JPH08112882A - Woody decorative panel and manufacture thereof - Google Patents

Abstract

PURPOSE: To obtain enough practical strength and rigidity even when the panel is thinner than the panel manufactured by the conventional technique by a method wherein a thermosetting resin-impregnated glass fiber base material is thermocompression-bonded onto the rear side of decorative sheet having a thin surface layer of natural wood and finally the thermosetting resin is set. CONSTITUTION: This decorative panel is obtained by thermocompression-bonding a thermosetting resin-impregnated glass fiber base material 2 onto the rear side of a decorative sheet 1 having a thin surface layer 1a of natural wood and finally the thermosetting resin is set. The decorative sheet 1 is formed by laminating thin surface layer 1a of a natural wood veneer, a thin intermediate layer 1b of a metal such as aluminum or the like and the rear surface layer 1c of incombustible paper or cloth to one another in the order named through an adhesive. Since the decorative sheet 1 has its rear surface layer 1c of paper, cloth or the like, the thermosetting resin in the glass fiber base material 2 permeates in the rear surface layer 1c at the thermocompression- bonding so as to realize strong bonding of the decorative sheet 1 with the glass fiber base material 2 through the setting of the thermosetting resin.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a wood decorative panel suitable for use in, for example, a fire door in an entrance or a room, an incombustible wall covering or a partition, and a method for producing the same.

[0002]

2. Description of the Related Art In conventional fire doors and the like, wood-like decorative panels are used in which a decorative plywood of natural wood is attached to an inorganic substrate such as gypsum or calcium silicate with an adhesive. In addition, a wood-like decorative panel in which a decorative plate made of natural wood is bonded to a foam substrate made of non-flammable resin such as phenol with an adhesive is also used.

[0003]

However, in the above decorative panel, since the decorative board of natural wood stuck to the surface is difficult to bend, the panel surface is flat in all cases, and the decorativeness is intentionally increased. When an uneven surface is formed in order to increase the appearance of the decorative panel 100, as shown in FIG.
It is necessary to form a concave groove 101 on the surface of the mold and fit and bond the molding material 102 or the like, or to grind the decorative board itself of natural wood into unevenness, and in either case, the processing is troublesome and costly. There was a problem of becoming.

A decorative panel in which a decorative board made of natural wood is bonded to an inorganic substrate has a problem that it is difficult to carry because the weight of the inorganic substrate is large. However, there is a problem that warping, bending, cracking or the like occurs due to heating. In addition, when the decorative plate is bonded, it is necessary to reduce the bonding pressure so that the inorganic substrate will not be broken, and therefore there is a problem that a partial bonding failure or the like is likely to occur.

On the other hand, a decorative panel in which a decorative board made of natural wood is adhered to a foam substrate made of non-combustible resin has an advantage that it is easy to carry because the foam substrate is relatively lightweight. Since the strength and rigidity are not so large, it is necessary to use a substrate having a considerable thickness, and there is a problem that the thickness of the entire panel cannot be extremely thin.

The present invention has been made in view of the above problems, and an object of the present invention is to firmly bond and integrate a woody decorative sheet on the surface with a base material without damaging the surface by heat during molding by hot pressing. Provided is a wooden decorative panel which has sufficient strength and rigidity even if the thickness of the panel is thinner than that of a conventional product and can easily form an uneven pattern having a three-dimensional effect on the panel surface, and a manufacturing method thereof. It is in.

[0007]

In order to achieve the above object, the wood decorative panel according to claim 1 of the present invention is a glass in which a back surface of a decorative sheet having a thin surface layer of natural wood is impregnated with a thermosetting resin. 3. The wood decorative panel according to claim 2, wherein the fiber base material is thermocompression-bonded to cure a thermosetting resin, and the wood decorative panel has an uneven pattern having unevenness larger than the thickness of the decorative sheet on at least the surface side of the panel. It is characterized by being formed.

