JP2016068443A - 加飾パネル及び加飾パネルの製造方法 - Google Patents
加飾パネル及び加飾パネルの製造方法 Download PDFInfo
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- JP2016068443A JP2016068443A JP2014201153A JP2014201153A JP2016068443A JP 2016068443 A JP2016068443 A JP 2016068443A JP 2014201153 A JP2014201153 A JP 2014201153A JP 2014201153 A JP2014201153 A JP 2014201153A JP 2016068443 A JP2016068443 A JP 2016068443A
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- Prior art keywords
- layer
- decorative
- outer layer
- hole
- contact
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- 230000008569 process Effects 0.000 description 8
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Abstract
【解決手段】本発明の加飾パネル1は、装飾を有する表面2aと表面2aの反対側の裏面2bとに開口する貫通孔3が形成された外層2と、裏面2b側から貫通孔3内に一部が入り込んだ形状をなして湾曲変形された象嵌模様部6を有し略一様な層厚を有して外層2の裏面2bの全面に配された加飾層5とを備えた。
【選択図】図2
Description
特許文献1に記載の方法では、外層と内層とが積層されてなる複合体に対して、所定のデザインパターンの貫通孔が外層に形成されるようにレーザー加工によって外層の一部を除去する。特許文献1に開示された技術を用いて積層体の外層をレーザー加工等によって除去すると、外層の貫通孔から見える内層は、外層の最外面に対して窪んだ位置に平面状に露出する。
また、象嵌模様を有する加飾パネルを効率よく生産するための方法として、特許文献2には、象嵌部材を挿入することができる窓孔を有する化粧材に対して、象嵌部材を窓孔内に装填した後に背面側から射出成形をすることが開示されている。
本発明の第1実施形態について説明する。図1は、本実施形態の加飾パネルの平面図である。図2は、図1のA−A線における断面図である。図3は、図2の拡大図である。
図1及び図2に示すように、加飾パネル1は、外層2と、加飾層5と、成形樹脂層7とを備える。
加飾パネル1は、外層2と加飾層5とがこの順に積層された積層体8に対して、加飾層5に接する成形樹脂層7がインサート成形により一体化されたパネルである。
ステップS1において第一層2Aのどの領域を取り除くかは、加飾パネル1のデザインに応じて決まっている。すなわち、ステップS1では、デザインに対応する所定の模様をなす貫通孔3が第一層2Aに形成される。第一層2Aの一部を取り除く方法は、特に限定されない。第一層2Aの一部を取り除く方法の一例として、レーザー加工により第一層2Aを除去する方法が挙げられる。レーザー加工を用いた場合、レーザー加工幅に応じた微細な加工が可能である。また、レーザー加工では、木質材料からなる第一層2A及び第一層2Aと第二層5Aとの間の接着剤は除去できるが金属材料からなる第二層5Aは除去されないように出力やパルス等を適切に設定することにより、第二層5Aの外面が露出するように第一層2Aがパターン状に取り除かれる。
これでステップS1は終了し、ステップS2へ進む。
ステップS2では、たとえば、第一層2Aの一部が取り除かれることで第一層2Aに形成される貫通孔3を覆うように第一層2Aの表面に沿う成形型Mや、貫通孔3が位置する部分に凹凸等を有する成形型M等、デザインの応じて様々な形状の成形型Mから選択されてインサート成形が行われる。
たとえば、第一層2Aに形成される貫通孔3を覆うように第一層2Aの表面に沿う成形型Mを用いた場合、成形型M内に積層体8を取り付けた後にインサート樹脂の流動体を成形型M内に流入することで、第二層5Aにインサート樹脂が接して第二層5A側から積層体8が加圧される。さらに、インサート樹脂の流動体は、第二層5Aにインサート樹脂が接触した状態で成形型Mの形状に倣った所定の形状に固化する。
インサート樹脂が第二層5A側から積層体8を加圧すると、第一層2Aの貫通孔3に第二層5Aの一部が嵌入するように第二層5Aが湾曲変形する。第一層2Aの貫通孔3内での第二層5Aの湾曲変形の態様は、インサート樹脂の射出圧によって異なる。インサート樹脂の射出圧は、第一層2Aの貫通孔3の開口面積及び開口形状と第二層5Aの材質及び層厚とに応じて設定される。
たとえば、第一層2Aの貫通孔3に、第一層2Aの裏面から表面に向かって凸となるように第二層5Aが入り込むと、第二層5Aが成形型Mに接触するまでは第二層5Aの外面はアーチ型となる。第一層2Aの貫通孔3と通過して成形型Mに第二層5Aが到達すると、第二層5Aは成形型Mに倣った形状となるように変形する。第一層2Aに形成される貫通孔3を覆うように第一層2Aの表面に沿う成形型Mにおいて第二層5Aが成形型Mに到達すると、第二層5Aの最表面は第一層2Aの表面と面一となる。また、第一層2Aに形成される貫通孔3を覆うように第一層2Aの表面に沿う成形型Mでは、インサート樹脂の射出圧が好適に設定されると、第一層2Aの貫通孔3を完全に第二層5Aが埋めて積層体8の最表面が平滑になるように第二層5Aが変形する。
これでステップS2は終了する。ステップS2の終了後、積層体8の表面には、第二層5Aが貫通孔3に埋め込まれているように見える象嵌模様が形成されている。
このため、多様なデザインの製品を少量生産する場合に、デザインごとの製造設備や設定の変更箇所が少なくて済むので、生産性が高い。
