JP2001105407A - Laminate and manufacturing method therefor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To easily manufacture a laminate with a curved face formed on the edge part and also make it possible to correct warpage when it is generated. SOLUTION: First a decorative material 2 such as a printed paper is bonded on the surface of a base material 1 without orientation properties such as MDF using an adhesive 4 and a synthetic resin layer 3 is formed on the decorative material 2. Next, a stepped part 1b is formed by cutting the specified region (k) of an edge part of the base material 1. When the base material 1 is cut, the backing layer of the base material 1 is left as it is on the back of the decorative material 2 and at the same time, a protruding part (t) is formed on the end part. After that, the decorative material 2 in the cut region of the base material 1 is curved and the back face of the edge side of the decorative material 2 is bonded to the side end face 1c of the base material 1 and a synthetic resin 10 is fully packed in a void part S between the base material 1 and the decorative material 2 to be cured to obtain a laminate X having a curved face R. When the laminate X is warped, the warpage can be corrected by stacking or a heating press. Besides, even after the laminate X is left alone for a ling time, the warpage does not occur again.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a non-oriented material such as a fiberboard or a particle board as a base material, a thin decorative material adhered to the surface thereof, and a curved surface provided at an edge. In particular, the present invention relates to a technology for a laminated board, which is intended for a long product and provides a means for easily correcting a warp when it occurs or a means for manufacturing a product without a warp. The purpose is to:

[0002]

2. Description of the Related Art Laminates having a decorative material adhered to the surface of a substrate have been known. Conventional laminated boards are mainly
Using thick or plywood as a base material, printing paper, attached board, cloth,
It is manufactured by attaching a thin decorative material such as a synthetic resin sheet to the surface of the base material. Further, in order to obtain gloss and luster, a synthetic resin may be applied on a decorative material in advance, or a veneer may be adhered to a surface of a base material and then applied with a synthetic resin. Further, if necessary, an appropriate surface material such as paper, cloth, sheet or the like may be attached to the back surface of the base material or a synthetic resin may be applied.

In the case where a curved portion is formed at the edge of the laminate, a part of the base material and the back surface of the veneer are cut in advance at the edge, and the cut portion of the veneer is bent while being curved. By adhering to the substrate surface, a gap is formed between the cut portion of the veneer and the cut portion of the substrate, and the gap is filled with a synthetic resin or a combination of a synthetic resin and a bar. Is adopted.

[0004]

A conventional laminated plate, particularly a long one having a length of 1 m or more, often warps. One of the causes of the warpage is as follows. Generally, when a synthetic resin is applied to both the front surface and the back surface of a substrate, the front side requires aesthetics and strength, so that the amount of the synthetic resin used is relatively large (for example, 100 to 600 g / m2 in the case of a polyester resin). ² ) On the other hand, the back side does not require any particular aesthetics or strength, so the amount of synthetic resin used is small (for example, 5 to 7 g / m 2 in the case of urethane resin).
² ). Therefore, it is presumed that the amount of the synthetic resin used on the front and back sides of the laminate is very different, so that the magnitude of the tensile strength is generated, and as a result, warpage may occur. In addition, the above problem also occurs when the synthetic resin is applied only to the surface of the base material. However, the cause of the warpage may not always be specified because various factors other than the above are involved.

[0005] In the conventional laminated board, since the base material is a thick board or a plywood, it is difficult to correct the warp when the thickness exceeds 9 mm. Therefore, the warped product must be appropriately cut into a short product or disposed as a defective product, resulting in a decrease in yield and an increase in cost. In particular, in the case of a product having a curved surface at the edge as described above, if warpage occurs, it is difficult to use the product for another purpose. In addition, the conventional laminated plate has a problem that it is difficult to increase the manufacturing efficiency because the laminating step is performed by laminating a veneer on which a decorative material is adhered to the surface of the base material. ing.

Conventionally, it has been attempted to correct the warpage by heating the surface on the convex side of the laminated board having the warp with hot air or the like. However, by simply heating one side of the laminate, the warp is not so much corrected, or even if the warp is temporarily eliminated, the warp often recurs with the passage of time and permanently corrects the warp It was difficult.

[0007]

SUMMARY OF THE INVENTION The present invention provides a technique for easily manufacturing a laminated board which is long and has no warpage. The feature of the laminated board adopted by the present invention is that, as described in claim 1, a thin decorative material is adhered to the surface of the base material, and the base material on the back side of the decorative material at the edge portion. Cutting, curving the decorative material in the region where the base material has been cut, forming a gap between the base material and the base material, and filling the gap with a synthetic resin or a combination of a synthetic resin and a rod material to form an edge. In a laminated board having a curved surface in a portion, a base material is a plate material having a thickness of 9 mm or more made of a non-oriented material such as a fiber board or a particle board. According to this configuration, since the base material of the laminate is made of a non-oriented material, 9 mm
Even a plate having the above thickness can be slightly deformed. The synthetic resin filling the voids at the edges has some plasticity even after curing. Therefore, when a warp occurs, the warp can be easily corrected, and the warp can be corrected even after the completion of the laminate.

