JP2972471B2 - Laminated panel manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a laminated panel, and more particularly to a method for manufacturing a laminated panel having a curved surface with a decorative sheet adhered to a metal plate surface. The present invention relates to a method for manufacturing a laminated panel suitable as a wall material for a living space.

[0002]

2. Description of the Related Art Conventionally, a wall material constituting a wall of a living space such as a railway car, a car, a ship, a house, or the like, has a surface that is smoothly curved from a decorative point of view or a corner is curved. When three-dimensionally formed, a fiber-reinforced plastic (hereinafter simply referred to as FR
P) was often used. The wall material made of the FRP must have a certain thickness in order to secure a predetermined strength, and the weight increases, so that the workability or the weight reduction of railway vehicles, automobiles and the like are required. Was disadvantaged from In addition, the color or pattern of the FRP can be selected relatively freely, but when the color or pattern is changed, the FRP itself must be replaced. Also, when molding using a mold, complicated work such as heat molding is necessary,
In some cases, it took a lot of production time.

On the other hand, instead of the FRP wall material, a metal plate coated with a resin sheet on its surface is press-molded and used as a wall material or decorative plate. Such a laminated material has a predetermined strength even if the thickness is reduced, and can be reduced in weight depending on the selection of the material. It has features such as being able to do.

[0004] The laminated material is formed by applying an adhesive to one side of a metal plate and baking it, then extruding a synthetic resin film by an extruder and laminating it in a molten state, or by a coextrusion method in an outline. It is manufactured by laminating two or three layers of film. Then, the material cut to a required size is drawn or bent by a press or the like to form a required shape. A related example of such a laminated plate is disclosed in, for example, JP-A-63-306032.

[0005]

The FRP wall material cannot be used in cases where the demand for weight reduction is high,
Also, it is disadvantageous to change the color and pattern because a large amount of cost is required. The laminated material requires large-scale equipment for coating the synthetic resin film on the metal plate, and is designed so that it can be laminated on the base material by a simple operation without considering special equipment or heating conditions. I didn't.

Further, the laminated material is not considered to be used as a wall material of a living space, but is considered to have a thin synthetic resin film and to form a grain on the surface of the synthetic resin film itself. In addition, there was a problem that a sense of discomfort such as coldness of the metal plate was easily transmitted to the user.

An object of the present invention is to enable a decorative sheet to be easily adhered to the surface of a metal sheet as a base material without requiring special equipment or skill, and to form a curved surface on the surface of the decorative sheet. An object of the present invention is to provide a method of manufacturing a laminated panel that can be easily performed without causing damage.

[0008]

According to the present invention, a flat metal plate as a base material is prepared, and a decorative sheet is stuck to one surface of the metal plate with an adhesive at a normal temperature, and the surface of the decorative sheet and the A protective film is stuck at room temperature with an adhesive having a weaker adhesive force than the adhesive on the opposite side of the metal plate to which the decorative sheet has been stuck, and the metal sheet on which the decorative sheet and a plurality of protective films are stuck is attached. It is characterized by being formed by press forming.

Further, the present invention provides a flat metal plate having a decorative sheet adhered on one surface thereof with an adhesive at a normal temperature, and a surface opposite to the surface of the decorative sheet and the surface of the metal plate on which the decorative sheet is adhered. On the side surface, a protective film is stuck at a room temperature with an adhesive having a weaker adhesive force than the adhesive, and a metal plate on which the decorative sheet and the plurality of protective films are stuck is formed by press molding. Things.

[0010]

The decorative sheet is adhered to a flat metal plate as a base material with an adhesive, so that special equipment such as baking is not required. The sticking operation can be performed easily and easily without any skill. In addition, in order to perform press molding in a state where a protective film is stuck to the surface of the decorative sheet and a surface of the metal plate opposite to the surface to which the decorative sheet is stuck, the plurality of protective films are pressed. Since the lubricant acts as a lubricant between the metal sheet and the mold, the metal sheet can be formed without locally applying a large force to the decorative sheet. Therefore, without damaging the decorative sheet,
A curved surface of a laminate can be formed.

[0011]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described below with reference to the drawings. Here, a wall material used for a railway vehicle, that is, an interior panel will be described. FIG. 1 shows an indoor structure diagram of a railway vehicle. An interior panel such as a ceiling panel 2 or a side panel 3 is attached to the inner surface of the vehicle body 1. FIG. 2 shows a cross section AA of the side panel 3. The side panel 3 has a metal plate 4 as a base material and a vinyl chloride-based decorative sheet 5 adhered to the surface thereof. Here, the side panel 3 will be described as an example.

