JPH10286898A - Production of board covered with resin sheet - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for producing a board covered with a resin sheet in which chamfered shapes of all circumferential corner parts on the surface of a base plate are easily given in the producing method of the board covered with the resin sheet by covering the surface and the end face of the base plate with the resin sheet. SOLUTION: The sheet, in which resin component is thermoplastic resin, is used as a resin sheet 3 for covering the surface and a resin sheet 4 for covering an end face. Firstly, both the end face of the sheet of one hand and the surface of the sheet of the other hand are arranged and bonded on a base plate 2 so that two sides essentially touch in the peripheral edge end part of the base plate 2. Then, chamfering is performed to a chamfering face 6 crossing the contact face 5 of the above-mentioned respective resin sheets 3, 4 in the peripheral edge end part of the base plate 2 covered with the resin sheet.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a resin sheet-coated board, and more particularly, to a surface-coated resin sheet coated on at least the surface and an end surface of a substrate and a peripheral edge corner of the end-coated resin sheet. The present invention relates to a method for manufacturing a resin sheet-coated board that can easily impart at least a part of a chamfered shape.

[0002]

2. Description of the Related Art Conventionally, as a resin decorative board used for a table, a top plate of a counter, etc., conventionally, a shielding paper or a desired pattern printing paper as a decorative layer is provided on a surface of a substrate, and a melamine resin impregnated overlay is further provided thereon. BACKGROUND ART A melamine resin decorative board having a sheet attached and having a design and an improved scratch resistance on the surface is widely used.

[0003] The above-mentioned melamine resin decorative board is usually a mass-produced product, and is produced as a ready-made product having standard dimensions. Therefore, it is a plate-like material in which a substrate, a decorative sheet and an overlay sheet are laminated, and an end face is provided. Each of the above-mentioned layers is exposed, and the angle between the surface and the end face is almost a right angle. Therefore, a problem arises in safety during use, so that chamfering or the like is usually required.

[0004] However, as described above, the melamine resin decorative board has a thin melamine resin-impregnated overlay sheet and a decorative sheet, and is hard and brittle in physical properties. As a result, the substrate is exposed on the surface, and further, the laminated section of the substrate and the resin sheet is exposed on the end surface, so that the commercial value is low. This is particularly problematic when the substrate is a particle board, plywood or the like.

[0005] Therefore, as a countermeasure against the above-mentioned problem, usually, a flexible band-shaped material having a rounded end portion is separately coated on the end surface of the decorative plate to ensure safety and improved appearance. . However, according to this method, the seam is conspicuous at the peripheral portion, and it is impossible to give a sense of unity of the material.

[0006]

SUMMARY OF THE INVENTION The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a method for manufacturing a resin sheet-covered board in which a resin sheet is laminated on a substrate surface and an end surface. It is an object of the present invention to provide a method for manufacturing a resin sheet-covered board which can easily provide a chamfered shape at a peripheral corner of the resin sheet.

[0007]

That is, the gist of the present invention is a method of manufacturing a resin sheet-coated board (1) in which a resin sheet is coated on at least a surface and an end face of a substrate (2), comprising a resin for surface coating. A sheet whose resin component is a thermoplastic resin is used as the sheet (3) and the resin sheet for end face coating (4), and first, the end face of one sheet and the surface of the other sheet are the peripheral edge of the substrate (2). The two resin sheets described above are arranged and adhered on the substrate (2) so that at least a part of the portions substantially contact, and then at least the corners formed when the two resin sheets (3) and (4) contact each other. The present invention resides in a method for manufacturing a resin sheet-coated board, characterized in that chamfering is performed to a chamfered surface (6) crossing a contact surface (5) in a part.

[0008]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, the present invention will be described in detail with reference to the attached drawings. FIG. 1 is a vertical cross-sectional explanatory view showing a state in which the surface and the end face of the substrate (2) are coated with a surface-coating resin sheet (3) and an end-face coating resin sheet (4), respectively. FIG. It is a vertical cross-sectional explanatory view in the state where the corner part including the contact surface (5) of the resin sheet for surface coating (3) and the resin sheet for end face coating (4) was chamfered.

According to the present invention, at least the surface and the end face of the substrate (2) are coated with a surface-coating resin sheet (3) and an end-face coating resin sheet (4), respectively, and both resin sheets are formed on the peripheral edge of the substrate (2). Chamfering a corner formed in the portion.

