JP7208626B2 - Decorative composite board and method for manufacturing drawn decorative composite board - Google Patents

Description

The present invention relates to a decorative composite board and a method for manufacturing a drawn decorative composite board.

Furniture, cabinets for electric appliances, doors, interior walls of buildings, etc. often have deep uneven patterns. Most of them are made by sticking a vinyl chloride sheet or the like printed with a veneer or wood grain pattern on a base material such as a particle board or plywood processed into a deep uneven pattern. Woodworking machines such as NC routers are used to form deep uneven patterns on substrates such as particle board and plywood, but the more complicated the shape, the more expensive the machine becomes. In addition, there is a drawback that the consumption of cutting tools is much higher than that of wood, and the processing cost is high.

On the other hand, a surface layer made of a thermosetting resin decorative board 1 deep-drawn in an arbitrary pattern in which convex parts surrounded by concave parts draw smooth curves toward the center, and this thermosetting resin decorative board An intermediate layer made of a synthetic resin foam 2 molded into an uneven shape according to the deep drawing pattern of , and an intermediate layer made of a synthetic resin foam 2 are laminated and integrated with a base material 4 via an adhesive layer 3. Patent document 1). According to this concave-convex decorative composite board, a thermosetting resin decorative board is used as a surface decorative material, a synthetic resin foam is interposed between it and the base material, and when integrated by an adhesive layer, the thermosetting resin By applying a texture imparting material of arbitrary shape to the surface of the decorative board and performing thermocompression molding, the characteristics such as elasticity and thermal deformation properties of the synthetic resin foam in the intermediate layer are effectively used to create a textured pattern on the base material. It is said that a deep-drawn pattern of arbitrary shape can be added to the thermosetting resin decorative board of the surface layer without applying.

In addition, in a processed top plate formed by bonding a thermosetting resin veneer to the surface of a wood core material via an adhesive, a part or a plurality of parts of the surface of the processed top plate has a draw-shaped concave portion. A processed top plate has been proposed (Patent Document 2). According to this drawn top plate, there is no cutting marks of the knife and no unevenness of the base material, and the appearance is excellent. It is said that a drawn top plate of a decorative plate which is excellent in quality and does not crack even if an object hits the surface of the decorative plate can be obtained.

Further, a molding material for FRP is laminated on the surface of a molding plate-like or mat-like base material mainly made of wood fiber, and the laminated material is heated and pressed using a mold material to be molded by drawing. has proposed a method for manufacturing a decorative molded body in which a base material is compressed and cured and an FRP decorative layer is integrally formed on the surface (Patent Document 3). As a result, unevenness can be formed on the surface of the decorative composite board for furniture, building interior materials, and the like.

Furthermore, after a plurality of plate-shaped objects are arranged adjacent to each other and pasted on the flat portion of the surface side of the plate substrate to which the decorative board of melamine resin is to be adhered, the side surface of the plate-shaped object is attached to the surface side of the plate-shaped object. A wooden base material has been proposed for post-form drawing in which curved surface processing is performed so as to extend from the top plate base material to the surface side of the top plate base material (Patent Document 4).

Furthermore, by inserting a wedge-shaped object from the periphery of the object obtained by flat-bonding the wooden core material and the thermosetting synthetic resin veneer, the concave drawing is formed without using male and female press dies. A method for producing a drawn product using such a thermosetting synthetic resin decorative board has been proposed (Patent Document 5).

Japanese Patent Publication No. 1-59103 JP-A-61-172735 Japanese Patent Publication No. 3-73448 JP-A-59-20648 Japanese Patent Publication No. 59-13350

However, in all of these decorative molded boards and their processing methods, since the surface is a synthetic resin layer such as a thermosetting resin, artificial objects are exposed, and it is difficult to enjoy the original beauty of natural wood grain. I couldn't do it. On the other hand, there has been proposed a method of imparting bendability by forming slits on the surface of the natural woody layer, but it is necessary to form slits in advance, and the slits expand during bending. There were problems such as cracking.

One of the objects of the present invention is to provide a decorative composite board which can be drawn while using a wooden board, and a manufacturing method of the drawn decorative composite board.

