JP2017105096A - Method for manufacturing decorative panel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing a decorative panel capable of achieving a decorative panel which can improve reduction in weight and designability, has high productivity, and has good hardness and strength on the surface, surface smoothness and dimensional stability even when a decorative layer is thin.SOLUTION: A method for manufacturing a decorative panel 1 includes at least following steps (a), (b) and (c): (a) bringing spacer die 7 having a projection portion 7a on a surface and a rear face that are substantially flush with a frame body 21 and a core material 22 of a core layer 2 into contact with outside of the frame body 21 accommodating the core material 22; (b) laminating a fiber-containing resin layer 4 and a decorative layer 3 on the surface and the rear face of the core layer 2 and the spacer die 7, heating, pressing and molding the layers, and simultaneously transferring a bending groove 5 having such a shape as to correspond to the projection portion 7a of the spacer die 7 onto the core layer 2 side of the fiber-containing resin layer 4; and (c) bending the fiber-containing resin layer 4 and the decorative layer 3 in the bending groove 5, and covering a side end face 2A of the core layer 2 with the bent layers.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a method for manufacturing a decorative panel.

  Conventionally, a decorative panel having a decorative layer on both front and back surfaces of a hollow and lightweight core layer is widely known as a fitting such as a swing door and a sliding door. As such a decorative panel, for example, a panel using a honeycomb core as a core layer is known.

  In conventional decorative panels using honeycomb cores, weight reduction is possible, but due to the need to consider the strength, it is usually a hard plate to maintain the strength and hardness of the decorative panel surface. A decorative layer is used.

  In addition, since a large number of cells are open on the front and back surfaces of the honeycomb core, and the cross-sectional area that can be bonded is small, in the conventional method for manufacturing a decorative panel, the hard plate-shaped decorative layer is bonded to the core layer. Ingenuity has been given. For example, a method of providing a plate-like or sheet-like intermediate layer between the decorative layer and the core layer, applying an adhesive on the front and back surfaces, and bonding the decorative layer and the core layer is exemplified.

  As such an intermediate layer, for example, MDF (Medium density fiberboard) is used. However, since MDF contains abundant wood fibers, there is a problem that moisture contained in the adhesive is absorbed and the dimensional change becomes large, and it is necessary to attach a moisture-proof sheet or the like.

  On the other hand, for the purpose of improving the adhesive strength by an adhesive while suppressing dimensional change, a soft core material made of a fiber-like material such as glass fiber or paper or cloth between a hard plate-like decorative layer and a honeycomb core There has been proposed a method for manufacturing a decorative panel in which a fiber-containing resin layer impregnated with a thermosetting resin is interposed therebetween for adhesion (see Patent Document 1).

Japanese Patent Laid-Open No. 3-90340

  However, in the method for manufacturing a decorative panel described in Patent Document 1, a hard plate-like decorative layer, a fiber-containing resin layer, and a honeycomb core on one side are laminated and pressed at a predetermined pressure to obtain a thermosetting resin. After curing, the hard plate-like decorative layer and the fiber-containing resin layer on the other surface were laminated on the non-bonded surface of the honeycomb core to cure the thermosetting resin. For this reason, there existed a problem that there were many processes like the manufacturing method of the conventional decorative panel, and productivity was low.

  Moreover, in the decorative panel obtained by the manufacturing method of the decorative panel described in Patent Document 1, since a hard substrate such as FRP or a metal plate is used for the decorative layer, there is a restriction from the viewpoint of weight reduction of the panel configuration. In addition, work steps such as attaching a decorative sheet to the substrate surface are indispensable, and there is a difficulty in improving the design.

  The present invention has been made in view of the circumstances as described above, and can achieve weight reduction and improvement in design, high productivity, and even if the decorative layer is thin, the hardness and strength of the surface, the surface It is an object of the present invention to provide a method for manufacturing a decorative panel capable of realizing a decorative panel having good smoothness and dimensional stability.

  In order to solve the above-described problems, a method for manufacturing a decorative panel according to the present invention includes a frame layer, a core layer including a core member housed inside a frame body in which the frame member is assembled, and the core layer. A decorative layer made of a resin film or a veneer disposed on the front and back surfaces, and a fiber-containing resin layer interposed between the core layer and the decorative layer, wherein the decorative layer and the core layer are the fibers A method for producing a decorative panel, wherein the decorative layer and the fiber-containing resin layer cover the side end surface of the core layer while being bonded to the containing resin layer, and include at least the following steps: .

(A) a step of abutting a spacer mold having protrusions on the front and back surfaces of the core layer frame and the core material on the outer side of the frame body housing the core material;
(B) Laminating the fiber-containing resin layer and the decorative layer on the front and back surfaces of the core layer and the spacer type, and heating and pressing, and at the same time, the spacer-type protrusion on the core layer side of the fiber-containing resin layer Transferring a bent groove having a shape corresponding to
(C) A step of bending the fiber-containing resin layer and the decorative layer in the bent groove to cover the side end surface of the core layer.