The manufacturing method according to claim 3 of the present invention is
A decorative sheet with a thin surface layer of natural wood and a glass fiber base material impregnated with thermosetting resin are placed between the upper and lower molds attached to the upper and lower heating plates of the hot press machine. Then, set one heating plate located on the side of the decorative sheet to 1
While heating to a relatively low temperature of 00 to 140 ° C. and heating the other heating plate located on the glass fiber base material side to a temperature higher than the temperature of the one heating plate, an upper mold and a lower mold are used. The present invention is characterized in that a decorative sheet and a glass fiber base material are thermocompression-bonded to cure a thermosetting resin.
The manufacturing method according to claim 4, wherein in the manufacturing method described above, as one of the upper mold and the lower mold located at least on the decorative sheet side, an uneven pattern forming surface having an uneven difference larger than the thickness of the decorative sheet. Using a metal mold engraved with, the thermosetting resin is cured by thermocompression bonding the decorative sheet and the glass fiber base material with the upper mold and the lower mold, and at least the surface of the decorative sheet side by the concave-convex pattern molding surface. It is characterized in that an uneven pattern is formed at the same time.

Further, in the manufacturing method of claim 5, a decorative sheet having a thin surface layer of natural wood and a glass fiber base material impregnated with a thermosetting resin are superposed and set between upper and lower heating plates of a hot press machine. When at least one heating plate located on the side of the decorative sheet and the decorative sheet, the uneven pattern forming spacer having a thickness larger than the thickness of the decorative sheet is arranged, and one of the heating located on the decorative sheet side is heated. While heating the plate to a relatively low temperature of 100 to 140 ° C. and heating the other heating plate located on the glass fiber base material side to a temperature higher than the temperature of the one heating plate, the uneven pattern forming spacer is formed. Via the upper and lower heating plates to thermocompress the decorative sheet and the glass fiber base material to cure the thermosetting resin,
It is characterized in that an uneven pattern is simultaneously formed on at least the surface of the decorative sheet side.

[0010]

In the wood decorative panel according to claim 1 of the present invention, a glass fiber base material impregnated with a thermosetting resin is thermocompression-bonded to the back surface of the decorative sheet to cure the thermosetting resin. The glass fiber base material is firmly bonded and integrated,
There is no fear of peeling. Moreover, since the glass fiber base material in which the thermosetting resin is cured is far tougher than the inorganic substrate of the conventional panel, it has sufficient strength and rigidity even if the thickness of the glass fiber base material is reduced. Further, since the decorative sheet on the surface is also a thin sheet having a thin surface layer of natural wood, the wood decorative panel according to claim 1 of the present invention can be made much thinner than the conventional panel. And
This wooden decorative panel is manufactured by the manufacturing method according to claim 3.
One heating plate located on the decorative sheet side is 100 to 140
While heating to a relatively low temperature of ℃, while heating the other heating plate located on the glass fiber substrate side to a temperature higher than the temperature of the one heating plate, with a mold attached to both heating plates. Since the decorative sheet and the glass fiber base material are produced by thermocompression bonding, the thermosetting resin in the glass fiber base material is rapidly cured by the heat of the heating plate heated to a high temperature, and the decorative sheet. On the other hand, since the decorative sheet is heated firmly with a heating plate having a relatively low temperature of 100 to 140 ° C., the surface layer of the natural wood of the decorative sheet can be prevented from being damaged by heat.

In addition to the above, the wood decorative panel according to claim 2 has an uneven pattern having a difference in unevenness larger than the thickness of the decorative sheet on at least the surface side of the panel. The property is further improved. In this wood decorative panel, the uneven pattern is formed at the time of thermocompression bonding of the decorative sheet and the glass fiber base material by the manufacturing method according to claim 4 or 5, so that no complicated uneven processing is required unlike the conventional panel. Moreover, since the surface layer of the natural wood of the decorative sheet is thin and can be bent, even if an uneven pattern is formed, the surface layer of the natural wood does not break at the bent portion and cracks or the like occur.

