JP2019111798A - Veneer/resin lamination structure housing and method for manufacturing the same - Google Patents

Abstract

To provide a veneer/resin lamination structure housing capable of surely preventing occurrence of cracking of a veneer manufactured by a wooden thin plate for three-dimensional molding.SOLUTION: A veneer/resin lamination structure housing 40 includes a veneer 3 manufactured from a wooden thin plate for three-dimensional molding, a non-woven fabric layer 5 bonded to the veneer 3 through an adhesive resin layer 4 from the thin non-woven fabric 2 side, and a base resin layer 6 which is wet to a gap between each fiber of the non-woven fabric layer 5 and is stuck to the non-woven fabric layer 5, in which the veneer 3 is manufactured from a wooden thin plate 50 from three-dimensional molding.SELECTED DRAWING: Figure 2

Description

  The present invention relates to a raised plate / resin laminated structure housing and a device for manufacturing the same, and more particularly to a raised plate / resin laminated structure housing in which a raised plate is stacked on a base resin layer and a device for manufacturing the same.

  In the technical fields of housings for electronic devices and home appliances and housings for automobile interior parts, the housings may be made by resin molding in which a facing plate is laminated on the outer surface (see, for example, Patent Document 1). In addition, although there is a wood sheet as a veneer, since a dried wood sheet has a small tensile strain, it tends to be cracked or the like during its three-dimensional processing. Therefore, conventionally, in order to prevent cracking or the like of a wood sheet, a dry wood sheet is impregnated with a solution such as polyethylene glycol to swell / soften the wood sheet before three-dimensional processing of the wood sheet. The slitting process orthogonal to the fiber direction of wood is performed at equal intervals on both surfaces of the thin plate (see, for example, Patent Document 2).

JP, 2013-01813, A JP, 2011-93249, A

  However, since the projecting plate in the conventional projecting plate / resin laminated structure housing has a grain, there is a problem that a crack is easily generated at the time of molding of the housing.

  An object of the present invention is to provide a projecting plate / resin laminated structure housing capable of preventing the occurrence of a crack in a projecting plate at the time of molding the housing, and a manufacturing apparatus therefor.

  In order to achieve the above object, the veneer / resin laminated structure housing according to claim 1 comprises a veneer layer, a nonwoven fabric layer bonded to the veneer layer via an adhesive resin layer, and fibers of the nonwoven fabric layer. And a base resin layer fixed to the non-woven fabric layer by infiltrating the gap, and the protruding plate layer is made of a protruding plate manufactured from a three-dimensional processing wooden thin plate.

  The apparatus for manufacturing a veneer / resin laminated structure housing according to claim 11 comprises: a veneer plate layer consisting of a veneer plate manufactured from a three-dimensional processing wooden thin plate; and a non-woven fabric layer bonded to the veneer plate layer via an adhesive resin layer. A stationary mold receiving the laminate with the nonwoven layer facing up, and moving toward the stationary mold to push the received laminate into the stationary mold to form the laminate Movable molds to be made, other fixed molds for receiving the formed laminate with the plate layer facing up, and injection molding moved toward the laminated body received in the other fixed molds A mold is provided, and injection means for injecting a resin solution of the base resin layer into a space defined by the laminated body received by the other fixed mold and the injection mold is characterized.

  According to the projecting plate / resin laminated structure housing according to claim 1, since the base resin layer is bonded to the projecting plate manufactured from the three-dimensional processing wooden thin plate through the non-woven fabric layer, the base plate resin layer is cracked in the projecting plate Can be reliably prevented.

  According to the apparatus for manufacturing a raised plate / resin laminated structure housing according to claim 11, the base resin layer is bonded to the raised plate layer formed of the raised plate manufactured from the three-dimensional processing wooden thin plate through the non-woven fabric layer. At the same time, it is possible to reliably prevent the occurrence of cracks in the end plate.

It is an external appearance perspective view of a protruding plate / resin laminated structure housing according to an embodiment of the present invention. FIG. 2 is a cross-sectional view of a raised plate / resin laminated structure housing taken along line II-II of FIG. It is a figure used for demonstrating the manufacturing apparatus of the plate / resin laminated structure housing which concerns on embodiment of this invention. It is a fragmentary sectional view of the modification of the veneer / resin laminated structure housing of FIG. It is a perspective view of the wooden thin plate for three-dimensional processes which concerns on the specific example of the protruding plate 3 in FIG. It is a figure which shows roughly the manufacturing apparatus of the wooden thin plate for three-dimensional processes of FIG. It is a figure used in demonstrating the 1st modification of the wooden sheet for three-dimensional processes of FIG. It is a figure used in order to demonstrate the 2nd modification of the wooden sheet for three-dimensional processes of FIG.