  According to the method for producing a decorative panel of the present invention, by adopting the process using the spacer mold, the front and back surfaces of the core layer and the end facet of the core layer are coated and formed almost simultaneously with the decorative layer, thereby producing the decorative panel. Can increase the sex. Moreover, the decorative layer and the core layer are bonded together with the fiber-containing resin layer, and the core layer side end surface is covered, and even if the decorative layer is thin, the surface hardness, strength, surface smoothness, dimensional stability, etc. are good. A decorative panel is realized. Moreover, since a resin film or a veneer is used as the decorative layer, weight reduction and design improvement can be achieved.

It is the partially cutaway perspective view which showed one Embodiment which illustrated the decorative panel obtained by the manufacturing method of the decorative panel of this invention. It is the partially notched front view which showed another one Embodiment of the decorative panel obtained by the manufacturing method of the decorative panel of this invention. It is the schematic sectional drawing which showed the core layer end surface in one Embodiment of a decorative panel. At the end face of the core layer, the outermost ends of the fiber-containing resin layer and the decorative layer are attached and bonded. (1), (2), (3), (4), (5), and (6) are schematic cross-sectional process diagrams illustrating an embodiment of a method for manufacturing a decorative panel of the present invention. In the manufacturing method of the decorative panel of this invention, it is a schematic sectional drawing which showed the modification of the bending groove formed in a fiber containing resin layer. (A) (B) (C) (D) is the figure which illustrated the cross section in one Embodiment of the decorative panel of this invention. (A) has shown sectional drawing in the process of making a fiber sheet impregnate resin, (B) is sectional drawing of the fiber containing resin layer and core layer after integral molding. (C) is an enlarged view of a region surrounded by a circle in (B), and (D) is a diagram schematically showing a cross section of the fiber-containing resin layer in (C). It is the perspective view which showed the spacer type | mold. In the spacer type, the detachable tapered portion can be removed in the direction of the arrow. It is the side view which showed the modified example of the spacer type | mold. It is the side view which showed another modification of the spacer type | mold. (A) (B) is the plane schematic which showed the fitting which provided the reinforcing material in the frame of the decorative panel, attached the handle to the surface of the decorative layer, and made it a hinged door. (A) (B) is the plane schematic which showed the fitting which provided the through-hole in the surface of the decorative layer of the decorative panel, attached a handle to this through-hole, and was used as the sliding door.

The manufacturing method of the decorative panel of the present invention, as described above, at least,
(A) a step of abutting a spacer mold having protrusions on the front and back surfaces of the core layer frame and the core material on the outer side of the frame body housing the core material;
(B) Laminating the fiber-containing resin layer and the decorative layer on the front and back surfaces of the core layer and the spacer type, and heating and pressing, and at the same time, the spacer-type protrusion on the core layer side of the fiber-containing resin layer Transferring a bent groove having a shape corresponding to
(C) the step of bending the fiber-containing resin layer and the decorative layer in the bent groove to cover the side end surface of the core layer;
Must be included. According to this method, in the present invention, a frame layer and a core layer including a core member housed inside the frame body in which the frame member is assembled, and a resin film or a bump disposed on the front and back surfaces of the core layer are provided. A decorative layer made of a plate, and a fiber-containing resin layer interposed between the core layer and the decorative layer, wherein the decorative layer and the core layer are bonded to the fiber-containing resin layer; A decorative panel in which the layer and the fiber-containing resin layer also cover the side end surface of the core layer is manufactured.

  The embodiment will be described in detail below.

  FIG. 1 is a partially cutaway perspective view illustrating a decorative panel obtained by the method for manufacturing a decorative panel of the present invention.

  For example, as shown in FIG. 1, the decorative panel 1 includes a core layer 2 including a core material 22 housed inside a region surrounded by a frame material and a frame body 21 in which the frame material is assembled. It has a decorative layer 3 made of a resin film or a veneer disposed on the surface of the core layer 2. The decorative panel 1 also has a fiber-containing resin layer 4 in which fibers and a resin interposed between the core layer 2 and the decorative layer 3 are mixed. In such a decorative panel 1, the decorative layer 3 and the fiber-containing resin layer 4 also cover the side end face 2 </ b> A of the core layer 2.

  In the example of FIG. 1, the frame body 21 is assembled by a first frame member 21 </ b> A disposed at the panel edge in the longitudinal direction and a second frame member 21 </ b> B disposed at the panel edge in the short direction. . The second frame member 21B is joined to each of both end portions in the length direction of the first frame member 21A.

  The combination of the frame bodies 21 in the core layer 2 is not limited to the example of FIG. The core material 22 is housed inside the frame body 21 of the decorative panel 1, but the term “inside” here means that it is not outward of the decorative panel 1. The term “storage” does not necessarily surround the four circumferences with a frame material as in the example of FIG. 1 but also arranges a frame material on one side or a part of the four circumferences and accommodates the core material 22 inside the frame material. Is included.

  As shown in FIG. 2, an intermediate frame material in the region surrounded by the frame body 21 composed of a pair of the first frame material 21 </ b> A and the second frame material 21 </ b> B, taking into account the strength of the decorative panel 1. 21C may be provided. The intermediate frame material 21 </ b> C constitutes a frame by dividing the area where the core material 22 is disposed. The arrangement of the intermediate core material 21C may be various. For example, as shown in FIG. 2, the intermediate core material 21C is arranged in parallel with the second frame material 21B. Of course, the intermediate frame member 21 </ b> C can be arranged in a single or a plurality as required.