Means for solving the problem and effects of the invention

According to the decorative composite board according to the first aspect of the present invention, the decorative composite board comprises a core material containing a wood material, an intervening sheet covering the surface of the core material, and a surface of the intervening sheet covering the surface of the intervening sheet. A decorative composite board comprising: a decorative board having a wood grain on its surface; and a first adhesive that joins the core material and the intervening sheet, and the intervening sheet and the decorative board, wherein the intervening sheet is made of a thermoplastic resin wherein both surfaces of the wooden material are covered with the intervening sheets, and the surface of each intervening sheet is covered with the decorative board, and at least a part of the wooden material has a drawn curved surface. The drawn curved surface appears in a similar pattern on the front and back surfaces of the decorative composite plate, and the first adhesive is a vinyl acetate adhesive, a polypropylene adhesive, or a polyethylene adhesive An adhesive, an ethylene-vinyl acetate copolymer resin, or a mixture thereof can be used. With the above configuration, the adhesion and followability between the core material of the wooden material and the intervening sheet are improved, and three-dimensional drawing can be performed even on the wooden material. As a result, it is possible to process wooden materials to form irregularities and curved surfaces like metal plates and resin plates, expanding the use of wood materials, and is expected to contribute to the expansion of the use of wood in Japan. be. In addition, by enabling drawing, it is possible to increase the strength of even thin wooden materials.

Moreover, according to the decorative composite panel according to the second aspect of the present invention, in addition to the above configuration, the drawn curved surfaces may include curved surfaces that are bent in two mutually intersecting directions.

Furthermore, according to the decorative composite panel according to the third aspect of the present invention, in addition to any one of the above configurations, the intervening sheet can be made of nonwoven fabric or woven fabric.

Furthermore, according to the decorative composite board according to the fourth aspect of the present invention, in addition to any one of the above configurations, the intervening sheet is made of polypropylene-based fiber, polyester-based fiber, polyamide-based fiber, rayon-based fiber, or acrylic fiber. fiber, polyvinyl alcohol-based fiber, aramid-based fiber, glass-based fiber, or pulp fiber.

Furthermore, according to the decorative composite board according to the fifth aspect of the present invention, in addition to any one of the above configurations, the core material can be configured by laminating a plurality of wooden materials.

Furthermore, according to the decorative composite board according to the sixth aspect of the present invention, in addition to any one of the above configurations, a second adhesive is interposed between the plurality of wooden members, Two adhesives can be formed into sheets.

Furthermore, according to the decorative composite board according to the seventh aspect of the present invention, in addition to any one of the above configurations, the basis weight of the intervening sheet with respect to the wooden material is equal to the thickness of the intervening sheet. Converting to the above conditions, it can be 20 g/m ² to 70 g/m ² .

Furthermore, according to the method for manufacturing a drawn decorative composite panel according to the eighth aspect of the present invention, the method includes a core material containing a wood material, a decorative panel and an intervening sheet, and a first adhesive that bonds them together. a step of preparing a surface portion; a step of bonding the surface portions to both surfaces of the core material by heating via a second adhesive to obtain a decorative composite plate; and drawing the decorative composite plate to form a curved surface. and allowing the drawn curved surfaces to appear in the same pattern on the front and back surfaces of the decorative composite plate, wherein the intervening sheet may contain a thermoplastic resin, and the first adhesive may be a vinyl acetate-based adhesive, a polypropylene-based adhesive, a polyethylene-based adhesive, an ethylene-vinyl acetate copolymer-based resin, or a mixture of these adhesives. can. As a result, the adhesion and followability between the core material of the wooden material and the intervening sheet are improved, and three-dimensional drawing can be performed even on the wooden material. As a result, it is possible to process wooden materials to form irregularities and curved surfaces like metal plates and resin plates, expanding the use of wood materials, and is expected to contribute to the expansion of the use of wood in Japan. be. In addition, by enabling drawing, it is possible to increase the strength of even thin wooden materials.

Furthermore, according to the method for manufacturing a drawn decorative composite board according to the ninth aspect of the present invention, in addition to any of the above, the step of preparing the surface portion comprises: the decorative board and the first adhesive In the state in which the intervening sheet and the intervening sheet are laminated, the first adhesive can be melted and bonded by hot pressing.

Furthermore, according to the method for manufacturing a drawn decorative composite panel according to the tenth aspect of the present invention, in addition to any of the above, the step of preparing the core material includes forming a plurality of wooden materials into sheets. obtaining a laminate by sandwiching the second adhesive made of a thermoplastic resin formed into a shape; and gluing the material together.