  Hereinafter, the present invention will be described in detail with reference to the drawings.

  FIG. 1 is an external perspective view of a raised plate / resin laminated structure housing according to an embodiment of the present invention.

  In FIG. 1, a projecting plate / resin laminated structure housing 40 (hereinafter, sometimes simply referred to as “housing 40”) is a casing of a reverse tray structure, and one protrusion 41 and one opening at the bottom of the reverse tray structure. Having 42.

  The protrusion 41 and the opening 42 are shown in FIG. 2 as a cross-sectional view of the salient plate / resin laminate structure housing along the line II-II in FIG.

  The housing 40 includes the projecting plate 3, the non-woven fabric layer 5 bonded to the projecting plate 3 via the adhesive resin layer 4, and the base resin layer 6 infiltrated into the gaps between the fibers of the non-woven fabric layer 5 and fixed to the non-woven fabric layer 5. Equipped with The protruding plate 3 may be impregnated or coated with PVB or polyurethane in advance.

  The specific example of the protruding plate 3 will be described later with reference to FIGS.

  The adhesive resin layer 4 is made of a polyvinyl acetal resin having thermoplasticity and having a viscosity such that bubbles in the adhesive resin layer 4 can be released by softening when the housing 40 is molded.

  The polyvinyl acetal resin is obtained by acetalizing polyvinyl alcohol (PVA) resin with aldehyde, and in particular, polyvinyl butyral (PVB) resin acetalized with butyraldehyde is preferable.

  In addition, the adhesive resin layer 4 is made of polyvinyl acetal resin, ethylene / vinyl acetate copolymer resin, ethylene / acrylic copolymer resin, propylene resin, propylene / 1-butene copolymer resin, propylene / isobutene copolymer System resin, styrene / propylene / isobutene copolymer resin, styrene / isoprene copolymer resin, styrene / isoprene / isobutene copolymer resin, and resin selected from the group of styrene / isoprene / butene copolymer resin It is also good.

  The nonwoven fabric layer 5 is made of a spunbonded nonwoven fabric or a papermaking nonwoven fabric containing polyester (specifically, PY-100 manufactured by Awa Paper Industries Co., Ltd.). The thickness of the non-woven fabric layer 5 is 50 to 1000 μm.

  The non-woven fabric layer 5 is made of thermoplastic resin fiber. Specifically, each fiber of the thermoplastic resin fiber has a thickness of 1 to 50 μm and a length of 1 to 50 mm, preferably 2 to 15 mm.

  Each of the thermoplastic resin fibers is made of at least one selected from the group consisting of polyester, polyamide, polypropylene, polyethylene, acrylic, polyacetal, and polycarbonate, and preferably made of polyester.

  The base resin layer 6 is made of a thermoplastic synthetic resin, preferably a synthetic resin for injection molding, and specifically, ABS (acrylonitrile / butadiene / styrene copolymer), PC (polycarbonate), PMMA (polymethyl methacrylate) ), PP (polypropylene), nylon, and one material selected from the group of ABS + PC, preferably ABS or nylon, more preferably nylon, the thickness is arbitrarily set according to the product, In form, it is about 1.2 mm. The base resin layer 6 may contain 10 to 40% of a glass fiber filler. The resin solution of the base resin layer 6 is heated and melted by the injection molding machine 20 of FIG. 3 described later, and the protruding plate 3 and the non-woven fabric layer 5 adhered to each other by the adhesive resin layer 4 are attached. The resin is injected into the female mold 22 in FIG. 3 and infiltrates into the gaps of the fibers of the projecting plate layer 4 and solidifies (FIG. 3). When the resin solution of the base resin layer 6 is cooled and solidified, the non-woven fabric layer 5 is shrunk to make the adhesion with the base resin layer 6 stronger.