According to the manufacturing method of the fourth aspect, since the decorative sheet and the glass fiber base material are thermocompression-bonded at the same time with the mold having the concave-convex pattern forming surface, the concave-convex pattern is formed. This is advantageous when mass-producing wooden decorative panels, but when producing panels with different uneven patterns little by little, the die must be replaced each time, which is disadvantageous because the die cost increases. is there. On the other hand, according to the manufacturing method of claim 5, since the uneven pattern forming spacer simultaneously forms the uneven pattern, various uneven patterns can be formed by changing the arrangement and shape of the spacers. Since it is much cheaper than the mold even if it is replaced, it is advantageous when small quantities of wooden decorative panels having different uneven patterns are produced.

[0013]

Embodiments of the present invention will be described below with reference to the drawings.

FIG. 1 is an enlarged cross-sectional view of an end portion showing an embodiment of a wood decorative panel according to claim 1 of the present invention. As shown, the back surface of a decorative sheet 1 having a thin surface layer 1a of natural wood. Further, the glass fiber base material 2 impregnated with the thermosetting resin is thermocompression bonded to cure the thermosetting resin, and the decorative sheet 1 and the glass fiber base material 2 are firmly bonded.

The decorative sheet 1 is a thin surface layer 1a made of a natural wood wood board such as mahogany, teak, olive, walnut, taro, oak, etc., an intermediate thin layer 1b made of a metal such as aluminum, and noncombustible paper. And a back surface layer 1c made of cloth or the like, which is laminated with an adhesive,
Preferably, the thickness of the surface layer 1a is about 150 to 250 μm, the thickness of the intermediate thin layer 1b is about 40 to 70 μm, the thickness of the back surface layer 1c is about 50 to 150 μm, and the total thickness is 24.
A sheet of about 0 to 470 μm is used.

Since such a decorative sheet 1 has a back surface layer 1c such as paper or cloth, the glass fiber base material 2 during thermocompression bonding is used.
The thermosetting resin therein penetrates into the back surface layer 1c and can be firmly bonded to the glass fiber base material 2 by curing the thermosetting resin. In addition, the surface layer 1a of natural wood is 150 to 25
Since it is as thin as 0 μm, it can be bent and the surface layer 1
Since a is laminated with the metal intermediate thin layer 1b, even if the natural wood of the surface layer 1a burns, it will not be cut off by the metal intermediate thin layer 1b and will not burn inside.

The glass fiber base material 2 is made of glass fiber cloth (plain weave, satin weave, three-dimensional hollow weave, etc.) or chopped strand mat. The base material 2 is impregnated with a thermosetting resin. It is hardened. Glass fiber three-dimensional hollow woven cloth is lighter and thicker than plain woven or satin woven cloth, and the thickness can be easily adjusted by the springback characteristics of the glass fiber in the vertical direction. It is particularly preferable as the glass fiber base material 2 because a base material layer having a large amount of heat insulation can be formed.

As the thermosetting resin with which the glass fiber base material 2 is impregnated, a highly flame-retardant phenol resin, melamine resin, resorcin resin, or a mixed resin obtained by mixing a phenol resin with a resorcin resin is used. Of these, resorcin resin and the above-mentioned mixed resin having a relatively low curing temperature are preferably used. This is because when the curing temperature is low, the temperature at the time of thermocompression bonding with the decorative sheet 1 can be further lowered, and deterioration due to heat, discoloration, damage, etc. can be prevented. When the above three types of resins are used, the flame retardancy of the glass fiber base material 2 can be increased and the wood decorative panel can be made nonflammable.

The impregnated amount of the thermosetting resin is not particularly limited, but if the impregnated amount is too small, a tough base material layer is not formed, so 100 parts by weight of the glass fiber base material is mixed with 20 parts of the thermosetting resin. -100 parts by weight, preferably 20-40
It is preferable to impregnate it in a ratio of parts by weight.

The glass fiber base material 2 thus impregnated with the thermosetting resin and cured is much tougher than a conventional inorganic substrate, and the thickness of the glass fiber base material 2 is, for example, 2 mm.
It has sufficient practical strength and rigidity even if it is made as thin as possible. And the decorative sheet 1 on the surface is also 470 μm as described above.
Since it is the following thin sheet, this wooden decorative panel can be made significantly thinner than the conventional panel.

