JP6094966B2 - Manufacturing method for flooring - Google Patents

Description

  The present invention relates to a method for manufacturing a flooring.

  It is known to chamfer the corner between the surface and the side of a wooden decorative board provided with a decorative sheet on the surface of the wooden base material, and then apply the paint. For example, Patent Document 1 proposes a coating apparatus for coating a narrow slope such as a chamfered surface formed on a ridge between an upper surface and a side surface of an object to be coated such as a building board. .

  The coating apparatus of Patent Document 1 includes a coating roll in which at least a part of an outer peripheral surface forms a downward slope that can be in contact with a narrow slope, and an outer peripheral surface excluding a peripheral portion between the narrow slope of the coating roll. The rotating shaft that is in contact with a part other than the lowermost part of the outer peripheral surface in the part includes a non-vertical paint supply roll. Furthermore, the paint tank which immerses the lowest part of the outer peripheral surface of a coating-material supply roll in a coating material is also provided.

  When painting a narrow slope formed at the ridge between the upper surface and the side surface of the object to be coated using this coating apparatus, the object to be coated is not turned upside down and the upper surface is directed upward. Coating is performed using a coating roll whose contact surface with the coating surface is a downward slope. Since painting is performed with the top surface of the object to be coated facing upward, it is easy to check the state of painting even during painting work, and it is possible to effectively prevent a decrease in product yield due to oversight of defective painting. it can.

JP 2005-118735 A

  However, when painting a narrow slope using the above-mentioned coating equipment, when a coating roll is placed around the narrow slope of the object to be coated, the paint protrudes from the narrow slope and adheres to the upper surface, resulting in the appearance of the product. May worsen. In order to prevent the paint from protruding from a narrow slope, it is conceivable to reduce the amount of paint supplied from the paint supply roll to the paint roll. However, if the amount of paint supplied from the paint supply roll to the painting roll is reduced, the amount of coating applied to the narrow slope by the painting roll will be reduced, and there will be a problem that sufficient coating cannot be applied to the narrow slope. obtain.

  The present invention has been made in view of the above circumstances, and when a plurality of flooring materials are joined and laid, the gaps and steps generated in the joined portion are made inconspicuous, and the decorative effect is improved. It is an object of the present invention to provide a method of manufacturing a floor material that can manufacture a floor material that can be used.

In order to solve the above-mentioned problems, the floor material manufacturing method of the present invention reaches the wooden base material at the corner between the surface and the side surface of the wooden decorative board provided with a decorative sheet on the surface of the wooden base material. Chamfering to form a chamfered surface on which the wooden substrate is exposed between the surface and the side surface of the wooden decorative board; heating the chamfered surface; and facing the decorative sheet upward in the vertical direction In a ridge portion between the chamfered surface and the side surface of the wooden decorative board so as to form a gap between the chamfered surface and the coating roll that is in a non-contact state with the surface of the decorative sheet And a step of coating the chamfered surface by coloring the chamfered surface heated by contact and rotating.

In this floor covering manufacturing method, in the step of coloring and painting the chamfered surface, a part of the paint supply roll for supplying the paint to the coating roll is immersed in the paint, and the rotation speed of the paint supply roll is adjusted. Adjusting the supply amount of the paint from the paint supply roll to the coating roll, supplying the paint to the coating roll, applying the paint on the chamfered surface heated by rotating the coating roll, and It is preferable to color-paint.
Further, in this method for producing a flooring, in the step of coloring and painting the chamfered surface, contact is an angle formed by the roll surface of the painting roll and the chamfered surface of the wooden decorative board with respect to the surface of the decorative sheet. It is preferable to arrange the coating roll so that the angle is within 20 °.

  According to the present invention, when a plurality of floor materials are joined and laid, a floor material capable of making a gap or a step generated in a joint portion inconspicuous or improving a decorative effect is manufactured. Can do.

It is the schematic diagram which showed one Embodiment of the manufacturing method of the flooring of this invention in process order. It is a perspective view which shows one Embodiment of the flooring manufactured with the manufacturing method of the flooring of this invention .

  Hereinafter, an embodiment of a flooring manufacturing method of the present invention will be described with reference to the drawings.

  FIG. 1 is a schematic diagram showing an embodiment of a flooring manufacturing method of the present invention in the order of steps, and FIG. 2 shows an embodiment of a flooring manufactured by the flooring manufacturing method of the present invention. It is a perspective view. In the following embodiments, the longitudinal direction is the paper surface penetration direction in FIGS. 1A and 1B, the paper surface right and left directions in FIGS. 1C, 1D, and 1E, and the short direction is 1 (a) and 1 (b), the description will be made in the left-right direction of the paper surface, and FIGS.

