JP3010316B2 - Relief panel, manufacturing method and apparatus therefor - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a relief panel in which an uneven pattern is formed on the surface of a synthetic resin foam plate, and a method and apparatus for manufacturing the same.

[0002]

2. Description of the Related Art Heretofore, the following are known as relief panels having an uneven pattern formed on the surface of a synthetic resin foam plate.

(1) A relief panel manufactured by sticking a pattern piece obtained by punching a synthetic resin foam-based plate material into a pattern shape onto the surface of a separately prepared similar plate material.

(2) A relief panel in which a cut is made in a pattern through a synthetic resin foam-based plate material, and a portion surrounded by the cut is shifted to the surface side and projected to thereby form an uneven pattern.

[0005]

However, in the relief panel of the above (1), the adhesive is likely to protrude and the appearance is likely to be impaired, and the excess portion of the plate material is wasted when the pattern pieces are punched. is there. Also,
It takes time and effort to adhere a large number of punched pattern pieces to predetermined positions, and there is also a problem that a pattern that is not so complicated cannot be formed.

In the relief panel of the above (2), it is necessary to bond and fix the protruding portion in order to prevent the protruding portion from coming off. However, this bonding is difficult to be performed, so that a large burden is imposed on the workplace, and also the adhesive is used. There is a problem that easily causes dirt. Further, even if this bonding is performed, a wide bonding surface cannot be obtained, so that peeling is likely to occur, and it is difficult to completely prevent the protrusion from coming off. Furthermore, since the cuts penetrating through the plate material are provided, the strength of the obtained relief panel is likely to be reduced, and there are limitations on the patterns that can be formed.

SUMMARY OF THE INVENTION The present invention has been made in view of the above-mentioned problems, and provides a relief pattern without wasting material or using an adhesive. It is an object of the present invention to be able to form easily without significantly lowering the strength.

[0008]

For this purpose, according to the first aspect of the present invention, as shown in FIG. 1, a notch 2 which is kept within a thickness from the surface of a synthetic resin foam-based plate 1 is formed to cut the surface. A plurality of sections are divided, and some of the sections divided by the cuts 2 are compressed until a permanent set is generated to form the concave portions 3 and the remaining regions are formed as the convex portions 4, and the concave and convex pattern is formed by the concave portions 3 and the convex portions 4. It is to be configured.

According to the second aspect of the present invention, in the relief panel in which the concave and convex portions are formed by the concave portions and the convex portions on the surface of the synthetic resin foam-based plate material, the boundary between the concave portions and the convex portions is A cut 2 is formed that stays within the thickness from the surface, and at least the recess 3 is a relief panel that is compressed and has permanent deformation remaining.

According to the third aspect of the present invention, as shown in FIGS. 4 and 5, a base 5 on which the synthetic resin foam plate 1 is placed, and a vertically movable upper part of the base 5 are provided. The moving table 6, a cutting blade 7 protruding from the lower surface of the moving table 6, and a hard presser mat 10 also protruding from the lower surface of the moving table 6, And the hard holding mat 10 is arranged along the contour of the pattern
Is a device for manufacturing a relief panel provided with a slightly smaller projection than the cutting blade 7 corresponding to a part of the surface of the plate material 1 which is divided into a plurality of regions by the cutting blade 7 biting. Is what it is.

[0011]

In the present invention, the notch 2 formed on the surface of the synthetic resin foam-based plate 1 makes the boundary between the concave portion 3 and the convex portion 4 formed by compression clear, and makes the uneven pattern clear. Then, since the cuts 2 remain within the thickness of the plate material 1, the strength of the obtained relief panel is maintained.

Further, since the concave portion 3 is formed by compression and the remaining portion becomes the convex portion 4 and the concave portion 3 and the convex portion 4 are integrally formed, an adhesive is used or a punched pattern piece is prepared. There is no need, and there is no dirt due to the adhesive, peeling due to poor bonding, and no waste of material.

Further, in the present apparatus, as the movable table 6 is lowered, the cutting 2 is formed by the cutting blade 7 and the compression for forming the recess 3 by the hard pressing mat 10 is performed simultaneously.

