JPH07102551B2 - Manufacturing method of furniture panel with resin edge - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method of manufacturing a furniture panel with a resin edge, in which the step of injecting a liquid resin and curing the resin can be carried out easily and easily.

[0002]

2. Description of the Related Art In recent years, as furniture members such as table tops and partition plates used in office spaces and residential spaces, resin edged furniture members having resin edges integrally attached to peripheral edges have begun to be used. In these furniture members with a resin edge, a groove is formed in a predetermined peripheral portion of the core material of the main body, a liquid resin is injected into the groove to be cured, and then the cured resin portion is finished into a decorative surface shape. (JP-A-3
(-131369)

At this time, in order to enhance the aesthetic effect of the resin edge, it is desired that all or most of the peripheral edge portion of the furniture panel is covered with the resin edge, so that the bottom of the groove is thin. It is generally practiced to form a deep groove that leaves only the flange portion.

Therefore, when the grooved core material is handled, there arises a problem that the flange portion, which is weak in strength, is easily damaged.

The grooved core material needs to be filled with a liquid resin and cured while being held horizontally. Therefore, a large work space is required and the curing is completed so that the liquid resin does not spill out from the groove. It has a drawback that it must be kept horizontal until it is stopped.

Further , in the conventional method, when the core material is warped, it is impossible to maintain the horizontal level of the entire groove at the same level, so that the entire groove cannot be uniformly filled with the liquid resin. is there.

[0007]

SUMMARY OF THE INVENTION It is an object of the present invention to provide a method for easily and easily manufacturing a furniture panel with a resin edge by solving the above problems or drawbacks all at once.

[0008]

In order to achieve the above object, the method of manufacturing a furniture panel with a resin edge according to the invention of claim 1 comprises the following steps (1) to (6). (1) A step of preparing the following materials (a) to (e). (A) A plate-shaped core material having a plane shape selected in advance. (B) A plate-shaped auxiliary core material that follows the planar shape of the core material, has an inner surface hole larger than this planar shape, and has an opening from the inner surface hole to the outer edge. (C) Top sheet. (D) Back sheet. (E) An adhesive capable of adhering the above two sheets to the core material and the auxiliary core material. (2) The core material and the auxiliary core material are sandwiched and adhered between the top sheet and the back sheet while maintaining a predetermined gap between the side surface of the core material and the side surface of the inner hole of the auxiliary core material. , Forming a series of tunnels inside the adhesive body. (3) A step of holding the adhesive body substantially vertically such that the opening is located at the highest part of the tunnel. (4) A step of injecting a curable liquid resin having adhesiveness with the core material through the opening to fill the inside of the tunnel and reach a certain level in the opening, and then to cure. (5) A step of cutting the resin portion of the cured tunnel through the top sheet and the back sheet and cutting it so as to form a decorative surface shape to form a resin edge. (6) A step of polishing and finishing the formed resin edge.

In the method for manufacturing a furniture panel with a resin edge according to the second aspect of the present invention, the side surface of the core material and / or the side surface of the inner surface hole of the auxiliary core material is pre-sealed before bonding to prevent the penetration of the liquid resin. This includes prevention. In the method for manufacturing a furniture panel with a resin edge according to the invention of claim 3, a melamine resin decorative board is used for the surface sheet.

A description will be given below with reference to the drawings. Figure 1
FIG. 3 is an exploded perspective view of an example of an adhesive body used in the present invention that incorporates a tunnel and an opening. Reference numeral 1 is a surface sheet that forms the surface of the product, and may be a decorative material that is impermeable to liquid resin. Specifically, synthetic resin-based sheets such as melamine resin decorative boards and vinyl chloride boards, wood-based sheets such as veneer decorative boards, and metal-based sheets such as aluminum boards. When pouring the liquid resin into the adhesive body, it is convenient for the surface sheet to be a rigid plate in order to lean the adhesive body and work, but it is not necessary to limit the rigid sheet to a rigid plate. Good. When the flexible sheet is used, the liquid resin may be injected by suspending the adhesive body and holding it vertically.