As the substrate (2), a material generally used as a substrate can be used. For example, a natural wood plate, veneer plywood, particle board, resin impregnated plate,
Synthetic wood, paper honeycomb, metal honeycomb, and
Examples include a plate made of a thermoplastic resin such as polyolefin, polystyrene, and polymethylpentene. The substrate (2) is not limited to a thin plate, but may be a block or a column, and may have a triangular, square, or circular surface shape.

The back surface of the substrate (2) is coated with a surface coating resin sheet (3) described later to prevent the occurrence of warpage of the coating board (1), and A backer material can be coated as necessary for protection, improvement of appearance and prevention of mold generation.
As such a backer material, the same sheet as the resin sheet coated on the surface or a sheet having the same coefficient of thermal expansion is preferable.

From the viewpoint of workability, it is preferable to coat the backer material before coating the surface-coated resin sheet. The adhesive used for coating is, for example, a saturated or unsaturated polyester system, vinyl acetate system, polyurethane system, melamine system, urea system, alkyd system, acrylic system,
Phenolic and rubber adhesives are appropriately selected and used according to the adhesive properties of the substrate (2) and the backer material.

The above-mentioned resin sheet contains a thermoplastic resin as a main resin component and may contain a filler if necessary. Examples of the above thermoplastic resin include, for example, polyolefin resin, polystyrene resin, AS resin, ABS resin, polyamide resin, polyester resin, polycarbonate resin, and other various resins. It can be used by blending.
Among the above resins, as a thermoplastic resin used for a top plate such as a table or a counter, a resin composition containing a polyester resin or a polycarbonate resin as a main component is preferably used from a practical viewpoint.

As the above-mentioned filler, a granular, flake or fibrous filler of an inorganic material or an organic material can be used. Above all, in order to increase the uniformity of the sheet or to make the seam less noticeable, the maximum size of the filler is 100 μm.
m, preferably 50 μm or less, more preferably 20 μm or less.
μm or less.

Examples of the inorganic material include particles of barium sulfate, strontium sulfate, zirconium oxide, zirconium silicate, zinc oxide, zinc sulfate, talc, clay, mica, glass, wollastonite, and various metals. Above all, barium sulfate gives a feeling of weight and ceramic to the sheet, so that commercial value can be improved and barium sulfate is suitably used. Such fillers can be used by blending two or more kinds.

If necessary, well-known heat stabilizers, light stabilizers, impact resistance improvers, flame retardants, coloring agents, sheet adhesion improvers, etc. can be added to the resin sheet. Further, the resin sheet may be a single layer sheet or a laminated sheet, and may be stretched.

The thickness of the single-layer or laminated resin sheet is not particularly limited, but is usually 0.1 to 10 m.
m, preferably 0.3 to 6 mm. When the thickness is insufficient as the thickness of the coating layer laminated on the substrate, two or more resin sheets can be laminated and coated.

Examples of the composition of the resin sheet containing the above thermoplastic resin, filler and other additives include, for example, 1 to 25% by weight of polyethylene terephthalate, 5 to 30% by weight of polybutylene terephthalate, Polycarbonate 10-40% by weight, barium sulfate 20-
A composition containing 80% by weight, 0 to 15% by weight of an impact resistance improver, and 0.01 to 10% by weight of a light stabilizer is exemplified.

The above-mentioned resin sheet is prepared by melting a thermoplastic resin, a filler and other additives by a known method, for example, by a melting and kneading apparatus, extruding the sheet from a T-die or the like, and cooling it by a cooling roll or the like. By doing
Can be manufactured.

When the surface and the end face of the substrate (2) are coated with the resin sheet, the end face coating resin sheet (4) may be provided, if necessary, for example, at least a part of the peripheral edge such as only a portion that is visible to the public. And the other end surfaces can be omitted.

In a portion where the two resin sheets are in contact at the peripheral edge of the substrate (2), the substrate (2) is so arranged that one end surface and the other surface edge substantially contact at the peripheral edge of the substrate (2). ) The above both resin sheets are arranged and bonded. In order to make the joint of the contact surface (5) less noticeable, it is preferable that both resin sheets use resin sheets having the same hue. Specific methods for coating include, for example, the following methods (A) and (B).

(A) After laminating and adhering the resin sheet (4) for covering the end face so as to match the end face of the substrate (2), the resin sheet (4) for covering the surface is coated on the end face of the resin sheet (4) for covering the end face. The surface covering resin sheet (3) is coated so that the surface edge of (3) is in contact. At this time, the surface covering resin sheet (3) may be cut into approximate dimensions, and the protruding portion after the covering may be cut off.