  In addition, the frame body 21 does not necessarily include both the first frame member 21A and the second frame member 21B, and the frame body 21 includes only the first frame member 21A at the panel edge in the longitudinal direction. A frame 21 having only the second frame member 21B at the panel edge in the short direction is also considered.

  Due to the presence of the frame body 21 of the core layer 2, the overall structural strength of the decorative panel 1 having the core material 22, the strength of the surface, and the like can be made suitable. In addition, it becomes easier to finish the front end. In particular, in the frame body 21 including the first frame member 21 </ b> A extending in the longitudinal direction of the core layer 2, when the decorative panel 1 is used as a fitting, the door contact is good. Moreover, the provision of a function as a reinforcing material for mounting the metal fitting is also considered.

  For example, the types of the frame materials such as the first frame material 21A and the second frame material 21B that form the frame body 21 are not particularly limited as long as the materials are relatively less warped. For example, a wood material, a metal material, a resin material, or a composite material thereof is exemplified.

  As the wood material, for example, solid square wood, LVL (Laminated Veneer Lumber), PB (Particle Board, Particle board) or the like can be used. In the case of using a wood material as the first frame material 21A and the second frame material 21B, it is preferable to use a solid square material or LVL which has a relatively excellent bending strength. When wood materials are used as the first frame material 21A and the second frame material 21B, they can be joined easily, the weight of the frame body 21 can be reduced, and consequently the weight of the decorative panel 1 can be reduced.

  Examples of the metal material include an iron plate and a steel plate. Among them, a stainless steel plate in which generation of rust and the like is suppressed is preferably exemplified.

  In general, adhesives, staples, or fixtures such as nails, screws, bolts, and nuts are preferably used for joining the frame members such as the first frame member 21A and the second frame member 21B. Staples can be driven by a tucker or the like from the same surface side of the wood material of the first frame material 21A and the second frame material 21B. For this reason, the fixing strength of both is ensured as necessary and sufficient.

  As for the intermediate frame material 21C disposed as necessary, the material and bonding can be considered in the same manner as described above.

  The core material 22 constituting the core layer 2 is not particularly limited and may be various types as long as it is a core material 22 that is generally used for a panel having a flash structure. Among these, a resin foam and a honeycomb core are preferably considered. When a honeycomb core is used as the core material 22, considering the strength, durability, dimensional stability, etc. of the decorative panel 1, the material is, for example, kraft paper, cardboard, corrugated cardboard, plastic molded product, etc. Is preferred.

  In the case of a honeycomb core as the core material 22, cells having a regular hexagonal cross section generally share a wall surface corresponding to one side of the regular hexagon with adjacent cells and are connected in a large number. In the honeycomb core used for the core material 22, the cross-sectional shape of the cells is not limited to the regular hexagonal shape described above, and may take various other shapes such as a vertically long or horizontally long hexagonal shape, a square shape, a trapezoidal shape, or the like. .

  Examples of the average diameter of the cells of the honeycomb core include a range of about 10 mm, preferably 10 mm or less, although it depends on the basis weight of the fiber sheet described later. When the average diameter of the cells is within the above range, the core layer 2 having both light weight and strength, and thus the decorative panel 1 is realized.

  As the decorative layer 3, it is preferable to use a resin film or a veneer.

  The resin film constituting the decorative layer 3 is not particularly limited as long as it is usually used for manufacturing a decorative panel or a decorative board. Examples thereof include a vinyl chloride resin film, a polyethylene resin film, a polyethylene terephthalate resin film, a polypropylene resin film, a polycarbonate resin film, an acrylic resin film, and a urethane resin film.

  Examples of the thickness of the resin film include a range of 0.02 to 1 mm, preferably 0.05 to 0.2 mm, and more preferably 60 to 120 μm. When the strength characteristics, handling properties, etc. of the decorative layer 3 are taken into consideration, the above range is preferable. As the resin film, a melamine resin plate, a phenol resin plate, or a non-combustible surface material using these can also be used.

  The veneer constituting the decorative layer 3 is not particularly limited as long as it is normally used for manufacturing a decorative panel or a decorative board. For example, a woody thin plate having a thickness of 0.2 to 1 mm is exemplified.

  In addition, in the veneer, in consideration of the surface smoothness and strength of the decorative layer 3, a non-woven fabric or the like is attached to the surface facing the fiber-containing resin layer 4 via an adhesive and is reinforced by backing. Is preferred.

  The adhesive in this case is preferably exemplified by a water-insoluble adhesive that hardly transfers moisture to the veneer. Examples of water-insoluble adhesives include, for example, solution-type acrylic copolymers, synthetic rubber adhesives, hot-melt adhesives that are thermoplastic synthetic resins, or a combination of two or more types. can do. Known hot melt adhesives include, for example, ethylene vinyl acetate (EVA) and urethane hot melt (PUR). Moreover, what used the epoxy resin type | system | group, urethane type, vinyl chloride type, the vinyl acetate type adhesive agent etc. individually or in combination of 2 or more types can be illustrated.

