CN105459713B - 装饰板及装饰板的制造方法 - Google Patents

装饰板及装饰板的制造方法 Download PDF

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Publication number
CN105459713B
CN105459713B CN201510627625.5A CN201510627625A CN105459713B CN 105459713 B CN105459713 B CN 105459713B CN 201510627625 A CN201510627625 A CN 201510627625A CN 105459713 B CN105459713 B CN 105459713B
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China
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layer
decorative
hole
outer layer
decorative panel
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CN105459713A (zh
Inventor
滨田宽
佐沟亚衣子
丸山喜久
平户雅浩
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Yamaha Fine Technologies Co Ltd
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Yamaha Fine Technologies Co Ltd
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Abstract

本发明提供装饰板及装饰板的制造方法，该装饰板具备：外层，其形成有贯通孔，该贯通孔在具有装饰物的表面和该表面的相反侧的背面开口；装饰层，其具有镶嵌图案部，具有大致相同的层厚，并配置于外层的整个背面，该镶嵌图案部以形成一部分从背面侧进入贯通孔内的形状的方式弯曲变形。

Description

装饰板及装饰板的制造方法
技术领域
本发明涉及装饰板及装饰板的制造方法。
本申请基于2014年9月30日在日本申请的特愿2014-201153号主张优先权，在此引用其内容。
背景技术
以往，公知如下装饰板的制造方法，该装饰板设计成在重叠相互不同的多层的层叠体的外层的一部分形成贯通孔，经由外层的贯通孔可以看见内层(例如参照美国专利第6633019号)。
在美国专利第6633019号所记载的方法中，相对于外层和内层层叠而成的复合体，通过激光加工将外层的一部分除去，以在外层形成规定的设计图案的贯通孔。使用该文献所公开的技术通过激光加工等将层叠体的外层除去后，从外层的贯通孔看到的内层在相对于外层的最外表面凹陷的位置处呈平面状露出。
另外，作为用于高效地生产具有镶嵌图案的装饰板的方法，在日本特开2003-326897号公报中公开了如下技术，相对于具有能够插入镶嵌部件的窗孔的装饰件，在将镶嵌部件装填到窗孔内后，从背面侧进行注塑成型。
在美国专利第6633019号所记载的技术中，经由外层的贯通孔能够看到的内层的外表面是单调的平面，设计的自由度低。在日本国特开2003-326897号所记载的技术中，将镶嵌部件装填到窗孔内的加工花费功夫，并且需要镶嵌部件与窗孔的尺寸高精度一致，因此生产率低。
发明内容