  A wooden base material 1 shown in FIG. 1 (a) has a convex male fruit 2 formed on one of a pair of side surfaces 1b, 1b along the longitudinal direction among four surrounding side surfaces, and a concave female fruit 3 on the other side. Is formed. Each of the male fruit 2 and the female fruit 3 is a male between two floor materials 40 arranged adjacent to each other when a plurality of floor materials 40 shown in FIG. The fruit 2 has a shape that can be fitted to the female fruit 3. Specifically, the outer peripheral shape of the male fruit 2 and the inner peripheral shape of the female fruit 3 are substantially the same. Such male fruit 2 and female fruit 3 are the same not only for the pair of side surfaces 1b and 1b along the longitudinal direction of the wooden substrate 1, but also for the pair of side surfaces 1c and 1c along the short direction of the wooden substrate 1. (See FIGS. 1C, 1D and 1E, and FIG. 2).

  A chamfered surface 4 is formed along the longitudinal direction at the boundary between the surface 1a of the wooden substrate 1 and the side surface 1b along the longitudinal direction. The chamfered surface 4 is formed, for example, by chamfering the corner between the surface 1a and the side surface 1b of the wooden substrate 1 using a cutting tool such as a saw or a router. In the present embodiment, the chamfered surface 4 is formed in a flat shape (C chamfer), but may be formed in a curved surface (R chamfer) having an arcuate cross section.

  When the chamfered surface 4 is a C chamfer, when a plurality of floor materials 40 are joined and laid, a groove having a V-shaped cross section is formed as a joint or the like in the joint. This groove prevents a gap or a step generated in the joint from being noticeable. In addition, the decorative effect is improved by, for example, making a three-dimensional appearance appear on the floor surface formed by laying the flooring 40. When the chamfered surface 4 is an R chamfer, a U-shaped groove is formed in the joint.

  The wood substrate 1 has a decorative groove 5 formed in the longitudinal direction in the surface 1a and having substantially the same shape as the groove of the joint. In the present embodiment, since the chamfered surface 4 is a C chamfer, a decorative groove 5 having a V-shaped cross section is formed. When the chamfered surface 4 is an R chamfer, a decorative groove 5 having a U-shaped cross section is formed. The decorative groove 5 is formed by, for example, cutting the surface 1a of the wooden substrate 1 using a cutting tool as described above. This decorative groove 5 also has a decorative effect such that a three-dimensional effect appears on the floor surface when a plurality of floor materials 40 are joined and laid. Moreover, it has the effect of making the position of the joint portion inconspicuous.

  The wood substrate 1 includes plywood, particle board, medium density fiberboard (MDF), and a mixed board (Wood Plastic Board: WPB) formed by molding a mixture of wood flour and resin into a plate shape. And an oriented strand board. Or what combined these can also be used as the wooden base material 1. FIG. For example, a composite material obtained by bonding MDF or WPB to the surface of a plywood can be used as the wood substrate 1.

  Next, as shown in FIG. 1B, a decorative sheet 6 is laminated on the surface 1 a of the wooden substrate 1 to obtain a wooden decorative board 10.

  Examples of the decorative sheet 6 include a single layer structure in which a pattern layer is provided on the front and back surfaces of a thermoplastic resin sheet, and a multilayer structure in which a pattern layer and a thermoplastic resin layer are laminated.

  As the thermoplastic resin constituting the sheet of the decorative sheet 6 and the thermoplastic resin layer, for example, a polyolefin resin, a polyester resin, an acrylic resin, a polystyrene resin, a polyamide resin, a polyvinyl chloride resin, or the like may be used. it can. Among these, it is desirable to use a polyolefin-based resin or a polyester-based resin in consideration of surface properties, processability, economic efficiency, discardability, and the like as a flooring material.

  As for the thickness of the decorative sheet 6, it is desirable to adopt a thin one in consideration of cost and workability.

  The decorative sheet 6 is laminated on the surface 1a of the wooden substrate 1 using an adhesive. As the adhesive, it is desirable to use an adhesive having excellent water resistance after bonding. Specific examples include an ethylene-vinyl acetate copolymer emulsion adhesive, a two-component curable urethane-based adhesive, a one-component moisture-curable urethane-based hot melt adhesive, and the like.

