JP2000345699A - Decorative paper form and its manufacture - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a form usable over a long period by fusing and sticking a synthetic resin sheet formed with laminate sheets having melting points of the prescribed values respectively on the surface layer of a paper form body formed with an irregular pattern on the surface. SOLUTION: A high-density PE sheet 4 is covered via a low-density PE sheet 3 on the surface of a form body 2 to form a decorative paper form 1. Many vertically penetrating vent holes are provided on a metal die or a resin die of a vacuum molding dedicated die. The form body 2 is mounted on the surface of the vacuum molding dedicated die. A synthetic resin sheet 10 is heated by hot wind to fuse the low-density PE sheet 3, then evacuation is made by utilizing the air permeability and vent holes of the form body 2, and the synthetic resin sheet 10 is stuck to the form body 2. The synthetic resin sheet 10 is a laminate sheet laminated and stuck with the high-density PE sheet 4 and the low-density PE sheet 3, and their melting points are 110-120 deg. C and 90-100 deg.C respectively, thereby reliable water resistance and a mold releasing property can be achieved.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative paper frame and a method for producing the same.

[0002]

2. Description of the Related Art In recent years, as a measure against industrial waste, a paper-made decorative form making use of papermaking technology has been developed. However,
In this paper decorative form, the moisture in the ready-mixed concrete permeates into the paper material (pulp fibers) of the paper decorative form when casting concrete.
As a result, problems such as paper adhering to the concrete surface, being unable to be removed from the concrete, and the uneven pattern of the surface (design surface) of the paper decorative form being collapsed, making it impossible to put into practical use. Have.

[0003] Therefore, as a technique for improving the water resistance of paper decorative formwork and the removability from concrete, water resistance is imparted by impregnating pulp fibers with resin.
A method of securing release properties by applying a release agent such as a wax to the surface, or imparting water resistance by impregnating a pulp fiber with a thermoplastic resin, and using a wax system as the thermoplastic resin. Some methods have been adopted, such as a method of imparting a mold releasability, and a method of performing a surface treatment with a heat-shrinkable sheet.

[0004]

However, each of the above methods has the following problems. That is, the first method includes a step of impregnating the pulp fiber with a resin, a step of applying a release agent to the surface, a step of drying the applied release agent, and the like, and further requires a release agent. ,
The number of man-hours for manufacturing paper decorative formwork increases, leading to increased costs. Further, in the second method, the wax-based thermoplastic resin is not impregnated into the interior of the decorative form main body having a thickness of 1 to 3 mm manufactured by making pulp fibers, and the surface is merely coated. It is necessary to thickly coat the front and back surfaces with a thermoplastic resin, which is difficult in terms of cost and design reproducibility. In addition, depending on the situation in which the paper decorative form is used, there are cases where the decorative form is cut and the dimensions are adjusted before use. In this case, water penetrates from the cut surface and the strength is reduced. However, it is difficult to work because it breaks into small pieces when it is removed from the mold. In the third method, even if the surface is coated with a heat-shrinkable sheet, the shrinkable sheet has a surface (this surface is
(It is fluffed by pulp fiber), so it is easy to peel off and does not withstand use. On the other hand, when the front and back surfaces are sandwiched between heat-shrinkable sheets, it is difficult to maintain the shape of the decorative form body due to heat shrinkage, and practical application is practically impossible.

SUMMARY OF THE INVENTION The present invention has been made in view of the above-mentioned circumstances, and a paper-made decorative frame which has a small number of manufacturing steps, is excellent in cost and design reproducibility, can be used for a long period of time, and can be easily removed, and a method of manufacturing the same. Its purpose is to provide a manufacturing method.

[0006]

In order to achieve the above-mentioned object, the present invention relates to a decorative paper frame having an uneven pattern formed on a surface and a synthetic resin sheet coated on a surface layer. The synthetic resin sheet is composed of a laminate sheet of a top sheet and a back sheet, and the first gist is a paper decorative form in which the back sheet is set to have a lower melting point than the top sheet. A ventilation mold, a paper-made decorative frame main body formed on the surface with an uneven pattern similar to the irregularity pattern on the surface of the ventilation type and removably fitted to the surface of the ventilation type, a topsheet and the topsheet A step of preparing a synthetic resin sheet composed of a laminate sheet with a lower melting back sheet and a step of arranging the decorative form body on the surface of the ventilation mold; Faced back sheet By heating the synthetic resin sheet in a state and evacuating using the ventilation type ventilation path, the synthetic resin sheet is brought into close contact with the surface of the decorative frame body via the back sheet melted by the heating. A second aspect of the present invention is a method for manufacturing a decorative paper frame that is integrated with a paper mold.