FIG. 3 shows a procedure for manufacturing the side panel 3. First, the metal plate 4 serving as a base material has a thickness of 1.2 mm.
This aluminum plate is corrosion-resistant, has a magnesium content of about 5%, and has an elongation of about 30%. Further, the surface is roughened into an uneven shape having a surface roughness of about 5 to 10 μm by a shot dull finish or the like, and then degreased to obtain a surface state in which the adhesive strength of the adhesive is improved.

Next, the vinyl chloride-based decorative sheet 5 to which the adhesive has been applied is mechanically attached to the metal plate 4 while being pressed by a rubber roller 11 at room temperature. The adhesive strength of the adhesive portion applied in this manner is 25 mm width 180 at 20 ° C.
° Peeling force measured value is 5 to 8 kg. The vinyl chloride decorative sheet 5 has a thickness of about 0.2 mm, is provided with a pattern or grain suitable for the interior of the vehicle, and is provided with a grain-like grain on the surface for improving the feel. Fluorine coated to prevent contamination and to facilitate peeling of the vinyl chloride protective film for press molding described below. Furthermore, the vinyl chloride-based decorative sheet 5 has an elongation of 150 to
Use a material having about 300%. The decorative sheet 5 is described by taking a vinyl chloride type as an example. However, if the decorative sheet 5 has the above-mentioned thickness or elongation, for example, a polyethylene-based resin, a polyester-based resin, a fluorine-based resin, a nylon-based resin, etc. May be used. Although the decorative sheet 5 is coated with an adhesive in advance, the metal sheet 4 may be coated with an adhesive.

Next, a vinyl chloride-based protective film 6 having a thickness of about 5 μm with an adhesive is pressed on the front surface of the vinyl chloride decorative sheet 5 and the back surface of the metal plate 4 with a rubber roller 11. While applying the machine. This vinyl chloride protective film 6
Silicon is applied to the surface of the substrate, and 25 m at 20.degree. C., which has a much lower adhesive strength than the adhesive applied to the vinyl chloride decorative sheet 5, is applied on the bonding surface side of the back surface.
An adhesive having a m width of 180 ° peeling force of about 120 g is applied. Therefore, the protective film 6 can be relatively easily peeled off after the press working, and does not adversely affect the decorative sheet 5.
Further, since the vinyl chloride protective film 6 covers the surfaces of the vinyl chloride decorative sheet 5 and the metal plate 4, it is possible to prevent contamination during press molding or transportation. Further, since the protective film 6 has its own physical properties and silicon coated on its surface, it plays a role of preventing damage to the decorative sheet 5 such as wrinkles, tears and tears, and a role of lubricating oil at the time of press molding. Things. By applying silicon, moldability is further improved as compared with the case where silicon is not applied.

Since the operation of laminating the decorative sheet 5 and the two protective films 6 on the metal plate 4 using the adhesive 10 is performed in a state where the metal plate 4 is a flat plate, the rubber roller 1
This can be easily performed by mechanical bonding using No. 1. In addition, since the heating is performed at normal temperature, no special equipment for heating is required. By the way, as described above, the procedure for attaching the decorative sheet 5 and the protective film 6 to the metal plate 4 is as follows.
A method of pasting the decorative sheet 5 on the metal plate 4 and then pasting two protective sheets 6 and a method of pasting the protective sheet 6 on one side of the metal plate 4 in advance and sequentially or once applying the decorative sheet 5 and the protective sheet 6 You may put on. Further, the three sheets can be stuck at once by a simple device combining a plurality of rubber rollers. The protective sheet 6 attached to the back side of the metal plate 4 may not be used depending on the degree of processing or the physical properties of the metal plate.

Next, the four-layer flat plate is press-formed by an upper forming die 7 and a lower forming die 8 set in a press to form a formed panel 9 having a three-dimensional curved surface shape. Vinyl chloride
After press molding, the protective film 6 is peeled off and discarded.

If a lubricating oil is used at the time of press molding, the vinyl chloride decorative sheet 5 becomes dirty, and it takes time to remove and clean the vinyl chloride decorative sheet 5. Therefore, the vinyl chloride protective film 6 serves as a lubricating oil. . Further, since the vinyl chloride-based protective film 6 is adhered with the adhesive 10, it can withstand use in all processes without peeling off even in a case where there are many pressing processes such as molding, trimming and flange bending. .
That is, since the protective film 6 is adhered to the decorative sheet 5 with the adhesive 10, the two are not displaced at the time of press molding, and no force or deformation is locally generated in the decorative sheet 5. Therefore, since the decorative sheet 5 can be provided with a substantially uniform extension, a three-dimensional curved surface can be formed without damaging the surface of the decorative sheet 5.