  When laminating the decorative sheet 6 on the surface 1a of the wooden substrate 1, the inner surface of the decorative groove 5 on the surface 1a of the wooden substrate 1 and the chamfered surface 4 formed along the longitudinal direction using a narrow roll or the like. The decorative sheets 6 are laminated along.

  Next, as shown in FIG. 1 (c), the corner portion between the surface 10a of the wooden decorative board 10 and the side surface 10b along the short direction is applied to the wooden substrate 1 using the cutting tool as described above. Chamfering to reach. As a result, a chamfered surface 11 from which the wooden substrate 1 is exposed is formed along the short direction at the boundary between the surface 10a of the wooden decorative board 10 and the side surface 10b along the short direction. In the present embodiment, the chamfered surface 11 is formed in a flat shape (C chamfer), but may be formed in a curved surface (R chamfer) having an arcuate cross section.

  Next, as shown in FIG. 1 (d), the chamfered surface 11 of the wooden decorative board 10 is heated using a heating means 20 such as an infrared condensing heater. A heating furnace can also be used as the heating means 20. In this case, it is only necessary to heat at least the chamfered surface 11 through the wood decorative board 10 through the heating furnace. As long as the chamfered surface 11 can be heated in this way, the heating method is not particularly limited.

  The heating of the chamfered surface 11 can be performed on the wooden decorative board 10 fed out in the short direction before the colored coating of the chamfered surface 11 in the step of coloring and painting the chamfered surface 11 described later.

  By heating the chamfered surface 11, the paint applied to the chamfered surface 11 in the colored coating of the chamfered surface 11 described later is heated, the paint temperature rises instantaneously, and the permeability to the chamfered surface 11 is improved. Therefore, it is considered that the chamfered surface 11 is heated to such an extent that the paint temperature of the paint applied to the chamfered surface 11 increases. For example, when using an infrared condensing heater, the chamfered surface 11 may be heated with an infrared condensing heater equivalent to at least 1 kW.

  Next, as shown in FIG. 1 (e), the chamfered surface 11 is colored and coated by applying a paint 30 to the chamfered surface 11 using a coating roll 21.

  As the coating material 30, it is desirable to use a paint having a color tone approximate to the color tone of the surface 6 a of the decorative sheet 6. Since the color tone of the surface 6a of the decorative sheet 6 is similar to the color tone of the colored coating film of the chamfered surface 11 described later, a flooring material with better design can be obtained.

  The shape of the coating roll 21 is cylindrical if it can rotate while contacting the ridge 12 between the chamfered surface 11 and the side surface 10b of the wooden decorative board 10 in a non-contact state with respect to the surface 6a of the decorative sheet 6. There is no particular limitation such as a conical shape or a truncated cone shape. In this embodiment, the coating roll 21 has a truncated cone shape, a portion corresponding to the side surface of the truncated cone is a roll surface 22, and the roll surface 22 is in a non-contact state with respect to the surface 6 a of the decorative sheet 6. It is formed to be able to contact the ridge 12.

  The material of the coating roll 21 is not particularly limited, such as a synthetic resin material, a rubber material, or a metal material, but it is preferable to use a material that is inexpensive and easy to process.

  When the chamfered surface 11 of the wooden decorative board 10 is colored and coated using such a coating roll 21, the decorative sheet 6 side surface of the wooden decorative board 10 is directed upward in the vertical direction. The coating roll 21 is such that the tip side portion of the roll surface 22 contacts the ridge portion 12 of the wooden decorative board 10 and the base side portion of the roll surface 22 does not contact the surface 6 a of the decorative sheet 6. The shaft is rotatably supported around the rotation shaft 23. The rotating shaft 23 is formed to extend in a substantially vertical direction. In the coating roll 21 having the truncated cone shape, the tip side refers to the small diameter side of the truncated cone, and the base side refers to the large diameter side of the truncated cone.

  The roll surface 22 of the painting roll 21 and the chamfered surface 11 of the wooden decorative board 10 are in a non-contact state except for the ridge portion 12, and between the roll surface 22 of the coating roll 21 and the chamfered surface 11 of the wooden decorative board 10. Is formed with a gap Q.

  In this embodiment, the coating material 30 is supplied to the coating roll 21 using the coating material supply roll 50, and the coating material roll 30 is rotated to supply the coating material 30 from the roll surface 22 of the coating roll 21 to the gap Q. Yes.

