forming grooves that open on the surface side between the veneer lamination process and the separation process.

7. A method for manufacturing a wood laminated board according to any one of claims 1 to 6, characterized in that the outermost veneer of the plurality of veneers is a decorative veneer whose fiber direction is a first direction, and the other veneers of the plurality of veneers include an assembled cross veneer formed from a laminated lumber in which a plurality of pieces of wood, each of which has its fiber direction in a second direction perpendicular to the first direction, are assembled in parallel in the first direction, and an assembled long veneer formed from a laminated lumber in which a plurality of pieces of wood, each of which has its fiber direction in the first direction, are assembled.

8. A method for producing a wood laminate according to any one of claims 1 to 7, wherein at least one of said plurality of veneers is impregnated with a dimensionally stabilizing resin.

9. A method for producing a wood laminate according to any one of claims 1 to 8, wherein at least one of the plurality of veneers is formed from wood that has been heat-treated with high-pressure steam.

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