[0014]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The manufacturing method of the present invention will be described with reference to FIG.

First, as shown in FIG. 1A, a cut 2 is made at a depth from the surface of the synthetic resin foam-based plate 1 so as to remain within the thickness, and the surface of the plate 1 is divided into a plurality of sections.

As the plate material 1 of the synthetic resin foam system, for example, a plate of an extruded foam molded product such as polystyrene, polyvinyl chloride, polyethylene, polypropylene, polymethyl methacrylate, polycarbonate, polyurethane or a bead foam molded product can be used. As this foam molded product, the ease with which the concave portion 3 is formed by compression, which will be described later,
From the viewpoints of maintaining the strength and lightness of the obtained relief panel, the overall average foaming density is 30 to 120 kg / m ^3.
Is more preferable, and more preferably 40 to 100 kg /
m is ^3. Further, at least one surface of these foamed molded products may be formed by laminating or painting metal foil, paper, woven fabric, knitted fabric, synthetic resin film, or the like.

When the above foam molded article is used alone as the plate material 1 or when the surface thereof is coated and used as the plate material 1, it is preferable that at least one surface has a skin layer having a higher density than the inside. In the case of the sheet material 1 of the foam molded article having the skin layer, there is an advantage that the strength of the obtained relief panel can be easily maintained by leaving the skin layer which is not cut by the cut 2 on the back surface side.
In addition, even in the case of a plate material 1 in which a synthetic resin film or the like is laminated on at least one surface of a foam molded product, the same advantage can be obtained by leaving a synthetic resin film or the like that is not cut by the cut 2 on the back surface side.

The synthetic resin foam plate 1 preferably has a compression modulus in the thickness direction of 40 to 150 kg / cm ² . If the compression modulus is too large, the amount of permanent strain obtained during compression performed later is small, and it is difficult to obtain a clear uneven pattern, and the obtained relief panel has a weak stiffness, and its use form is limited, conversely If the compression modulus is too small, the plate 1 is liable to crack during compression.

Although the thickness of the plate 1 varies depending on the use of the obtained relief panel, it is preferably about 3 to 15 mm, more preferably about 5 to 10 mm. If it is too thin, it is difficult to form a clear concavo-convex pattern, and if it is too thick, practicality is lost.

The notch 2 is formed in a planar shape along the concave and convex pattern to be obtained, that is, a planar shape along the boundary between the concave portion 3 and the convex portion 4 of the concave and convex pattern to be obtained.
Is divided into a plurality of areas.

The depth of the notch 2 may be at least as long as its tip remains within the thickness of the plate 1, but it is preferable to form the cut 2 at a depth of at least １ ／ of the thickness of the plate 1. If it is too shallow, it will be difficult to form a clear uneven pattern. Notch 2
The maximum depth of the plate differs depending on the material of the plate 1 or the like, but it is sufficient to leave a thickness that does not easily cause cracking from the cut 2 portion. In the plate material 1 having a skin layer 1 and a skin layer, it is preferable to leave at least the synthetic resin film and the skin layer without cutting.

The cut 2 is preferably a series of continuous ones, but may be a perforated one as long as the connection part is easily cut at the time of compression as described later and is made continuous.

Next, as shown in (b), at least a part of the plurality of sections of the surface of the plate material 1 divided by the cuts 2 to be the concave portions 3 is compressed, and the part is permanently set. Generate.

The compression may be performed only on the area to be formed into the concave portion 3, but may also be performed on the area to be formed into the convex portion 4 at the same time. In this case, the compression of the area to be the convex portion 4 is made smaller than that of the area to be the concave portion 3 so that a large permanent strain remains in the area to be the concave portion 3 as compared to the area to be the convex portion 4. I just need.

Further, the amount of compression of the area to be formed as the concave portion 3 may be divided into several stages, and the convex portion 4 and the concave portion 3 having different levels of dent may be formed. This makes it possible to express a more complicated uneven pattern.

