JPH0698630B2 - Veneer manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION [Industrial field of application] The present invention is a cosmetic in which casting is performed on the entire surface and / or back surface of a wood-based material using a casting mold, and then post-coating is performed if necessary. Regarding improvement in plate manufacturing method (Note that in the present invention, the specific method of casting is not particularly limited, and RIM (Reaction Injection Moldin
Methods such as g) are naturally included).

[Prior Art] Conventionally, as a method for producing a decorative plate with makeup applied to the mouth or front and back surfaces, as shown in FIG. On the other hand, a member (13) formed by extruding or cutting a plastic material such as vinyl chloride is adhered by an adhesive such as hot melt, or such a member is used as a base material as shown in Fig. 3B. On the other hand, it is known to manufacture by grooving (14) and then embedding.

Further, the bonded or embedded member is subjected to shape processing such as cutting with a knife, and then a high-viscosity sealer is applied many times (15) (Fig. 3C), or the opening of the base material A soft forming method in which a material such as vinyl chloride is attached along a curved surface such as
Alternatively, it is known to attach (16) by a means such as a vacuum press (Fig. 3D).

[Problems to be Solved by the Invention] However, none of the above-mentioned methods is necessarily satisfactory in terms of finish or workability.

For example, as shown in FIGS. 3A and 3B, in a case where a molded member is adhered or embedded in the mouth or front and back surfaces of a base material, a gap or a step is formed between the member and the base material. It is likely to occur and the bonded portion is likely to be peeled off. Further, adhering or embedding such a member to the base material itself is a laborious and difficult task. Further, when it is necessary to perform coating after adhesion or embedding, it is inevitable that the surface of the member is subjected to primer treatment or sanding treatment in order to improve adhesion with the coating material. In the case of the decorative board prepared by the method of 1), it is difficult to eliminate the appearance of the step between the base material and the member even if the post-coating is sufficiently performed, and the appearance is sufficiently obtained. It was difficult. In addition, even if the processing and post-treatment are performed sufficiently satisfactorily, it is often observed that cracks occur at the joint portion with the passage of time. That is extremely difficult in itself.

Further, as shown in FIG. 3C and D, in the case where the sealer is applied many times or the resin sheet or the like is applied after the shape processing, it is very troublesome to apply the sealer. In addition to the above, it is necessary to carry out a sanding treatment after that, and when the base material is particle board, it is virtually difficult to fill the pinhole at the mouth end, and the finished state is not always good. I can't say. Furthermore, when a resin sheet or the like is attached by a vacuum press, in addition to poor productivity, the sheet may get into the pinholes of the base material and unevenness may be formed on the surface. There are cases where

Furthermore, the need for cutting shape processing is inevitable that a wavy pattern is generated by cutting the knife,
It is difficult to obtain a smooth finished state due to unevenness on the surface due to attachment of facets. Further, the need for the cutting step means that the shape of the processed surface is limited, and it is necessary to perform the cutting processing or the sanding processing after the wood block is embedded in the surface, if necessary. In the case of soft forming, it is relatively easy to form the surface, but it is unavoidable to form a gap or a step at the connection between the base material part and the soft forming part. The condition is inadequate.

The present inventor eliminates the above-mentioned inconveniences of the conventional decorative board and the manufacturing method thereof, and is manufactured by a smaller number of working steps. Invented and filed a method for producing a decorative board that can be held and has a continuous connecting point between the base material portion and the uneven portion, and that has a good-looking appearance and a color tone that matches the design. (1)). However, when the decorative board is manufactured by the method of the invention, if the resin is cast by casting over the entire surface of the substrate, the resin may not be uniformly injected over the entire surface.

[Means for Solving the Problems] In order to solve the above-mentioned problems, the present invention uses a casting mold in which an uneven surface of a predetermined shape is formed on the inner surface, and in the casting mold, Part of the space between the lower surface of the base material formed when the base material is set in the casting mold and the inner surface of the casting mold, and the space between the mouth surface of the base material and the inner surface of the casting mold. Inject a molding resin material in an amount that can be filled in advance, set the base material in the casting mold after injection, then fix the upper lid of the casting mold, and then inject additional molding resin material. By filling a space formed by the base material and the casting mold with a molding resin material, the resin material is molded into a desired shape on the surface of the base material.