  The same material may be used as the decorative layer 3 on the front and back surfaces of the decorative panel 1, or different materials may be used on the front and back surfaces.

  The fiber-containing resin layer 4 is a mixture of fibers and resin. Here, the term “fiber” refers to a variety of shapes that can be referred to as so-called fibers, whiskers, rods, etc., in which the shape as a solid is larger in length in the direction perpendicular to the cross section than the diameter or length of the cross section. Good. In the mixing with the resin, such fibers may have an aggregate form of a wire sheet or fiber mat in advance as a woven fabric, a nonwoven fabric, etc., or are monodispersed or dispersed in a resin in the aggregated state. It may be. Further, mixing of the fiber and the resin includes methods such as coating and impregnation. In the following embodiments, a fiber sheet which is one of the suitable fibers is used, and the mixing of the fiber sheet and the resin will be described by taking impregnation as an example.

  Examples of the fiber sheet include glass fiber woven fabric, nonwoven fabric or mat. Examples of the glass fiber woven fabric include glass cloth, which is a woven fabric made by weaving warp yarn and weft yarn using glass roving. As a glass fiber nonwoven fabric, for example, a glass fiber having a length of about 10 mm is dispersed in water, then scooped by a wet papermaking method, dehydrated and formed into a sheet, and an adhesive such as an epoxy resin or an acrylic resin is applied. The glass paper etc. which are are illustrated. Examples of the glass fiber mat include a glass mat that is obtained by uniformly dispersing non-directional glass strands cut to a length of about 50 mm and molding the glass strand into a mat using a binder such as a polyester binder. . Among these fiber sheets, glass cloths such as plain weaves and entangled weaves are preferable, and plain cloths are more preferable.

  A fiber sheet having a thickness of 0.1 to 0.5 mm is preferably used. In particular, a glass mat having a thickness of 0.3 to 0.4 mm is preferably used. A glass cloth having a thickness of 0.1 to 0.3 mm is preferably used. Moreover, as a density of a glass cloth, a 30-120 piece / 25mm thing is used, for example. Moreover, as a count of a glass cloth, the range of 67-135 tex is illustrated, for example.

  As the fiber sheet, a laminate of the above-described glass fiber woven fabric, nonwoven fabric or mat and vegetable fiber woven fabric, nonwoven fabric, film, paper or mat is also considered. The plant fiber is not particularly limited as long as it is a plant fiber that is usually used for plant fiber mats and papermaking, but considering the strength, durability, dimensional stability, etc. of the fiber sheet, hemp natural fiber, palm fiber, or agricultural products It is preferable that it is any one or more of waste fibers.

For example, the basis weight of the fiber sheet is preferably considered to be in the range of 150 g / m ^{2 to} 350 g / m ² . If the fabric weight of the fiber sheet is within the above range, the resulting decorative panel 1 can exhibit desired surface strength and surface smoothness. When glass cloth is used as the fiber sheet, the basis weight is preferably considered to be 200 g / m ² or more. When glass paper is used as the fiber sheet, it is preferably considered that the basis weight is 50 g / m ² or more. When a glass mat is used as the fiber sheet, the basis weight is preferably considered to be 300 g / m ² or more.

  As the resin impregnated in the fiber sheet, a non-foaming or low-foaming resin is preferably considered. For example, a urethane resin, a polystyrene resin, a polyethylene resin, a polypropylene resin, a phenol resin, or the like may be used alone or in combination of two or more.

  On the other hand, when a liquid unsaturated polyester resin or epoxy resin is used as in the decorative panel described in Patent Document 1, it is excellent for bonding a hard substrate, but in bonding with the core material 22, It is not always satisfactory in terms of performance, handleability, cost, and the like.

  In the case of a foamed resin, although depending on the type, it is generally considered that the foaming ratio is low foaming of 7 times or less, more preferably 5 times or less. Furthermore, although urethane resin is illustrated as a suitable thing, in this case, it is considered that a foaming ratio is 1 to 5 times, More preferably, it is 1-3 times, Furthermore, it is 1-2 times.

  In the case of such a urethane resin, the resin sheet or veneer as the decorative layer 3 and the adhesiveness with the core material 22 of the core layer 2 are excellent and well balanced. Become. Moreover, a hardening | curing agent, a flame retardant, etc. can be added to resin.

In the fiber-containing resin layer 4, physical properties such as surface strength, surface smoothness, and dimensional stability of the decorative panel 1 after integral molding are improved with an increase in the amount of resin impregnated into the fiber sheet. An example of the resin impregnation amount is 150 g / m ² or more. Considering the production cost of the decorative panel 1, a range of 150 g / m ² or more and 250 g / m ² or less is particularly preferable.

  The impregnation of the resin into the fiber sheet is exemplified by uniformly applying the resin by spray coating or roller coating from above the fiber sheet. Further, after the resin is uniformly applied to the surface of the resin film or veneer as the decorative layer 3 by spray coating or roller coating, a fiber sheet may be placed and impregnated with the resin. Furthermore, after immersing the fiber sheet in a resin storage container, excess resin may be squeezed out with a roller or the like, and the fiber sheet may be impregnated with the resin.