Furthermore, according to the method for manufacturing a drawn decorative composite board according to the eleventh aspect of the present invention, the decorative board and the intervening sheet and the first bonding for bonding these are respectively on both sides of the core material containing the wood material. A step of obtaining a decorative composite plate by laminating the surface portion containing the material via a second adhesive and joining by heating to obtain a decorative composite plate, drawing the decorative composite plate to form a curved surface, and A method for manufacturing a drawn decorative composite board, comprising a step of exposing curved surfaces in a similar pattern on the front and back surfaces of the decorative composite board, wherein the intermediate sheet contains a thermoplastic resin, and the intervening sheet contains a thermoplastic resin; The first adhesive is a vinyl acetate-based adhesive, a polypropylene-based adhesive, a polyethylene-based adhesive, an ethylene-vinyl acetate copolymer-based resin, or a mixture of these adhesives.

Furthermore, according to the method for manufacturing a drawn decorative composite plate according to the twelfth aspect of the present invention, in addition to the above, the step of forming a curved surface on the decorative composite plate is the step of obtaining the decorative composite plate. can be formed by pressing while maintaining the heated state. As a result, drawing can be performed even using a cold mold by utilizing the heating during the formation of the decorative composite board, and the drawing of wooden materials with good thermal efficiency is realized.

Furthermore, according to the method for manufacturing a drawn decorative composite plate according to the thirteenth aspect of the present invention, in addition to any of the above, the step of drawing the decorative composite plate to form a curved surface. The step of drawing the decorative composite plate to form a curved surface includes the step of drawing the decorative composite plate and drawing the cut decorative composite plate by cold pressing. be able to. As a result, the decorative composite board can be formed into a desired shape and then subjected to further drawing processing, so that curved members, which have been difficult to achieve with conventional wooden boards, can be realized with the decorative composite board.
Furthermore, according to the method for manufacturing a drawn decorative composite panel according to the fourteenth aspect of the present invention, in addition to any of the above, the drawn curved surfaces are bent in two mutually intersecting directions. can contain curved surfaces.

1 is an exploded perspective view showing a decorative composite board according to an embodiment of the present invention; FIG. 2 is a cross-sectional view of the decorative composite plate of FIG. 1; FIG. 1 is a schematic cross-sectional view of a decorative composite plate obtained by a method for manufacturing a decorative composite plate according to Embodiment 1. FIG. FIG. 4 is a schematic exploded perspective view showing how surface portions are joined to both surfaces of a core material. FIG. 3 is an exploded perspective view showing how a decorative composite plate is drawn using a mold. FIG. 2 is a perspective view of a decorative composite plate with curved surfaces; FIG. 10 is a perspective view of a chair with a folded decorative composite panel; FIG. 8 is a plan view showing how the decorative composite plate is cut in the development view of the chair of FIG. 7; FIG. 9 is a perspective view showing how the decorative composite plate cut in the developed view of FIG. 8 is formed into a curved surface using a core. It is a perspective view of a chair according to a modification. FIG. 4 is a perspective view showing a decorative composite plate that is bent in a crossing direction; Figure 10 is a plan view of the chair of Figure 9; FIG. 11 is a plan view of a chair according to another modified example; FIG. 11 is a perspective view showing a wooden tray according to another embodiment; FIG. 11 is a perspective view showing a wooden container according to still another embodiment;

BEST MODE FOR CARRYING OUT THE INVENTION Hereinafter, embodiments of the present invention will be described with reference to the drawings. However, the embodiments shown below are examples for embodying the technical idea of the present invention, and the present invention is not limited to the following. In addition, this specification does not specify the members shown in the claims as the members of the embodiment. In particular, unless there is a specific description, the dimensions, materials, shapes, relative arrangements, etc. of the components described in the embodiment are not intended to limit the scope of the present invention, but are merely illustrative examples. It's nothing more than Note that the sizes and positional relationships of members shown in each drawing may be exaggerated for clarity of explanation. Furthermore, in the following description, the same names and symbols indicate the same or homogeneous members, and detailed description thereof will be omitted as appropriate. Furthermore, each of the elements constituting the present invention may be configured with the same member so that a single member may serve as a plurality of elements, or conversely, the function of one member may be performed by a plurality of members. It can also be realized by sharing.
[Embodiment 1]

FIG. 1 is an exploded perspective view showing a decorative composite board according to Embodiment 1 of the present invention, and FIG. 2 is a cross-sectional view of the decorative composite board shown in FIG. The decorative composite board 100 shown in these figures includes a core material 10 , an intervening sheet 20 and a decorative board 30 .
(Core material 10)

Core material 10 includes wooden material 12 . The wooden material 12 is composed of a wooden member such as a veneer.

