JP2002036350A - Bent processed product and processing method therefor - Google Patents

Abstract

PROBLEM TO BE SOLVED: To solve such a problem that a material obtained by bonding a decorative material to a woody core material such as plywood, particle board or the like is used in a bent processed member heretofore but, when the processed product of this kind is used in a member adapted to a water using area such as the top panel or the like of a washstand, a kitchen or the like, water penetrates into a joint or the bonded part with other part to swell or corrode the core material and anxiety has been left in long-term use and, in such a case that a hard decorative material is used, the decorative material is necessarily cracked, broken or depressed when an article falls on the surface of the decorative material. SOLUTION: In consideration of this problem, a thick decorative sheet obtained by laminating and molding a surface layer and a core layer, both of which comprise a resin material is used and a recessed part is provided in the decorative sheet at a proper place so as to leave the surface layer and, after the surface layer is heated if necessary to bend the decorative sheet, and an appropriate fixture is brought into contact with the bent part to inject a curable resin in the space, which is surrounded by the fixture and the surface layer, and the cured resin is integrated with the surface layer to obtain the bent processed product.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a bent product used for members such as a house, a building, and furniture, and a method of processing the same.

[0002]

2. Description of the Related Art Heretofore, a bent top plate has been widely used for members of houses, buildings, furniture and the like. These are finished by bonding a decorative sheet to the surface of the assembled core material,
L-shaped cores with rounded corners, post-formed decorative panels, and cut-off and bent parts of the back side of the plate with the decorative sheet bonded are finished. Had been used. These are all made of wood core material such as plywood and particle board. When penetrated, it causes problems such as swelling of the core material, corrosion, peeling of decorative sheets and decorative plates, and the like, making it difficult to use as a member such as a top plate for a long time. In addition, when a hard decorative material such as a melamine resin decorative board is laminated, when the article falls and hits the surface strongly, the core material is softer than the decorative material and the strength is insufficient. Due to the large movement upon receiving and the insufficient backing strength, problems such as cracking, chipping, and depression of the surface material alone were unavoidable.

[0003]

SUMMARY OF THE INVENTION The present invention solves the problems of swelling, corrosion, and peeling due to water penetration in a top plate or other member in which a decorative plate is attached to a conventional wood core as described above. In addition, in order to solve the problem of the decorative material on the surface cracking or chipping due to the article hitting the surface strongly, the core and the surface layer are processed using a thick decorative board made of synthetic resin material. This is to provide a processing method.

[0004]

According to the present invention, as a result of various investigations, a concave portion is provided on a thick decorative board while leaving a surface layer at an appropriate position, the surface layer is heated as necessary, and an appropriate jig is abutted. While bending, the curable resin is injected into the space surrounded by the jig in contact with the surface layer and the position to be bent,
The conventional problem can be solved by a bent product which is integrally processed by curing of the curable resin, and is provided together with the processing method.

Next, the present invention will be described in detail with reference to the drawings of embodiments. 1 to 4 are views showing an embodiment showing a situation in which a bent product according to the present invention is processed.
80g phenolic resin on 50g / m2 kraft paper
% Core paper impregnated with 60% by weight of melamine resin on titanium oxide paper having a basis weight of 120 g / m2, and two sheets each for a surface layer are laminated on the front and back sides and hot-press molded to form a surface layer (2). The concave portion (1) is left in place of the surface layer (2) at an appropriate position of the thick decorative board (3) in which the core layer (1) is integrated.
a) is cut. Next, after heating the surface layer (2) from above the surface layer (2) with the heater (4), the jig (5) having an arc-shaped tip is inserted into the recess (1).
a), the surface layer (2) is bent until it comes into close contact with the jig (5), the jig (5) is pulled out, and the bent part of the thick decorative board (3) is set. The curable resin liquid (6) is injected into a space formed by bringing the tool (7) into contact, and is cured, whereby the thick decorative board (3) is finished in an L-shaped externally bent state. .

On the other hand, FIGS. 5 to 7 show a situation in which the same thick decorative board (10) as described above is bent inwardly into an L shape. Heater (11) from above the recess (8a) formed leaving the layer (9)
And a jig (12) having an arcuate corner is brought into contact with the surface layer (9) and bent, and then the surface layer (9) side is fixed by the jig (12). The jig (13) is also brought into contact with the outside, and the curable resin (14) is injected into a space surrounded by the jig (13) facing the recess (8a) and the surface layer (9). By the curing of the curable resin (14), the thick decorative board (10) is integrally formed to be finished into a bent product.

In the thick decorative panel according to the present invention, a light-colored, preferably transparent, curable resin such as melamine resin, polyester resin or acrylic resin is processed from fibers such as cellulose, synthetic fiber and glass fiber for the surface layer. Paper, non-woven fabric,
A molded sheet in which a fiber base material such as cloth is impregnated with a resin, and a molded sheet in which a curable resin such as a phenol resin, an epoxy resin, or a urethane resin is applied to the fiber base material for the core layer is used. You. Appropriate number of surface layer forming sheets are laminated on these core layer forming sheets, and they are formed into a thickness of 3 to 20 mm by heat and pressure, or formed in advance using the core layer forming sheet. A sheet formed by laminating the molded sheet for a surface layer on a plate body and the like are used.