  The shape of the coating material supply roll 50 is not particularly limited as long as the coating material 30 can be supplied to the coating roll 21, such as a columnar shape, a conical shape, and a truncated cone shape. In the present embodiment, the coating material supply roll 50 has a truncated cone shape similar to that of the coating roll 21, and a portion corresponding to the side surface of the truncated cone is a roll surface 51.

  The material of the coating material supply roll 50 is not particularly limited, such as a synthetic resin material, a rubber material, or a metal material, but it is preferable to use a material that is inexpensive and easy to process.

  The coating material supply roll 50 is disposed so that the roll surface 51 and the roll surface 22 of the coating roll 21 face each other at a portion located on the upper side in the vertical direction, and is rotatably supported around a rotation shaft 52. The rotating shaft 52 is orthogonal to the rotating shaft 23 of the coating roll 21 and is formed to extend in a substantially horizontal direction. The coating material supply roll 50 may be disposed so that the roll surface 51 abuts on the roll surface 22 of the coating roll 21 as long as the coating material 30 can be supplied to the coating roll 21, and is disposed at a predetermined interval. Also good.

  Below the paint supply roll 50, a paint storage tank 31 storing the paint 30 is installed. The paint storage tank 31 is disposed such that a portion of the paint supply roll 50 located on the lower side in the vertical direction is immersed in the paint 30 of the paint storage tank 31.

  By rotating the coating material supply roll 50, the coating material 30 can be spread over the entire circumference of the roll surface 51 of the coating material supply roller 50, and the coating material 30 can be carried to a portion located on the upper side in the vertical direction. The coating material 30 carried to the portion located on the upper side in the vertical direction is supplied to the roll surface 22 of the coating roll 21 facing the roll surface 51 in that portion. The coating material 30 supplied to the roll surface 22 of the coating roll 21 is spread over the entire circumference of the rolling surface 22 of the coating roll 21 by rotating the coating roll 21, and the coating material 30 can be supplied to the gap Q. The coating material 30 supplied to the gap Q has its coating temperature instantaneously increased by the heat of the heated chamfered surface 11 and the permeability of the coating material 30 into the chamfered surface 11 is improved.

  Here, the supply amount of the paint 30 from the paint supply roll 50 to the coating roll 21 can be adjusted by adjusting the rotation speed of the paint supply roll 50. For this reason, what is necessary is just to set the rotational speed of the coating material supply roll 50 suitably so that the chamfering surface 11 may be coated with the optimal application quantity.

  The coating roll 21 and the paint supply roll 50 are rotated synchronously by providing a gear on the rotation shaft of the coating roll 21 and the paint supply roll 50 or on the extension thereof and connecting the rotary shafts 23 and 52 via the gear. You can also. By this synchronized rotation, a certain amount of the paint 30 can be supplied from the paint supply roll 50 to the coating roll 21, and the chamfered surface 11 of the wooden decorative board 10 can be applied with a uniform thickness.

  In coloring and painting the chamfered surface 11, the wooden decorative board 10 is sent out along the short direction, and the painting roll 21 is rotated in the same direction as the feeding direction of the wooden decorative board 10. Accordingly, the chamfered surface 11 can be colored and applied by applying the coating material 30 over the entire length of the chamfered surface 11 of the wooden decorative board 10 in the short direction. The coated surface is dried as necessary. By performing the drying process, the obtained flooring material can be loaded and packed.

  In the color painting of the chamfered surface 11, the wooden decorative board 10 is sent out along the short direction. Before the colored decorative coating of the chamfered surface 11 is applied to the wooden decorative board 10 being sent out, FIG. The chamfered surface 11 shown can also be heated. For example, the wooden decorative board 10 is fed out in the short direction at a feed rate of 15 m / min, the chamfered surface 11 of the wooden decorative board 10 is heated with an infrared condensing heater 1 kw, and then the chamfered surface 11 is applied by the coating roll 21. The coating material 30 is applied to the surface. Thereafter, the coated surface can be dried with an infrared condensing heater equivalent to 2 kw as required. Of course, the feeding speed of the wooden decorative board 10, the heating method of the chamfered surface 11, and the drying method of the coated surface are not limited to the above-described configuration, but depending on the configuration of the equipment, the type of paint, the type of target flooring, etc. Is set as appropriate.