Further, the core material 10 is preferably constructed by laminating a plurality of wooden materials 12 . In this case, a second adhesive 14 is interposed between the plurality of wooden members 12 . The second adhesive 14 can be made of a thermoplastic resin. For example, polypropylene-based resin, ethylene-vinyl acetate copolymer-based resin (EVA-based resin), polyvinyl alcohol-based resin, polyurethane-based resin, or the like can be used for the second adhesive 14 . Polypropylene-based resin adhesives and EVA are particularly preferable because they have a low melting point, do not damage wooden materials, have high strength, have low hygroscopicity, and are inexpensive.

Further, the second adhesive material 14 made of thermoplastic resin is preferably formed in a sheet shape as shown in FIG. As a result, it is integrally adhered to the core material 10 by hot pressing during manufacturing, and the followability at the time of bending is improved.
(Interposition sheet 20)

The intervening sheets 20 respectively cover the surfaces of the core material 10 . Preferably, the intervening sheet 20 is made of thermoplastic resin. Moreover, the intervening sheet 20 preferably contains a nonwoven fabric or a woven fabric. Specifically, polypropylene fibers, polyester fibers, polyamide fibers, rayon fibers, acrylic fibers, polyvinyl alcohol fibers, aramid fibers, glass fibers, pulp fibers, etc. can constitute nonwoven fabrics and woven fabrics. .
(Decorative board 30)

The decorative plate 30 covers the surface of each intervening sheet 20 respectively. Wood grain is displayed on the surface of the decorative board 30. - 特許庁The veneer is made of wood material.
(First adhesive 40)

Also, the core material 10 and the intervening sheet 20, and the intervening sheet 20 and the decorative board 30 are joined with the first adhesive 40, respectively. A vinyl acetate-based adhesive is used as the first adhesive 40 . Also, the first adhesive 40 can be made of the same thermoplastic resin as the second adhesive 14 . For example, vinyl acetate-based adhesives, polypropylene-based resins, polyethylene-based resins, ethylene-vinyl acetate copolymer-based resins (EVA-based resins), polyurethane-based resins, and polyamide-based resins can be used as the first adhesive 40 .

In the above example, a laminated structure is adopted in which both surfaces of the core material 10 are covered with the intervening sheets 20 and the decorative sheets 30, respectively. However, the present invention is not limited to this configuration, and a configuration in which only one surface of the core material is covered with the intervening sheet and the decorative plate 30 and the other surface is not covered may be employed. This makes it possible to reduce the thickness and cost when applying to a configuration in which only one side is exposed, for example, a signboard or the surface portion 50 having unevenness.
[Method for manufacturing decorative composite plate according to Embodiment 1]

Next, a method for manufacturing this decorative composite plate will be described. Here, as shown in the exploded perspective view of FIG. 4, the decorative composite plate 100 is divided into three parts: the core material 10 and the surface parts 50 laminated on both sides of the core material 10, respectively. The surface portion 50 is composed of the decorative plate 30, the intervening sheet 20, and the second wooden material 12B. A first adhesive material 40 is interposed on each surface of the intervening sheet 20 to adhere to the decorative board 30 and the second wooden material 12B. The surface portions 50 are joined to both surfaces of the core member 10 with the second wooden member 12B side of the surface portion 50 facing the core member 10 . A second adhesive 14 is used for bonding. As shown in the cross-sectional view of FIG. 3 , the bonded decorative composite board 100 is formed by attaching decorative boards 30 is placed. The second wooden material 12B may be made of the same material as the wooden material 12 and may have the same thickness. In this case, the configuration is similar to that of FIG. However, the second wooden material 12B may be made of a material different from that of the wooden material of the core material 10, or may have a different thickness.

As the members constituting the surface portion 50, for example, the second wooden material 12B is a heather with a thickness of 0.2 mm to 0.6 mm, the intervening sheet 20 is a polypropylene resin non-woven fabric, and the decorative plate 30 is 0.8 mm to 2 mm in thickness. A veneer of .0 mm or the like can be used, respectively. In the embodiment, the second wooden material 12B is made of 0.25 mm thick beech heather, the intervening sheet 20 is made of polypropylene resin of 40 g/m ² , and the decorative board 30 is made of veneer with a thickness of 1.0 mm. . The surface portion 50 can be formed by heat pressing or the like that heats and presses the second wooden material 12B, the intervening sheet 20, and the decorative board 30 in a laminated state.