As a result, even when using a casting mold in which an uneven surface of a predetermined shape is formed on the inner surface and attempting to apply the molding surface of the resin by casting to the entire surface of the substrate, the resin is evenly distributed over the entire surface. At the same time as the injection, the resin will sufficiently enter the place where the gap between the base material and the casting mold surface is extremely small.
It has become possible to form a desired resin film over almost the entire surface of the substrate. Further, by forming the grooves on the surface of the base material in advance, the area in which the base material is impregnated with the resin increases, and it becomes possible to obtain a more stable resin molding surface. Further, after cast molding, by applying post-coating as required, a decorative board having a desired design can be obtained.

[Examples] Hereinafter, a decorative board and a method for manufacturing a decorative board according to the present invention will be further described with reference to the drawings. FIG. 1 schematically shows each step of the method for manufacturing a decorative board according to the present invention.

In the first step, a base material 1 made of a wood material such as particle board or medium fiber board (MDF) is formed into a predetermined shape.

In the second step, the synthetic resin molding surface 2 having a desired shape is molded on the surface of the base material 1 and the entire surface of the wood mouth by a casting method using a casting mold. The molding method which is the technical problem to be solved by the present invention will be described later. As synthetic resin materials for cast molding, polyurethane resin, epoxy resin,
In addition to unsaturated polyester resin, various thermoplastic resins such as vinyl chloride, nylon and polypropylene are used.

In the third step, the post-coating 3 is applied to the surface-molded substrate 1 obtained in the second step, if necessary. As the paint, polyester resin polyurethane resin or the like is used.

2 (a), (b), and (c) are views showing one embodiment when cast molding is performed on the substrate 1 according to the present invention.
Is a casting mold, and a conventionally known mold resin mold or the like is used. The inner surface of the casting mold is formed with an uneven surface having a predetermined shape. In the present invention, before the base material 1 is set in the casting mold 4, a predetermined amount of molding resin material is first injected (FIG. 2B). The amount of the resin to be injected is such that the space between the lower surface of the base material 1 and the inner surface of the casting mold 4 formed when the base material 1 is set in the casting mold 4 and the cusp surface of the base material 1 and the casting The amount is such that a part of the space with the inner surface of the mold can be filled (see FIG. 2C). After that, the base material 1 is set in the casting mold 4 and the upper lid 6
Is fixed, and additional resin is injected through the resin injection hole 7 according to a normal casting method. In addition, as a mold release agent that is usually used at the time of casting, WAX
It is desirable to use a system.

The base material 3 taken out from the casting mold 4 is then subjected to post-coating if necessary.

[Advantages of the Invention] According to the present invention, since the resin is preliminarily injected into the inner bottom surface of the casting mold and the base material is set thereafter, a portion having a large area such as the surface of the decorative plate is used. Even when the resin material is integrally molded by cast molding, it is possible to spread the resin material equally over the entire area. Further, in a portion where the thickness of the resin layer is extremely narrow as shown by A in FIG. 2C, the resin does not uniformly enter by the injection of the resin by the usual casting method and the surface is uneven. However, in the present invention, by injecting the resin into such a portion in advance, the resin can be sufficiently spread, and a good-looking decorative plate can be formed. .

In addition, due to the pressing force when setting the base material, the resin material that has been injected in advance can fully infiltrate into the concave portions such as the concave grooves that form the uneven surface formed on the inner surface of the casting mold. A decorative board with a sharp uneven surface can be obtained.

[Brief description of drawings]

FIG. 1 is a diagram showing an outline of a manufacturing process of a decorative sheet according to the present invention, FIG. 2 is a diagram showing a mode of casting on a base material according to the present invention, and FIG. 3 is a diagram showing a conventional example. DESCRIPTION OF SYMBOLS 1 ... Base material, 2 ... Casting molding part 3 ... Post-coating film, 4 ... Casting mold 5 ... Pre-injected resin material, 7 ... Injection hole

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Claims (1)

[Claims] 1. A lower surface of a base material formed when a base material is set in the casting mold by using a casting mold having an uneven surface of a predetermined shape formed on the inner surface. And a space between the casting mold inner surface and a part of the space between the mouth surface of the base material and the inner surface of the casting mold are pre-injected, and the base material is poured after the injection. Set in the casting mold, then fix the upper lid of the casting mold, then inject additional molding resin material to fill the molding resin material in the space formed by the base material and the casting mold. A method for manufacturing a decorative board, which comprises molding a resin material on a surface of a base material into a desired shape by filling.