[0008] The laminate according to the present invention may be such that a synthetic resin layer is formed on a decorative material. Alternatively, as described in claim 3, a cosmetic material previously coated or impregnated with a synthetic resin may be attached to the surface of the base material.

On the other hand, a feature of the method for manufacturing a laminate according to the present invention is that, as described in claim 4, a thin-walled decorative material is coated on the surface of a non-oriented base material having a thickness of 9 mm or more. Attach and cut the base material on the back side of the decorative material at the edge, curve the decorative material in the area where the base material was cut, form a gap between the base material, and synthesize it with the gap In the method for manufacturing a laminated board in which a curved surface is provided at an edge portion by filling a combination of a resin or a synthetic resin and a bar, when a warp is found after attaching a decorative material, the laminate is referred to as the warp. The object of the present invention is to correct the above-mentioned warpage by stacking and standing on a non-horizontal mounting surface that is curved in the opposite direction. According to such a method, the warpage can be corrected only by stacking the laminates on the non-horizontal mounting surface and leaving it to stand, so that a product without warpage can be easily obtained.

According to a fifth aspect of the present invention, there is provided a method for manufacturing a laminated board according to the present invention, wherein the warpage is detected by applying heat to the laminated board to prevent the warpage when a warp is found after attaching a decorative material. A correction method may be adopted. In this method, since the warpage is corrected by a hot press, it is possible to produce a product without warpage in a short time.

In the method for manufacturing a laminate according to the fourth and fifth aspects, when the base material of the laminate is made non-oriented,
The present invention has been made based on a newly discovered finding that warpage can be corrected by stacking or heating press. Here, the correction of the warp includes not only eliminating the warp but also keeping the degree of the warp within an allowable range. The allowable range of warpage varies depending on the application, but is usually 15/1000 or less, preferably 3/100.
0 or less.

In the above-mentioned manufacturing method, the warpage may be corrected before the curved surface is provided on the edge portion as described in claim 6. It may be after the curved surface is provided in the portion.

Further, as set forth in claim 8, a step of attaching a decorative material on the surface of the base material and then forming a synthetic resin layer on the decorative material may be adopted. As described in the above, the decorative material adhered to the surface of the base material may be a decorative material coated or impregnated with a synthetic resin. In the latter case, since a thin decorative material which has been previously coated or impregnated with a synthetic resin is adhered to the base material, the synthetic resin layer is free from deformation due to shrinkage during curing.

One of the causes of warpage of the laminated board is, as described above, shrinkage when the synthetic resin applied thereon is cured after the decorative material is adhered to the surface of the base material. Can be In view of this point, the present invention has devised a method for manufacturing a laminated board as described in claim 10. That is, a thin decorative material is stuck on the surface of a non-oriented base material having a thickness of 9 mm or more, and a synthetic resin layer is formed on the decorative material. The base material is cut, the decorative material in the region where the base material is cut is curved to form a gap between the base material, and the gap is filled with a synthetic resin or a combination of a synthetic resin and a bar. In the method for manufacturing a laminated board having a curved surface at an edge portion by forming a synthetic resin layer on a decorative material on the surface of the substrate, a warp is previously applied to the substrate such that the decorative material side is convex. After that, a synthetic resin layer is formed on the decorative material on the surface of the base material, and the synthetic resin layer is cured to cancel the warpage. According to such a method, a predetermined warp is previously applied to the base material, and the warp is canceled by utilizing the deformation due to the contraction force when the synthetic resin layer is cured, thereby obtaining a straight product without warp. be able to.

[0015]

DESCRIPTION OF THE PREFERRED EMBODIMENTS [1] Laminate The production procedure of a laminate targeted by the present invention is roughly classified into two types. One is to apply a cosmetic material on the surface of the base material and then form a synthetic resin layer on it, and the other is to apply a cosmetic material previously coated or impregnated with a synthetic resin on the surface of the base material. It is a method of sticking. It should be noted that, for each type, either a case where the surface is glossy or a case where the surface is not glossy can be selected. First, a description will be given of a laminate manufactured by the former procedure, that is, a method in which a cosmetic material is attached to the surface of a base material and then a synthetic resin layer is formed thereon.

1-1. 1. Laminate (1) FIG. 1 is a drawing showing a manufacturing process of the laminate X according to the present invention, and FIG. 2 is a drawing showing the structure of the laminate X according to the present invention. The main constituent members of the laminate X are a substrate 1 and a thin decorative material 2 adhered to the surface thereof with an adhesive 4. A synthetic resin layer 3 is formed on the decorative material 2. If necessary, a surface layer material 5 (see FIG. 2B) may be provided on the back surface of the substrate 1. A curved surface R is formed at the edge.

The type of the base material 1 may be any material that is non-oriented and capable of being cut, for example, a medium fiberboard (MDF).
Organic materials such as fiber boards such as hard fiber boards and soft fiber boards, and particle boards, and non-combustible inorganic materials such as calcium silicate boards and compression molded boards of ash can be used. Good. For example, for furniture and interior use, it is preferable to use a fiberboard or a particle board in view of strength, price, ease of handling, and the like.
DF is considered optimal.

