JPH11207704A - Manufacture of panel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To bond a surface decorative veneer and a low moisture permeable material layer comprising a wet-type veneer without developing the swelling of a surface, puncture and the like by a method wherein a moisture permeating function is given to a mold, by which the surface decorative veneer and the low moisture permeable material are laminated to each other, so as to escape moisture to the mold at the lamination. SOLUTION: By separating a top mold 5a from a bottom mold 5b, a surface decorative veneer 3 and a base material 2 are arranged between these molds. At the time, the surface decorative veneer 3 is arranged on the surface of the base material 2 under the state that an adhesive is interposed between them. At this time, in order not to develop cracks under heat and pressure, a wet type veneer is adopted as the surface decorative veneer 3 and a wet setting type adhesive is adopted as the adhesive. Next, by clamping, the top mold 5a and the bottom mold 5b integrate the base material 2 and the surface veneer 3 under heat and pressure. At this time, the moisture evaporated with heat is escaped smoothly through a moisture permeable layer 6 to the direction indicated with the arrows (a). As a result, the surface decorative veneer 3 can be bonded onto the base material 2 having the low moisture permeable material layer 1 without developing swelling and puncture.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a panel manufacturing method used for manufacturing a panel in which a decorative surface veneer is laminated on a surface of a substrate having at least a low moisture permeable material layer on the surface.

[0002]

2. Description of the Related Art Conventionally, a veneered surface veneer (wet veneer) has been bonded to a surface of a base material (board) made of a wood material such as plywood or MDF by hot pressing for the purpose of surface decoration.
Water vapor generated from the wet veneer at the time of hot pressing is absorbed by a substrate made of a wood material.

[0003]

However, the surface hardness of a substrate made of a woody material tends to cause damage or dents due to the use of furniture with casters, impacts such as falling objects, and the surface is very smooth. Therefore, stockings in the V-grooves on the surface and socks may be easily caught. In addition, problems such as cracking of the veneer veneer due to moisture absorption are likely to occur. Therefore, when a material such as a resin is used for the base material instead of the wood material in order to improve the surface hardness, smoothness and dimensional stability, the surface of the low moisture permeable material layer having a smaller moisture absorption rate than the wood material is used. Since the veneer veneer will be mounted on the surface, there is no escape for moisture evaporated by heat when laminating by hot pressing with a mold, so it will swell into a surface veneer veneer,
There is a problem that punctures and the like occur.

[0004] The present invention has been made in view of the above description, and is intended to bond a decorative veneer, which is a wet veneer, to a low-moisture permeable material layer without causing surface swelling, puncture, etc.
It is an object of the present invention to provide a panel manufacturing method capable of obtaining a panel with improved surface hardness, smoothness, and dimensional stability due to temperature and humidity.

[0005]

According to a first aspect of the present invention, there is provided a panel manufacturing method comprising the steps of: providing a surface of a base material having a low moisture permeable material layer on at least a surface thereof; In manufacturing the panel A in which the veneers 3 are laminated and integrated, the mold 5 for laminating the surface decorative veneer 3 and the low moisture-permeable material layer 1 is provided with a moisture-permeable function, and moisture is applied to the mold during lamination. It is characterized by escape. Surface decorative veneer 3 which is a wet veneer is provided on the surface of low moisture permeable material layer 1 having a lower moisture absorption rate than wood material.
Is bonded by heat and pressure by the mold 5, the moisture evaporated by the heat is released by the moisture permeability function of the mold 5 in contact with the surface decorative veneer 3, so that the surface decorative veneer 3 does not swell and is flat. The moisture-permeable material layer 1 can be bonded. That is, by providing a portion of a material such as a resin on at least the surface of the substrate 2, it is possible to obtain a panel A having improved surface hardness, smoothness, and dimensional stability due to temperature and humidity, and at least a surface such as a resin on the surface. Even if the material portion is provided to form the low moisture permeable material layer 1, the surface decorative veneer 3 can be bonded without swelling or puncturing of the surface.

A second aspect of the present invention is a panel manufacturing method according to the first aspect, wherein the mold 5 is provided with a moisture permeable layer 6 to have a moisture permeable function. The moisture-permeable function of the moisture-permeable layer 6 allows moisture to escape smoothly, and the surface decorative veneer 3 and the low moisture-permeable material layer 1 can be easily bonded without swelling and puncturing. According to a third aspect of the present invention, there is provided a panel manufacturing method according to the first aspect, wherein the mold 5 has a porous structure, and the mold 5 has a moisture permeable function.
Moisture can be smoothly released by the moisture-permeable function of the mold 5 being made porous, and the veneer veneer 3 and the low moisture-permeable material layer 1 can be easily bonded without swelling and puncturing.