  In addition, when using fiber chips that are not formed into a sheet as fibers, for example, a method of applying a solid or liquid resin to the fiber chips, or putting the fiber chips into a liquid resin storage container And a method of mixing them.

  In the decorative panel 1, the decorative layer 3 and the fiber-containing resin layer 4 are bent to the side end face 2A side of the core layer 2 on the side end face 2A of the core layer 2, for example, as shown in FIG. The side end face 2A of the layer 2 is covered.

  In this coating, for example, as shown in the example of FIG. 3, the side end surface 2 </ b> A of the core layer 2 is coated by being glued in a state where the outermost ends of the decorative layer 3 and the fiber-containing resin layer 4 are in contact with each other. Can be. That is, the side end surface of the frame body 21 located on the side end surface 2A of the core layer 2 is covered.

  A gap may be provided in a portion where the outermost end of the fiber-containing resin layer 4 is abutted, and a joint material may be filled in the gap. By filling the joint material, the water-tightness and air-tightness of the decorative panel are improved. For example, dimensional changes due to moisture absorption when wood materials are used as the frame materials 21A and 21B can be suppressed. The joint material is not particularly limited as long as it is normally used as a joint material for buildings, and examples thereof include silicone resins, modified silicone resins, and polyurethane resins.

  Furthermore, in FIG. 3 and FIG. 1, an example in which the decorative layer 3 and the fiber-containing resin layer 4 from both sides of the front and back are abutted is shown. May be different from each other, or may be covered only from either one of the front and back sides.

  In addition, the coating on the side end surface 2A of the core layer 2 described above may be a coating on all four sides of the decorative panel 1, or may be appropriately partially coated according to the use of the decorative panel. May be omitted. For example, in a side-sliding door, a partition, or the like, the frame material of the core layer 2 may remain exposed without covering the upper and lower ends of the decorative panel as in the example of FIG.

  As will be described later, the frame members 21A and 21B that assemble the frame body 21 of the core layer 2 are provided with grooves in the longitudinal direction of the side end surfaces thereof, and the ends of the decorative layer 3 and the fiber-containing resin layer 4 are bent and stored in the grooves. In addition, it is preferable to cover the side end surface 2A of the core layer 2. Such covering of the side end surface 2A of the core layer 2 may be at least partially covered according to the use of the decorative panel 1. For example, only a pair of edges of the decorative panel 1 may be covered, or only part of the side end faces of the frame members 21A and 21B may be covered. For example, when the decorative panel 1 is used as a hanging door, the door end is good if the side end face of the long frame member 21A is covered. Therefore, the core layer 2 is formed on the side end face of the short frame member 21B. It may be exposed.

  About the above decorative panel 1, the manufacturing method is demonstrated in detail according to the general | schematic cross-sectional process drawing shown in FIG. A groove 6 is provided in advance in the longitudinal direction of the side end surface 2A of the frame member 21 of the core layer 2.

  First, the step (a), that is, a spacer type provided with protrusions on the outer surface of the frame body 21 containing the core material 22 on the front and back surfaces substantially flush with the frame body 21 and the core material 22 of the core layer 2. 4 (1), the side end surface 2A of the core layer 2 has a ridge 7a parallel to the core layer 2 side end surface 2A on the surface facing the fiber-containing resin layer 4, as shown in FIG. The spacer mold 7 is brought into contact. A groove 6 is provided in advance in the longitudinal direction of the side end face of the frame member 21 of the core layer 2. The width and depth of the groove 6 depend on the thickness and size of the resin film and veneer that will be the decorative layer 3 housed in the groove 6 and the thickness and size of the fiber sheet that will be the fiber-containing resin layer 4. Can be determined as appropriate.

  In addition, the fiber layer-containing resin layer 4 and the decorative layer 3 are laminated on the front and back surfaces of the core layer 2 and the spacer mold 7 and heat-pressed at the same time as the core layer 2 of the fiber-containing resin layer 4. As a step of transferring the bent groove 5 having a shape corresponding to the spacer-shaped protrusion on the side, a decorative layer 3 and a fiber-impregnated resin layer 4 are laminated as shown in FIG. As the decorative layer 3 and the fiber-containing resin layer 4, the side end surface of the frame body 21 located on the side end surface 2A of the core layer 2 is used in one or preferably both of the core layer 2 of the decorative panel 1 and the spacer-type front and back surfaces. Have an area that can be covered. In this case, preferably, it is considered that the decorative layer 3 and the fiber-containing resin layer 4 are extended from all the edges of the frame body 21.

  Then, as shown in FIG. 4 (2), the decorative layer 3 and the fiber-containing resin layer 4 laminated on the front and back surfaces of the core layer 2 and the spacer mold 7 are heat-press molded to form the decorative layer 3 and the fiber-containing resin. The hardening of the layer 4 and the transfer of the protrusion 7a of the spacer mold 7 are performed simultaneously. In this case, first, a resin film or a veneer as the decorative layer 3 cut to a predetermined size is placed on the die surface of the lower die 8b, and the fiber sheet 41 is placed thereon. In this state, the resin 42 which is also an adhesive is uniformly applied to the fiber sheet 41 by spray application or roller application, and the fiber sheet 41 is impregnated. Next, the core layer 2 including the frame body 21 and the core material 22 accommodated in the space surrounded by the frame body 21 is placed on the fiber sheet 41 and the resin 42. The spacer mold 7 may be brought into contact with the side end surface 2A of the core layer 2.