  According to the housing 40 of FIG. 1, since the adhesive resin layer 4 is used to bond the projecting plate 3 and the non-woven fabric layer 5 to each other, air bubbles are prevented from remaining in the adhesive layer of the projecting plate 3 and non-woven fabric layer 5 each other. can do. Further, according to the housing 40 of FIG. 1, since the resin solution of the base resin layer 6 infiltrates into the gaps of the fibers of the non-woven fabric layer 5 and solidifies, the adhesiveness of the non-woven fabric layer 5 and the base resin layer 6 and the housing In addition to the improvement of the mechanical strength of 40, the generation of air bubbles between the projecting plate 3 and the base resin layer 6 can be prevented.

  In addition, according to the housing 40 of FIG. 1, since the base resin layer 6 is adhered to the projecting plate 3 via the non-woven fabric layer 5, it is possible to prevent the occurrence of cracks in the projecting plate 3 at the time of manufacturing the housing 40. Furthermore, in addition, since the projecting plate 3 is made of a projecting plate manufactured from a three-dimensional processing wooden thin plate, it is possible to reliably prevent the occurrence of a crack in the projecting plate 3 when the housing 40 is manufactured.

  Although the housing 40 of FIG. 1 has a reverse tray-shaped structure with the protruding plate 3 as the front, the housing 40 may have a reverse tray-shaped structure with the base resin layer 6 as the front.

  FIG. 3 is a view used to explain an apparatus for manufacturing a raised plate / resin laminated structure housing according to an embodiment of the present invention.

  In FIG. 3, steps I and II are performed by a press, and steps III and IV are performed by an injection molding machine. Finally, step V described later is performed by an appropriate method.

  First, a laminate of non-woven fabric layers 5 is prepared, which is bonded to the end plates 3 and 3 via the adhesive resin layer 4 and in which the gaps between the fibers are impregnated with PVB resin in advance.

  In step I of FIG. 3, the laminate of the protruding plate 3 and the non-woven fabric layer 5 is placed on the female die 10 (fixed die) of the press with the non-woven fabric layer 5 facing up. The laminate may be cut into a predetermined shape in advance.

  Next, in step II, the male mold 11 (movable mold) of the press is moved to the female mold 10 so that the laminate of the projecting plate 3 and the non-woven fabric layer 5 placed in step I is pushed into the female mold 10. Move towards Thus, after the laminate is formed into a shape defined by the female die 10 and the male die 11, the formed laminate is taken out from the press. At this time, the periphery of the molded laminate may be cut with a laser cutter or a cutting die (cutting unit) to remove burrs.

  Subsequently, in step III of FIG. 3, the laminate molded by the press machine is mounted in the female die 22 (other fixed die) with the nonwoven fabric layer 5 facing up, and then placed in the female die 22. While moving the injection molding male mold 12 (injection molding mold) toward the received laminate, the injection hole 20a of the injection machine 20 is pressed against the injection molding hole 12a of the injection molding male mold 12 The injection screw 21 is rotated clockwise to inject the resin solution 31 of the base resin layer 6 in the tank 30 into the space defined by the laminate and the injection molding male mold 12.

  Next, in step IV, after the injection molded base resin layer 6 is cooled and solidified, the injection machine 20 and the injection molded male mold 12 are separated from the female mold 10 and the molded article is taken out

  The female mold 10 and the male mold 11 constitute a press, and the female mold 22, the injection molding male mold 12 and the injection machine 20 constitute an injection molding machine, and the press and the injection molding machine are housings 40. Configure the manufacturing equipment of As a modification, the press and the injection molding machine may be integrated, and the female mold 10 may be used as the female mold 22. In this case, the injection molding male mold 12 is moved toward the laminate of the projecting plate 3 and the non-woven fabric layer 5 molded in the female mold 10.

  According to the apparatus for manufacturing the projecting plate / resin laminated structure housing of FIG. 3, the resin solution 31 of the base resin layer 6 reliably melts in the gaps of the fibers of the non-woven fabric layer 5 into PVB resin. The shrinkage of the non-woven fabric layer 5 and the base resin layer 6 in the above makes the adhesion to the non-woven fabric layer 5 stronger.

  Further, according to the apparatus for manufacturing a laminated plate / resin laminated structure housing of FIG. 3, the non-woven fabric layer 5 is interposed between the laminated plate 3 and the base resin layer 6 consisting of a laminated plate manufactured from a three-dimensional processing wooden thin plate. Therefore, the influence of heat on the projecting plate 3 can be reduced at the time of injection molding of the base resin layer 6.