本发明正是鉴于上述情况而完成的，其目的在于能够提供设计的自由度高且能够容易地生产的装饰板及其制造方法。
本发明的一个方式的装饰板具备：外层，其形成有贯通孔，该贯通孔在表面和背面开口；装饰层，其具有大致相同的层厚并配置于所述外层的整个背面；所述装饰层具有镶嵌图案部，该镶嵌图案部以一部分从所述外层的背面侧进入所述贯通孔内的方式弯曲。
所述装饰层可以形成为，在所述镶嵌图案部，至少紧贴于所述贯通孔的所述背面侧的开口端并朝向所述贯通孔的内部弯曲。
上述方式的装饰板还可以具备：内层，其配置在所述装饰层的与相接于所述外层的面相反的面上并具有大致相同的层厚，并且在从所述外层的层厚方向观察时，在位于所述贯通孔的开口内的区域，具有沿着所述外层的层厚方向，从所述外层的背面朝向所述外层的表面的方向上凸起的弯曲面；成型树脂层，其配置在所述内层的与相接于所述装饰层的面相反的面上。
本发明的其他方式的装饰板具备：外层，其形成有贯通孔，该贯通孔在表面和背面开口；装饰层，其配置在所述外层的整个背面，覆盖所述贯通孔的所述背面侧的开口并具有大致相同的层厚；内层，其配置在所述装饰层的与相接于所述外层的面相反的面上；成型树脂层，其配置在所述内层的与相接于所述装饰层的面相反的面上。
在上述各方式中，可以是所述外层由木质材料形成，所述装饰层由与所述外层不同的材料形成。所述装饰层可以由金属材料形成。
本发明的装饰板的制造方法为：准备具有第一层和第二层的层积体，以使所述第二层露出的方式将所述第一层的一部分从所述层叠体除去，从所述第二层侧朝向所述第一层侧对所述层积体进行加压，以所述第二层的一部分嵌入所述贯通孔的方式使所述第二层弯曲变形。
在所述成型工序中，也可以在从所述第二层侧朝向所述第一层侧对所述层积体进行加压时，使所述层积体的一面与成型模具接触，而将所述层积体设置于所述成型模具。
在所述成型工序中，也可以将所述层积体设置于成型模具，以树脂的流动体与所述第二层相接的方式使所述流动体流入所述成型模具内，并在加压下使所述流动体固化。
根据本发明，对装饰板的设计的自由度高且能够容易地生产。
附图说明
图1是表示本发明的第一实施方式的装饰板的俯视图。
图2是图1的A-A线的剖视图。
图3是将图2的一部分放大的剖视图。
图4是表示第一实施方式的装饰板的制造方法的流程图。
图5是表示第一实施方式的装饰板的制造工序的剖视图。
图6是表示第一实施方式的装饰板的制造工序的剖视图。
图7是表示第一实施方式的装饰板的制造工序的剖视图。
图8是表示第一实施方式的装饰板的制造工序的剖视图。
图9是表示本发明的第二实施方式的装饰板的俯视图。
图10是图9的B-B线的剖视图。
图11是表示本发明的实施例中的层叠体的俯视图。
图12是图11的C-C线的剖视图。
具体实施方式
(第一实施方式)
对本发明的第一实施方式进行说明。图1是本实施方式的装饰板的俯视图。图2是图1的A-A线的剖视图。图3是图2的放大图。
如图1及图2所示，装饰板1具备外层2、装饰层5和成型树脂层7。
装饰板1是与装饰层5相接的成型树脂层7通过嵌件成型而相对于外层2和装饰层5依次层叠的层叠体8一体化的板。
图3所示的外层2是在表面2a具有装饰物的片状的部件。在外层2上形成有在表面2a和其相反面(背面2b)双方开口的贯通孔3。在本实施方式中，外层2由木质材料形成。在本实施方式中举例示出的外层2的表面的装饰物是天然木纹。
图3所示的装饰层5是由金属材料形成的具有大致相同的层厚的部件。另外，在本实施方式中，装饰层5的层厚定义为，装饰层5的外表面中的相接于外层2的一侧的面(表面5a)与相接于成型树脂层7的一侧的面(背面5b)之间的最短距离。装饰层5配置在外层2的背面2b的整个面。
