JPH06335922A - Manufacture of mold for preparing woodgrained decorative sheet - Google Patents

Abstract

PURPOSE:To provide a method for manufacturing a mold for the manufacture of a woodgrained decorative sheet by means of which a woodgrained decorative sheet demonstrating strongly a wood feel and a real wood feel can be inexpensively and easily manufactured. CONSTITUTION:A manuscript 22 wherein an uneven pattern 22a in accordance with a hardness and chem. resistance of the texture is formed on the surface of a natural wood 21 by applying rubbing treatment by means of a metal brush, deterioration treatment by applying one of chemicals such as dilute sulfuric acid and heating treatment by means of a burner, is formed and an original mold 30 wherein the uneven pattern 22a of the manuscript 22 is transferred based on this manuscript 22 is manufactured and a mold for manufacturing woodgrained decorative sheets is manufactured therefrom.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for producing a mold for producing a wood grain decorative board, and more specifically, it utilizes not only the conduit pattern and the wood grain pattern appearing on the surface of natural wood but also the physical or chemical characteristics of the surface texture. The present invention relates to a method for producing a production mold for producing a more realistic wood grain decorative board.

[0002]

2. Description of the Related Art Conventionally, a decorative board having a natural wood texture (hereinafter referred to as a wood grain decorative board) is disclosed in Japanese Patent Laid-Open No. 4-11984.
It was manufactured as described in Japanese Patent Publication No. In this conventional method, first, the conduit pattern on the surface of the veneer of natural wood is taken out, and the conduit pattern is transferred as an uneven pattern on the surface of the polyester resin to produce a decorative board with an uneven pattern. Then, the concave portion of this decorative plate was filled with a coloring agent to expose a conduit pattern, thereby obtaining a final product.

[0003]

However, in the above-mentioned manufacturing method, the uneven pattern appearing by the conduit is merely transferred to the surface of the natural wood, and there is a problem that a sufficient wood texture cannot be obtained. there were. The present invention has been made in view of the above problems, and has been made by paying attention to the fact that the wood texture received by a viewer is greatly affected not only by the conduit pattern etc. but also by the condition of the wood pattern caused by the hardness or softness or densification of the tissue itself. It is an object of the present invention to provide a method for manufacturing a wood grain decorative board manufacturing mold capable of strongly emphasizing the wood texture of natural wood.

[0004]

In order to achieve the above object, a method for manufacturing a wood grain decorative board manufacturing mold according to the invention of claim 1 is a method for manufacturing a veneer or a natural wood surface by rubbing or treating the surface of the natural wood. The hardness due to the tissue structure is expressed as a concavo-convex pattern, or a manuscript is produced in which the conduit pattern is emphasized or shaving marks are left, and the surface of the manuscript is coated with a fluid resin and then cured to cure the concavity and convexity of the manuscript. The pattern was cast to mold an original mold, and then a replica mold was prepared based on the original mold, and then a production mold was prepared based on the replica mold.

According to the second aspect of the present invention, the surface of the natural wood is rubbed by brushing with a metal brush, sanding or sand blasting so that the hardness of the texture of the natural wood surface appears as an uneven pattern. . Further, in the invention described in claim 3, after being burned by a burner or after being deteriorated by a chemical such as dilute sulfuric acid, rubbing is performed so that easiness of carbonization and resistance to the chemical appear as an uneven pattern.

[0006]

According to the method of manufacturing the wood grain decorative board manufacturing mold according to the present invention, not only the conduit pattern but also the physical or chemical characteristics of the natural wood tissue can be expressed in the manuscript as an uneven pattern. It is possible to produce a manuscript in which the wood-like texture of wood appears more strongly, and the wood grain decorative board manufactured using the production mold made based on this manuscript is more beautiful and the wood texture can be emphasized more strongly.

[0007]

Embodiments of the present invention will be described below with reference to the drawings. 1 to 4 are views for explaining a method for manufacturing a wood grain decorative board manufacturing mold according to an embodiment of the present invention, and FIG. 1 is a cross-sectional view schematically showing a state when a prototype mold is manufactured. 2 is a cross-sectional view schematically showing a state in which the replication mold is produced, FIG. 3 is a cross-sectional view schematically showing a state in which the production mold is produced, and FIG. It is a schematic cross section of the manufactured wood grain decorative board.

In this embodiment, a manuscript is prepared (manufacturing process of the manuscript), a prototype is formed based on this manuscript (manufacturing process of the master mold), and a replica mold is prepared from the master mold ( A step of producing a duplicate document), a production die is further produced from the duplication die (production die production step), and the wood grain decorative board is produced using the molding die (decorative board production step). Hereinafter, each step will be described for each step.