The type of the decorative material 2 is not particularly limited as long as it has a small thickness and can be easily attached to the substrate 1 with an adhesive. Paper, printing paper, veneer, attached plate, melamine / vinyl chloride・ Synthetic resin sheet or film, cloth (woven or non-woven) consisting of DAP, PET, etc.
Etc. can be used. The appropriate thickness of the decorative material 2 is about 0.08 to 1.5 mm, depending on the material.

The manufacturing procedure of the laminate X will be described as follows. First, as shown in FIG. 1A, a base material 1 and a thin decorative material 2 are prepared. Next, as shown in FIG. 1B, a decorative material 2 is adhered to the surface of the substrate 1 with an adhesive 4. The type of the adhesive is not particularly limited, but may be selected in consideration of the compatibility between the base material 1 and the decorative material 2. Generally, vinyl acetate or urea adhesives are often used. It is preferable to use a hot press to attach the decorative material 2 because productivity is improved. The conditions for hot pressing are set as appropriate depending on the type and amount of adhesive used.
Usually, the pressing is performed at a temperature in the range of 60 to 120 ° C. and the pressing time is in a range of about 30 seconds to 1 minute. The decorative material 2 to be adhered to the surface of the substrate 1 may have a two-layer structure. For example, when using a material such as a veneer that may be broken at the time of bending to form a curved surface at the edge, such as a veneer, the distance between the base material 1 and the veneer 2 such as a veneer In addition, paper, cloth, nonwoven fabric, or the like may be interposed as a reinforcing material. In this case, it is considered that a procedure of attaching a reinforcing material such as paper to the base material 1 and then attaching a decorative material 2 such as a veneer thereon is efficient from the viewpoint of workability. It is also possible to apply a procedure in which a reinforcing material such as paper is previously attached to the back surface of the decorative material 2 such as a veneer, and this is attached to the base material 1.

After the decorative material 2 is adhered to the surface of the substrate 1, a synthetic resin layer 3 is formed on the decorative material 2. As the kind of the synthetic resin, polyester, urethane, acryl, vinyl chloride, dap, melamine and the like are used.
Of these, polyester, urethane, and acrylic are preferred in consideration of aesthetics and surface hardness. If desired, various medicinal components and chemical components such as insect repellents, insect repellents, and antibacterial agents, and additives such as metal powder and glass powder may be blended in the synthetic resin layer 3. Means for forming the synthetic resin layer 3 on the decorative material 2 include a method of applying the synthetic resin by an appropriate coating device 6 such as a spray, a flow coater, and a roll coater, or a method in which an appropriate amount of the synthetic resin is placed on the surface of the decorative material 2, For example, a method of rolling a film on the film with a roller is adopted. Generally, the surface side of a product requires aesthetics and strength, so the amount of synthetic resin used is set relatively large (for example, 100 to 600 in the case of polyester resin).
g / m ² ). The method of forming the synthetic resin layer 3 after the decorative material 2 is adhered to the base material 1 is such that even if irregularities on the surface of the base material 1 appear on the surface of the decorative material 2, the synthetic resin layer 3 is formed later.
There is an advantage that the surface of the product can be made smooth by absorbing the unevenness. Therefore, the method is suitable for producing glossy products. However, it does not prevent the method from being applied to the production of matte products.

If desired, the surface of the decorative material 2 adhered to the substrate 1 is sanded and then coated with a synthetic resin.
Alternatively, the synthetic resin may be applied after applying a sealer or the like after sanding, and the synthetic resin layer may be further subjected to sanding treatment and then overcoated with the synthetic resin. Alternatively, it is also conceivable that the surface of the synthetic resin applied to the decorative material 2 is subjected to sanding treatment, and then the surface treatment is completed without further finishing the surface treatment to produce a product, which is then shipped in a semi-finished state. In this case, after the semi-finished laminated plate is constructed on site, lacquer or the like is sprayed on the surface to finish. According to such a use mode, the color can be specified on site, and thus color matching and color change become easy. Further, since the surface is finished after the construction, even if there is a scratch or the like during the construction, it can be repaired, and the advantage that the finish can be beautiful without flaws can be obtained.

The method of treating the back surface of the substrate 1 may be determined in consideration of the use of the laminate X. A surface material may or may not be attached to the back surface. When the surface material is not adhered, specifically, it is left untreated or only applied with a synthetic resin. When sticking the surface material, at least three types of processing such as using only the surface material, sticking the surface material and applying a synthetic resin, or sticking the surface material coated or impregnated with the synthetic resin Embodiments are possible. Here, the surface material to be adhered to the back surface has the same material as that of the decorative material 2 on the front surface side, and is not particularly limited in aesthetic appearance, thickness, and the like. Of course, in the case of manufacturing a laminated board X having no distinction between the front and back surfaces or when it is desired to impart aesthetics to the back surface, the same or different decorative materials 2 are stuck on the front and back surfaces of the base material 1 to make both surfaces a decorative surface. And it is sufficient. In order to make the laminate X less likely to warp, it is preferable to attach a surface layer material also to the back surface.