  Then, after the fiber sheet 41 is placed on the upper surface in the thickness direction of the core layer 2 and the spacer mold 7 and the fiber sheet 41 is impregnated with the resin 42, the resin film or the veneer as the decorative layer 3 thereon Is placed.

  In this case, the decorative sheet placed on the upper side in the thickness direction of the core layer 2 and the spacer mold 7 by contacting the spacer mold 7 with the core layer 2 substantially flush with the side end surface 2A of the core layer 2. 41, the resin 42, and the decorative layer 3 can be supported from the back surface side, the bending can be suppressed, and the surface of the decorative panel 1 can be finished flat.

  When a foamed resin is used as the core material 22, the foamed resin material can be injected at this stage.

  Further, in the step (b), heat and pressure molding is performed using the upper mold 8a and the lower mold 8b. By heating and pressing, the resin 42 is impregnated into the fiber sheet 41 to form the fiber-containing resin layer 4, and at the same time, the core layer 2 and the decorative layer 3 can be bonded and bonded together to be integrally formed. At this time, the protrusions 7a provided on the front and back surfaces of the spacer mold 7 are pressed against the surface facing the core layer 2 of the uncured resin-impregnated fiber sheet 4, and are projected at the same time as the heating and pressing. The bent groove 5 corresponding to the shape of the strip portion 7 a can be transferred to the fiber-containing resin layer 4. As the shape of the protruding portion 7a, when the decorative layer 3 and the fiber-impregnated resin layer 4 are bent in the transferred bent groove 5, the inclined surfaces of the bent groove 5 overlap each other, and the appearance is good. You may adjust the opening angle of the vertex. In the case where the decorative panel corner is substantially right-angled, a right-angled isosceles triangle having a vertex opening angle of 90 ° is preferably used. Further, when the corner portion of the decorative panel is a curved surface, as shown in FIG. 5, a plurality of minute slits are provided in the thickness direction of the fiber-containing resin layer at the apex portion of the right triangle of the bent groove 5, It is also preferable to consider the bent groove 5 having a rounded curved surface at the apex portion of the right triangle. Note that the number of the bent grooves 5 can be appropriately changed according to the type of the fiber sheet 41 constituting the fiber-containing resin layer 4.

Examples of the conditions for heat and pressure molding include heating and pressing at 80 ° C. and 1.25 kg / cm ² for 2 minutes.

  Then, as shown in FIG. 4 (3), the spacer mold 7, the upper mold 8a and the lower mold 8b are removed by pressure removal, and the core layer 2, the decorative layer 3, and the fiber-containing resin layer 4 are laminated and integrated. The laminated body made is taken out.

  Thus, the uncured resin-impregnated fiber sheet 4 is cured and the fiber-containing resin layer 4 is pressed by pressing a spacer mold having a protruding portion on the core layer 2 side of the fiber-containing resin layer 4 and performing heat-pressure molding. The bent groove 5 can be formed in one step.

  As the step (c), that is, the step of bending the fiber-containing resin layer 4 and the decorative layer 3 in the bending groove 5 to cover the side end surface 2A of the core layer 2, first, as shown in FIG. As described above, the end portions of the fiber-containing resin layer 4 and the decorative layer 3 that are laminated and integrated are cut and trimmed to a predetermined dimension. Various methods known in the art can be used for cutting the ends of the fiber-containing resin layer 4 and the decorative layer 3. For example, a method of cutting unnecessary portions of the decorative layer 3 and the fiber-containing resin layer 4 using the blade 9 is exemplified. Moreover, it is preferable to consider that the bending groove | channel 5 is previously provided in the surface which opposes the core layer 2 side of the fiber containing resin layer 4 in the cutting | disconnection site | part. By providing the bent groove 5 at the cut site, trimming accuracy at the ends of the integrated decorative layer 3 and fiber-containing resin layer 4 is improved, leading to improvement in productivity and quality of the decorative panel 1. . In this case, it is preferable to consider that the spacer mold 7 includes the protrusions 7a at positions corresponding to the cut portions of the decorative layer 3 and the fiber-containing resin layer 4.

  Next, as shown in FIG. 4 (5), the decorative layer 3 and the fiber-containing resin layer 4 are bent to the side end face 2A side of the core layer 2 in the bending groove 5, and the side pressure jig 10 is pressed, for example, The extended portion is accommodated in the groove 6 provided along the longitudinal direction of the side end surface of the one frame member 21A. By applying an adhesive to the side end face 2A of the core layer 2 in advance, the fiber-containing resin layer 4 and the side end face 2A of the core layer 2 can be firmly adhered and covered. As the side pressure jig 10, various types used in the manufacturing process of an existing decorative panel can be used, but it is preferably considered that it can be heated. The outermost ends of the decorative layer 3 and the fiber-containing resin layer 4 are housed in the groove 6 in a state of being in close contact with each other, and are heated and pressed by the side pressure jig 10.