(1) Manuscript preparation process Using natural wood or a veneer as a manuscript material, the surface of the manuscript material is polished with a belt sander or the like to adjust the material (smoothing of the surface), and then the surface of the manuscript material. Is rubbed with a metal brush (rubbing treatment). As a specific example, for example,
A plywood (base material) 21 having a thickness of 4 mm is pasted with a plywood (original) 22 (see FIG. 1), and the surface of the plywood 22 (hereinafter, referred to as natural wood) is ground with sanding paper No. 320. After performing the smoothing treatment, the smoothed surface is rubbed with an electric metal brush such as a wheel sander manufactured by Makita Co., Ltd.

Here, by rubbing the surface of the natural wood 22 with a metal brush, the surface of the natural wood 22 has concaves and convexes in which the soft portion is concave according to the difference in hardness between the hard portion and the soft portion of the surface texture. A pattern, in other words, an uneven pattern corresponding to the hardness of the surface texture is formed. In other words, in the smoothing process, the parts other than the conduit become almost flat, but the smoothing process followed by the rubbing process causes the difference in the hardness and softness of the tissue even in the flat part (for example, the difference between the spring wood part and the autumn wood part). , A concave portion (concavo-convex pattern) according to the difference between the fiber portion and the lignin, the difference in hardness between the presence and absence of a cord and the like.
a (see FIG. 1) appears. Then, using the natural wood on which the uneven pattern 22a corresponding to the difference in hardness of the tissue is formed as an original, a prototype is produced in the next step.

The rubbing process in the above-mentioned document manufacturing process is not limited to the above-mentioned process, and the following processes 1 to
7 can be substituted, and two or more processes can be performed together. -Treatment 1 After smoothing treatment, rubbing with a metal brush to dig up the conduit to deepen and widen the width of the conduit.・ Treatment 2 Even if there is no conduit such as coniferous wood, rub it with a metal brush and soften it according to the difference in hardness between the hard part such as autumn wood and knots and the soft part such as spring wood. A process for forming a concave-convex pattern corresponding to the difference between hardness and softness.

Treatment 3 In addition to the uneven pattern corresponding to the hardness difference of the natural wood surface, a metal brush or a nylon brush (roughness 80, 100, 240 mesh) is rubbed to form a hairline along the flow line of the brush. A process of forming a recess. -Treatment 4 A treatment in which the surface of natural wood is roughly cut with a special blade to leave a cut mark. Treatment 5 A treatment of applying a chemical such as sulfuric acid to the surface of natural wood to deteriorate the surface texture, and then rubbing the surface with a metal brush or the like to form an uneven pattern due to the difference in deterioration due to sulfuric acid. -Treatment 6 A treatment of burning the surface of the natural wood with a burner or the like and then rubbing it with a metal brush or the like to form an uneven pattern corresponding to the difference in heat deterioration of the surface texture. -Process 7 A process in which a veneer is attached to an aluminum plate, rubber sheets are overlaid, and heat and pressure are applied to form an uneven pattern according to the density difference of the veneer structure. -Process 8 A process of sandblasting the surface of natural wood to form an uneven pattern according to hardness and softness.

(2) Process for Producing the Prototype In this process, as shown in FIG. 1, a silicone resin (for example, a silicon resin) is formed on the surface of the ridge plate 22 produced in the above process, that is, the surface on which the uneven pattern 22a is formed. , Shin-Etsu Chemical Co., Ltd. KE1300T) 31 0.1-1.0
The silicone resin 31 is hardened by applying it as evenly as possible so as to have a thickness of mm. Then, a silicone resin 32 is further added on the silicone resin 31 by 0.1 to 1.0.
The silk screen stencil is applied as evenly as possible to a thickness of mm and stretched over the silicone resin 32 in a frame 33 (for example, 100 mesh made by Tetron)
Put on 34. Here, in the stencil 34, the silicone resin 32 exudes on the upper side thereof, sinks into the silicone resin 32, and is buried in the silicone resin 32. Then, when the silicone resin 32 is hardened and integrally fixed to the stencil 34 and the silicone resin 31, the silicone resins 31, 32 and the stencil 34 are peeled off from the bump plate 22 and used as the prototype mold 30. The original mold 30 is formed with a concave-convex pattern 31a formed by transferring, that is, the concave-convex pattern 22a of the convex plate 22 described above.

In the above-mentioned process, it is possible to coat the silicone resin 31 with the stencil 34 and then apply the silicone resin 32. Further, after the stencil 34 is coated on the silicone resin 32, three layers are further added. It is also possible to apply an eye silicone resin.