The specific compressive strength is as follows: when a foamed product having an average foaming density of 40 to 100 kg / m ³ as a whole is used as the plate 1, the average density of the convex portions 4 after the compression process is D, Assuming that the average density of the later concave portion 3 is d, D is 40 kg.
/ M ³ or more and 100 kg / m ³ or less, d is 70 kg / m ³ or more and 240 kg / m ³ or less, and d / D is 1.75 or more and 2.
It is preferably about 4 or less. In this case, the height of the concave portion 3 can be about 60 to 85% of the height of the convex portion 4.

In this description, for convenience of explanation, compression is performed after the cut 2 is completely formed. However, the present invention is not necessarily required to perform the compression, but the cut 2 is formed slightly earlier. The cut 2 may be formed following the compression while performing the compression while performing the compression slightly earlier. Further, the compression can be completed by pressing the entire surface of one area to be the concave portion 3, but if the one area can be compressed almost uniformly, it is not always necessary to press the entire surface. It may be performed by pressing a part of one area to be operated.

By performing the above-mentioned compression, a concave and convex pattern is formed by the concave portion 3 and the convex portion 4 as shown in (c). If necessary, an unnecessary portion of the peripheral edge of the plate 1 is cut and removed, thereby forming a relief panel. Can be obtained. In this relief panel, the concave portion 3 is formed by the permanent strain remaining upon compression, and the notch 2 formed at the boundary between the concave portion 3 and the convex portion 4 forms a clear uneven pattern, and the notch 2 penetrates. Not doing so maintains the integrity of the whole.

Here, in the present invention, a pattern is a figure,
In terms of characters, symbols, etc., the concavo-convex pattern may be one in which the pattern is represented as a convex portion 4 as shown in FIG. 2 or one in which the pattern is represented as a concave portion 3 as shown in FIG. Good.

FIG. 4 shows an example of an apparatus for manufacturing the relief panel. A gantry 5 on which the plate 1 is placed, a gantry 6 movably provided above the gantry 5, and a The notch 2 is provided so as to protrude from the lower surface side of the base 6 and
And a cutting blade 8 that is also provided protruding from the lower surface side of the moving table 6 and that cuts and removes an unnecessary portion of the peripheral edge of the plate 1, and is provided outside the cutting blade 7. And a hard pressing mat 10 provided inside the cutting blade 7.

The cutting blade 7 is arranged along the contour of a desired pattern, and the hard pressing mat 10 is
Are provided with a slightly larger protrusion amount than the cutting blade 7 corresponding to a part of the surface of the plate material 1 which is divided into a plurality of areas by biting. Further, the cutting blade 8 is provided with a slightly larger projection than the cutting blade 7, and the soft holding mat 9 is provided with a slightly larger projection than the cutting blade 7.

In the case of the present apparatus, the plate 1 is placed on the
This relief panel can be manufactured only by lowering the movable table 6.

FIG. 5 shows a state where the movable table 6 is lowered.

As is clear from FIGS. 4 and 5, when the movable table 6 is lowered, first, the soft pressing mat 9 comes into contact with the plate 1, the cutting blade 8 bites into the plate 1, and then the hard pressing mat 10 is After contacting the plate 1, the cutting blade 7 bites into the plate 1. With the lowering of the moving table 6, the soft presser mat 9 compresses itself without hardly compressing the plate 1, while the hard presser mat 10 compresses itself only slightly, Compressed area. Then, the compression proceeds along with the biting of the cutting blade 7 as the moving table 6 descends to form the concave portion 3, and the other area becomes the convex portion 4.

When the movable table 6 comes into contact with the stopper 11,
The lowering of the movable table 6 is stopped, and the movable table 6 is returned to the original position. At the time when the moving table 6 comes into contact with the stopper 11, the cutting blade 8 cuts an unnecessary portion of the peripheral edge of the plate 1 and the cutting blade 7 cuts into a necessary depth within a range not penetrating the plate 1. Hard presser mat 10
, The necessary compression has been completed. Therefore,
If the movable table 6 is taken out after returning, the relief panel can be obtained.