It should be noted that the glass fiber base material 2 may contain an appropriate amount of an inorganic powder having crystal water such as aluminum hydroxide or magnesium hydroxide to further improve the incombustibility. In some cases, a calcium silicate plate, a cement-based inorganic plate, or a resin foam plate made of highly flame-retardant resin may be laminated on the back surface of the glass fiber base material 2.

The wooden decorative panel having the above structure is manufactured by the following method.

That is, as shown in FIG. 3, between the upper and lower flat molds 11a and 11b attached to the upper and lower heating plates 10a and 10b of the hot press machine, the above-mentioned decorative sheet 1 and heat are applied. A plurality of glass fiber base materials 2 impregnated with a curable resin
Set by stacking. The upper heating plate 10a located on the decorative sheet side is heated to a relatively low temperature of 100 to 140 ° C., preferably 100 to 120 ° C., and the lower heating plate 10b located on the glass fiber base material side is described above. While heating to a temperature higher than the temperature of the upper heating plate 10a, the upper heating plate 10a is lowered, and the decorative sheet 1 and the glass fiber base material 2 are thermocompression bonded by the upper mold 11a and the lower mold 11b. The thermosetting resin in the base material 2 is cured.

In this case, the lower heating plate 10b is used so that the thermosetting resin in the glass fiber base material 2 can be quickly cured to shorten the curing time and improve the productivity.
It is desirable to heat to a temperature of 40 to 190 ° C., and the pressure condition of thermocompression bonding should be 1 to 20 kgf / c so as to prevent defective bonding between the decorative sheet 1 and the glass fiber base material 2.
It is desirable to set m ² and the pressure bonding time to 5 to 60 minutes.

When the decorative sheet 1 and the glass fiber base material 2 impregnated with the thermosetting resin are thermocompression bonded as described above, part of the thermosetting resin penetrates into the back surface layer 1c of the decorative sheet 1 such as paper or cloth. Then, the thermosetting resin is rapidly cured by the heat of the lower heating plate 10b heated to a high temperature of 140 to 190 ° C. to form a tough base material layer, and at the same time, the decorative sheet 1 is firmly bonded and integrated. Be converted. Since the decorative sheet 1 is heated by the upper heating plate 10a at a relatively low temperature of 100 to 140 ° C., the surface layer 1a of the natural tree of the decorative sheet 1 is damaged by being burnt, discolored or deteriorated by heat. There is no such thing. Therefore, according to this manufacturing method, the decorative sheet 1 and the tough glass fiber base material 2 containing the thermosetting resin are firmly bonded to each other, and a wooden decorative panel having a beautiful natural wood surface and excellent in strength and rigidity is obtained. It can be easily manufactured.

The temperature of the upper heating plate 10a needs to be set in the range of 100 to 140 ° C. as described above.
If the temperature is higher than 140 ° C, the surface layer 1a of the natural wood of the decorative sheet 1 may be burnt, discolored or deteriorated by heat and may be damaged, and if the temperature is lower than 100 ° C, the glass fiber base material may be damaged. The thermosetting resin impregnated in the portion near the second heating plate 10a may cause curing failure.

FIG. 2 is a sectional view showing an embodiment of the wood decorative panel according to claim 2 of the present invention. This wood decorative panel is a panel in which a glass fiber base material 2 impregnated with a thermosetting resin is thermocompression-bonded to the back surface of the decorative sheet 1 to cure the thermosetting resin, and unevenness is provided on both front and back surfaces thereof. Pattern 3
Is formed. The uneven pattern 3 does not necessarily have to be formed on the back surface of the panel, and may be formed on at least the front surface of the panel.

It is necessary to make the unevenness of the uneven pattern 3 larger than the thickness (about 0.5 mm) of the decorative sheet 1. If it is smaller than this, it becomes difficult to give a three-dimensional effect to the panel surface and enhance the decorativeness. . However, if the unevenness difference is made too large, the decorative sheet 1 is broken or cracked. Therefore, it is desirable that the unevenness difference be about 1 to 10 mm. In addition, the stepped portion of the uneven pattern 3 is formed so that the bending angle θ1 of the decorative sheet 1 is an obtuse angle of 135 to 165 °, or the decorative sheet 1 is formed so as to be rounded and bent. desirable. If the refraction angle θ1 is smaller than 135 °, the surface layer 1a of the natural wood of the decorative sheet 1 is likely to be broken and cracks are easily generated.