The surface portions 50 thus obtained are joined to both surfaces of the core material 10 . The core material 10 may be a laminate of a plurality of wooden materials, or may be a single plate. In the embodiment, as shown in the perspective view of FIG. 4, three sheets of 1.0 mm thick heather are laminated and adhered with the second adhesive 14 . A surface portion 50 is bonded to each surface of the core material 10 with a second adhesive 14 . Here, too, the core member 10 and the surface portion 50 are joined together by hot pressing or the like that applies heat and pressure while interposing the second adhesive 14 of thermoplastic resin between them. Thereby, the decorative composite board 100 is formed.

Furthermore, the decorative composite plate 100 that has been hot-pressed and heated is formed with a curved surface by deep drawing. At this time, by cold-pressing the already heated decorative composite plate 100 before it is cooled, it is unnecessary to heat a mold such as a metal mold or wooden mold or a press plate, and cold pressing is performed. Energy for heating is reduced, and efficient molding becomes possible. Here, cold pressurization refers to a state of pressurization without applying heat, and is also called cold press, cold press, or the like. Cold pressurization is preferably cold isostatic pressurization. In the example shown in the exploded perspective view of FIG. 5, a mold DI such as a metal mold or a wooden mold is prepared in advance on the pole surface to be formed on the decorative composite panel 100, and the mold is hot-pressed without being particularly heated. A curved surface is formed by pressing the decorative composite plate 100 already in a heated state. As a result, a decorative composite panel 100 having a curved surface as shown in the perspective view of FIG. 6 is obtained.

It goes without saying that either the core material 10 or the surface part 50 may be prepared first in the step of preparing the core material 10 and the surface part 50 in the above-described method.
[Method for manufacturing decorative composite plate according to Embodiment 2]

In the above method, the method of directly molding the decorative composite plate 100 in which the surface portion 50 and the core material 10 are joined has been described. The method is not limited to this method, and drawing may be performed after the obtained flat plate-like decorative composite plate is once adjusted in shape by a method such as die-cutting. As a result, it becomes possible to draw a decorative composite board in a desired shape, and a curved surface-shaped member, which has been difficult to achieve with a conventional wooden board, can be realized with the decorative composite board. For example, a chair CH1 as shown in FIG. 7 can be made of a wooden decorative composite board. Such a method will be described below as a method for manufacturing a decorative composite panel according to the second embodiment. First, the core material 10 and the surface portion 50 are respectively prepared. Then, the surface portion 50 is joined to the surface of the core material 10 via the second adhesive 14 by heating to obtain the decorative composite plate 100 . The steps up to this point are the same as the method according to the first embodiment described above.

Next, the obtained decorative composite board 100 is cut into a desired shape. For example, the decorative composite plate 100 is punched into a desired shape by punching with a Thomson die or the like, as shown in FIG. Here, an example of die-cutting the developed view of the chair in FIG. 7 is shown. In addition, any processing method capable of cutting the decorative composite plate, such as cutting or cutting using a lathe or a saw, can be used without being limited to die-cutting.

In addition, it is necessary to harden the decorative composite plate once during processing such as die-cutting. Therefore, the decorative composite plate 100 having the surface portion 50 joined to the core material 10 by hot pressing is cold-pressed or naturally cooled to harden the second adhesive 14 . Then, the cooled and hardened decorative composite board 100 is subjected to cutting such as die cutting.

Then, the decorative composite plate 100 cut into a desired shape is subjected to deep drawing. For example, the die-cut decorative composite plate 100 is heated again by a method such as a hot press that involves heating and pressing, and then cold-pressed to bend it into a desired shape. Here, the decorative composite panel 100 cut into the developed view of FIG. 8 is formed into a curved surface using a core CR as shown in FIG. In this specification, heat press or heat press can be applied by a method of heating and pressing a flat plate, a method of heating a mold, or the like. The chair-shaped decorative composite plate 100 is cooled and hardened, and then removed from the mold to obtain a chair. In addition, in the chair CH2 shown in FIG. 10 according to the modified example, the upper edge is further curved after FIG. To achieve this, a separate mold can be used or the core of FIG. 9 can be preformed with a curvature of the upper edge.
[Method for manufacturing decorative composite plate according to Embodiment 3]

In the manufacturing method of the decorative composite plate described above, the procedure of once preparing the surface portion 50 and then adhering the surface portion 50 to each surface of the core material 10 has been described. However, the present invention is not limited to this method, and can also be formed by laminating the surface portion and the core material collectively. Such a procedure will be described below as a method for manufacturing a decorative composite panel according to Example 3.