Among the above-mentioned surface sheets, the melamine resin decorative plate is suitable for the surface sheet of the present invention because it has excellent surface physical properties such as abrasion resistance and excellent machinability.

The core material 2 is a plate-shaped board preformed so as to follow the outer shape of the product. The material is preferably a wood material such as plywood, particle board and MDF from the viewpoint of workability and economy, but may be an inorganic material such as a calcium silicate plate, a metal material such as an aluminum plate or a plastic material. Furthermore, a honeycomb core made of aluminum or paper, a polyethylene foam or the like can be used alone or in the form of a board in combination with the above materials.

The outer shape of the core material must be preliminarily shaped so as to follow the outer shape of the product. As a method of shaping, a wood material is cut by a woodworking machine, a plastic foam is cut by a hot wire, or For a plastic material, a commonly used method such as injection molding may be selected according to the material used.

For example, FIG. 2 shows an example in which a plurality of materials are combined to form a flash core material. This is an example in which a wooden frame 6 is fixed by pins of an air tacker 8 to form a wooden frame, and a honeycomb core 7 is fitted into a space surrounded by the wooden frame to form a core material. Further, plywood having the same length and width can be bonded to the top and bottom of the core material. (Figure 3)

The auxiliary core material 3 shown in FIG.
The same kind of material as the core material, which is a constituent member required for forming 0, but different from the core material,
It is discarded when the resin edge is carved out.
As shown in FIG. 4-A, the auxiliary core material is generally made to have the same thickness as the core material. In this method, the core material is cut out from one board using an NC router, and the remaining outer periphery is cut out. Since a part can be used as an auxiliary core material, it is advantageous to use the material without waste. When one or both of the top sheet and the back sheet is a flexible sheet, the core material and the auxiliary core material may have different thicknesses. For example, as shown in FIG. When the thickness of the material is large,
It is also possible to form a resin edge thicker than the panel body.

The auxiliary core material 3 is provided with an opening 5 serving as a liquid resin injection port. The opening is usually opened in advance before bonding, but after bonding, a hole may be drilled from the side surface of the auxiliary core material toward the tunnel with a drill or the like to form the opening, both of which are included in the present invention. The opening is for guiding the liquid resin into the tunnel and filling it, and it is usually a single hole, but there should be multiple holes to distinguish the inlet from the outlet, or the width of the opening. May be widened to form a groove.

Reference numeral 4 in FIG. 1 denotes a back sheet, and the same kind of material as the surface material can be used. Since the back surface of the product is formed, the material is usually selected with emphasis on economy rather than aesthetics. For example, a phenol resin laminated plate called a backer can be said to be suitable. However,
For applications that require aesthetics on both sides, such as movable partition plates, the back sheet must also be selected in consideration of aesthetics.

Since the above-described furniture panel of the present invention has a three-layer structure in which the top and bottom of the core material are sandwiched by the top sheet and the back sheet, it has the effect of less warpage as compared with a single-layer or two-layer panel. There is.

The adhesive structure in which the liquid resin is injected has been described above in the present invention, but the method of adhering the adhesive will be described below step by step. The surface sheet, core material, auxiliary core material, and back surface sheet prepared in advance are bonded and integrated under the configuration shown in FIG. 1, and a series of tunnels and an opening communicating from the tunnel to the outside are shown in FIG. Create an adhesive body that The adhesive is selected from known adhesives such as urea adhesives, vinyl acetate adhesives, water-based vinyl urethane adhesives, urethane resin adhesives, epoxy resin adhesives, and synthetic rubber adhesives. A material having adhesiveness may be appropriately selected and used.For example, the core material and the auxiliary core material are wood materials, and the top sheet and the back sheet are a combination of laminated sheets such as a melamine resin decorative board. If so, a urea-based adhesive or a vinyl acetate-based adhesive is suitable. Further, the adhesive to be used is not limited to one kind for one adhesive, and a plurality of kinds of adhesives may be used, such as different kinds of adhesives for the top sheet and the back sheet.