When a synthetic resin is applied to the back side of the substrate 1, polyester, urethane, acryl, vinyl chloride, melamine, dap, etc., similar to the front side, can be used. If desired, various kinds of medicinal components and chemical components such as insect repellents, insect repellents, and antibacterial agents may be added to the synthetic resin. In this case, it is considered optimal to use a urethane resin in order to minimize the efficacy of the medicinal and chemical components. The amount of the synthetic resin used is generally not required to be as beautiful and strong as the front surface side, so the amount of the synthetic resin used may be small (for example, about 5 to 7 g / m ^{2 in} the case of urethane resin).

In the case where a decorative material such as a veneer is adhered to the surface of the base material 1, a synthetic resin is applied thereon, and then sanding is performed, and then the synthetic resin is applied again.
When the decorative material is also adhered to the back surface of the substrate 1, the decorative material on the back surface may be damaged in the above sanding step. However, it is not preferable to omit the cosmetic material on the back surface in order to prevent warpage of the product. Therefore, in such a case, it is desirable to apply a decorative material on the back surface after finishing the sanding step on the front surface.

If the decorative material 2 is stuck on the surface of the base material 1 and the surface material (or the decorative material) is stuck on the back surface as needed, the edge of the base material 1 on the back surface side of the decorative material 2 A predetermined region k of the portion (a region indicated by oblique lines in FIG. 1B) is cut as shown in FIG. 1C to form a stepped portion 1b. The size of the cutting area of the base material 1 is set according to the size of the curved surface formed on the laminate X, and the like. In the drawings, the case where the curved surface R is formed at the edge portions on both sides is illustrated, but it is not precluded that only one of them is formed. In cutting the base material 1, as shown in FIG. 2C and FIG. 3, a backing layer 1 a made of the base material 1 is left thinly on the back surface of the decorative material 2, and as shown in FIG. A triangular projection t is formed at an end of the material 2. The thickness p of the backing layer 1a of the substrate 1 is 0.08 to
It is about 1.5 mm. If the value of the thickness p is set too small, the cutting tool may affect the decorative material 2 when the base material 1 is cut. On the other hand, if the thickness p of the backing layer 1a is too large, there is a possibility that the step of bending the edge portion described later may be hindered. On the other hand, the total thickness q of the decorative material 2, the synthetic resin layer 3, and the adhesive 4 is about 0.1 to 1.6 mm. The value of p + q is desirably 2 mm or less so that it is not difficult to form a curved surface at the edge.

Subsequently, the decorative material 2 in the region where the substrate 1 has been cut is curved as shown in FIG. 1 (D), and the back surface of the edge of the decorative material 2 is adhered to the side end surface 1c of the substrate 1. Thus, a gap S is provided between the step 1b of the base material 1 and the decorative material 2, and a curved surface R is formed on the edge surface. The protruding portion t provided at the end of the back surface of the decorative material 2 functions as an auxiliary member for facilitating the sticking operation at this time. When the makeup material 2 has been applied, the protrusion t is cut off.

Subsequently, as shown in FIG. 1 (E), a synthetic resin 10 is filled in a gap S between the step 1b formed on the edge of the base material 1 and the back surface of the decorative material 2, and this is filled. Cured,
If the shape of the curved surface R is fixed, the intended laminated board X having the curved surface R at the edge can be manufactured. Foamed polyurethane is used as the synthetic resin 10 that fills the voids S. Foamed polyurethane has an advantage that the production efficiency can be increased because the curing time is short and the process can be quickly shifted to post-treatment. Note that the filling of the voids S is not performed entirely with the synthetic resin alone, but as shown in FIG.
It is also possible to insert a rod 20 made of wood, synthetic resin, rubber, paper, metal, ceramic, or the like into the gap S and fill the periphery with the synthetic resin 10. The synthetic resin or the combination of the synthetic resin and the rod material filled in the voids S exhibits a large rigidity after the hardening of the synthetic resin, and thus has an effect of improving the bending strength of the laminate X.
Further, since it is possible to prevent the laminate X from being warped and becoming a defective product, there is obtained an advantage that the yield is improved.

1-2. Laminate board (2) Instead of forming the synthetic resin layer 3 thereon after attaching the decorative material 2 to the surface of the substrate 1, the decorative material 2 previously coated or impregnated with a synthetic resin is It is also possible to adopt a procedure of sticking to the surface of No. 1. When this method is adopted, the step of applying the synthetic resin can be omitted, and therefore, there is an advantage that the number of manufacturing steps of the laminated board can be reduced. However, substrate 1
When there is unevenness on the surface of the decorative material 2, the unevenness may be reflected on the surface of the decorative material 2 and may cause unevenness on the product surface. Therefore, it is desirable that the manufacturing method be applied to the case where a matte product is manufactured.