Since the decorative sheet 1 and the glass fiber base material 2 impregnated with the thermosetting resin are the same as those described above,
Description is omitted.

The wooden decorative panel having the concavo-convex pattern formed as described above is manufactured by the following method.

That is, as shown in FIG. 4, the upper and lower heating plates 10a and 10b of the hot press machine are provided with uneven pattern forming surfaces 12a and 12 having a difference in unevenness larger than the thickness of the decorative sheet 1.
The upper mold 11a and the lower mold 11b, which are engraved with b, are attached, and the decorative sheet 1 and the glass fiber base material 2 impregnated with the thermosetting resin 2 are attached.
Is heat-pressed by the upper mold 11a and the lower mold 11b to cure the thermosetting resin, and the concavo-convex pattern is simultaneously formed on the front and back surfaces by the concavo-convex pattern forming surfaces 12a and 12b. Also in this case, the upper heating plate 10a is set to a relatively low temperature of 100 to 140 ° C. so that the surface layer of the natural wood of the decorative sheet 1 is not damaged by heat, and the lower heating plate 10b is set to the glass fiber substrate 2 The upper heating plate 10 so that the thermosetting resin therein is quickly cured.
It is set to 140 to 190 ° C., which is a temperature higher than a. Then, the pressure condition of the thermocompression bonding is set to 1 to 20 kgf / cm so that the defective bonding between the decorative sheet 1 and the glass fiber base material 2 does not occur.
^2. Set the crimping time to 5-60 minutes.

When the concavo-convex pattern 3 is formed only on the surface of the panel, the upper mold 1 having the concavo-convex pattern forming surface 12a is engraved.
1a and a plate-shaped lower mold 11b, and upper and lower heating plates 10a, 1
0b, and similarly, the decorative sheet 1 and the glass fiber base material 2 impregnated with the thermoplastic resin may be thermocompression bonded.

According to the above-mentioned manufacturing method, since the concavo-convex pattern 3 is simultaneously formed when the decorative sheet 1 and the glass fiber base material 2 impregnated with the thermosetting resin are thermocompression bonded, it is troublesome like a conventional panel. Since it is not necessary to carry out uneven processing, it is possible to efficiently manufacture a wooden decorative panel having a three-dimensional effect and excellent decorative properties in one step. Moreover, since the decorative sheet 1 can be bent as described above, even if an uneven pattern is formed, the surface layer 1a of the natural wood is unlikely to be broken at the bent portion to cause cracks or the like, and in particular, the unevenness difference is 1 to 10 mm. When the concavo-convex pattern 3 is formed so that the bending angle θ1 of the decorative sheet 1 is 135 to 165 °, cracking of the surface layer 1a of the natural wood can be almost certainly prevented.

5 and 6 show another embodiment of a method for manufacturing a wood decorative panel having an uneven pattern. FIG. 5 shows a state in which the upper and lower heating plates 10a and 10b of the hot press machine are opened. FIG. 6 shows a thermocompression bonding state in which the upper and lower heating plates 10a and 10b are closed.

According to this manufacturing method, as shown in FIG. 5, the above-mentioned decorative sheet 1 is provided between the upper and lower heating plates 10a and 10b.
And the glass fiber base material 2 impregnated with the thermosetting resin are stacked and set, an uneven pattern forming spacer 1 is provided between the lower heating plate 10b and the central portion of the glass fiber base material 2.
3b is arranged, and an uneven pattern forming spacer 13a is provided between the upper heating plate 10a and the peripheral portion of the decorative sheet 1.
And an auxiliary spacer 13c between the upper heating plate 10a and the central portion of the decorative sheet 1. Then, the upper heating plate 10a is heated to a relatively low temperature of 100 to 140 ° C., preferably 120 to 140 ° C., and the lower heating plate 10b is heated to 150 to 190 ° C. which is a higher temperature than the upper heating plate 10a. While heating, the upper heating plate 10a is lowered, and as shown in FIG. 6, the upper and lower heating plates 10 are interposed via the uneven pattern forming spacers 13a and 13b.
When the decorative sheet 1 and the glass fiber base material 2 are thermocompressed with a and 10b to cure the thermosetting resin, uneven patterns are simultaneously formed on both front and back surfaces. Also in this case, the pressure condition of thermocompression bonding is set to 1 to ²⁰ kgf / cm ² and the pressure bonding time is set to 5 to 60 minutes so that the decorative sheet 1 and the glass fiber base material 2 containing the thermosetting resin are firmly bonded. .

