JP3985777B2 - Manufacturing method of composite molded product - Google Patents

Description

  The present invention relates to a method for producing a composite molded article, and more particularly to a method for producing a composite molded article produced by attaching a cosmetic material to a surface of a substrate having a curved surface or irregularities on a part of the surface.

  Conventionally, as luxury furniture materials and luxury passenger car interior materials, etc., from a base material made of wood board or synthetic resin board and a decorative material made of wood board or synthetic resin board stuck on the surface of this base material A composite molded product is used.

  As a method for producing such a composite molded article, there is a method in which a cosmetic material is attached to the entire surface of a base material via an adhesive and then applied to the entire surface of the cosmetic material (for example, Patent Document 1, (See Patent Document 2 and Patent Document 3.)

  However, in the conventional method for producing a composite molded article, when a decorative material is stuck on the surface of the base material, the corner portion extending from the surface of the base material to the end face (side surface) or the uneven portion on the surface of the base material is stuck. It was easy to cause poor wearing, and it was difficult to stick the cosmetic material firmly. In addition, wrinkles and cracks due to poor adhesion may occur on the surface of the decorative material adhered to the corners and irregularities of the base material, and the cosmetic material is easily peeled off from the base material due to poor adhesion. It was.

  In particular, when a cosmetic material is applied separately on the surface and the end surface of the base material, the cosmetic material applied on the surface and the cosmetic material applied on the end surface meet at the corner of the base material. Therefore, if the corner of the resulting composite molded product is formed into a curved surface, one of the decorative materials must be pasted up to the curved surface, and it is easy to peel off, so that a gap is provided to avoid the curved surface at the corner. Was.

In this way, when a plurality of decorative materials are applied to the surface of the base material or to the surface and the end surface, a decorative material is applied with a gap between the decorative material and the decorative material. When coating with a paint that uses a different organic solvent as the solvent, the organic solvent penetrates into the interface between the base material and the cosmetic material, and the adhesive that pastes the base material and the cosmetic material dissolves in this organic solvent. The cosmetic material may be peeled off from the base material.
JP-A-8-155914 Japanese Utility Model Publication No. 6-30391 Japanese Utility Model Publication No. 6-35582

  The present invention has been made in view of the above circumstances, and the cosmetic material is peeled off from the base material when a composite material is obtained by sticking the cosmetic material on the surface of the base material having a curved surface or unevenness on a part of the surface. It aims at providing the manufacturing method of the composite molded product which prevents this.

  The present invention relates to a method for producing a composite molded article comprising a base material, and a decorative material having a gap portion provided at a corner portion extending from the surface to the end portion of the base material. Provided is a method for producing a composite molded article in which a non-organic solvent paint is applied in a part.

  The present invention relates to a method for producing a composite molded article comprising a base material and a decorative material adhered to the surface of the base material, the corner portion being sandwiched between corners extending from the surface of the base material to the end surface. Then, the decorative material is attached to the surface and end surface of the base material, the corner portion of the base material to which the decorative material is attached is cut, and at least the non-organic solvent paint is applied in the gap portion. A method for producing a composite molded article is provided.

  In the method for producing a composite molded article, the non-organic solvent paint is preferably an aqueous paint or an ultraviolet curable paint.

  According to the method for producing a composite molded product of the present invention, the decorative material is adhered to the surface of the base material so that the unevenly shaped portion on the surface of the base material is disposed in the gap provided between the decorative materials. In this case, since the decorative material is not attached onto the concave / convex shaped portion, no defective attachment occurs between the base material and the decorative material. Also, if a non-organic solvent paint is applied to the gap, it is a water-based paint or UV curable paint that does not contain an organic solvent, so the adhesive that bonds the base material to the cosmetic material dissolves in the organic solvent. Thus, the phenomenon that the decorative material is peeled off from the base material does not occur.

  Further, at the corner from the surface of the base material to the end face, when a decorative material is stuck on the surface and end face of the base material, the corner of the decorative material is subjected to R chamfering or the like to form a gap portion, If a non-organic solvent paint is applied to the part, the corner part of the composite molded product finally obtained can be slid to form a curved surface without peeling.