First, a decorative composite board is constructed. Here, the decorative board 30, the first adhesive 40, the intervening sheet 20, the first adhesive 40, the second wooden material 12B, the second adhesive 14, the core material 12, the second adhesive 14, the second wooden material 12B , the first adhesive 40, the intervening sheet 20, the first adhesive 40, and the decorative board 30 are laminated. Sheet-like materials are used for the first adhesive 40 and the second adhesive 14 . Heating and pressurization are performed in a state in which these are laminated. Then, the obtained decorative composite plate is subjected to drawing by cold pressurization in the heated state in the same manner as in Example 1 to form a curved surface. As a result, the decorative composite board 100 can be obtained collectively without separately preparing the decorative board 30, and it is also possible to form a curved surface.
[Method for manufacturing decorative composite plate according to Embodiment 4]

Furthermore, in the method of collectively obtaining a decorative composite board, as in Example 2, die-cutting may be followed by drawing. Such a procedure will be described below as a method for manufacturing a decorative composite panel according to Example 4.

First, a decorative composite board is constructed. Here, as in Example 3, the decorative board 30, the first adhesive 40, the intervening sheet 20, the first adhesive 40, the second wooden material 12B, the second adhesive 14, the core 12, and the second adhesive 14 , the second wooden material 12B, the first adhesive material 40, the intervening sheet 20, the first adhesive material 40, and the decorative board 30 are laminated, and heat and pressure are applied in the laminated state. Then, the obtained decorative composite plate is cold-heated to cure the first adhesive 40 and the second adhesive 14 . In this state, it is die-cut into a desired shape in the same manner as in the second embodiment. By curing the adhesive by temporarily cooling or the like in this way, a decorative composite board having a stable shape can be obtained, and processing such as cutting and die cutting becomes possible.

Then, the decorative composite plate 100 cut into a desired shape is drawn in the same manner as in the second embodiment. First, the die-cut decorative composite plate 100 is heated again by a method such as a hot press in which heat and pressure are applied, and then cold-pressed to bend it into a desired shape. Thus, it is possible to obtain the decorative composite plate 100 without preparing the decorative plate 30, and to form a curved surface after once curing and processing such as cutting and die cutting.

By such a method, a curved surface can be formed by drawing on the die-cut decorative composite plate. That is, as shown in the perspective view of FIG. 11, with the conventional wooden board, when the wooden board is bent in a crossing direction, cracks occur, making it difficult to draw the board with a good appearance. According to the manufacturing method of the drawn decorative composite board according to the embodiment, it is possible to bend the board in the intersecting direction while maintaining a fine surface finish. The reason is as follows. This decorative composite board has a three-layer structure of a core material and decorative boards on both sides thereof. Here, the non-woven fabric of the intervening sheet interposed between the wooden materials such as the heather and the veneer acts as a reinforcement in the direction of cracking of the wooden material. Due to the strength and extensibility of this intervening sheet, even minute cracks that are not visible to the naked eye are evenly generated in the wooden material during the drawing process, while absorbing and correcting the dimensional changes due to the deformation to follow the drawing process. is realized. In addition, the heather and the veneer are aligned so that the wood grain is in the same direction. This makes it possible to intentionally define the direction in which cracking occurs.

On the other hand, the core material is composed of laminated single plates. Here, the wood grains of each layer are arranged so as to intersect alternately. Thus, the alternately arranged grains suppress cracking of each layer. Further, the layers are semi-bonded with a thermoplastic resin adhesive, and drawing is performed. Such a semi-bonded state allows slippage between the layers to allow deformation.

Further, in the example of the chair described above, as shown in the plan view of FIG. 12, the seams where the backrest and the armrest are joined are overlapped. However, the present invention is not limited to this example, and like a chair CH3 according to another modified example shown in FIG. As a result, it is possible to finish a flat surface without causing a large difference in level at the seams.

In this specification, the term "drawing" means a process of curving a decorative composite board, in which the curving directions are not parallel but at least intersect. For example, the bending part itself is curved like a spherical surface, and the edge is curved along the opening edge. Processing such as bending only is not included. In particular, wooden materials are relatively easy to bend in parallel directions, but when the bending directions intersect each other, the directionality of the wood grain causes them to crack easily. On the other hand, the decorative composite panel according to the present embodiment is capable of bending in such intersecting directions. In this specification, not only the bottomed cylindrical shape obtained by pressing the plate into the hole of the die with a punch, but also the stretch forming in which the plate material is formed into a curved surface by applying surface pressure. Include in drawing process.