(3) Process for producing duplication mold In this process, as shown in FIG. 2, an aluminum plate having a thickness of about 2 mm, an MDF having a thickness of about 4.0 to 5.5 mm or a thickness of about 4.0 mm to 5.5 mm is used. A urethane paint-based primer layer (for example, Stron Stop Sealer 5 manufactured by Cashew Co., Ltd.) on a base material 41 such as a particle board having a size of 7 to 10 mm.
No.) 43, and the primer layer 43 is dried and semi-cured for several hours. Then, the resin 42 such as unsaturated polyester is poured on the primer layer 43 to cover the original mold 30, and while defoaming, the resin is spread by pressing with a roll or the like from the back side of the original mold 30 to cure the resin 42. Let Then, after curing, the original mold 30 is peeled off, and the uneven pattern 42 in which the uneven pattern 31 a of the original mold 30 is transferred to the resin 42 on the base material 41.
A duplication die 40 having a is obtained, and defects such as scratches and bubbles in the duplication die 40 are repaired.

(4) Production Mold Production Process In this process, as shown in FIG.
Is covered with a thermoplastic sheet 51, and then, while the thermoplastic sheet 51 is covered with the duplication mold 40, the uneven pattern 42a of the duplication mold 40 is transferred to the thermoplastic sheet 51 by a hot press for production. Obtain the mold 50. This production mold 50 has an uneven pattern 42 of the replication mold 40 on the surface of the sheet 51.
It has an uneven pattern 51a to which a is transferred.

In this step, the production die 50 can be produced in the same manner as the production of the original die 30. That is, after applying a barrier coat to the surface of the replication mold 40 in order to block the curing catalyst poison of the silicone resin,
Silicone resin (for example, K manufactured by Shin-Etsu Chemical Co., Ltd.
E1300T) is applied to a thickness of about 1 mm, dried and cured, then covered with a stencil and further covered with a silicone resin, and the stencil is embedded in the silicone resin. Then, after the silicone resin is cured, the silicone resin is peeled off from the replication mold 40 integrally with the stencil,
A production mold 50 in which a resin pattern is formed is obtained.

(5) Decorative Board Production Step In this step, a decorative board as shown in FIG. 4 is produced. First, the paper 13 is attached to the substrate 11 with the adhesive 12, and the primer layer 14 is formed on the paper 13. Substrate 1
1 is an aluminum plate with a thickness of about 2 mm, MD with a thickness of about 5 mm
The adhesive layer 12 is made of F (medium density fiberboard) or particle board having a thickness of about 7 to 10 mm, the vinyl acetate emulsion adhesive is used as the adhesive layer 12, and the construction paper is thin paper or titanium paper. In addition, the primer layer 14
Is composed of a polyol-based resin mixed with an isocyanate-based curing agent and a coloring pigment so as to have the same color as the resin layer 15 described later.

Next, the flowable resin 15 is flowed on the primer layer 14, the production mold 50 is covered on the resin (layer) 15, and the resin is spread by pressing the production mold 50 with a roll or the like. Spread on the primer layer 14 of the substrate 11. The resin 15 is formed to be colored and opaque by mixing a curing accelerator and a coloring pigment with an unsaturated polyester resin or the like, or a coloring pigment and a bright pigment. Then, after the resin 15 is cured, the production mold 50 is peeled off. Here, the surface of the resin layer 15 has an uneven pattern 51 of the production mold 50.
A concave-convex pattern (concave portion) 15a in which a is transferred is formed.

Then, a wiping paint layer 16 is provided in the recess 15a, and a top coat layer 17 is formed on the resin layer 15. The wiping paint layer 16 is formed by adding a pigment to a binder made of urethane resin or adding a pigment and a pearl pigment to the binder. The top coat layer 17 is Polyurex 5 manufactured by Wakoshin Chemical Industry Co., Ltd.
It is composed of 48-7.

As described above, in this embodiment, not only the wood pattern or the conduit pattern but also the physical properties such as the hardness of the surface texture of natural wood, the chemical resistance, the flame resistance and the like of the texture are applied to the decorative board. Since the uneven pattern 15a that reflects the nature is formed, the wood texture is strongly expressed, and a new texture is created, which is beautiful and
Veneer with high commercial value can be produced. Then, in this example, a manuscript is prepared by performing a process such as rubbing on the basis of natural wood,
The original mold is produced from this manuscript, the replica mold is made from the original mold, the production mold is made from the reproduction mold, and the decorative plate is produced from this production mold. It is possible to produce large numbers of decorative sheets of, and it is possible to reduce costs.