(B) After laminating and adhering a resin sheet for surface coating (3) so as to match the surface of the substrate (2), the resin sheet for surface coating (3) is attached to the end face of the resin sheet for edge coating (3). The resin sheet (4) for covering the end surface is coated so that the surface end of (4) is in contact with and covers the end surface of the substrate (2). On this occasion,
The end surface coating resin sheet (4) is cut into approximate dimensions,
After coating, the portion protruding from the coating surface may be cut off.

The adhesive used for the above coating includes:
For example, saturated or unsaturated polyester-based, vinyl acetate-based, polyurethane-based, melamine-based, urea-based, alkyd-based, acrylic, phenol-based, and rubber-based adhesives are used, and the adhesive properties of the substrate (2) and the resin sheet material are exemplified. Is appropriately selected and used according to the conditions.

For joining the resin sheet layer portions, the end surfaces of the resin sheets on both sides can be sufficiently adhered without using an adhesive, but it is preferable to use an adhesive to join. As the adhesive used for joining the resin sheet layer portions, an adhesive based on an acrylic resin is preferably used. At that time, it is preferable to give the adhesive substantially the same hue as the resin sheet, and, for example,
It is preferable to mix the same type of filler as the filler of the resin sheet into the adhesive.

As described above, the right-angle surface corner formed by coating the surface and the end surface of the substrate (2) with the resin sheet is chamfered. Such a chamfering process can be performed only on a portion where there is a problem in safety when using a table, furniture, or the like, but is usually performed on the entire peripheral portion of the surface.

The above-mentioned chamfering is usually performed by using a kind of milling machine called a router or other tools or devices to make the corners round or to form a polygonal surface having two or more obtuse angles. Is performed by grinding or cutting so that At this time, when the cross section of the corner obtained by processing is an arc, the radius of curvature is usually 0.3 to 50 m.
m, preferably 1 to 30 mm.

The chamfered surface (6) is set so as to intersect with the contact surface (5) of the surface covering resin sheet (3) and the end surface covering resin sheet (4). In the present invention,
Since the chamfering is performed so as to intersect with the contact surface (5) of the resin sheets (3) and (4), it is characterized in that the boundary between the joints of the resin sheets becomes less noticeable.

The resin sheet for surface coating (3) and the resin sheet for end face coating (4) both contain a thermoplastic resin and are substantially in close contact with their contact surfaces (5). Since they are smoothed by grinding or cutting by chamfering so as to intersect, the boundary line by the contact surface (5) becomes relatively inconspicuous. Although the reason is not clear, it is presumed that the thermoplastic resin is locally melted and integrated by heat generated during polishing or cutting.

When both resin sheets are opaque, the appearance becomes less noticeable. Furthermore, when the bonding surface between the resin sheet for surface coating (3) and the resin sheet for end surface coating (4) is coated with an adhesive having the same hue as the resin sheet, the bonding boundary is substantially visible. It becomes a so-called covering sheet layer having a pseudo-seamless surface.

The resin sheet-covered board (1) obtained as described above can be suitably used as a top plate of a table or a counter, taking advantage of the above-mentioned features, as well as furniture, building panels, tiles and flooring materials. , Display boards, and other various applications.

[0032]

EXAMPLES Hereinafter, the present invention will be described in more detail with reference to examples, but the present invention is not limited to the following examples unless it exceeds the gist of the present invention.

Example 1 Composition comprising 30% by weight of polycarbonate, 20% by weight of polybutylene terephthalate, 10% by weight of polyethylene terephthalate, 35% by weight of barium sulfate having an average particle size of 8 μm, and 5% by weight of zinc sulfide having an average particle size of 0.3 μm. 26 things
After melt-kneading at 0 to 270 ° C, the mixture was melt-extruded at 255 ° C from a T-die and rapidly cooled by a metal roll nip device at 60 ° C to obtain an inorganic-filled resin sheet having a width of 50 cm and a thickness of 1.5 mm. The resulting resin sheet was a matte, gray-white, opaque sheet full of weight.

On the other hand, thickness 10 mm, width 45 cm, length 2
A particle board of 00 cm was cut, and four corners thereof were cut into a curved surface having a radius of curvature of 15 mm to obtain a substrate (2). Then, a phenol resin sheet having a thickness of 0.3 mm as a backer material was coated on the back surface of the substrate (2) with a chloroprene rubber-based adhesive (“Konishi Super G Ace” manufactured by Konishi Co., Ltd.).