In the above-mentioned apparatus, the soft holding mat 9 may not be particularly provided. However, if the soft holding mat 9 is provided and the cutting blade 7 is sandwiched between the hard holding mat 10 and the cutting blade 7, the soft holding mat 9 is supported. This is preferable because the biting state can be easily stabilized. In addition, the soft holding mat 10 and the hard holding mat 10 may have a smaller protrusion amount than the cutting blade 8 and the cutting blade 7. However, according to the present embodiment, the stableness of the cutting blade 8 and the cutting blade 7 is improved. Good and soft and hard presser mat 9,
It is preferable because the cutting blade 7 and the cutting blade 8 can be stably applied to the plate material 1 in a state where the plate material 1 is pressed.

When both the soft holding mat 9 and the hard holding mat 10 are provided, the soft holding mat 9 has a Rockwell hardness of 5 in order to obtain a clear uneven pattern and obtain the above-mentioned supporting effect.
It is preferable that the hard pressing mat 10 has a Rockwell hardness of 70 to 80. Also, if the hardness of the hard holding mat 10 is changed depending on the location, a plurality of recesses 3 having different degrees of compression can be formed.

In order to obtain the present relief panel, the plate material 1
When it is not necessary to trim the peripheral edge, the cutting blade 8 is unnecessary.

The use of the relief panel is as follows.
For example, decorative panels, materials for boxes and trays, plaster product molds, concrete forms and the like can be mentioned.

[0040]

The present invention is as described above, and has the following effects.

(1) Since the concave and convex pattern becomes clear due to the presence of the cut 2, the appearance is good and the appearance is excellent.

(2) Since an integrated relief panel can be obtained without using an adhesive, there is no need to worry about dirt due to the protrusion of the adhesive, and the production yield is good.

(3) Since it is an integrated product formed from one plate material 1, it is easy to maintain necessary strength, and it is not necessary to cut out a pattern piece from another plate material 1 separately. The accompanying waste of material can be prevented.

(4) The formation of the notch 2 and the compression for forming the recess 3 can be performed simultaneously in one step, so that the manufacturing process is simple and excellent in manufacturing efficiency, and the cutting blade 7 and the hard holding mat 10 By simply arranging the patterns, even a considerably complicated uneven pattern can be easily mass-produced.

[Brief description of the drawings]

FIG. 1 is an explanatory diagram of the present invention.

FIG. 2 is a perspective view showing an example of an uneven pattern.

FIG. 3 is a perspective view showing another example of the uneven pattern.

FIG. 4 is a longitudinal sectional view showing one embodiment of the invention of the present apparatus.

FIG. 5 is a longitudinal sectional view showing a state in which a moving table of the apparatus of FIG. 4 is lowered.

[Explanation of symbols]

 REFERENCE SIGNS LIST 1 plate material 2 cut 3 concave portion 4 convex portion 5 gantry 6 movable base 7 cutting blade 8 cutting blade 9 soft holding mat 10 hard holding mat 11 stopper

Claims (3)

(57) [Claims] 1. A cut is made from the surface of a synthetic resin foam-based plate to remain within the wall thickness to divide the surface into a plurality of areas,
A part of the area divided by the cut is compressed until a permanent set is generated to form a concave part and the remaining area is a convex part,
A method for manufacturing a relief panel, wherein a concave and convex pattern is formed by a concave portion and a convex portion. 2. A relief panel having a concave and convex pattern formed on a surface of a synthetic resin foam-based plate material,
A relief panel, wherein a cut is formed at the boundary between the concave portion and the convex portion so as to remain within the thickness from the surface, and at least the concave portion is compressed and permanent strain remains. 3. A gantry on which a synthetic resin foam-based plate material is placed, a gantry provided to be movable up and down above the gantry, and a cutting blade protruding from a lower surface of the gantry. The cutting blade is also arranged along the contour of a desired pattern, and the hard holding mat is formed in a plurality of areas by the cutting blade biting. An apparatus for manufacturing a relief panel, wherein the apparatus is provided corresponding to a part of a surface of a plate material classified into the following.