Hereinafter, the present invention will be described in detail.
FIG. 1 is a schematic perspective view showing a first embodiment of a method for producing a composite molded article of the present invention.
In the first embodiment of the method for producing a composite molded article of the present invention, first, as shown in FIG. 1A, a part of the surface of the base material 1 that has been subjected to predetermined shape processing (curved surface processing or the like). Adhere the cosmetics 2 and 2 to the (such as a flat part on which the cosmetic material is easy to attach) via an adhesive at a predetermined interval, and apply the cosmetic material between the cosmetics 2 and 2 The gap portion 3 is provided in a difficult curved surface portion. In addition, after adhering the decorative material 2 to the entire surface of the substrate 1, the gap 3 may be provided by cutting or the like. Concavities and convexities (concave / convex shaped portions 4) may be formed in the gap portion 3.

Next, as shown in FIG. 1B, a non-organic solvent paint is applied so as to fill the gap 3 and cover the surface 4 a of the concavo-convex shaped portion 4, and then dried to form the colored layer 5. At this time, the upper surface of the decorative material 2 may be masked so that the paint is not applied.
Thereafter, as shown in FIG. 1 (c), a top coat is applied on the decorative material 2 and the colored layer 5 and then dried to form a surface layer 6, thereby obtaining a composite molded article 10.

  As the base material 1, MDF (medium density fiberboard), particle board, plywood, OSB (oriented strand board), wood materials such as various solid materials, acrylonitrile-butadiene-styrene copolymer (ABS) resin, A resin material made of acrylonitrile-styrene copolymer (AS) resin, acrylic resin, polycarbonate resin, polyester resin, polyurethane resin, phenol resin, melamine resin, fiber reinforced plastic (FRP), or the like is used. Moreover, as the base material 1, what consists of a single layer or multiple layers of these woody materials and resin materials is also used.

  The decorative material 2 includes wood veneer such as various solid materials, paper, polyvinyl chloride resin, polyethylene resin, polypropylene resin, polystyrene resin, polyester resin, polyurethane resin, ethylene-vinyl acetate copolymer resin, polymethyl methacrylate resin. A resin sheet made of polyethylene terephthalate resin, polybutylene terephthalate resin, polyvinylidene chloride resin, polyvinyl alcohol resin, polymethylpentene resin, ethylene-vinyl alcohol copolymer resin, polyacrylonitrile resin, polycarbonate resin, or the like is used. Further, as the decorative material 2, a material such as a wood veneer, paper, a resin sheet, or the like on which the surface is printed with various patterns or designs can also be used.

  Adhesives used when adhering the decorative material 2 to the surface of the substrate 1 are vinyl acetate resin adhesive, acrylic resin adhesive, vinyl acetate-acrylic resin adhesive, vinyl acetate-polyvinyl chloride resin adhesive. , Ethylene-vinyl acetate copolymer resin adhesive, ethylene-acrylic resin adhesive, polyvinyl alcohol resin adhesive, urea resin adhesive, various rubber adhesives, α-olefin adhesive, urethane resin emulsion adhesive, etc. It is done.

  Non-organic solvent paints for forming the colored layer 5 include water-based alkyd resin paints, water-soluble acrylic resin paints, water-based epoxy resin paints, water-based urethane resin paints, acrylic resin emulsion paints, vinyl acetate emulsion resin paints, acrylic-styrene emulsions. Water-based paints such as resin paints and ultraviolet curable paints such as solventless urethane acrylate resins are used.

  As the top coat for forming the surface layer 6, urethane resin paint, water-based urethane resin paint, lacquer, unsaturated polyester resin paint, urethane acrylate resin paint, or a mixed paint thereof is used.

Here, the base material, the decorative material, the adhesive, the non-organic solvent paint and the top coat used in the method for producing a composite molded article of the present invention are shown in Table 1.
Table 2 shows examples of combinations of the base material, the decorative material, the adhesive, the non-organic solvent paint, and the top coat in the method for producing the composite molded article of the present invention.