When a panel is manufactured by such a manufacturing method, the metal plate 4 is formed into a three-dimensional curved surface as in the prior art,
Compared to the artisan production method of hand-pasting the vinyl chloride decorative sheet 5 while heating it, even amateurs can work and can be mechanized, making it possible to produce high quality panels quickly and inexpensively. .

The effects obtained when the laminated panel is manufactured by the method described above are summarized as follows. (1) Since a three-dimensional curved panel on which a decorative sheet made of resin such as vinyl chloride is pasted can be press-molded at room temperature, a laminated panel of stable quality can be manufactured quickly and cheaply as compared with hand pasting. Further, since the resin-made decorative sheet is attached when the metal plate is in a flat state, it is not a task requiring special skills, and can be easily performed by an amateur. Furthermore, since the decorative sheet is stuck to a metal plate at normal temperature, it can be manufactured in a simple facility without requiring special heating equipment or the like.

(2) Since the metal plate serving as the base material may be an aluminum plate or a thin iron plate, the weight can be reduced and the dimensional accuracy can be improved as compared with a panel made of a conventional FRP. In addition to becoming non-combustible material, it does not become industrial waste when disposed,
Resources can be recycled.

(3) In the case of a conventional three-dimensional curved panel made of FRP, a pattern is not provided and the color is monotonous. However, a decorative sheet made of a resin such as vinyl chloride with a pattern or a grain can be used. Therefore, the design is improved, and it is possible to cope with diversification of interior patterns.

(4) Since a decorative sheet made of resin such as vinyl chloride is adhered to a metal plate as a base material with an adhesive, no heating is required and curing time is required as compared with a conventional adhesive paste. Since less work is required, workability is good and it can be manufactured at low cost.

In the above embodiment, an example was described in which the metal plate as the base material was an aluminum plate.
The present invention is not limited to this, and the elongation is 30%.
For example, a steel plate, a stainless steel plate, or the like may be used as long as it is a material having good press formability.

[0024]

As described above, according to the present invention, a decorative sheet can be easily attached to the surface of a metal plate as a base material without requiring special equipment or skill, and a plurality of protective sheets can be protected. By using the sheet, the curved surface of the laminated panel can be easily formed without damaging the decorative sheet surface.

[Brief description of the drawings]

FIG. 1 is a front view showing a cross-section in the vehicle width direction showing an arrangement state of ceiling panels, side panels, and the like in a passenger compartment of a railway vehicle.

FIG. 2 is a sectional view taken along the line AA of the side panel in FIG.

FIG. 3 is a view showing a manufacturing procedure in one embodiment of a method of manufacturing a laminated panel according to the present invention.

[Explanation of symbols]

1 ... body, 2 ... ceiling panel, 3 ... side panel, 4 ...
... metal plate, 5 ... decorative sheet, 6 ... protective film, 7
... upper mold, 8 ... lower mold, 9 ... molded panel, 1
0: adhesive, 11: rubber roller.

──────────────────────────────────────────────────続 き Continuation of the front page (72) Inventor Kiyotaka Kikumoto 794, Higashi-Toyoi, Kazamatsu-shi, Yamaguchi Pref. Kasado Plant, Hitachi, Ltd. (56) References JP-A-4-182127 (JP, A) (58) ) Surveyed field (Int.Cl. ⁶ , DB name) B32B 31/20 B32B 15/08 E04F 13/12 B60R 13/02

Claims (3)

(57) [Claims] 1. A flat metal plate serving as a base material is prepared, and a decorative sheet is stuck to one surface of the metal plate with an adhesive at a normal temperature, and the surface of the decorative sheet and the metal plate are adhered to each other. A protective film is stuck on the opposite surface where the decorative sheet is stuck with an adhesive having a weaker adhesive force than the adhesive at room temperature, and a metal plate on which the decorative sheet and a plurality of the protective films are stuck is formed by press molding. A method of manufacturing a laminated panel, characterized in that: 2. A decorative sheet is placed on one side with an adhesive at room temperature.
Prepare a flat metal plate attached in a state, a protective film with an adhesive having a weaker adhesive force than the adhesive on the surface of the decorative sheet and the surface opposite to the surface of the metal plate on which the decorative sheet is attached. A laminated panel manufacturing method, characterized in that a metal plate to which the decorative sheet and a plurality of protective films are attached is formed by press molding at a normal temperature . 3. The method for manufacturing a laminated panel according to claim 1, wherein the plurality of protective films are coated with silicon in advance on a surface that contacts a forming die before press forming. Characterized laminated panel manufacturing method.