The adhesion here is not limited to simply overlapping and adhering the materials, but in order to secure a tunnel width necessary for obtaining a resin edge, the core material is positioned in the inner hole of the auxiliary core material, and Both must be adhered with a predetermined gap. Generally, the material is temporarily fixed and fixed and adhered, but the temporary fixing must be done so as not to adversely affect the appearance of the product and the resin injection work. For that purpose, a thin pin made of wood or plastic is sandwiched between the core material and the auxiliary core material so as to be bonded, and before the compression hardening, It is also possible to adopt a method in which the back sheet or the top sheet and the core material and the auxiliary core material are pinpointed at high frequency and temporarily fixed.

Further, it is possible to adopt a method of securing a predetermined interval by gradually adhering instead of adhering all at once. In this method, a core material is first adhered to the back sheet, then an auxiliary core material is adhered to the core material at a predetermined interval, and finally a top sheet is adhered. Of course, the order of adhering materials does not have to be in this order.

If the side surface of the core material and / or the side surface of the inner surface hole of the auxiliary core material are sealed before being bonded, the liquid resin will be excessive inside the material when the liquid resin is injected and cured. It has the effect of preventing penetration. The sealing process has a great effect when the core material or the auxiliary core material is a porous material such as MDF. As a sealing method, it is common to apply a sealer, which is an undercoating agent for paint, several times, but in addition to this, sticking an adhesive sheet made of an impermeable base material and sealing used for construction. Applying an agent is also effective.

Next, the adhesive body thus prepared is
In preparation for injecting the liquid resin, the opening is placed at the highest position of the tunnel and held substantially vertically. The holding means is not particularly limited, but it may be leaned or hung. Then, a curable liquid resin is prepared, and the liquid resin is injected through the opening to fill the inside of the tunnel and the opening and cure. An auxiliary tool such as a funnel may be used to perform the injection work efficiently.

The resin for injection may be any curable resin, and known resins such as urethane resin, epoxy resin, unsaturated polyester resin, acrylic resin and melamine resin can be used. The liquid resin may contain known additives such as a colorant, a filler and an antifoaming agent.

After the liquid resin is hardened, it is cut along the tunnel portion of the adhesive body through the top sheet and the back sheet, and is cut so as to form a decorative surface shape to form a resin edge. The cutting method may be any method including manual processing as long as a decorative surface shape is formed. In particular, an NC router for woodworking equipped with a forming blade or a vertical for woodworking. If you use a shaft moulder, you can work efficiently. Here, the moulder is suitable for processing a straight line portion, while the NC router is suitable for accurately processing both straight and curved lines. A typical example of the obtained surface shape is shown in FIG.

The resin edge portion formed by the cutting process is then appropriately combined with sandpaper, steel scrubbing brush or compound wax of various roughness, and the surface thereof is polished to obtain knife marks and rough surface of the surface caused by the cutting process. To make a resin edge that has a smooth surface and a beautiful appearance. Since the machining accuracy of NC routers has been improved in recent years, if the number of times of cutting by the NC router is set to 2 passes or 3 passes, a considerably smooth cutting surface can be obtained, and therefore polishing work can be reduced.

The resin panel with resin edges produced in this manner is used as a table top, a partition panel, etc. in a building space such as an office or a house. At this time, subsequent to the above-mentioned polishing step, the resin edge portion or the entire furniture panel including the resin edge may be subjected to a known coating finish such as urethane resin coating or amino resin coating before use.

Hereinafter, the present invention will be described in more detail with reference to examples. The present invention was carried out as shown in Table 1 with the materials and combinations of the top sheet, back sheet, core material, auxiliary core material, adhesive and injection resin, and Example 1 and Example 2 respectively.
And Example 3. Table 2 shows the characteristic values of the products obtained in each example.

[0029]

[Example] [Example 1] A straight bit for grooving is attached to an NC router for woodworking, and a core material having a radius of 350 mm is cut out from the central portion of plywood.
The remaining plywood is cut again using the same blade, and the radius is 3
An auxiliary core material is provided by forming an inner hole of 80 mm and an opening of 30 mm in width, which is the shortest distance from the inner hole to the peripheral edge of the plywood at a right angle. Spray the rubber adhesive shown in Table 1 on both sides of the core material and auxiliary core material, and the adhesive surface of the melamine resin decorative plate and the backer, place the core material in the center of the backer first, and lightly press it by hand to temporarily Stop. Then, the auxiliary core material is temporarily fixed in the same manner with a spacing of 30 mm from this core material, then the melamine decorative board is placed on the top, and it is pressed at a pressure of 3 kg / cm ² using a woodworking press machine. Then create an adhesive body.