次に、上記実施形態の変形例について説明する。
成形型Mの形状は上記実施形態で説明された形状に限定されない。たとえば、第一層2Aの表面2aに接する第一の成形面と、第一の成形面に対して窪んだ第二の成形面とを有する成形型であれば、第一層2Aの表面2aから第二層5Aが突出した象嵌模様がインサート成形によって形成される。本変形例の加飾パネルの製造方法も、溝に対して隙間なく象嵌部材がはめ込まれたように精度が高く美観に優れた象嵌模様を容易に形成できる。
本発明の第2実施形態について説明する。図9は、本実施形態の加飾パネルを示す平面図である。図10は、図9のB−B線における断面図である。
加飾パネル11は、外層2と加飾層5と内層9とがこの順に積層された積層体10に対して内層9に接するように成形樹脂層7がインサート成形により一体化されたパネルである。
外層2の層厚方向から内層9を見たときに外層2の貫通孔3の開口内に存する領域には、外層2の層厚方向に沿って外層2の裏面から外層2の表面へ向かう方向に凸となる湾曲面9c,9dを有する。内層9の湾曲面9c,9dは、成形樹脂層7のインサート成形の過程で形成される面である。
本実施形態の積層体10は、第一層2Aと第三層9Aとが第二層5Aを間に挟んだサンドイッチ状の積層構造を有している。第三層9Aは略一様な層厚を有している。さらに、第一層2Aと第三層9Aとは、同一素材で形成されているか、あるいは、熱または水分による膨張率とが同程度の素材で形成されている。このため、本実施形態の積層体10は、温度や湿度などの環境変化の影響による歪みが起こりにくい。
本実施形態の積層体10に対して上記第1実施形態と同様に第一層2Aの一部を取り除いてデザインを形成し(第1実施形態のステップS1参照)、その後、第三層9Aにインサート樹脂が接触するように成形型M内でインサート成形を行う(第1実施形態のステップS2参照)。
このような製造方法により、上記第1実施形態と同様に象嵌細工が精度よく形成されているように見える美観に優れた象嵌模様を容易に形成できる。
外層2及び内層9となる第一層2A及び第三層9Aは、互いに同じ天然木からなる0.2mm厚のシート状である。
加飾層5となる第二層5Aは、金属からなる薄板材である。
本実施例に示す外層2及び内層9並びに加飾層5の材種と、加飾層5の層厚とが下記表1に示される。表1の「加飾層材種」の欄に示された「A1050」及び「A5052」は、JIS H 4000(アルミニウム及びアルミニウム合金の板及び条)に規定された等級である。
また、外層2及び内層9の材種の違いは好適な象嵌模様を形成するために必要な射出圧への影響が少ない。そのため、外層2及び内層9の材種は、木質材料であれば、デザイン上の要請に応じて幅広い選択肢から適宜選択可能であると考えられる。
Claims (8)
- 装飾を有する表面と前記表面の反対側の裏面とに開口する貫通孔が形成された外層と、
略一様な層厚を有して前記外層の裏面の全面に配された加飾層と、
を備え、
前記加飾層は、前記外層の裏面側から前記貫通孔内に一部が入り込んで湾曲変形された象嵌模様部を有することを特徴とする加飾パネル。 - 請求項1に記載の加飾パネルであって、
前記加飾層は、前記象嵌模様部において少なくとも前記貫通孔の開口のうち前記裏面側の開口端に密着して前記貫通孔の内部へ向けて湾曲されている
加飾パネル。 - 請求項1に記載の加飾パネルであって、
前記加飾層の前記外層に接する面とは反対の面に配され略一様な層厚を有し、前記外層の層厚方向から見たときに前記貫通孔の開口内に存する領域に、前記外層の層厚方向に沿って前記外層の裏面から前記外層の表面へ向かう方向に凸となる湾曲面を有する内層と、
前記内層の前記加飾層に接する面とは反対の面に配され前記外層と前記加飾層と前記内層とを所定の立体形状に保持する成形樹脂層と、
をさらに備えた加飾パネル。 - 装飾を有する表面と前記表面の反対側の裏面とに開口する貫通孔が形成された外層と、
前記外層の裏面の全面に配され前記貫通孔の前記裏面側の開口を覆い略一様な層厚を有する加飾層と、
前記加飾層の前記外層に接する面とは反対の面に配された内層と、
前記内層の前記加飾層に接する面とは反対の面に配され前記外層と前記加飾層と前記内層とを所定の立体形状に保持する成形樹脂層と、
を備えた加飾パネル。 - 請求項1から請求項4のいずれか一項に記載の加飾パネルであって、
前記外層は木質材料からなり、
前記加飾層は前記外層とは異なる材料からなる
加飾パネル。 - 請求項5に記載の加飾パネルであって、
前記加飾層は金属材料からなる
加飾パネル。 - 第一層と第二層とが積層状態で固定されてなる平板状の積層体が前記平板状をなした状態で前記第二層が露出するように前記第一層の一部を前記積層体から取り除き所定の模様をなす貫通孔を前記第一層に形成する外層加工工程と、
前記外層加工工程の後に前記第一層の外面のうち前記第二層に接する面と反対側の面を所定の成形型に接触させて前記第二層側から加圧することにより前記貫通孔に前記第二層の一部が嵌入するように前記第二層を湾曲変形させる成形工程と、
を備えた加飾パネルの製造方法。 - 請求項7に記載の加飾パネルの製造方法であって、
前記成形工程では、前記第二層に樹脂の流動体が接するように前記成形型内に前記流動体を流入させて加圧下で前記流動体を固化させる
加飾パネルの製造方法。
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US10166739B2 (en) | 2019-01-01 |
JP6510208B2 (ja) | 2019-05-08 |
CN105459713B (zh) | 2019-10-11 |
EP3002121B1 (en) | 2017-09-20 |
US20160089850A1 (en) | 2016-03-31 |
EP3002121A1 (en) | 2016-04-06 |
CN105459713A (zh) | 2016-04-06 |
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