  Thus, in the manufacturing method of the decorative panel 1, the frame members 21A and 21B that assemble the frame body 21 of the core layer 2 have the groove 6 on the outer side end surface in the longitudinal direction, and the fiber-containing resin layer 4 and the end of the decorative layer 3 are preferably folded and accommodated in the groove 6 to cover the side end face 2A of the core layer 2. The decorative layer 3 and the fiber-containing resin layer 4 are accommodated in the groove 6 of the frame material 21 of the core layer 2 in a state of being in close contact with each other. The fiber-containing resin layer 4 is suppressed from peeling off from the end.

  Examples of the method of providing the grooves 6 in the frame materials 21A and 21B include, for example, producing the frame materials 21A and 21B having the grooves 6 in a factory in advance using a tool such as a milling cutter. Of course, you may provide the groove | channel 6 in frame material 21A, 21B in a construction site.

  As already described above, the groove 6 is not provided on the side end surface of the frame body 21, but the endmost portions of the decorative layer 3 and the fiber-containing resin layer 4 are abutted to cover the side end surface 2A of the glued core layer 2. May be.

  By passing through the above process, the decorative panel 1 in which the side end face 2A of the core layer 2 is covered with the fiber-containing resin layer 4 and the decorative layer 3 is obtained as shown in FIG.

  In the decorative panel 1, as illustrated in FIG. 6A, fibers are formed on both front and back surfaces of the core layer 2 including a frame body 21 and a core material 22 housed inside a region surrounded by the frame body 21. A sheet 41 is provided, and the surface of the fiber sheet 41 is spray-coated with a resin 42 and impregnated, followed by heat and pressure molding. As shown in FIG. 6B, a strong fiber-containing resin layer 4 is formed by curing the fiber sheet 41 and the resin 42. FIG. 6C is an enlarged view of a region surrounded by a circle in FIG. 6B, and shows that the fiber-containing resin layer 4 is cured and bonded together with the core material 22. . Moreover, as shown in FIG. 6D, the fiber sheet 41 ensures the hardness and strength of the surface of the decorative panel 1 and is integrated with the resin 42 to improve the surface smoothness.

  In the manufacturing example of the decorative panel 1 described above, a spacer provided with protrusions 7a on the outer surface of the frame body 21 containing the core material 22 and on the front and back surfaces of the frame body 21 and the core material 22 of the core layer 2. Although the mold is in contact, various types of spacer mold 7 are considered. For example, as shown in FIG. 7, it is preferable to provide a taper-shaped split mold 7b that extends toward the outer end at the center in the thickness direction. The split mold 7b is detachable from the spacer mold 7. The split mold 7b can be easily detached from the spacer mold 7 by pulling the split mold 7b toward the outer end portion of the spacer mold 7 indicated by an arrow in the drawing.

  In such a spacer mold 7, the core layer 2, the fiber-containing resin layer 4, and the decorative layer 3 are integrated by heat and pressure molding, and then the split mold 7 b is preliminarily formed before the spacer mold 7 is removed. Removal is preferably considered. By removing the split mold 7b, the spacer mold 7 can be removed without bending the integrally formed decorative layer 3 and fiber-containing resin layer 4. Moreover, it is possible to prevent the integrally formed decorative layer 3 and fiber-containing resin layer 4 from being damaged.

  In addition, it is preferable that the spacer mold 7 includes a plurality of protrusions 7 a at positions corresponding to the corners of the decorative panel 1. For example, as shown in FIGS. 7, 8, and 9, a plurality of protrusions 7 a are provided at positions corresponding to the corners of the decorative panel 1. In the fiber-containing resin layer 4, a plurality of bent grooves 5 corresponding to the protrusions 7a can be formed. The plurality of ridges 7a may be arranged apart from each other or may be arranged adjacent to each other. As shown in FIG. 8, when a plurality of protrusions 7a are arranged adjacent to each other, a plurality of bent grooves 5 are formed on the back surface of the fiber-containing resin layer 4 facing the spacer mold 7 in the heat and pressure molding process. Are formed adjacent to each other. Since the fiber-containing resin layer 4 includes a plurality of bent grooves 5, the fiber-containing resin layer 4 can be easily bent as compared with the case where the single bent groove 5 is provided. In particular, when a glass fiber sheet is used as the fiber sheet 41, the strength of the fiber-containing resin layer 4 is increased. Therefore, a cured resin is formed by forming a plurality of bent grooves 5 adjacent to each other. The impregnated fiber sheet 4 can be bent step by step, and the bending process becomes much easier.

  Furthermore, as shown in FIG. 9, it is preferably considered that the spacer mold 7 includes a protruding portion 7 a at a position corresponding to the cut portion of the decorative layer 3 and the fiber-containing resin layer 4. By providing the bent groove 5 at the cut site, the trimming accuracy of the integrated decorative layer 3 and the fiber-containing resin layer 4 is improved, leading to improvement in productivity and quality of the decorative panel 1.