On the other hand, the liquid A of the urethane resin shown in Table 1 was mixed with black toner in an amount of 3% in advance to be colored, and then mixed with the liquid B to prepare a liquid resin. Pour into the tunnel from the opening. And
The liquid resin is filled up to the tunnel and the upper end of the opening, and the resin is allowed to stand for 1 day to cure the resin.

Next, the tunnel portion filled with the cured resin is cut along the tunnel through the top sheet and the back sheet by an NC router for woodworking equipped with a chamfering bit, and as shown in FIG. 6-A. A circular resin that forms a series of decorative surface shapes, then polishes the resin part with No. 500 sandpaper and ultra-fine grade polishing compound, and is covered with a black and smooth surface resin edge all around the outer edge. Get an edged furniture panel. This furniture panel with a resin edge has high strength at the edge part, and the entire panel has no warp and has an excellent appearance.

[0032]

[Table 1]

[Example 2] The type 2 plywood in Example 1 was changed to MDF (medium wood fiberboard), and the side surface of the core material and the inner hole side surface of the auxiliary core material were coated with a urethane resin paint primer for woodworking. A furniture panel with a circular resin edge, which is manufactured in the same manner as in Example 1 except that the sealing treatment is performed by coating three times, and the outer periphery of which is black and covered with a resin edge having a smooth surface, is obtained.
This furniture panel with a resin edge has high strength at the edge, and the entire panel has no warp and is aesthetically pleasing.

[Example 3] A wooden frame having a width of 60 mm and a thickness of 35 mm is pinned and joined by an air tacker to form a wooden frame. A honeycomb core of the same thickness is fitted in the frame of this wooden frame, and a water-based vinyl urethane adhesive is further applied to it, with a width of 700 mm and a length of 12
A plywood plate having a thickness of 20 mm and a thickness of 3 mm is placed on the top and bottom, and pressed and bonded at a pressure of 3 kg / cm ² for 5 hours to form a rectangular flash core material having the cross section of FIG. 3 and the size shown in Table 1. Then, a wooden frame material having a width of 60 mm and a thickness of 41 mm is similarly air-tacked to prepare a rectangular wooden frame auxiliary core material having a size shown in Table 1. A urethane sealant for construction is applied to the wooden frame joint portion of the core material and the auxiliary core material to prevent the penetration of the liquid resin, and a sealing treatment is applied.

Then, a vinyl acetate emulsion adhesive is applied to both surfaces of the core material and the auxiliary core material so that the core material is positioned in the inner hole portion of the auxiliary core material and sandwiched between the top sheet and the back sheet. Adhere by squeezing and pressing with a woodworking press at a pressure of 5 kg / cm ² for 18 hours. At this time, a bamboo round bar having a diameter of 1 mm and a length of 40 mm is inserted into the six important places between the core material and the auxiliary core material so that the core material and the auxiliary core material are 40 mm apart. It is glued at regular intervals. Further, after the bonding is completed, two holes having a diameter of 30 mm leading to the internal tunnel are drilled in the auxiliary core member on one long side of the bonded body to form openings for injecting the liquid resin.

The adhesive body was held upright with the opening facing upward, and was colored ivory.
The epoxy resin formulation shown in 1 is poured into the tunnel from one opening, and filled up to the top of the opening.
Let stand for one day at room temperature to cure the liquid resin. On this occasion,
The other opening plays a role of an exhaust port during resin injection and helps to inject quickly. Next, using an NC router for woodworking, which is equipped with a chamfering bit different from that of Example 1, the resin edge having the cross-sectional shape of FIG. 6-C is cut and formed along the tunnel portion in the same manner as in Example 1. Are formed on the peripheral edge of the panel.