[2] Correction of Warpage According to the manufacturing process of the laminate described in the above section 1-1, the base material 1
When the synthetic resin layer 3 is formed thereon after the decorative material 2 is adhered to the surface of the laminate, there is a problem that the completed laminated board X is warped due to the contraction force when the synthetic resin layer 3 is cured. This has been pointed out as described above. Further, it is considered that there is a cause of causing the laminate X to warp other than the curing shrinkage of the synthetic resin applied on the decorative material 2, and the synthetic resin was previously applied or impregnated as described in the section 1-2. It is known that warping also occurs in a laminated board manufactured by attaching the decorative material 2 to the base material 1. In particular,
It has generally been considered that a long laminated board is likely to be warped, and when the board thickness is relatively large (for example, 9 mm or more), it is difficult to correct the once-formed warpage. If there is a warp, it will be an obstacle to smoothly proceeding the manufacturing process of the laminated board, and the final product will be defective. In particular, substrate 1
After applying the decorative board 2 such as a veneer, it is difficult to apply sanding before applying the synthetic resin. The inventor has
The inventors have found that the warpage generated in the laminate can be corrected or prevented from being generated by the method described below, and the present invention has been made.

2-1. Method of Correcting Warpage (1) When a warp is found in the laminate X, the laminate X is stacked on a non-horizontal mounting surface having a height difference between the center portion and both end portions to thereby warp. Can be modified. In this example, as shown in FIG. 5, a spacer 7 for scooping up with a forklift is laid under the stacked boards X to be stacked, and by appropriately setting the height of the spacer 7, the stacked boards X Were formed in a non-horizontal manner such that the central portion or both ends became higher. Then, using any one of the mounting surfaces shown in FIGS. 5A and 5B, the laminates X are stacked so as to be curved in a direction opposite to the direction of the warp, and are appropriately timed (about 2 hours or more). put. However, the standing time after stacking is appropriately increased or decreased according to the material and dimensions of the laminate X or the degree of warpage. The number of stacked layers X is not particularly limited, but is usually about 40 to 50. Further, if necessary, it is possible to arrange a weight on the stacked laminates X to promote the correction of the warpage.

The above-described warp correcting method uses a decorative material in which a synthetic resin is applied or impregnated in advance to a laminated board manufactured by forming a synthetic resin layer after pasting the decorative material on the surface of the base material. The present invention can be applied to a laminated board manufactured by sticking the resin onto a base material. The timing of correcting the warp can be either before or after the curved surface is formed at the edge of the laminate. When the warpage is corrected before the curved surface is formed, the void S is thereafter formed in the synthetic resin 10.
Alternatively, by filling with the combination of the synthetic resin 10 and the bar 20, the shape stability of the laminated board X is improved, so that the recurrence of the warpage is surely prevented.

2-2. Warp Correction Method (2) The present inventor has performed various trials on the warp correction means, and as a result, the warp can be corrected by heating and pressing the laminated board X in which the warp has occurred. Even later, they found that recurrence of the warp did not occur. That is, if a warp is found in the laminate X, the warp can be eliminated or corrected to an allowable range by subjecting the laminate X to a heat press treatment.

The details of the mechanism by which the warping is corrected by the hot press are unknown, but the laminate X according to the present invention is not disclosed.
It is considered that the fact that the substrate 1 is made non-oriented is important in correcting the warpage. That is, the laminated board X in which the warp has occurred
When the substrate is heated and pressed at an appropriate temperature and pressure, the base material 1 is non-oriented, so that a certain degree of plasticization occurs and plastic deformation can occur, and as a result, the warped shape is maintained even after the hot pressing It is speculated that it can be done.

The warp correction method using a heat press is a method in which a cosmetic material is adhered and then a synthetic resin layer is formed on the laminated plate, and a cosmetic material previously applied or impregnated with a synthetic resin is adhered. The same applies to plates. Regarding the timing of the heating press, either before or after forming the curved surface on the edge portion of the laminate X, it may be either.

The following is a specific example of a method for correcting warpage by a heating press. The manufacturing conditions of the laminated board to be implemented are as follows. 900mm in width X 2100mm in length X thickness 18
mm MDF board as a base material, and after adhering printing paper to the surface, further apply a polyester resin 400 to 50
0 g was applied to form a synthetic resin layer, and urethane-coated printing paper (urethane amount = 5 to 7 g / m ² ) was adhered to the back surface. A heat press treatment is applied to the laminated board in which warpage is found in the inspection of the edge of the base material before cutting. The degree of warpage was about 3/1000, and the conditions of the hot press were a temperature of 100 ° C., a pressure of 0.17 to 0.33 kg / cm ² , and a pressing time of 1 minute. The warpage of the laminate disappeared by the above-mentioned heat press treatment. After production, it was left for about one month,
No recurrence of warpage was observed.

By the way, at the time of the hot press treatment, the correction of the warpage can be promoted by changing the heating temperature between the front surface and the back surface of the laminate X. Specifically, when a temperature difference of about 20 to 30 ° C. is provided between the front and back surfaces,
Correction of warpage is facilitated. However, in implementing this method, it is necessary to overcome the drawbacks that it is difficult to control the temperature and that it takes time to change and adjust the product number.

Further, it is conceivable to correct the warpage of the laminate X efficiently by forming the shape of the pressing surface in the heating press device into a curved surface. However, since this method increases the manufacturing cost of the apparatus and deteriorates the versatility of the press machine, it is desirable to implement this method in the case of mass production of a small number of products.