  By the manufacturing method of the decorative panel 1 having the above-described configurations and including the respective steps, the shared structure of the frame body 21 and the core material 22, the laminated structure of the fiber-containing resin layer 4, and the side end face 2 </ b> A of the core layer 2. The decorative panel 1 having the characteristic of the covering structure is obtained. In addition, the uncured fiber-containing resin layer 4 and the decorative layer 3 are cured by heating and pressing to be cured and integrated, and at the same time, the protrusions 7 a provided on the front and back surfaces of the spacer mold 7 are made to The bent groove 5 can be provided by transferring to the core layer 2 side. For this reason, compared with the conventional method, the production method using the spacer mold 7 can be realized with a small number of steps and high productivity. Moreover, the decorative layer and the core layer are bonded together with the fiber-containing resin layer, and the core layer side end surface is covered, and even if the decorative layer is thin, the surface hardness, strength, surface smoothness, dimensional stability, etc. are good. A decorative panel is realized. And the weight reduction is achieved as the thin decorative layer 3, and the design property can be improved.

  Since the decorative panel 1 obtained by the manufacturing method of the present invention has such characteristics, it is particularly suitably used as a joinery panel.

  For example, in the decorative panel 1 illustrated in FIG. 10A, the metal fitting attachment reinforcing material 11 is provided in order to embed a handle, a handle base, or the like inside the frame material 21. The metal fitting attaching reinforcing material 11 is disposed, for example, at a height position of about 90 to 120 cm from the lower end in the longitudinal direction of the decorative panel 1 and in contact with one first frame material 21 </ b> A constituting the frame material 21. ing. The metal fitting attaching reinforcing material 11 may have the same thickness as or different from the first frame material 21A and the second frame material 21B. The material may be the same type as the first frame material 21A and the second frame material 21B, or may be another type. In the example of FIG. 10, the metal fitting attaching reinforcing material 11 is composed of a plurality of members and is arranged in a rectangular shape lacking one side.

  In the decorative panel 1 having the core layer 2 provided with the bracket mounting reinforcing material 11 as described above, for example, as shown in FIG. (Not shown) is inserted, the shaft portion of the handle 12 is attached to the handle insertion hole of the latch case, and the handle pedestal is attached to the surface of the decorative layer 3 using a fixing tool 13 such as a screw. A hinged door as a fitting is formed from 1.

  Further, as shown in FIGS. 11A and 11B, the handle 15 is attached from both sides of the through hole 14 provided on the surface of the decorative layer 3 of the facing decorative panel 1 using a fixing tool 13 such as a screw or an adhesive. It is also possible to use the decorative panel 1 as a sliding door.

  Furthermore, using a plurality of decorative panels 1 as a saddle material for joinery, combining it with a face material, etc., and joining and fixing it, or in a joinery using such a saddle material, facing surfaces of the saddle material It is also possible to provide a fitting having a light-transmitting property by providing a rail-like groove on the glass and fitting glass into the groove.

  Of course, the present invention is not limited to the above embodiment. Various changes and modifications in implementation details may be considered.

DESCRIPTION OF SYMBOLS 1 Makeup panel 2 Core layer 2A Side end surface 21 Frame 21A 1st frame material 21B 2nd frame material 21C Intermediate frame material 22 Core material 3 Makeup layer 4 Fiber-containing resin layer 41 Fiber sheet 42 Resin 5 Bending groove 6 Groove 7 Spacer Mold 7a Projection 7b Split mold 8a Upper mold 8b Lower mold 9 Blade 10 Side pressure jig 11 Reinforcing material for metal fitting 12 Handle 13 Fixing tool 14 Through hole 15 Pull handle

Claims (5)

A core layer comprising a frame material and a core material housed inside the frame body in which the frame material is assembled; a decorative layer made of a resin film or a veneer disposed on the front and back surfaces of the core layer; A fiber-containing resin layer interposed between the core layer and the decorative layer;
The decorative layer and the core layer are bonded to the fiber-containing resin layer, and the decorative layer and the fiber-containing resin layer also cover the side end surface of the core layer. The manufacturing method of the decorative panel characterized by including the process of.
(A) a step of abutting a spacer mold having protrusions on the front and back surfaces of the core layer frame and the core material on the outer side of the frame body housing the core material;
(B) Laminating the fiber-containing resin layer and the decorative layer on the front and back surfaces of the core layer and the spacer type, and heating and pressing, and at the same time, the spacer-type protrusion on the core layer side of the fiber-containing resin layer Transferring a bent groove having a shape corresponding to
(C) A step of bending the fiber-containing resin layer and the decorative layer in the bent groove to cover the side end surface of the core layer.   The frame material forming the frame of the core layer has a groove on the outer side end surface in the longitudinal direction, and the ends of the fiber-containing resin layer and the decorative layer are folded and stored in the groove, The method for manufacturing a decorative panel according to claim 1, wherein the side end face of the layer is covered.   3. The method for manufacturing a decorative panel according to claim 1, wherein the spacer type includes a plurality of the protrusions at positions corresponding to the corners of the decorative panel.   The makeup according to any one of claims 1 to 3, wherein the spacer type includes the protrusions at positions corresponding to the cut portions of the decorative layer and the fiber-containing resin layer. Panel manufacturing method.   The said spacer type | mold is provided with the taper-shaped division part which spreads toward an outer end part in the center part of thickness direction, The manufacturing method of the decorative panel as described in any one of Claim 1 to 4 characterized by the above-mentioned. .