Further, when the uneven pattern is formed only on the panel surface, the uneven pattern forming spacer 13b between the glass fiber substrate 2 and the lower heating plate 10b is removed, and the decorative sheet 1 and the upper heating plate are removed. The concavo-convex pattern forming spacer 13a and the auxiliary spacer 13c may be arranged only between 10a and 10a, and thermocompression bonding may be performed as described above.

As the spacers 13a and 13b for forming the concavo-convex pattern, spacers made of metal such as aluminum and steel and spacers made of heat-resistant synthetic resin such as polyphenylene sulfide are used. In particular, spacers made of polyphenylene sulfide resin are easy to process In addition to having good heat resistance, it has the advantage of being lightweight and less likely to stick to the thermosetting resin in the glass fiber base material 2.
It is very suitably used as 13b. It is necessary to use those having a thickness larger than the thickness of the decorative sheet 1 as the spacers 13a and 13b for forming the concavo-convex pattern, in order to form the concavo-convex pattern rich in three-dimensional effect, preferably a thickness of about 1 to 15 mm. Are used.

On the other hand, the auxiliary spacer 13c is not always necessary, but if there is a portion with spacers and a portion without spacers, the pressure will not be evenly applied between them, so the decorative sheet 1 and the heating plate 10a above it. Is arranged between the sheet and the glass fiber base material 2 so that pressure can be uniformly applied to the decorative sheet 1 and the glass fiber base material 2, and a plate spacer made of polyphenylene sulfide having a thickness of about 1 to 5 mm is preferably used. To be done.

When the auxiliary spacer 13c is arranged, the auxiliary spacer 13c and the uneven pattern forming spacer 13 are arranged.
Needless to say, it is necessary to set the thickness of each spacer so that the total thickness of the spacers b is equal to the thickness of the uneven pattern forming spacer 13a.

As shown in FIG. 7, the gap g between the concave-convex pattern forming spacer 13a and the concave-convex pattern forming spacer 13b.
So that the bending angle θ1 of the decorative sheet 1 is 135 to 165 °, in other words, the inclination angle θ2 of the step portion is 45 to 1
It is desirable that the thickness is about 1 to 4 times the thickness t of the uneven pattern forming spacer 13b so as to be 5 °. By setting the gap g in this manner, it is possible to reliably prevent the decorative sheet 1 from being bent at the bent portion and cracking or the like.

Further, using the concave-convex pattern forming spacers 13d and 13e as shown in FIG. 8, that is, the ones in which the curved surface 130 is formed without edges, the curved surfaces 130 and 130 are formed.
When placed on the upper side of the decorative sheet 1 and the lower side of the glass fiber base material 2 so as to have a space between them and thermocompression-bonded, the stepped portion bends with a rounded shape, and similarly, cracks of the decorative sheet are surely prevented. can do.

According to the above manufacturing method, when the decorative sheet 1 and the glass fiber base material 2 impregnated with the thermosetting resin are thermocompression-bonded, the central portion thereof is pushed up from below by the concave-convex pattern forming spacer 13b. At the same time, the peripheral portion is pressed down from above by the uneven pattern forming spacer 13a, and the uneven pattern is simultaneously formed. By changing the arrangement and shape of each spacer, it is possible to freely form various shapes of uneven patterns, and as shown in FIG. 9, several kinds of uneven pattern forming spacers 13f, 13g, 13h are formed. , 13i in combination and arranged above and below the decorative sheet 1 and the glass fiber base material 2, a concavo-convex pattern bent in multiple steps can be easily formed. Therefore, this manufacturing method is extremely advantageous when manufacturing wooden decorative panels with different uneven patterns little by little. Further, there is an advantage that it is not necessary to manufacture an expensive mold according to each shape, the cost can be reduced, and the manufacturing can be performed in a short period of time.