According to the present invention, not only the decorative plate shown in FIG. 4 but also the decorative plate shown in FIG. 5, FIG. 6 or FIG. 7 can be produced. That is, in the decorative plate shown in FIG. 5, the sealer layer 18 is made of a binder mixed with a pearl pigment or a binder further mixed with a coloring pigment.
Is formed on the resin layer 15, the wiping paint layer 16 is formed on the sealer layer 18, and the wiping paint layer 16 is covered with the top coat layer 17.

The decorative plate of FIG. 6 is formed by forming a wiping paint layer 16 on the resin layer 15 and forming a sealer layer 18 on the resin layer 15 and the wiping paint layer 16. Further, the decorative board of FIG. 7 is one in which the ink layer 19 is formed by printing on the paper 13 without providing the primer layer 14, and the transparent resin layer 15 is provided on the paper 13 on which the ink layer 19 is formed. is there. With respect to the aspects of FIGS. 5, 6 and 7 described above, the same parts as those in FIG. 4 are denoted by the same reference numerals and description thereof is omitted.

Although not shown in the drawing, after the wiping paint layer 16 is provided, a transparent unsaturated polyester resin layer is formed on the entire surface of the resin layer 15 and the wiping paint layer 16 by the mirror surface film method to give a mirror finish. It may be a finished product.

[0025]

As described above, according to the method for producing a wood grain decorative board producing mold according to the present invention, natural wood is subjected to treatment such as rubbing with a brush, blade treatment or chemical application to obtain a surface texture. Prepare a manuscript with an uneven pattern depending on the hardness and softness or chemical resistance, or a manuscript with a conduit pattern emphasized or a shaving mark left, and make a prototype, a copy mold, and a production mold in sequence based on this manuscript. Therefore, a wooden texture is strongly exhibited, and a veneer with a new texture can be produced inexpensively and in large quantities, and a large number of manuscripts or patterns can be produced from a small number of natural trees having an uneven pattern with excellent design. .

[Brief description of drawings]

FIG. 1 is a schematic cross-sectional view for explaining the production of an original mold in the method for producing a mold for producing a wood grain decorative board according to an embodiment of the present invention.

FIG. 2 is a schematic cross-sectional view for explaining the production of the replication mold in the same production method.

FIG. 3 is a schematic cross-sectional view for explaining the production of the production mold in the same production method.

FIG. 4 is a schematic cross-sectional view of a wood grain decorative board manufactured by the manufacturing method.

FIG. 5 is a schematic cross-sectional view of another embodiment of a wood grain decorative board manufactured by the manufacturing method.

FIG. 6 is a schematic cross-sectional view showing still another embodiment of a wood grain decorative board manufactured by the manufacturing method.

FIG. 7 is a schematic cross-sectional view showing still another aspect of a wood grain decorative board manufactured by the manufacturing method.

[Explanation of symbols]

 11 Base Material 13 Paper 14 Primer Layer 15 Resin Layer 15a Uneven Pattern 16 Wiping Paint Layer 17 Top Coat Layer 18 Sealer Layer 19 Ink Layer 21 Plywood (Base Material) 22 Rough Veneer (original) 22a Uneven Pattern 30 Prototype 31, 32 Silicone Resin 33 Frame 34 Stencil 40 Duplication type 50 Production type

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Yukiko Chika 4-14-12 Koishikawa, Bunkyo-ku, Tokyo Joint printing Co., Ltd. (72) Inventor Katsumi Shiina 4-14-12 Koishikawa, Bunkyo-ku, Tokyo Joint printing Within the corporation

Claims (3)

[Claims] 1. A veneer or the surface of a natural wood is rubbed or treated with a knife to express the hardness resulting from the texture structure of the surface of the natural wood as an uneven pattern, or to emphasize a conduit pattern,
A manuscript with shaving marks left is made, and a fluid resin is applied to the surface of the manuscript and then cured to mold the uneven pattern of the manuscript to form a master mold, and then a copy is made based on the master mold. A method for producing a mold for producing a wood grain decorative board, characterized in that a production die is produced based on the duplication die after the production die is produced. 2. The method for manufacturing a wood grain decorative board manufacturing mold according to claim 1, wherein the scraping of the veneer or the surface of the natural wood is performed by a metal brush, sanding or sandblasting. 3. The method for producing a wood decorative board production mold according to claim 1, wherein the veneer or the surface of the natural wood is burnt with a burner or is deteriorated with sulfuric acid and then rubbed.