装饰层5中的经由外层2的贯通孔3能够看到的部分成为看起来对外层2实施镶嵌细工的镶嵌图案部6。镶嵌图案部6是装饰层5中的以形成为一部分从外层2的背面2b侧进入外层2的贯通孔3内的形状的方式弯曲变形的部分。在本实施方式中，镶嵌图案部6以与外层2的表面2a大致共面的方式配置在贯通孔3的内部。镶嵌图案部6紧贴于外层2的贯通孔3的开口中位于外层2的背面侧的开口端4。而且，镶嵌图案部6相对于沿着外层2的背面2b的面，朝向外层2的贯通孔3的内部弯曲。
成型树脂层7配置在装饰层5的外表面中的与相接于外层2的一侧的面(表面5a)相反的面(背面5b)。成型树脂层7将外层2和装饰层5保持成规定的立体形状。
接下来，对本实施方式的装饰板1的制造方法进行说明。图4是表示本实施方式的装饰板的制造方法的流程图。图5至图8是表示本实施方式的装饰板的制造工序的剖视图。
在本实施方式中，如图5所示，使用平板状的层叠体8制造装饰板1，该层叠体8是将制造后成为图3所示的外层2的第一层2A、制造后成为图3所示的装饰层5的第二层5A层叠而成的。层叠体8的第一层2A和第二层5A通过粘接剂被相互固定。
首先，如图6所示，在层叠体8呈平板状的状态下将第一层2A的一部分除去以使第二层5A露出(外层加工工序，步骤S1，参照图4)。
在步骤S1中，根据装饰板1的设计决定除去第一层2A的哪个区域。即，在步骤S1中，形成与设计对应的规定的图案的贯通孔3形成于第一层2A。作为将第一层2A的一部分除去的方法的一例，举出通过激光加工除去第一层2A的方法。在使用激光加工的情况下，能够进行与激光加工宽度对应的精细加工。另外，在激光加工中，通过适当设定输出和脉冲等，以能够除去由木质材料形成的第一层2A及第一层2A与第二层5A之间的粘接剂，但不会除去由金属材料形成的第二层5A，来呈图案状除去第一层2A以使第二层5A的外表面露出。
另外，将第一层2A的一部分除去的方法不限定于激光加工。
至此步骤S1结束，进入步骤S2。
步骤S2是从第二层5A侧向第一层2A侧施加压力而使第二层5A的一部分嵌入第一层2A的贯通孔3内的成型工序。在本实施方式的步骤S2中，使第一层2A的外表面中相接于第二层5A的面的相反侧的面(第一层2A的表面)与规定的成型模具M接触，如图7及图8所示地进行嵌件成型。
在步骤S2中，例如，根据设计从各种形状的成型模具M中选择以覆盖通过除去第一层2A的一部分而在第一层2A上形成的贯通孔3的方式沿着第一层2A的表面的成型模具M、或在贯通孔3所在的部分具有凹凸等的成型模具M等，进行嵌件成型。
例如，在使用以覆盖形成于第一层2A的贯通孔3的方式沿着第一层2A的表面的成型模具M的情况下，通过在将层叠体8安装到成型模具M内后使嵌件树脂的流动体流入成型模具M内，而使嵌件树脂与第二层5A相接，并从第二层5A侧对层叠体8加压。而且，嵌件树脂的流动体在嵌件树脂与第二层5A接触的状态下固化成仿照成型模具M的形状的规定形状。
当嵌件树脂从第二层5A侧对层叠体8加压时，第二层5A弯曲变形成第二层5A的一部分向第一层2A的贯通孔3嵌入。第二层5A在第一层2A的贯通孔3内的弯曲变形的形态根据嵌件树脂的注射压而不同。嵌件树脂的注射压根据第一层2A的贯通孔3的开口面积及开口形状和第二层5A的材质及层厚设定。
例如，当第二层5A以从第一层2A的背面朝向表面凸起的方式进入第一层2A的贯通孔3时，第二层5A的外表面形成为弧形直到第二层5A与成型模具M接触。当第二层5A通过第一层2A的贯通孔3到达成型模具M时，第二层5A变形成仿照成型模具M的形状。在以覆盖形成于第一层2A的贯通孔3的方式沿着第一层2A的表面的成型模具M中，当第二层5A到达成型模具M时，第二层5A的最外表面与第一层2A的表面共面。另外，在以覆盖形成于第一层2A的贯通孔3的方式沿着第一层2A的表面的成型模具M中，若适当设定嵌件树脂的注射压，则第二层5A变形为第二层5A将第一层2A的贯通孔3完全填平并且层叠体8的最外表面变得平滑。