[3] Method of Preventing Warpage This method is intended to reduce the occurrence of warpage from the viewpoint that the laminate X is warped by the curing shrinkage of the synthetic resin applied after the decorative material 2 is adhered to the substrate 1. To prevent this, after applying the decorative material 2 to the base material 1 and before forming the synthetic resin layer 3, a warp is applied to the base material 1 in advance so that the applied decorative material 2 becomes more convex. That is, the above-mentioned means is adopted.

As a means for imparting warpage to the substrate 1, as shown in FIG. 6, there is a method of stacking the substrate 1 on which the decorative material 2 is adhered on a non-horizontal mounting surface. That is, as shown in FIG. 6 (A), the central portion of the base material 1 is set to be higher, or as shown in FIG. 6 (B), both end portions are set to be higher. (About 2 hours or more). Also in this example, a spacer 7 for scooping up with a forklift is laid below the base material 1 to be stacked, and the center or both ends of the base material 1 is increased by adjusting the height of the spacer 7. It can be set as follows. In the case where the base material 1 is stacked such that the surface of the base material 1 to which the decorative material 2 is adhered is on the upper surface side, the synthetic resin layer is formed by raising the central portion as shown in FIG. Warping is applied so that the decorative material 2 side is convex. Conversely, when stacking so that the surface of the base material 1 on which the decorative material 2 is adhered is on the lower surface side, it is necessary to set both ends high as shown in FIG.

The magnitude of the warp imparted to the base material 1 is, for example, as follows.
Assuming that the thickness is 0 mm and the thickness is 18 mm, when this is placed on a flat surface, the center part is about 10 to 15 mm with respect to both ends.
Protruding degree. However, the above numerical values are merely examples, and the degree of warpage is appropriately changed according to the material and dimensions of the target substrate 1 or the type and amount of synthetic resin material applied to the surface. The number of stacked substrates 1 is not particularly limited, but is usually about 40 to 50. Furthermore, if necessary, it is possible to arrange a weight on the stacked base materials 1 to promote the warpage.

When the base material 1 on which the decorative material 2 is adhered is warped as described above, a synthetic resin material such as a polyester resin is applied on the convex decorative material 2. This is cured by irradiation with infrared rays or the like to form the synthetic resin layer 3. Since the warpage of the base material 1 is canceled by the shrinkage when the synthetic resin is cured, a straight product without warpage can be obtained.

As a means for imparting a warp to the substrate 1, a method of changing the heating temperature between the front side and the back side of the substrate 1 during hot pressing when attaching the decorative material 2 to the surface of the substrate 1 is used. Is also conceivable. If a temperature difference of about 20 to 30 ° C. is provided between the front and back surfaces of the substrate 1, the substrate 1 can be warped. However, this method is difficult to control the temperature, and it takes time to change and adjust when changing the product number. Therefore, it is appropriate to adopt this method in the case of mass production of a small number of products.

Further, in the hot press apparatus, a method of giving a warp to the substrate 1 at the time of pressing by forming the pressing surface into a curved surface may be considered. However, as described above, this method has disadvantages in that the manufacturing cost of the device is high and the versatility of the hot press machine is low.

[4] Other Embodiments In order to manufacture a laminate having no warp according to the present invention, it is possible to use some of the above-described methods in combination. That is, if a warp is found in the product despite the fact that the laminate is manufactured by applying the warp prevention method described in the above item [3], the 2-1 stacking method in the above item [2] is used. Or 2-2 does not prevent the warpage from being corrected by the hot pressing method. Further, if necessary, the warp correcting step may be performed a plurality of times.

[5] Edge Shape of Laminated Plate FIGS. 7 to 10 illustrate various modes of the curved surface R formed on the edge of the laminated plate X. FIG. 7 shows a case where a semicircular curved surface R is formed at an edge portion. As shown in FIG. 7A, two steps 1b-1 and 1b-1 on the back side of the decorative material 2 are shown.
A region k indicated by hatching at the edge of the base material 1 is cut so that the backing layer 1a is located between the base material b-2 and the backing layer b-2. In this example, the thickness d ₁ of the stepped portions 1b-1 and 1b-2 formed by cutting is set to approximately half the thickness D of the substrate 1 (D = 2d ₁ ). Then, as shown in FIG. 2B, the decorative material 2 is bent in a region where the backing layer 1a is provided so as to be folded, and the step portions 1b-1 and 1b-2 are overlapped and bonded. Thereby, the semicircular curved surface R as shown
Is formed. Thereafter, if the voids S are filled with a synthetic resin or a combination of a synthetic resin and a bar, a laminate X having a semicircular cross-sectional shape at the edge can be obtained.

As shown in FIG. 8, by changing the thickness of the step formed by cutting the base material 1, it is possible to change the thickness of the edge portion of the laminated board X to be manufactured. That is, as shown in FIG. 1A, the thickness d ₂ of the steps 1b-1 and 1b-2 formed by cutting the region k of the base material 1 is changed to the thickness D of the base material 1.
(D <2d ₂ ). And then
As shown in FIG. 3B, the decorative material 2 is curved and the stepped portion 1b is formed.
By laminating -1 and 1b-2, it is possible to manufacture a laminate X in which the thickness of the edge portion is larger than the thickness of the base material 1.