That is, the decorative paper frame of the present invention has a surface layer coated with a synthetic resin sheet. The synthetic resin sheet includes a top sheet and a back surface having a lower melting point than the top sheet. It is composed of a laminated sheet with a sheet. Therefore, with the above synthetic resin sheet,
Reliable water resistance and releasability can be imparted. In addition, by coating the synthetic resin sheet on the surface layer in a state where the back sheet of the synthetic resin sheet is melted, the melted back sheet and the pulp fibers of the surface layer are firmly adhered to each other by an anchoring effect. However, the synthetic resin sheet does not peel off from the surface layer, and can be used for a long time. Moreover, as the above synthetic resin sheet,
By using a very thin sheet, even if the design has a fine uneven pattern, the design can be reproduced well, the design reproducibility is good, and the cost is excellent. Further, since a release agent on site is not required, the cost is further improved. In addition, in the case of cutting and using depending on the use situation, although the strength may be weakened due to the penetration of water from the cut surface, it is possible to easily remove the mold by peeling off from the synthetic resin sheet at the time of removing the mold. it can. In addition, since the synthetic resin sheet is composed of a laminated sheet of a top sheet and a back sheet set to have a lower melting point than this top sheet, the method for producing a decorative paper frame of the present invention can be used to reduce the production. It can be manufactured with man-hours.

[0008] The method for producing a decorative paper frame according to the present invention is a method of preparing a decorative mold main body made of a ventilation type and paper and the above-mentioned synthetic resin sheet, and disposing them on the surface of the ventilation type mold. With the back sheet facing the front surface, the synthetic resin sheet is heated and evacuated using the ventilation type ventilation path,
Thereby, the synthetic resin sheet is brought into close contact with the surface of the decorative frame main body via the back sheet melted by the heating to be integrated. At this time, the melted back sheet and the pulp fiber on the surface of the decorative form body are firmly adhered to each other by an anchoring effect. As described above, in the production method of the present invention, the decorative form of the decorative form body is manufactured by simply coating the surface of the decorative form body with the synthetic resin sheet by the vacuum molding method, utilizing the air permeability of the decorative form body. The number of manufacturing steps is small, and the cost is reduced. In the production method of the present invention, if the synthetic resin sheet is composed only of the high melting point sheet, the synthetic resin sheet and the decorative mold are combined because the pulp fibers are gathered in a fluffy state on the surface of the decorative form main body. Adhesion with the body is not possible. on the other hand,
If the above-mentioned synthetic resin sheet is composed only of a low melting point sheet and heated to such an extent that it enters into the pulp fiber, the synthetic resin sheet is broken and a hole is formed, so that coating cannot be performed. Therefore, in the method for producing a paper decorative formwork of the present invention,
As a synthetic resin sheet, a laminated sheet of a top sheet and a back sheet set to have a lower melting point than this top sheet is used, and the back sheet is melted, but the above-mentioned vacuum forming method is performed at a temperature at which the top sheet does not melt. By performing the above, the synthetic resin sheet can be adhered to the design surface of the decorative form frame main body as it is (even in a design having minute uneven patterns).

In the present invention, the top sheet is made of a polyethylene sheet and has a melting point of 110 to 120 ° C., and the back sheet is made of a polyethylene sheet and has a melting point of 90 to 120 ° C.
When the temperature is 100 ° C., a polyethylene sheet having a different melting point is used, and the synthetic resin sheet can be effectively adhered to the surface of the decorative frame main body due to the thermal adhesiveness of the polyethylene sheet.

In the present invention, when the compressed air is blown to the top sheet side of the synthetic resin sheet during the evacuation, the vacuum molding and the pressure molding can be used in combination, and the synthetic resin can be effectively produced. The sheet can be brought into close contact with the surface of the decorative form body.

Next, the present invention will be described in detail.

In the present invention, a synthetic resin sheet composed of a laminate sheet of a top sheet and a back sheet having a lower melting point than the top sheet is used.

The constituent materials of the synthetic resin sheet include:
Various synthetic resin materials such as polypropylene (PP), polyethylene (PE), vinyl chloride resin (PVC), and ethylene-vinyl acetate copolymer (EVA) are used. Therefore, polyolefin-based materials such as PP and PE are preferable. Further, in the case of PP and PE, a release agent is unnecessary, and even when the back surface absorbs water to some extent after concrete casting and the strength is weakened, it is possible to remove the mold by pulling the synthetic resin sheet. . The melting points of the top sheet and the back sheet constituting the synthetic resin sheet are set at 100 ° C. or higher for the top sheet and within the range of 80 to 100 ° C. for the back sheet, and the temperature difference between the two sheets is 1 to 40 ° C. It is set within the range of ° C. For example, PP has a high melting point at 130 to 160 ° C.
Those having a low melting point have a temperature of 100 to 120 ° C. On the other hand, PE has a high melting point of 110 to 120 ° C and a low melting point of 90 to 100 ° C. Also, the constituent materials of the top sheet and the back sheet do not need to be the same material,
Different materials may be used.