至此步骤S2结束。在步骤S2结束后，在层叠体8的表面形成有看起来第二层5A埋入贯通孔3的镶嵌图案。
也可以根据需要，在步骤S2后进行追加的工序，该追加的工序是对第一层2A的外表面进行涂装或者对第一层2A和第二层5A的表面进行抛光等后续加工。
根据本实施方式的装饰板1的制造方法，与以往的镶嵌细工不同，能够通过片状的第二层5A的成型制作出镶嵌部件。在上述步骤1中层叠体8是平板状，因此从层叠体8将第一层2A的一部分除去时的加工容易。特别地，在激光加工中，需要将激光的焦点聚焦于适当的位置进行加工，在对立体的结构物的激光加工中需要频繁地进行焦点的移动。与此相对，在本实施方式中，是相对于平板状的层叠体8将片状的第一层2A的一部分除去的加工，因此能够减少激光加工中的焦点位置的变更频率，能够进行容易且高精度的加工。
另外，在本实施方式中，在上述步骤S1中，第一层2A和第二层5A粘接，并且能够第一层2A和第二层5A不分离地在第一层2A的贯通孔3内形成第二层5A的镶嵌图案。因此，与如以往的镶嵌细工那样在槽中嵌入镶嵌部件的细工相比较，不存在槽(本实施方式中是贯通孔3)和镶嵌部件(本实施方式是第二层5A)的位置偏移。另外，在以往的镶嵌细工中，在向槽嵌入镶嵌部件的工序中，槽的加工误差与镶嵌部件的加工误差分别产生，因此存在镶嵌部件不能进入槽的情况、或者在槽和镶嵌部件之间产生多余的隙间的可能性。与此相对，在本实施方式中，形成于第一层2A的贯通孔3的轮廓成为第二层5A的弯曲变形的起点，因此能够容易地形成镶嵌部件无隙间地嵌入槽这样精度高且美观性优秀的镶嵌图案。
另外，在本实施方式中，相对于平板状的层叠体8将第一层2A的一部分除去来作出设计后，对层叠体8付与三维的弯曲形状，因此作出设计时的自由度高。另外，在以往的镶嵌细工中，在相对于立体形成用于镶嵌的槽的情况下存在设计变更时，需要变更槽的成型工序的繁杂的设定变更。与此相对，在先将平板状的层叠体8的第一层2A的一部分除去的本实施方式的制造方法中，存在设计变更时的设定变更容易。
因此，在少量生产多种设计的产品的情况下，每个设计的制造设备或设定的变更部位少，因此生产率高。
(变形例)
接下来，对上述实施方式的变形例进行说明。
成型模具M的形状不限定于上述实施方式中说明的形状。例如，如果是具有与第一层2A的表面2a相接的第一成型面和相对于第一成型面凹陷的第二成型面的成型模具，则通过嵌件成型来形成第二层5A从第一层2A的表面2a突出的镶嵌图案。本变形例的装饰板的制造方法也能够容易地形成镶嵌部件无隙间地嵌入槽这样精度高且美观性优秀的镶嵌图案。
(第二实施方式)
对本发明的第二实施方式进行说明。图9是表示本实施方式的装饰板的俯视图。图10是图9的B-B线的剖视图。
如图9及图10所示，装饰板11在装饰层5和成型树脂层7之间具有内层9这一点上结构与上述第一实施方式不同。
装饰板11是成型树脂层7以与内层9相接的方式通过嵌件成型相对于外层2、装饰层5和内层9依次层叠的层叠体10一体化的板。
内层9是配置于装饰层5的外表面中的与相接于外层2的面(表面5a)相反的面(背面5b)的片状的部件。内层9具有大致相同的层厚。内层9可以由与外层2相同的原材料形成。例如，当外层2是木材时，内层9也可以是木材，树种可以相同也可以不同。另外，优选的是，内层9的热或水分的膨胀率是与外层2相同的程度。
当从外层2的层厚方向观察内层9时，在存在于外层2的贯通孔3的开口内的区域具有沿着外层2的层厚方向在从外层2的背面朝向外层2的表面的方向上凸起的弯曲面9c、9d。内层9的弯曲面9c、9d是在成型树脂层7的嵌件成型的过程中形成的面。