In this embodiment, when the decorative materials 2 and 2 are attached to the surface of the base material 1, the gap 3 is provided between them. The width of the gap 3 can be arbitrarily set.
In particular, it is preferable that the gap 3 formed on the surface of the base material 1 has a gap 3 so that the bump 4 can be accommodated in the gap 3. Alternatively, after the decorative material 2 is adhered to the entire surface, the gap 3 may be cut until the base material 1 is exposed to form the gap 3 and the concavo-convex shaped portion 4. In this way, if the decorative materials 2 and 2 are attached to the surface of the base material 1 so that the concave / convex shaped portion 4 on the surface of the base material 1 is disposed in the gap 3, the decorative materials 2 and 2 are Since it is not stuck on the concavo-convex shaped part 4, no sticking failure occurs between the base material and the decorative material.
Next, a non-organic solvent paint is applied to form the colored layer 5 so as to completely cover the concavo-convex shaped portion 4 in the gap portion 3 and to have substantially the same height as the decorative materials 2 and 2.

  The non-organic solvent paint applied in the gap 3 is an aqueous paint or an ultraviolet curable paint that does not contain an organic solvent, so that the organic solvent penetrates into the interface between the base material 1 and the decorative material 2, and the base material There is no possibility that the adhesive bonding 1 and the decorative material 2 is dissolved in the organic solvent and the decorative material 2 is peeled off from the base material 1. That is, if a non-organic solvent paint is used as the colored layer 5 applied in the gap 3, the base material 1 and the decorative material 2 can be maintained in a state of being firmly bonded by the adhesive as described above. Can do.

FIG. 2 is a schematic cross-sectional view showing a second embodiment of the method for producing a composite molded article of the present invention.
In the second embodiment of the method for producing a composite molded article of the present invention, first, as shown in FIG. 2 (a), the end surface from the surface 11b of the base material 11 is applied to the base material 11 that has been subjected to predetermined shape processing. (Surface) The decorative material 12 is stuck to the surface 11b of the base material 11 via an adhesive so that the gap portion 14 is provided at the corner portion 11a reaching the side surface 11c. The decorative material 13 is stuck to the end surface (side surface) 11c of the adhesive layer via an adhesive.
Next, as shown in FIG. 2B, a non-organic solvent paint is applied so as to fill the gap portion 14 and then dried to form the colored layer 15. At this time, a non-organic solvent paint is applied in the gap 14 so that the surface of the colored layer 15 forms a curved surface, or a decorative process such as an R chamfering process is performed after the colored layer 15 is formed. And the surface of the colored layer 15 is curved.
Thereafter, as shown in FIG. 2 (c), a top coating is applied on the decorative materials 12, 13 and the colored layer 15 and then dried to form a surface layer 16, thereby obtaining a composite molded product 20.
In this embodiment, the same materials as those used in the first embodiment can be used as the base material 11, the decorative materials 12, 13, the adhesive, the non-organic solvent paint, the top coat paint, and the like.

  In this embodiment, the decorative material 12 is adhered to the surface 11b with the corner portion 11a sandwiched so that the gap portion 14 is provided in the corner portion 11a of the base material 11, and the decorative material 13 is applied to the end surface (side surface) 11c. Adhering and applying a non-organic solvent paint in the gap portion 14 so that the surface of the colored layer 15 forms a curved surface, or after forming the colored layer 15, a decorative process such as R chamfering When the surface of the colored layer 15 is curved, the corners of the finally obtained composite molded product 20 can be formed into a smooth curved surface.

  Similarly to the above-described first embodiment, when unevenness is formed on the surface near the corner of the base material 11, the interval between the gap portions 14 can be accommodated in the gap portion 14. Is preferable. In this way, the uneven modeling part on the surface of the base material 11 is arranged in the gap part 14, and the non-organic solvent paint is applied in the gap part 14 so as to completely cover the uneven modeling part. 15 may be formed.

  Since the non-organic solvent paint is applied in the gap 14, the organic solvent penetrates into the interface between the base material 11 and the decorative materials 12 and 13, and the base material 11 and the decorative materials 12 and 13 are adhered. The adhesive is not dissolved in the organic solvent and the decorative materials 12 and 13 are not peeled off from the base material 11.

FIG. 3 is a schematic cross-sectional view showing a third embodiment of the method for producing a composite molded article of the present invention.
In 3rd Embodiment of the manufacturing method of the composite molded product of this invention, as shown to Fig.3 (a), first, the end surface from the surface 21b of the base material 21 is given to the base material 21 to which the predetermined shape process was given. The decorative material 22 is attached to the surface 21b of the base material 21 with an adhesive across the corner 21a reaching 21c, and the decorative material 23 is attached to the end face (side surface) 21c of the base material 21 with the adhesive. And stick.