The synthetic resin sheet has a thickness of 40
The thickness of the top sheet and the thickness of the back sheet are each set in the range of 20 to 100 μm. The thickness of each of such sheets is determined by the height of the unevenness of the uneven pattern, and the higher the height of the unevenness, the thicker the sheet needs to secure the elongation.

As a raw material of the paper decorative mold of the present invention, pulp, waste paper (disused cardboard, copy paper, waste newspaper, etc.) and the like are preferably used. Further, as the uneven pattern formed on the surface of the paper decorative formwork, various uneven patterns can be mentioned, but a pattern that becomes masonry-like, brick-like, natural stone-like when transferred is preferably used. .

[0016]

Next, embodiments of the present invention will be described with reference to the drawings.

FIG. 1 shows an embodiment of a paper decorative formwork of the present invention. In this embodiment, the paper decorative form 1 is a form body (decorative form body) 2 made of waste paper.
And a high-density PE sheet 4 coated on the surface of the mold body 2 via a molten low-density PE sheet 3 (acting as an adhesive layer).

The decorative paper frame 1 can be manufactured, for example, as follows. That is, first, as shown in FIG. 2, a mold body 2, a synthetic resin sheet 10, a dedicated vacuum forming type (ventilated type) 11, and a vacuum forming means (FIG. Only a frame 12 is shown) and a heating means (not shown) are prepared.

The synthetic resin sheet 10 is a high-density PE sheet 4 (top sheet: melting point 110 to 120 ° C., thickness 10).
0 μm, 1000 mm × 1000 mm) and low density PE sheet 3 (back sheet: melting point 90-100 ° C., thickness 100)
μm, 1000 mm × 1000 mm). Vacuum forming exclusive mold 1
1 (a 900 mm × 900 mm mold, a gypsum mold, a resin mold, etc.) has an uneven pattern corresponding to the uneven pattern of the mold body 2 formed on the surface thereof. In addition, a large number of ventilation holes 11a penetrating vertically are uniformly formed at a pitch of 20 to 50 mm in the dedicated mold 11 for vacuum molding. The frame 12 has a mounting portion 12a projecting inward from an upper end thereof.
And a vacuum evacuation hole 12b formed in the center of the bottom plate. As the heating means, a warm air blower, a far-infrared irradiator, or the like is used.

Next, as shown in FIG.
The special mold 11 for vacuum forming is mounted on the mounting portion 12a of the above, and the mold body 2 is mounted on the surface of the special mold 11 for vacuum forming. Next, as shown in FIG.
Then, the synthetic resin sheet 10 is heated by (shown by an arrow) (1).
(About 00 ° C.), and the low-density PE sheet 3 is melted. After the melting, the heating means is stopped, and a vacuum pump (not shown) of the vacuum molding means is operated to evacuate the air using the air permeability of the mold body 2 and the air holes 11a of the vacuum molding exclusive mold 11 (6).
(Approximately 0 seconds), the synthetic resin sheet 10 is adhered to the surface of the mold body 2 via the molten low-density PE sheet 3. (See FIG. 5). After that, the synthetic resin sheet 10 is cooled by blowing cooling air or the like, and is released. Thereby, the decorative paper frame 1 shown in FIG. 1 can be obtained.

As described above, in the above embodiment, since the synthetic resin sheet 10 is adhered to the surface of the mold body 2,
It is possible to impart reliable water resistance and releasability to the paper decorative form 1. Further, even if the strength is weakened due to the penetration of water from the back surface or the like, it can be easily removed from the synthetic resin sheet 10 by peeling it off. Further, the synthetic resin sheet 10 is hardly peeled off from the surface of the mold body 2, and can be used for a long period of time. In addition, the synthetic resin sheet 10 is very thin, and the uneven pattern on the surface of the mold body 2 is well reproduced on the surface of the decorative paper mold 1. In addition, it can be manufactured at low cost because a release agent is not required. Moreover,
It can be manufactured by a vacuum molding method, and the number of manufacturing steps is small. Furthermore, since the synthetic resin sheet 10 is cooled and then removed from the mold, the synthetic resin sheet 10 does not shrink after the mold is removed, and is hardly peeled off from the frame body 2.

FIG. 6 shows a modification of the method of manufacturing the paper decorative form 1 described above. In this example, in the above-described method of manufacturing the decorative paper frame 1, compressed air is blown onto the upper surface of the synthetic resin sheet 10 in an air curtain shape during vacuum molding.
Pressure is applied to the synthetic resin sheet 10 from above. As described above, when the vacuum molding and the pressure molding are used in combination, the synthetic resin sheet 10 can be adhered to the entire surface of the mold body 2 in a close contact state.