  The apparatus for manufacturing the veneer / resin laminated structure housing shown in FIG. 3 has a housing 40 having a reverse basin structure with the veneer 3 as a front surface, but the housing 40 has a reverse basin structure with the base resin layer 6 as a front surface. It is also good.

  The projecting plate 3 may be replaced by a projecting plate layer 9 described below.

  That is, the plate layer 9 is bonded to the other surface of the plate 3, the plate 3 made of a plate made of wood thin plate for three-dimensional processing, the transparent acrylic film layer 7 bonded to the plate 3 via an adhesive, and And another transparent acrylic film layer 8 bonded via an agent (FIG. 4).

  The transparent acryl film layer 7 is made of an acryl film having a thickness of 0.01 to 0.4 mm, preferably 0.02 to 0.3 mm, containing an elastomer.

  The transparent acrylic film layer 7 is preferably, for example, an acrylic film (trade name: Technoroy) manufactured and sold by Sumitomo Chemical Co., Ltd. These acrylic films are excellent in impact resistance and abrasion resistance. The above elastomer has a kneading ratio of 10 to 60 parts by weight with respect to 100 parts by weight of the acrylic film. Further, the elastomer contained in the acrylic film (trade name: Technoloy) is made of synthetic rubber containing one material selected from the group of acrylic rubber, nitrile rubber, and isoprene rubber.

  The adhesive preferably makes it easy to adhere both the transparent acrylic film 7 and the projecting plate 3 to each other, and it is preferable that the adhesive has properties such as low viscosity and ability to release air bubbles. The adhesive 8 is made of one material selected from the group of aldehyde-modified adhesives of polyvinyl alcohol (PVB), polyurethane adhesives, acrylic adhesives, epoxy resin adhesives, and vinyl chloride adhesives. .

  Hereinafter, one specific example of the manufacturing method of the protruding plate 3 in FIG. 2 will be described. In this case, the projecting plate 3 is manufactured from the three-dimensional processing wooden thin plate 10 of FIG. 5 described later.

  FIG. 5 is a perspective view of a three-dimensional processing wooden thin plate according to a specific example of the protruding plate 3 in FIG.

  In FIG. 5, the three-dimensional processing wooden thin plate 50 is made of a material such as waltnut, china, beech, nara, etc., and is formed in a corrugated shape having peaks and valleys crossing or preferably orthogonal to the fiber direction of the wood. ing. The cross-sectional shape of this waveform is sinusoidal.

  The plate thickness t of the three-dimensional processing wooden sheet 50 is 0.15 to 0.80 mm. If the thickness t is less than 0.15 mm, cracking may occur in the fiber direction of the wood during three-dimensional processing of the three-dimensional processing wooden sheet 10. If the thickness exceeds 0.80 mm, the three-dimensional processing wooden sheet At the time of 50 three-dimensional processing, it may be broken in the direction crossing the fiber direction of the wood.

  In the above waveform, the height h of the valleys is 1.0 to 8.0 mm, and the pitch p is 1.0 to 10.0 mm, preferably 2.0 to 8.0 mm.

  According to the three-dimensional processing wood sheet 50 of FIG. 5, three-dimensional processing of the wood sheet can be easily performed without impregnating the solution with ethylene glycol or the like into the wood sheet or cutting on both sides of the wood sheet. be able to.

  FIG. 6 is a view schematically showing an apparatus for producing the three-dimensional processing wooden sheet of FIG.

  In FIG. 6, the apparatus for producing a three-dimensional processing wooden sheet comprises a pair of corrugated gear-shaped rollers 51 and 52 which mesh with each other to roll the three-dimensional processing sheet 50 in the direction of the fiber of the tree. In the cross direction of the fiber direction of the thin wood sheet 50, preferably in a perpendicular direction, it has peaks and valleys, and the cross-sectional shape of the corrugation is sinusoidal. The meshing surfaces of the rollers 51 and 52 of the manufacturing apparatus in this case form a complementary shape of the three-dimensional processing wooden sheet 50 shown in FIG. The rollers 51, 52 roll the three-dimensional processing wooden sheet 50 at 1 to 60 m / min according to their rotation to produce the three-dimensional processing wooden sheet 50 of FIG.