In addition to the above-described manufacturing method, the wooden decorative panel having an uneven pattern is formed by a pressure molding method shown in FIG. 10, that is, a mold or spacer for molding the uneven pattern on the heating plate 14 at the bottom of the chamber. 15 is arranged, and the decorative sheet 1 and the glass fiber base material 2 impregnated with the thermosetting synthetic resin are stacked and set thereon, and heated high pressure air is supplied into the chamber and degassed from the intake passage 18. Then, the decorative sheet 1 and the glass fiber substrate 2 can be manufactured by a method of thermocompression bonding and simultaneously forming an uneven pattern.

Further, in the vacuum forming method shown in FIG. 11, that is, a mold or spacer 17 for forming an uneven pattern is arranged on the heating plate 16 at the bottom of the chamber, and the decorative sheet 1 and the thermosetting composition are formed thereon. The glass fiber base material 2 impregnated with the resin is set in a stacked manner, air is sucked from the heating plate 16 and the intake passage 18 provided in the mold or the spacer 17, and the heated air is sent into the chamber. It is also possible to manufacture the glass fiber base material 2 by applying atmospheric pressure to the glass fiber base material 2 for thermocompression bonding and at the same time forming an uneven pattern.

Further, in FIG. 10 or FIG.
While sucking air from the intake passage 18,
It is also possible to adopt a vacuum pressure molding method in which heated compressed air of ˜5 kgf / cm ² is fed to perform molding.

Although the decorative sheet 1 is arranged on the upper side of the glass fiber base material 1 in each of the above-mentioned embodiments, the decorative sheet 1 is arranged on the lower side and molding such as pressing is similarly performed. Of course, you can do it.

[0047]

As apparent from the above description, the wood decorative panel according to claim 1 of the present invention is impregnated with a thermosetting resin.
The cured glass fiber base material is tough, has a high bonding strength with the decorative sheet, and has sufficient practical strength and rigidity even if the thickness of the entire panel is thinner than that of the conventional panel. According to the method, it is possible to easily manufacture the surface layer of the natural wood of the decorative sheet without damaging the surface layer with heat.

In addition to the above effects, the woody decorative panel according to claim 2 of the present invention has further improved decorativeness due to the uneven pattern formed on the surface thereof. According to the manufacturing method of claim 4 or 5, , Without damaging the surface layer of the natural wood of the decorative sheet with heat or cracking at the bent part,
It is possible to efficiently manufacture a concavo-convex pattern at the same time as thermocompression bonding in a single process, and it is possible to eliminate the need for a complicated surface concavo-convex process as in a conventional panel. Particularly, in the manufacturing method of claim 5, various uneven patterns can be formed by changing the arrangement and shape of the uneven pattern forming spacer,
Since the spacer is much cheaper than the mold, it has an effect that it is suitable for producing a small amount of wood-made decorative panels having different uneven patterns in a short period of time.

[Brief description of drawings]

FIG. 1 is an enlarged cross-sectional view of an end showing an embodiment of the wood decorative panel according to claim 1 of the present invention.

FIG. 2 is a cross-sectional view showing an embodiment of a wood decorative panel according to claim 2 of the present invention.

FIG. 3 is an explanatory view of an embodiment of the manufacturing method according to claim 3 of the present invention, showing a state before the thermocompression bonding in which the upper and lower heating plates of the hot press machine are opened.

FIG. 4 is an explanatory view of an embodiment of a manufacturing method according to claim 4 of the present invention, showing a state before thermocompression bonding in which the upper and lower heating plates of the hot press machine are opened.

FIG. 5 is an explanatory view of an embodiment of a manufacturing method according to claim 5 of the present invention, showing a state before thermocompression bonding in which the upper and lower heating plates of the hot press machine are opened.