FIG. 9 shows the position of the backing layer 1a formed by cutting the base material 1 at a position at an appropriate distance from the side end surface. By setting the cut area k of the base material 1 in the illustrated range, the decorative material 2 is bent at a right angle in the area where the backing layer 1a is formed, and the stepped portions 1b-1 and 1b-2 are overlapped and adhered. A laminated plate X having a quarter-circle curved surface R formed at the edge and a long side end surface U can be obtained.

As shown in FIG. 10, cutting regions k are formed at two places on the base material 1 at appropriate intervals, and the decorative material 2 is curved at right angles in the two backing layers 1a, 1a. By laminating and bonding 1b-1 to 1b-4, a side end face U having a large length as shown in FIG. 4B is provided, and a decorative surface V of the decorative material 2 is partially formed on the back side. The laminated board X provided can be provided.

Further, the cutting region k of the base material 1 may be set as shown in FIG. 11, and a step portion 1b-3 having a slope continuous with the backing layer 1a may be provided. With this configuration, the decorative material 2 is curved in the backing layer 1a, and the step portion 1b-
By overlapping and fixing 1, 1b-2, it is possible to obtain a laminated board X on which a curved surface R whose entire edge is a quarter circle is formed as shown in FIG. . In addition, the form of the curved surface R formed on the laminate X according to the present invention does not prevent various changes.

[0050]

According to the laminate of the present invention, since a non-oriented member is selected as the substrate of the laminate, it is possible to correct the warp even if the substrate has a thickness of 9 mm or more. That is, when a decorative material is stuck on the surface of a base material and a warp is found in a laminated plate having a curved surface at an edge portion, the warp is found by stacking the warp on a non-horizontal mounting surface, or by using a hot press. By doing so, the warp can be corrected, and the recurrence of the warp can be almost permanently prevented. The correction of the warp is effective before and after the curved surface is provided at the edge of the laminate.

Further, in the case of a laminate having a synthetic resin layer formed thereon after the decorative material is adhered to the surface of the base material, an appropriate warp is applied to the base material in advance so that the base material can be formed later. A straight laminated board can be obtained by canceling out warpage caused by curing shrinkage of the applied synthetic resin. In any case, according to the present invention, it is possible to obtain a long product without warping, so that the number of defective products is greatly reduced, and the yield is improved.

Furthermore, the laminate according to the present invention is simple to manufacture because the edge of the substrate is cut after the decorative material is adhered to the surface of the substrate. Therefore, the production efficiency is improved, and the cost can be reduced. Further, since various edge shapes can be formed by changing the cutting shape of the edge of the base material, various types of laminated boards can be easily manufactured.

In addition, the gap strength formed between the decorative material and the base material at the edge is filled with a synthetic resin or a combination of a synthetic resin and a bar, so that the bending strength of the laminated plate is increased. . Further, since the shape stability is improved, there is also obtained an advantage that warpage hardly occurs.

[Brief description of the drawings]

1A and 1B show an embodiment of a manufacturing process of a laminate according to the present invention, in which FIG. 1A is an exploded side view showing a base material and a decorative material, and FIG. Side view showing a state in which a synthetic material is applied thereon after applying a cosmetic material thereon, and FIG. (C) is a side view showing a state in which the edge of the base material is cut on the back side of the decorative material. Fig. (D) is a side view showing a state in which the decorative material is curved on the side end surface of the base material to form a curved surface, and Fig. (E) is a void formed between the step portion of the base material and the decorative material. FIG. 4 is a side view showing a state in which is filled with a synthetic resin.

2A and 2B show an embodiment of a laminate according to the present invention, wherein FIG. 2A is a side sectional view, and FIG. 2B is an enlarged side sectional view showing an edge portion of the laminate. (C) is an enlarged cross-sectional view showing an α portion in FIG. (B).

FIG. 3 is an enlarged sectional view showing an end portion of the decorative material after cutting the base material shown in FIG. 1C.

FIG. 4 is a side sectional view showing another embodiment of the laminated board according to the present invention, in which an edge portion is enlarged.

FIG. 5 relates to an embodiment of a method for manufacturing a laminated board according to the present invention, and shows a situation in which laminated boards are stacked on a non-horizontal mounting surface for warpage correction, and FIG. FIG. 4B is a front view showing a stacked state when the height of the section is increased, and FIG.

FIG. 6 relates to an embodiment of the method for manufacturing a laminated board according to the present invention, and illustrates a means for imparting a warp in advance to a base material on which a decorative material is adhered before forming a synthetic resin layer. (A) is a front view showing a stacking state when the decorative material side is the upper side, and (B) is a front view showing a stacking state when the decorative material side is the lower side.

7A and 7B show another embodiment of the laminated board according to the present invention, wherein FIG. 7A is a side view of a main part showing a cutting area of a base material, and FIG. FIG. 4 is a side view of a main part showing a state in which a gap is formed between the substrate and the base material.