  According to the apparatus for manufacturing a three-dimensional processing wood sheet of FIG. 6, the three-dimensional processing wood sheet can be easily and efficiently manufactured.

  FIG. 7 is a view used to explain a first modified example of the three-dimensional processing wood sheet of FIG.

  The three-dimensional processing wooden thin plate 50 of FIG. 5 has a “double-wave developable surface”, a so-called “Miura fold” shape, in which the shape of the corrugation is formed by repeating four parallelograms (FIG. 7) . The meshing surfaces of the rollers 51 and 52 of the manufacturing apparatus in this case have a complementary shape of the “double-wave developable surface” of FIG. 7.

  FIG. 8 is a view used to explain a second modification of the three-dimensional processing wooden sheet of FIG. 1;

  In the wooden thin plate 50 for three-dimensional processing of FIG. 5, the corrugated shape is a kind of shape of “diacut” side, so-called “Miura fold” (FIG. 8). The meshing surfaces of the rollers 51 and 52 of the manufacturing apparatus in this case form a complementary shape of the "diamond cut" surface of FIG.

  In the embodiment of the present invention, although the projecting plate / resin laminated structure housing 40 is described merely as a general housing, the application technical field of the embodiment of the present invention is an in-mold having a surface coating layer. It covers decorative items by molding, specifically, general goods including containers and stationery, housings for electronic devices including cellular phones and laptop computers, housings for home appliances, housings for interiors and exteriors of buildings and automobiles, aircrafts , Railway cars, and ship interior housings.

Reference Signs List 3 projecting plate 4 adhesive resin layer 5 non-woven fabric layer 6 base resin layer 7, 8 transparent acrylic film 9 projecting plate layer 10 female die 11 male die 12 injection molding male die 20 injection machine 21 injection screw 22 female die 30 tank 31 resin Solution 40 Protrusive plate / resin laminated structure housing 41 Protrusive part 42 Opening part 50 Three-dimensional processing wooden thin sheet 51, 52 Corrugated gear-shaped roller

Claims (11)

  A projecting plate layer, a nonwoven fabric layer adhered to the projecting plate layer via an adhesive resin layer, and a base resin layer infiltrated in resin in gaps of respective fibers of the nonwoven fabric layer and adhered to the nonwoven fabric layer; A projecting plate / resin laminated structure housing characterized in that the projecting plate layer is made of a projecting plate manufactured from a wooden thin plate for three-dimensional processing.   The plate / resin laminated structure housing according to claim 1, wherein the non-woven fabric layer is adhered to the plate via the adhesive resin layer.   The projecting plate layer includes the projecting plate, a transparent acrylic film layer adhered to one surface of the projecting plate via an adhesive, and another transparent acrylic film adhered to the other surface of the projecting plate via an adhesive. The plate / resin laminated structure housing according to claim 1, comprising a layer. The plate / resin laminated structure housing according to claim 2 or 3, wherein the plate is impregnated or coated with a PVB resin or a polyurethane.   The projecting plate / resin laminate structure housing according to any one of claims 1 to 4, wherein the adhesive resin layer is made of a polyvinyl acetal resin.   The raised plate / resin laminate structure housing according to claim 5, wherein the polyvinyl acetal resin is polyvinyl butyral (PVB).   The plate / resin laminated structure housing according to any one of claims 1 to 6, wherein the base resin layer is made of a thermoplastic synthetic resin.   8. The plate / resin laminated structure housing according to claim 7, wherein the thermoplastic synthetic resin is made of a synthetic resin for injection molding.   9. The plate / resin laminated structure housing according to claim 8, wherein the synthetic resin for injection molding is made of one material selected from the group of ABS, PC, PMMA, PP, nylon, and PC + ABS.   The plate / resin laminated structure housing according to any one of claims 1 to 9, wherein the base resin layer contains a glass fiber filler.   A fixed plate for receiving a laminate of a non-woven fabric layer and a laminate of a non-woven fabric layer bonded to the high-profile plate layer via an adhesive resin layer with the non-woven fabric layer facing; A movable mold which is moved toward the stationary mold so as to press the received laminate into the stationary mold to form the laminate; Another fixed mold for receiving in a face-to-face manner, an injection mold which is moved toward a stack received in the other fixed mold, and a stack received in the other fixed mold And an injection means for injecting the resin solution of the base resin layer into the space defined by the injection molding die.