The basis weight of the intervening sheet 20 with respect to the wooden material 12 is preferably 20 g/m ² to 70 g/m ² in terms of equal thicknesses of the wooden material 12 and the intervening sheet 20 . With this range, the strength balance between the intervening sheet 20 and the decorative plate 30 can be appropriately maintained. If the weight per unit area is less than 20 g/m ² or greater than 70 g/m ² , grain splitting occurs during drawing. By setting the basis weight in the range of 20 g/m ² to 70 g/m ² , the displacement of the decorative plate 30 is dispersed without concentrating the cracks during the drawing process, and the surface is curved by causing minute cracks. It is possible to bend following the .

The decorative composite board obtained in this way has improved adhesion and conformability between the core material of the wooden material and the intervening sheet, and the wooden material can also be subjected to three-dimensional drawing processing, vacuum forming press, etc. becomes. As a result, it is possible to process wooden materials to form irregularities and curved surfaces like metal plates and resin plates, expanding the use of wood materials, and is expected to contribute to the expansion of the use of wood in Japan. be. In addition, by enabling drawing, it is possible to increase the strength of even thin wooden materials.

In addition, in conventional processing of a wooden board, although it is possible to bend the wooden board only in one direction (for example, the X direction) as described above, it is possible to bend the wooden board in two intersecting directions (for example, the X direction and the Y direction). It was difficult to bend. That is, there is a problem that when a wooden board is subjected to three-dimensional drawing, cracks occur and the appearance becomes poor.

On the other hand, according to the decorative composite plate according to the present embodiment, it is possible to realize the decorative composite plate 100 with improved followability, which is less likely to crack even when bent in two intersecting directions. This is because the intervening sheet 20 of thermoplastic resin is used when the core member 10 and the decorative plate 30 are joined together. Conventional wooden boards that are supposed to be bent use thermosetting resins from the standpoint of workability and ease of manufacture, but thermoplastic resins heat the wooden boards when they are bent. In this case, there is a problem that the already hardened intervening sheet is difficult to bend and cracks occur at this portion. On the other hand, if the thermoplastic resin is heated at the time of folding, the intervening sheet softens again, so that it can easily follow the deformation of the wooden board. In addition, by using a vinyl acetate-based adhesive, which is also a thermoplastic resin, for the first adhesive 40 that bonds such an intervening sheet to the core material and the decorative board, when the wooden board is heated at the time of folding, Furthermore, since the already hardened resin layer of the adhesive is also softened again, the core material and the decorative board are easily bent together through the intervening sheet, so that the following deformation is further enhanced, and the wood board is improved. However, three-dimensional drawing is realized. For example, when forming an integral chair, for example, a cell-type chair, with a wooden board, conventionally, only the backrest portion could be bent at most. It is possible to form the elbow rest part together, which increases the degree of freedom in processing and realizes a decorative composite board that can be adapted to various shapes.

In addition, articles formed using the decorative composite board 100 are not limited to chairs, and can be applied to various items made of wooden boards. For example, as shown in FIG. 14, a concave wooden tray 2 can be formed by drawing, or as shown in FIG. 15, a wooden container 3 with curved edges can be formed.

The method for manufacturing a decorative composite board and a drawn decorative composite board according to the present invention is a wooden article such as a chair, a tray, a container, etc., which is formed by bending or drawing a wooden board in an intersecting direction. can be suitably used as a material for

DESCRIPTION OF SYMBOLS 100... Decorative composite board 2... Wooden tray 3... Wooden container 10... Core material 12... Wooden material; Surface part DI... type CR... core CH1, CH2, CH3... chair

Claims (14)