8A and 8B show still another embodiment of the laminated board according to the present invention, wherein FIG. 8A is a side view of a main part showing a cutting area of a base material, and FIG. It is a side view of the important section showing the state where the gap was formed between the base material and the base material.

9A and 9B show still another embodiment of the laminated board according to the present invention, wherein FIG. 9A is a side view of a main part showing a cutting area of a base material, and FIG. FIG. 4 is a side view of a main part showing a state in which a gap is formed between the substrate and the base material.

FIGS. 10A and 10B show still another embodiment of the laminated board according to the present invention, wherein FIG. 10A is a side view of a main part showing a cutting area of a base material, and FIG. FIG. 4 is a side view of a main part showing a state in which a gap is formed between the substrate and the base material.

11A and 11B show still another embodiment of the laminated board according to the present invention, wherein FIG. 11A is a side view of a main part showing a cutting area of a base material, and FIG. FIG. 4 is a side view of a main part showing a state in which a gap is formed between the substrate and the base material.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 ... Base material 1a ... Backing layer 1b, 1b-1, 1b-
2, 1b-3, 1b-4: Step portion 1c: Side end surface 2: Cosmetic material 3: Synthetic resin layer 4: Adhesive 5: Surface material 6: Coating device 7: Spacer 10: Synthetic resin 20
... Bar material k ... Cutting area of base material p ... Thickness of backing layer q
... thickness of cosmetic material, synthetic resin layer and adhesive R ... curved surface
S: void t: protrusion X: laminate

──────────────────────────────────────────────────の Continued on the front page (51) Int.Cl. ⁷ Identification symbol FI Theme coat ゛ (Reference) B32B 33/00 B32B 33/00 F term (Reference) 2B002 AA03 AB03 BA18 BA20 BB08 2B250 BA02 CA11 DA03 FA21 HA01 2B260 AA12 BA19 CB01 CB04 4F100 AK15 AK25 AK36 AK41 AK51 AP03A AR00B AT00A BA02 CB05 DB15 DG01A EC182 EH312 EJ203 EJ423 GB07 GB81 HB00B JL04 JL10B

Claims (10)

[Claims] 1. A decorative material having a small thickness is adhered to a surface of a base material, a base material on a back surface side of the decorative material is cut at an edge portion, and the decorative material in a region where the base material is cut is curved to form a base material. In a laminated board in which a curved surface is provided at an edge portion by forming a void portion between the material and the void portion and filling the void portion with a synthetic resin or a combination of a synthetic resin and a bar, Alternatively, a laminate made of a non-oriented material such as a particle board and having a thickness of 9 mm or more. 2. The laminate according to claim 1, wherein a synthetic resin layer is formed on the decorative material. 3. The laminate according to claim 1, wherein a decorative material previously coated or impregnated with a synthetic resin is adhered to the substrate. 4. A thin decorative material is stuck on the surface of a non-oriented base material having a thickness of 9 mm or more, and the base material on the back surface side of the decorative material is cut at an edge portion, and the base material is cut. A curved portion is formed on the edge by curving the decorative material in the formed area to form a gap between the base material and the gap, and filling the gap with a synthetic resin or a combination of a synthetic resin and a bar. In the board manufacturing method, if a warp is found after attaching a decorative material,
A method for manufacturing a laminate, comprising correcting the warpage by stacking the laminates on a non-horizontal mounting surface that is curved in a direction opposite to the warp and leaving the laminate to stand. 5. A thin decorative material is stuck on the surface of a non-oriented base material having a thickness of 9 mm or more, and the base material on the back side of the decorative material is cut at an edge portion, and the base material is cut. A curved portion is formed on the edge by curving the decorative material in the formed area to form a gap between the base material and the gap, and filling the gap with a synthetic resin or a combination of a synthetic resin and a bar. In the board manufacturing method, if a warp is found after attaching a decorative material,
A method for manufacturing a laminate, wherein the warpage is corrected by hot pressing the laminate. 6. The method for manufacturing a laminate according to claim 4, wherein the correction of the warp is performed before providing a curved surface at an edge portion. 7. The method for manufacturing a laminate according to claim 4, wherein the correction of the warp is performed after a curved surface is provided at an edge portion. 8. The method for manufacturing a laminate according to claim 4, wherein after a decorative material is attached to the surface of the base material, a synthetic resin layer is formed on the decorative material. 9. The method for producing a laminate according to claim 4, wherein the decorative material to be adhered to the surface of the base material is a decorative material previously coated or impregnated with a synthetic resin. 10. A thin decorative material is stuck on the surface of a non-oriented base material having a thickness of 9 mm or more, and a synthetic resin layer is formed on the decorative material. The base material on the back side of the base material is cut, the decorative material in the region where the base material is cut is curved to form a gap between the base material, and a synthetic resin or a combination of a synthetic resin and a bar in the gap. In the method of manufacturing a laminated board in which a curved surface is provided at an edge portion by filling the base material, before forming the synthetic resin layer on the decorative material on the surface of the base material, the base material is warped such that the decorative material side becomes convex. A synthetic resin layer is formed on the decorative material on the surface of the base material, and the synthetic resin layer is cured to cancel the warpage.