本实施方式的成型树脂层7配置在内层9的外表面中的与相接于装饰层5的面(表面9a)相反的面(背面9b)。成型树脂层7将外层2、装饰层5和内层9保持成规定的立体形状。
本实施方式的装饰板1的制造方法，代替在第一实施方式中说明的层叠体8，而使用制造后成为外层2的第一层2A、制造后成为装饰层5的第二层5A、制造后成为内层9的第三层9A依次层叠并通过粘接成为固定状态的层叠体10(参照图12)。
本实施方式的层叠体10具有第一层2A和第三层9A将第二层5A夹在中间的三明治状的层叠结构。第三层9A具有大致相同的层厚。而且，第一层2A和第三层9A由相同的原材料形成，或者由热或水分的膨胀率为相同程度的原材料形成。因此，本实施方式的层叠体10难以引起温度或湿度等环境变化的影响导致的变形。
相对于本实施方式的层叠体10，与上述第一实施方式相同地将第一层2A的一部分除去来形成设计(参照第一实施方式的步骤S1)，然后，以嵌件树脂与第三层9A接触的方式在成型模具M内进行嵌件成型(参照第一实施方式的步骤S2)。
通过这样的制造方法，能够与上述第一实施方式相同地，容易地形成看起来高精度地形成镶嵌细工的美观性优秀的镶嵌图案。
(实施例)
接下来，对由第二实施方式中使用的层叠体10形成的装饰板的实施例进行更详细地说明。图11是表示本发明的实施例中的层叠体的俯视图。图12是图11的C-C线的剖视图。另外，在图11及图12中，图示出在第一层2A上形成有贯通孔3的状态下形成为平板状的层叠体10。
在本实施例中，如图11及图12所示，表示使用由木质材料形成的外层2、由金属材料形成的装饰层5和由木质材料形成的内层9依次层叠而成的层叠体10，制造上述第二实施方式所公开的装饰板11的例子。
由外层2和内层9形成的第一层2A及第三层9A是由彼此相同的天然木材形成的0.2mm厚的片状。
成为装饰层5的第二层5A是由金属形成的薄板件。
本实施例所示的外层2及内层9乃至装饰层5的材料种类和装饰层5的层厚如下述表1所示。表1的“装饰层材料种类”栏所示的“A1050”及“A5052”是JISH4000(铝及铝合金的板和条)中规定的等级。
表1
装饰层材料种类 装饰层厚 外层内层材料种类
实施例1 纯铝A1050 0.3mm 古夷苏木
实施例2 纯铝A1050 0.3mm 萨佩莱木
实施例3 纯铝A1050 0.5mm 古夷苏木
实施例4 纯铝A1050 0.5mm 萨佩莱木
实施例5 铝合金A5052 0.5mm 古夷苏木
实施例6 铝合金A5052 0.5mm 萨佩莱木
对于上述表1所示的实施例1至实施例6，在以下的表2中表示能够以目视判别因带状的贯通孔3而变形的第二层5A(装饰层5)的注射压的值，带状的贯通孔3是呈带状将成为外层2的第一层2A较长地除去而形成的。所谓“能够以目视判别因贯通孔而变形的第二层”是指，能够以目视区别出相对于在嵌件成型前的层叠体10中，在贯通孔3内看到的第二层5A的平板状的外表面，在嵌件成型后的带有嵌件树脂的层叠体10中，在贯通孔3内看到的第二层5A的外表面上产生弯曲的情况。
表2
在上述各实施例中，作为嵌件成型的注射压，设定900kgf/cm2、1200kgf/cm2、1500kgf/cm2及1800kgf/cm2这4种条件。在上述表2中表示出，在各实施例中对于每个贯通孔3的宽度能够以目视判别出因贯通孔3而变形的第二层5A的最低的注射压。上述表2中的空白栏部是在注射压为1800kgf/cm2的条件下无法以目视判别出因贯通孔3而变形的第二层5A。