Next, as shown in FIG. 3B, decoration processing such as R chamfering is performed on the end portions of the decorative materials 22 and 23 and the corner portions 21 a of the base material 21.
Next, as shown in FIG. 3 (c), a non-organic solvent paint is applied to the edges and the gaps 24 of the decorative materials 22 and 23 that have been decorated, and then dried to form a colored layer 25.

Thereafter, as shown in FIG. 3 (d), a top coating is applied on the decorative materials 22, 23 and the colored layer 25 and then dried to form a surface layer 26, thereby obtaining a composite molded product 30.
In this embodiment, the same materials as those used in the first embodiment can be used as the base material 21, the decorative materials 22, 23, the adhesive, the non-organic solvent paint, the top coat paint, and the like.

  In this embodiment, the decorative material 22 is attached to the surface 21b with the corner portion 21a interposed therebetween, the decorative material 23 is attached to the end surface (side surface) 21c, and the end portions of the decorative materials 22 and 23 and the corner portion 21a are attached. After applying a decorative process such as an R chamfering process, if a colored layer 25 is formed by applying a non-organic solvent paint to the corner 21a (gap 24), the surface of the colored layer 25 becomes a curved surface. The corners of the composite molded product 30 obtained can be formed into a smooth curved surface.

  Further, since the non-organic solvent paint is applied in the gap 24, the organic solvent penetrates into the interface between the base material 21 and the decorative materials 22, 23, and the base material 21 and the decorative materials 22, 23 are adhered. The adhesive is not dissolved in the organic solvent and the decorative materials 22 and 23 are not peeled off from the base material 21.

  Specific examples will be described below.

(Example)
First, a decorative material made of a polyvinyl chloride resin sheet was adhered to the front and back surfaces of the three-layer laminated MDF of the base material via a urethane resin emulsion adhesive.
Next, trimming was performed on the composite made of MDF and the decorative material to obtain a predetermined shape.
Thereafter, a decorative material made of a polyvinyl chloride resin sheet is attached to the side surface of the composite via an ethylene-vinyl acetate copolymer resin adhesive, and the decorative material is attached to the entire surface of the MDF. A complex was obtained.
Next, R corner chamfering was performed on the corner portion of the composite to form the corner portion into a curved surface.
Next, a water-based paint was applied so as to fill the gaps obtained by the R chamfering process, followed by drying to form a colored layer.
Thereafter, a urethane resin paint was applied to the entire surface of the composite and then dried to obtain a composite molded product.

  In the composite molded product obtained in the examples, the decorative material was not peeled off from the MDF of the base material.

It is a schematic perspective view which shows 1st Embodiment of the manufacturing method of the composite molded product of this invention. It is a schematic sectional drawing which shows 2nd Embodiment of the manufacturing method of the composite molded product of this invention. It is a schematic sectional drawing which shows 3rd Embodiment of the manufacturing method of the composite molded product of this invention.

Explanation of symbols

1, 11, 21 ... base material, 2, 12, 13, 22, 23 ... decorative material, 11a, 21a ... corner, 3, 14, 24 ... gap, 4 ... Concavity and convexity formation part, 4a ... surface, 5, 15, 25 ... colored layer, 6, 16, 26 ... surface layer, 10, 20, 30 ... composite molded product.

Claims (3)

In a method for producing a composite molded article comprising a base material, and a decorative material provided with a gap provided at a corner from the surface to the end of the base material and attached thereto,
A method for producing a composite molded article, wherein a non-organic solvent paint is applied at least in the gap. In a method for producing a composite molded article comprising a base material and a decorative material attached to the surface of the base material,
At the corner from the surface of the substrate to the end surface, the corner is sandwiched, and the cosmetic material is adhered to the surface and end surface of the substrate, and the corner of the substrate to which the cosmetic material is adhered is attached. A method for producing a composite molded article, comprising performing a cutting process and applying a non-organic solvent paint at least in the gap. In the manufacturing method of the composite molded product according to claim 1 or 2 ,
The method for producing a composite molded article, wherein the non-organic solvent paint is an aqueous paint or an ultraviolet curable paint.

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