  Since the coating roll 21 and the surface 6a of the decorative sheet 6 are in a non-contact state, only the chamfered surface 11 along the short direction can be colored and coated without coloring the surface 6a of the decorative sheet 6. . Further, in the colored coating of the chamfered surface 11, the paint 30 is applied to the heated chamfered surface 11, so that the paint 30 can be effectively penetrated into the chamfered surface 11 by the increase in the paint temperature due to the heat of the chamfered surface 11. Thereby, the application quantity to the chamfering surface 11 can be increased, and the quality of the flooring obtained can be improved. Since the wooden base material 1 exposed on the chamfered surface 11 is covered and covered by this colored coating, a sense of incongruity due to the difference between the color tone of the wooden base material 1 and the color tone of the decorative sheet 6 is reduced, and the design is excellent in FIG. Floor material 40 can be obtained.

  The contact angle θ between the contact surface 24 of the painting roll 21 with the wooden decorative board 10 and the chamfered surface 11 of the wooden decorative board 10 (the angle formed between the roll surface 22 of the painting roll 21 and the chamfered face 11 of the wooden decorative board 10). It is preferable to arrange the coating roll 21 so as to be within 20 °. More preferably, it is 3 ° or more and 15 ° or less. If the contact angle θ is within 20 °, the paint 30 can be supplied from the roll surface 22 of the coating roll 21 to the gap Q more efficiently. In addition, the paint 30 supplied to the gap Q can be applied to the chamfered surface 11 by effectively contacting the chamfered surface 11 of the wooden decorative board 10. Furthermore, the coating material 30 supplied to the gap Q is more effectively suppressed from entering the portion other than the chamfered surface 11 of the wooden decorative board 10 such as the surface 6a of the decorative sheet 6 and coloring the portions other than the chamfered surface 11. Paint can be suppressed.

  When the chamfered surface 11 of the wooden decorative board 10 is colored and coated as described above, a flooring 40 in which the colored coating film 13 is formed on the chamfered surface 11 of the wooden decorative board 10 is obtained as shown in FIG. It is done. When a plurality of the obtained flooring materials 40 are bonded to each other and laid, it is possible to make a gap or a step generated in the bonding portion inconspicuous or improve a decorative effect.

In the above embodiment, the decorative sheet 6 is laminated on the chamfered surface 4 formed at the corner in the longitudinal direction of the wooden decorative board 10, and the chamfered surface 4 formed at the corner in the short direction is colored. Although the form which forms the coating film 13 was shown, it is not limited to this. The colored coating film 13 is formed on both the chamfered surfaces in the longitudinal direction and the short side direction, the decorative sheet 6 is laminated on the chamfered surface in the short side direction, and the colored coating film 13 is formed on the chamfered surface in the longitudinal direction. You may do it. In the above embodiment, the paint supply roll 50 is used for coloring the chamfered surface 11, but the chamfered surface 11 can be colored and coated without using the paint supply roll .

DESCRIPTION OF SYMBOLS 1 Woody base material 1a Surface 6 Decorative sheet 6a Surface 10 Wooden decorative board 10a Surface 10b Side surface 11 Chamfered surface 12 Ridge part 21 Paint roll 30 Paint 40 Floor material 50 Paint supply roll

Claims (3)

A chamfering process that reaches the wooden base material is performed at a corner between the surface and the side surface of the wooden decorative board having a decorative sheet on the surface of the wooden base material, and the wooden material is provided between the surface and the side surface of the wooden decorative board. A step of forming a chamfered surface on which the base material is exposed, a step of heating the chamfered surface, and a coating roll which is in a non-contact state with respect to the surface of the decorative sheet in a state where the decorative sheet is directed upward in the vertical direction. And applying a paint to the chamfered surface heated by rotating while contacting the ridge between the chamfered surface and the side surface of the wooden decorative board so as to form a gap between the chamfered surface and the chamfered surface. And a process for producing a chamfered surface by coloring.   In the step of coloring and painting the chamfered surface, a part of the paint supply roll that supplies the paint to the paint roll is immersed in the paint, and the rotation speed of the paint supply roll is adjusted to change the paint roll from the paint roll. The paint supply amount is adjusted to supply the coating roll to the coating roll, and the coating roll is rotated to apply the coating to the heated chamfered surface, and the chamfered surface is colored. The manufacturing method of the flooring material of Claim 1. In the step of coloring and painting the chamfered surface, the coating is performed such that a contact angle, which is an angle between the roll surface of the coating roll and the chamfered surface of the wooden decorative board, is within 20 ° with respect to the surface of the decorative sheet. A method for producing a flooring according to claim 1 or 2, wherein a roll is disposed.

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