From the above resin sheet, a tape-like sheet having a width of 10 mm and a length of about 5 m was cut out as a resin sheet (4) for covering the end face, and a chloroprene rubber-based adhesive (“KONISHI SUPER G ACE” manufactured by Konishi Co., Ltd.) was applied. The substrate was used and adhered to the entire circumference to cover the end face of the substrate (2).

Thereafter, a resin sheet (3) for covering the surface from the above resin sheet was 45.3 cm wide and 200.000 cm long.
A 3 cm rectangular resin sheet is cut out, an adhesive is applied to the surface of the substrate (2) in the same manner as the above-mentioned resin sheet for end surface coating (3), and a resin is applied to the end surface of the resin sheet for end surface coating (4). Coating an end surface by applying an adhesive in which 20% by weight of barium sulfate particles having an average particle diameter of 8 μm and 4% by weight of zinc sulfate having an average particle diameter of 0.3 μm are added to an acrylic two-part adhesive, which is the same as that added to the sheet. The surface was coated so as to cover the coating layer of the resin sheet for use (4).

After cutting off the four corners of the coated resin sheet for surface coating (3), the portions protruding from the contour of the end surface coating layer were cut off.
Using a router (“Trimer 3701” manufactured by Makita Co., Ltd.), the corners formed on the entire peripheral edge of the surface are radius of curvature 2
It was cut so as to have a curved surface of mm. As a result, in the obtained resin sheet-coated board (1), the contact surfaces (5) of the coating resin sheets (3) and (4) on the surface and the end surface of the coating layer seemed to be continuous, and as a whole, There is a bodily sensation,
The coated board was suitable as a matte gray-white countertop full of weight.

[0038]

According to the present invention described above, a method for manufacturing a resin sheet-coated board (1) in which a resin sheet is coated on at least a surface and an end face of a substrate (2),
A sheet whose resin component is a thermoplastic resin is used as the resin sheet for coating, and first, the end surface of one sheet and the surface of the other sheet substantially correspond to at least a part of the peripheral edge of the surface of the substrate (2). Then, it is disposed on the substrate (2) so as to be in contact with and adheres to the substrate (2), and then, at the peripheral edge of the substrate (2) covered with the resin sheet, a chamfered surface ( By performing the chamfering process up to 6), the chamfering process of at least a part of the peripheral edge portion of the board is easy, and the joint between the contact surfaces (5) of both coated resin sheets is less noticeable, and the coated board (1) The production method of 1) can be provided, and the industrial value of the present invention is great.

[Brief description of the drawings]

FIG. 1 is a vertical cross-sectional explanatory view showing a state in which a front surface and an end surface of a substrate are coated with a surface covering resin sheet and an end surface covering resin sheet, respectively;

FIG. 2 is an explanatory vertical sectional view showing a state where a corner portion including a contact surface between the surface covering resin sheet and the end surface covering resin sheet of FIG. 1 is chamfered;

[Explanation of symbols]

 1: resin sheet coated board 2: board 3: resin sheet for surface coating 4: resin sheet for end surface coating 5: contact surface 6: chamfered surface

Claims (2)

[Claims] 1. A method for producing a resin sheet-coated board (1) in which at least a surface and an end face of a substrate (2) are coated with a resin sheet, comprising a resin sheet (3) for surface coating and a resin sheet (4) for end face coating. ), A sheet whose resin component is a thermoplastic resin is used. First, the end surface of one sheet and the surface of the other sheet are substantially in contact with at least a part of the peripheral edge of the substrate (2). The two resin sheets are placed and adhered on the substrate (2), and then the chamfer intersecting the contact surface (5) at least at a part of a corner formed when the two resin sheets (3) and (4) come into contact with each other. A method for producing a resin sheet-covered board, wherein chamfering is performed up to a processing surface (6). 2. The resin composition of the resin sheet is composed of 1 to 25% by weight of polyethylene terephthalate, 5 to 30% by weight of polybutylene terephthalate, 10 to 40% by weight of polycarbonate, 20 to 80% by weight of barium sulfate, and an impact modifier 0. The method according to claim 1, wherein the amount of the light stabilizer is 0.01 to 15% by weight, and the total amount of the light stabilizer is 0.01 to 10% by weight.