The shape of the concave portion processed while leaving the surface layer may be trapezoidal, rectangular or the like, depending on the size, shape, processing method and the like of the processed product. The thickness of the surface layer is appropriately selected depending on the shape of the processed product, the processing method, the resin composition, and the like. For example, when a molded sheet in which melamine resin is impregnated into titanium oxide paper is used, and the length of the concave portion on the surface layer is about 1 to 5 cm, the surface layer is 0.1 mm.
A range of about 5 to 2.0 mm is a preferable range when judged from bending workability, workability, and the like. It is desirable that the concave portion is cut by an NC machine having high mechanical accuracy or the like in order to make the thickness of the surface layer uniform.

If the resin material used for the surface layer has towability, the jig is brought into contact with the surface layer located in the concave portion without being necessarily heated, and then the curable resin is injected. The cured product can be processed by curing.

As the curable resin injected into the space surrounded by the bent surface layer and the jig, a room temperature curable resin such as an epoxy resin, a urethane resin, an unsaturated polyester resin, and a vinyl ester resin is used. . Among them, a urethane resin which is excellent in adhesiveness and curability and has a small cure shrinkage is suitable. A resin having a curing shrinkage of 2% or more is not preferable because shrinkage stress remains after injection and the resin is degraded with time, causing problems such as cracking.

In order to reinforce the curable resin, a fiber length of 0.
A fiber reinforcing material such as glass fiber of 5 to 5 mm, synthetic fiber such as vinylon, nylon or polypropylene may be mixed in a range that does not sacrifice fluidity for injection.

[0012] In the above embodiment, the outer bending machined at right angles,
Although this is an example of inner bending, depending on the shape of the jig, bending at a bending angle of 90 degrees or less or 90 degrees or more is possible, and various shapes can be processed depending on the use of the member. Also, various types of processing can be performed depending on the surface shape and size of the jig. Further, in the embodiment, a single example of the outer bending and the inner bending is used. However, in the bent product and the processing method of the present invention, various processing examples such as a case where the outer bending and the inner bending are plural, a case where the outer bending and the inner bending are used in combination are adopted. And various shapes can be adopted depending on the use of the processed product.

Since the processed product according to the present invention does not cause any influence on water permeation, it is preferably used for a water circulating member such as a kitchen counter, a wash counter or a toilet booth. In addition, it can be used as a member for various uses such as a partition and a desk. The length, width, processing shape, and the like of the processed product are determined by these uses. In addition, the outer bending, the inner bending, the combination thereof, and the like may be selected depending on the use, the place of use, and the like.

[0014]

[Effect] The processed product according to the present invention has a continuous surface without any seams, and since the bent portion is firmly backed and held by resin, there is no need to bond a backing material for reinforcement, and the plate body is not required. There is an advantage that it can be used as a member for various applications while maintaining the thickness of
It can be used for various uses as described above as a structural member.
Also, when a phenolic resin is used as the core material, it is excellent in flame retardancy, and when used as a building member, it is finished to be preferable in terms of fire prevention.

Further, in the case of a conventional processed product such as a top plate using a wood core material, problems such as swelling and corrosion of the core material due to permeation of water from a seam or a connection portion with other parts are unavoidable.
Although there remains uneasiness in use near water, the bent product according to the present invention can be used for a long time without any such anxiety. If a hard melamine resin decorative material is used as the surface material, if the article falls onto the surface and hits it strongly, the backing core material is soft and lacks strength, so it may not be strong enough. The movement was large, the cosmetic material cracked, and there were many problems such as chipping.However, in the processed product of the present invention, the surface layer was cracked or chipped because the core layer was also lined with a resin material having excellent strength.
There is no problem such as depression, and there is no problem for long-term use.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view of a thick decorative board (3) in which a surface layer (2) is laminated on both sides of a core layer (1).

FIG. 2 is a view showing a state in which a surface layer (2) of a thick decorative board (3) provided with a concave portion (1a) at an appropriate position is heated by a heater (4).

FIG. 3 is a diagram showing a state in which a jig (5) is brought into contact with a concave portion (1a) and bent after heating a surface layer (2) located in the concave portion.

FIG. 4 is a diagram showing a state in which a curable resin (6) is injected into a space formed by abutting a jig (7) on a corner portion after a surface layer (2) is bent and cured.

FIG. 5 is a diagram showing a state in which a concave portion (8a) is provided while leaving a surface layer (9) of a thick decorative board (10).

FIG. 6 is a diagram showing a state in which a surface layer (9) is heated by a heater (11) and bent inward.

FIG. 7 is a diagram showing a state in which a curable resin (14) is injected into a space formed by bringing a jig (12) into contact with a corner portion after being subjected to inward bending, and is cured.

[Explanation of symbols]

 1,8 Core layer 2,9 Surface layer 1a, 8a Depression 3,10 Thick decorative board 4,11 Heater 5,7,12,13 Jig 6,14 Curable resin

Claims (2)

[Claims] 1. A concave portion is provided in an appropriate place on a thick decorative board on which a surface layer made of a resin material and a core layer are laminated, and a surface layer located in the concave portion is heated as necessary. At the same time, after the jig abuts on the surface layer located in the concave portion and is bent, the jig is abutted at a position where one or more jigs are bent, and is surrounded by the jig and the surface layer. A bent product wherein a curable resin is injected into a space, cured, and integrally processed. 2. A concave portion is provided on a thick decorative board in which a surface layer made of a resin material and a core layer are laminated, leaving a surface layer in an appropriate position, and the surface layer located in the concave portion is heated as necessary, and The jig is brought into contact with the surface layer located in the concave portion and bent, and then a curable resin is injected into a space surrounded by one or more jigs and the surface layer, and the resin is cured to be integrally processed. Characteristic processing method.