Then, the surface of the resin edge is ground with No. 500 sandpaper, and the exposed cross section of the bamboo pin is coated with a coloring agent to modify it. Then, the entire panel including the resin edge is subjected to room temperature curing urethane for woodworking. A rectangular furniture panel is obtained which has a clear finish with resin paint and is covered with ivory colored resin edges all around the perimeter. This resin edged furniture panel has high strength at the edge portion, has no warp in the entire panel, and is excellent in aesthetics.

[0038]

[Table 2] * 1: Better Living Interior Door Performance Test TWD
According to -08, the plane tensile peel strength between the resin edge and the core material is evaluated. * 2: Japan Agricultural Standard JAS special plywood We processed the actual furniture panel by cold heat cyclic C test and evaluated the resin edge and the joint with the core material. * 3: Better Living Interior Door Performance Test TWD
Warpage is evaluated according to -11.

From the results in the above table, Examples 1 to 3
Have sufficient practicality as furniture panels.

[0040]

As described above, according to the present invention, an adhesive body having a built-in tunnel is formed, and liquid resin is injected while being held substantially vertically to be cured. Can manufacture products. Further, since the liquid resin is injected into the tunnel through the opening, there is an effect that the liquid resin can be injected without any trouble even if the adhesive body, which is an intermediate body of the furniture panel, is warped. Further, since the furniture panel of the present invention has a three-layer structure including the top sheet, the core material, and the back sheet, the furniture panel obtained also has an effect that the warpage is extremely small.

[Brief description of drawings]

FIG. 1 is an exploded perspective view of an embodiment of an adhesive body incorporating a tunnel and an opening according to the present invention.

FIG. 2 is an explanatory diagram of a flash core material that is an embodiment of the core material of the present invention.

FIG. 3 is a cross-sectional view of a plywood-attached flash core material that is another embodiment of the core material of the present invention.

FIG. 4 is a partial cross-sectional view of an adhesive body according to the present invention. A is an embodiment in which the core material and the auxiliary core material have the same thickness, and B is an embodiment in which the thickness is different.

FIG. 5 is an explanatory view showing an adhesive body according to the present invention and injecting a liquid resin into the adhesive body.

FIG. 6 is a sectional view showing a typical shape of a resin edge obtained by the present invention.

FIG. 7 is a perspective view of an embodiment of a furniture panel with resin edges according to the present invention.

[Explanation of symbols]

 1 Surface Sheet 2 Core Material 3 Auxiliary Core Material 4 Back Sheet 5 Opening 6 Wooden Frame 7 Honeycomb Core 8 Tucker Pin 9 Plywood 10 Tunnel 11 Liquid Resin 12 Resin Edge

Claims (3)

[Claims] 1. A method for producing a furniture panel with a resin edge, comprising the following steps (1) to (6). (1) A step of preparing the following materials (a) to (e). (A) A plate-shaped core material having a plane shape selected in advance. (B) A plate-shaped auxiliary core material that follows the planar shape of the core material, has an inner surface hole larger than this planar shape, and has an opening from the inner surface hole to the outer edge. (C) Top sheet. (D) Back sheet. (E) An adhesive capable of adhering the above two sheets to the core material and the auxiliary core material. (2) The core material and the auxiliary core material are sandwiched and adhered between the top sheet and the back sheet, while maintaining a predetermined gap between the side surface of the core material and the side surface of the inner hole of the auxiliary core material. , Forming a series of tunnels inside the adhesive body. (3) A step of holding the adhesive body substantially vertically such that the opening is located at the highest part of the tunnel. (4) A step of injecting a curable liquid resin having adhesiveness with the core material through the opening to fill the inside of the tunnel and reach a certain level of the opening, and then curing. (5) A step of cutting the resin portion of the cured tunnel along the tunnel through the top sheet and the back sheet and cutting it so as to form a decorative surface shape to form a resin edge. (6) A step of polishing and finishing the formed resin edge. 2. The method of manufacturing a furniture panel with a resin edge according to claim 1, wherein a side surface of the core material and / or a side surface of the inner surface hole of the auxiliary core material is pre-sealed before adhesion in order to prevent the liquid resin from permeating. 3. The method for producing a furniture panel with a resin edge according to claim 1, wherein the surface sheet is a melamine resin decorative board.