根据上述表2可知，为了形成合适的镶嵌图案所需要的注射压随着贯通孔3的宽度变大而逐渐降低。另外，在实施例1至实施例6中任一条件下，贯通孔3的宽度只要是1.5mm以上就能够形成合适的镶嵌图案。
另外，外层2和内层9的材料种类的不同对为了形成合适的镶嵌图案所需要的注射压的影响小。因此，外层2及内层9的材料种类，如果是木质材料，则认为可以根据设计上的要求，从比较大的范围内的选择项中适当选择。
以上，参照附图对本发明的实施方式进行了详细说明，但具体的结构不限于该实施方式，也包括不脱离本发明的主旨的范围的设计变更等。

Claims (8)

1.一种装饰板，其特征在于，具备：
层积体，其包括外层和装饰层，所述外层形成有贯通孔，该贯通孔在表面和背面开口，所述装饰层具有大致相同的层厚并配置于所述外层的整个背面；
内层，其配置在所述装饰层的与相接于所述外层的面相反的面上并具有大致相同的层厚，并且在从所述外层的层厚方向观察时，在位于所述贯通孔的开口内的区域，具有沿着所述外层的层厚方向，从所述外层的背面朝向所述外层的表面的方向上凸起的弯曲面，
成型树脂层，其配置在所述内层的与相接于所述装饰层的面相反的面上；
所述装饰层具有镶嵌图案部，通过从所述装饰层对所述层积体进行加压，使所述装饰层的一部分以从所述外层的背面侧进入所述贯通孔内的方式弯曲而形成所述镶嵌图案部。
2.根据权利要求1所述的装饰板，其特征在于，
所述装饰层形成为，在所述镶嵌图案部，至少紧贴于所述贯通孔的所述背面侧的开口端并朝向所述贯通孔的内部弯曲。
3.一种装饰板，其特征在于，具备：
外层，其形成有贯通孔，该贯通孔在表面和背面开口；
装饰层，其配置在所述外层的整个背面，覆盖所述贯通孔的所述背面侧的开口并具有大致相同的层厚；
内层，其配置在所述装饰层的与相接于所述外层的面相反的面上，由与所述外层相同的原材料形成；
成型树脂层，其配置在所述内层的与相接于所述装饰层的面相反的面上；
所述装饰层具有镶嵌图案部，通过从所述装饰层对由所述外层和所述装饰层以及所述内层构成的层积体进行加压，使所述装饰层的一部分以从所述外层的背面侧进入所述贯通孔内的方式弯曲而形成所述镶嵌图案部。
4.根据权利要求1至3中任意一项所述的装饰板，其特征在于，
所述外层由木质材料形成，
所述装饰层由与所述外层不同的材料形成。
5.根据权利要求4所述的装饰板，其特征在于，
所述装饰层由金属材料形成。
6.一种装饰板的制造方法，该装饰板的制造方法用于制造权利要求1～5中任一项所述的装饰板，该装饰板的制造方法的特征在于，
准备具有第一层和第二层的层积体，
以使所述第二层露出的方式将所述第一层的一部分从所述层积体除去，
从所述第二层侧朝向所述第一层侧对所述层积体进行加压，以所述第二层的一部分嵌入所述贯通孔的方式使所述第二层弯曲变形。
7.根据权利要求6所述的装饰板的制造方法，其特征在于，
在从所述第二层侧朝向所述第一层侧对所述层积体进行加压时，使所述层积体的一面与成型模具接触，而将所述层积体设置于所述成型模具。
8.根据权利要求6所述的装饰板的制造方法，其特征在于，
将所述层积体设置于成型模具，
以树脂的流动体与所述第二层相接的方式使所述流动体流入所述成型模具内，并在加压下使所述流动体固化。
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JP2016068443A (ja) 2016-05-09
US20160089850A1 (en) 2016-03-31
EP3002121A1 (en) 2016-04-06
EP3002121B1 (en) 2017-09-20

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