A decorative composite board,
a core material comprising a wood material;
an intervening sheet covering the surface of the core material;
a decorative board showing wood grain on the surface covering the surface of the intervening sheet;
A decorative composite board comprising the core material, an intervening sheet, and a first adhesive that joins the intervening sheet and the decorative board,
The intervening sheet contains a thermoplastic resin,
Both surfaces of the wooden material are covered with the intervening sheets, and the surface of each intervening sheet is covered with the decorative board,
At least a part has a drawn curved surface,
The drawn curved surface appears in a similar pattern on the front and back surfaces of the decorative composite plate,
The decorative composite board , wherein the first adhesive is a vinyl acetate-based adhesive, a polypropylene-based adhesive, a polyethylene-based adhesive, an ethylene-vinyl acetate copolymer resin, or a mixture of these adhesives . The decorative composite board according to claim 1,
The decorative composite plate , wherein the drawn curved surfaces include curved surfaces that are bent in two mutually intersecting directions . The decorative composite board according to claim 1 or 2,
A decorative composite board, wherein the intervening sheet is a non-woven fabric or a woven fabric. The decorative composite board according to claim 1 or 2,
The intermediate sheet is composed of a nonwoven fabric containing any one of polypropylene fiber, polyester fiber, polyamide fiber, rayon fiber, acrylic fiber, polyvinyl alcohol fiber, aramid fiber, glass fiber, and pulp fiber. Decorative composite board. The decorative composite board according to any one of claims 1 to 4,
The decorative composite board in which the core material is formed by laminating a plurality of wooden materials. The decorative composite board according to claim 5,
A second adhesive is interposed between the plurality of wooden materials,
A decorative composite board in which the second adhesive is formed into a sheet. The decorative composite board according to any one of claims 1 to 6,
The decorative composite board, wherein the basis weight of the intervening sheet with respect to the wooden material is 20 g/m ² to 70 g/m ² in terms of equal thicknesses of the wooden material and the intervening sheet. a core material comprising a wood material;
a step of respectively preparing a decorative plate, an intervening sheet, and a surface portion including a first adhesive for adhering them;
a step of bonding the surface portions to both surfaces of the core material by heating via a second adhesive to obtain a decorative composite board;
a step of drawing the decorative composite plate to form a curved surface, and causing the drawn curved surface to appear in a similar pattern on the front and back surfaces of the decorative composite plate ;
A method for manufacturing a drawn decorative composite board comprising
The intervening sheet contains a thermoplastic resin,
A method for producing a drawn decorative composite board, wherein the first adhesive is a vinyl acetate adhesive, a polypropylene adhesive, a polyethylene adhesive, an ethylene-vinyl acetate copolymer resin, or a mixture thereof. . A method for manufacturing a drawn decorative composite plate according to claim 8 ,
The step of preparing the surface portion comprises:
A method for manufacturing a drawn decorative composite board, wherein the decorative board, the first adhesive, and the intervening sheet are laminated, and the first adhesive is melted and adhered by hot pressing. A method for manufacturing a drawn decorative composite plate according to claim 8 ,
The step of preparing the core material
a step of obtaining a laminate by laminating a plurality of wooden materials with the second adhesive made of thermoplastic resin formed in a sheet shape sandwiched therebetween;
a step of hot-pressing the laminate to melt the second adhesive to bond the plurality of wooden members together. On both sides of a core material containing a wood material, a decorative board, an intervening sheet, and a surface part containing a first adhesive for adhering them are laminated via a second adhesive, and then bonded by heating to form a decorative composite board. a process of obtaining
a step of drawing the decorative composite plate to form a curved surface, and causing the drawn curved surface to appear in a similar pattern on the front and back surfaces of the decorative composite plate ;
A method for manufacturing a drawn decorative composite board comprising
The intervening sheet contains a thermoplastic resin,
A method for producing a drawn decorative composite board, wherein the first adhesive is a vinyl acetate adhesive, a polypropylene adhesive, a polyethylene adhesive, an ethylene-vinyl acetate copolymer resin, or a mixture thereof. . A method for manufacturing a drawn decorative composite board according to any one of claims 8 to 11 ,
A method for producing a drawn decorative composite plate, wherein the step of forming a curved surface on the decorative composite plate is formed by pressing while maintaining the heated state in the step of obtaining the decorative composite plate. A method for manufacturing a drawn decorative composite board according to any one of claims 8 to 11 , further comprising:
Before the step of drawing the decorative composite plate to form a curved surface,
including a step of die-cutting the decorative composite plate;
The step of drawing the decorative composite plate to form a curved surface is a method for manufacturing a drawn decorative composite plate, wherein the die-cut decorative composite plate is drawn by cold pressure. A method for manufacturing a drawn decorative composite board according to any one of claims 8 to 13,
A method for manufacturing a drawn decorative composite panel, wherein the drawn curved surfaces include curved surfaces that are bent in two mutually intersecting directions.

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