FIG. 6 is an explanatory diagram of the embodiment, showing a state during thermocompression bonding in which the upper and lower heating plates of the hot press machine are closed.

7 is a partially enlarged view of FIG.

FIG. 8 is a partially enlarged view of a case where the uneven pattern forming spacers having different shapes are used in FIG. 6;

FIG. 9 is an explanatory view of another embodiment of the manufacturing method according to claim 5 of the present invention, showing a state during thermocompression bonding in which the upper and lower heating plates of the hot press machine are closed.

FIG. 10 is an explanatory view of another method for manufacturing the wooden decorative panel according to claim 2 of the present invention.

FIG. 11 is an explanatory view of still another method of manufacturing the wood decorative panel according to claim 2 of the present invention.

FIG. 12 is a schematic cross-sectional view showing an example of a conventional panel having an uneven surface.

[Explanation of symbols]

DESCRIPTION OF SYMBOLS 1 Decorative sheet 1a Surface layer of natural wood 2 Glass fiber base material impregnated with thermosetting resin 3 Uneven pattern 10a, 10b Upper and lower heating plates 11a Upper mold 11b Lower mold 12a, 12b Uneven pattern molding surface 13a, 13b, 13d, 13e, 13f, 13g, 1
3h, 13i Uneven pattern forming spacer 13c Auxiliary spacer

─────────────────────────────────────────────────── ─── Continuation of the front page (51) Int.Cl. ⁶ Identification code Internal reference number FI technical display location B32B 21/08 101 9349-4F 31/20 9349-4F 33/00 9349-4F // B29K 101: 10 105: 08 105: 20 B29L 9:00 31:10

Claims (5)

[Claims] 1. A wood decorative panel comprising a decorative sheet having a thin surface layer of natural wood and a thermosetting resin impregnated on the back surface of the decorative sheet to cure the thermosetting resin. 2. A wood decorative panel comprising a thermosetting resin-impregnated glass fiber base material which is thermocompression-bonded to the back surface of a decorative sheet having a thin surface layer of natural wood to cure the thermosetting resin. A wooden decorative panel formed by forming an uneven pattern having unevenness larger than the thickness of a decorative sheet on at least the surface side of the panel. 3. A glass fiber substrate in which a decorative sheet having a thin surface layer of natural wood and a thermosetting resin are impregnated between upper and lower molds attached to the upper and lower heating plates of a hot press machine. And one heating plate located on the decorative sheet side are heated to a relatively low temperature of 100 to 140 ° C., and the other heating plate located on the glass fiber base material side is set to the one heating plate. While heating to a temperature higher than
A method for manufacturing a wood decorative panel, characterized by thermocompressing a decorative sheet and a glass fiber base material with an upper mold and a lower mold to cure a thermosetting resin. 4. A mold having an uneven pattern forming surface having an unevenness difference larger than the thickness of the decorative sheet is used as at least one of the upper mold and the lower mold located on the decorative sheet side. , The thermosetting resin is cured by thermocompression bonding the decorative sheet and the glass fiber base material with the upper mold and the lower mold, and the uneven pattern is simultaneously formed on at least the surface of the decorative sheet by the uneven pattern forming surface described above. The manufacturing method according to claim 3, wherein 5. A decorative sheet having a thin surface layer of natural wood and a glass fiber base material impregnated with a thermosetting resin are superposed between the upper and lower heating plates of a hot press machine, and at least the decorative sheet side is set. Between the one heating plate and the decorative sheet located on the side of the decorative sheet, a spacer for forming a concavo-convex pattern having a thickness larger than that of the decorative sheet is arranged, and the one heating plate located on the decorative sheet side is compared at 100 to 140 ° C. While heating to a relatively low temperature and heating the other heating plate located on the glass fiber base material side to a temperature higher than the temperature of the one heating plate, makeup is applied to the upper and lower heating plates through the uneven pattern forming spacer. A method for manufacturing a wooden decorative panel, characterized in that the sheet and the glass fiber base material are thermocompression-bonded to cure the thermosetting resin, and an uneven pattern is simultaneously formed on at least the surface of the decorative sheet side.