In the above-described embodiments, the evacuation is performed for 60 seconds. However, the present invention is not limited to this. The evacuation time can be changed depending on the melting state of the low-density PE sheet 3. Usually, it is set to 5 to 60 seconds. Further, in the above-described embodiments, the entire shape of the mold body 2 constituting the decorative paper mold 1 is formed in a shape along the uneven pattern on the surface, but the back surface may be formed flat or the like. .

[0024]

As described above, according to the paper decorative form frame of the present invention, it is possible to provide the synthetic resin sheet with reliable water resistance and releasability. In addition, by coating the synthetic resin sheet on the surface layer in a state where the back sheet of the synthetic resin sheet is melted, the melted back sheet and the pulp fibers of the surface layer are firmly adhered to each other by an anchoring effect. However, the synthetic resin sheet does not peel off from the surface layer, and can be used for a long time. In addition, by using a very thin sheet as the synthetic resin sheet, even if the design has a fine uneven pattern, the design can be reproduced well, the design reproducibility is good, and the cost is high. Excellent in terms of surface. Further, since a release agent on site is not required, the cost is further improved. In addition, in the case of cutting and using depending on the use situation, although the strength may be weakened due to the penetration of water from the cut surface, it is possible to easily remove the mold by peeling off from the synthetic resin sheet at the time of removing the mold. it can. Moreover, since the synthetic resin sheet is constituted by a laminate sheet of a top sheet and a back sheet set to have a lower melting point than this top sheet, the method for producing a decorative paper frame of the present invention is used.
It can be manufactured with a small number of manufacturing steps.

Further, according to the method for producing a decorative paper frame of the present invention, the surface of the decorative frame main body is simply coated with a synthetic resin sheet by a vacuum molding method utilizing the air permeability of the decorative frame main body. As a result, it is possible to manufacture a paper-made decorative form, thereby reducing the number of manufacturing steps and reducing costs.

In the present invention, the top sheet is made of a polyethylene sheet and has a melting point of 110 to 120 ° C., and the back sheet is made of a polyethylene sheet and has a melting point of 90 to 90 ° C.
When the temperature is 100 ° C., a polyethylene sheet having a different melting point is used, and the synthetic resin sheet can be effectively adhered to the surface of the decorative frame main body due to the thermal adhesiveness of the polyethylene sheet.

In the present invention, when the compressed air is blown to the top sheet side of the synthetic resin sheet during the evacuation, the vacuum molding and the pressure molding can be used in combination, and the synthetic resin can be effectively produced. The sheet can be brought into close contact with the surface of the decorative form body.

[Brief description of the drawings]

FIG. 1 is a sectional view showing an embodiment of a paper decorative formwork of the present invention.

FIG. 2 is an explanatory view of a decorative form main body and the like used for manufacturing the paper decorative form;

FIG. 3 is a cross-sectional view showing a method of manufacturing the paper decorative formwork.

FIG. 4 is a cross-sectional view showing a method of manufacturing the paper decorative form.

FIG. 5 is a cross-sectional view showing a method of manufacturing the paper decorative form.

FIG. 6 is a cross-sectional view showing a modified example of the method for manufacturing a paper decorative mold.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Paper decorative form 3 Low density PE sheet 4 High density PE sheet 10 Synthetic resin sheet

Claims (4)

[Claims] 1. A paper decorative formwork having an uneven pattern formed on a surface and a synthetic resin sheet coated on a surface layer, wherein the synthetic resin sheet is a laminate sheet of a topsheet and a backsheet. And a back sheet having a lower melting point than that of the top sheet. 2. The paper decorative form according to claim 1, wherein the top sheet is made of a polyethylene sheet and has a melting point of 110 to 120 ° C., and the back sheet is made of a polyethylene sheet and has a melting point of 90 to 100 ° C. 3. A ventilation type having an uneven pattern formed on a surface thereof.
A paper-made decorative frame main body on the surface of which a concave-convex pattern similar to the concave-convex pattern on the surface of the ventilation type is detachably fitted to the surface of the ventilation type, and a top sheet and a back surface having a lower melting point than the top sheet. A step of preparing a synthetic resin sheet composed of a sheet and a laminated sheet, a step of arranging the decorative form body on the surface of the ventilation mold, and a back sheet facing the surface of the decorative form body. In this state, the synthetic resin sheet is heated and evacuated using the ventilation type ventilation path, so that the synthetic resin sheet adheres to the surface of the decorative form body via the back sheet melted by the heating. A method of manufacturing a paper decorative formwork, wherein the decorative form is integrated. 4. The method for producing a decorative paper frame according to claim 3, wherein compressed air is blown onto the top sheet side of the synthetic resin sheet during the evacuation.