According to a fourth aspect of the present invention, there is provided a panel manufacturing method according to the first aspect, wherein the low moisture permeable material forming the low moisture permeable material layer 1 is a wood powder resin composite. By using a wood powder resin composite as a low moisture permeable material, a smooth surface having high hardness can be obtained. In addition, the wood flour resin composite material is a material having higher dimensional stability with respect to temperature and humidity than plywood or the like, and the occurrence of cracks and the like in the surface decorative veneer 3 is reduced.

[0008]

DESCRIPTION OF THE PREFERRED EMBODIMENTS As shown in FIG. 2, a panel A is formed by laminating and integrating a surface decorative veneer 3 on a surface of a base material 2 having a low moisture permeable material layer 1 on at least one surface. The low moisture permeable material layer 1 is a portion in which a material such as a resin is used instead of a wood material in order to improve surface hardness, smoothness, and dimensional stability, and is like a wood powder resin composite material. FIG.
FIG. 2A is a diagram in which a low moisture permeable material layer 1 is provided on the surface of a base material 2 made of a woody material, and FIG. The whole is formed as the low moisture permeable material layer 1. The surface decorative veneer 3 is a wet veneer sufficiently containing water before lamination and integration. FIG. 2 (a)
In the figure, a V-shaped groove 7 is recessed from the surface of the veneer 3.

FIG. 1 shows an example of a process for manufacturing a panel A as shown in FIG. 2 (b). The mold 5 includes a plate-shaped upper mold 5a and a lower mold 5b.
On the lower surface of a, a moisture permeable layer 6 is provided to give the upper mold 5a a moisture permeable function. The moisture permeable layer 6 is a porous material, such as a calcium silicate plate. The panel A is manufactured by laminating and integrating using the mold 5 as follows. With the upper mold 5a and the lower mold 5b separated from each other, the surface decorative veneer 3 and the base material 2 are arranged between the upper mold 5a and the lower mold 5b as shown in FIG. At this time, the surface decorative veneer 3 is arranged on the surface of the substrate 2 and an adhesive is interposed between them. The surface decorative veneer 3 is a wet veneer sufficiently containing water. The surface decorative veneer 3 is a wet veneer in order to prevent cracks from being generated by hot pressure. Also, a moisture-curable adhesive is used as the adhesive. The upper mold 5a and the lower mold 5a are clamped from the state of FIG.
The base material 2 and the decorative surface veneer 3 are integrated by hot pressing with a and the lower mold 5b. At this time, the moisture evaporated by heat is removed from the moisture permeable layer 6.
1 (b), and the surface decorative veneer 3 is adhered onto the substrate 2 having the low moisture permeable material layer 1 without swelling or puncture. After the surface decorative veneer 3 is bonded to the base material 2 to form the panel A, the upper mold 5a and the lower mold 5b are separated and opened as shown in FIG.

FIG. 3 shows another example of a process for manufacturing the panel A as shown in FIG. 2B. The mold 5 is composed of an upper mold 5a and a lower mold 5b. In this example, the upper mold 5a has a porous structure so that the upper mold 5a has a moisture-permeable function. That is, a large number of holes 8 are provided in the entire surface of the upper mold 5a so as to penetrate vertically. And FIG.
The state shown in FIG. 3A can be heat-pressed from the state shown in FIG. 3B. However, when the heat-pressure is applied, moisture evaporated by heat passes through the hole 8 and smoothly escapes as shown by the arrow b in FIG. The veneer veneer 3 is adhered onto the substrate 2 having the low moisture permeable material layer 1 without swelling or puncture. Then, the surface decorative veneer 3 is adhered to the base material 2 to form the panel A, and then the upper mold 5a and the lower mold 5b are separated from each other as shown in FIG.

A specific example of the conditions for pressing the panel A by hot pressing as shown in FIG. 1 is as shown in Table 1 below, and the bonding of the surface decorative veneer as a wet veneer bonded under these conditions. The properties are as shown in Table 2.

[0012]

[Table 1]

[0013]

[Table 2]

[0014]

According to the present invention, as described above, when manufacturing a panel in which a decorative veneer is laminated and integrated on the surface of a substrate having a low moisture permeable material layer on at least the surface, the surface decorative veneer and the decorative veneer are combined. The mold that is laminated with the moisture-permeable material layer has a moisture-permeable function and allows moisture to escape to the mold during lamination. When the surface veneer veneer is bonded by heat and pressure with a mold, the moisture evaporated by heat is released by the moisture permeability function of the mold in contact with the surface veneer veneer, so that the surface veneer veneer without swelling and puncturing And a low moisture permeable material layer can be adhered to, while providing a portion of a material such as a resin on at least the surface of the base material while improving surface hardness, smoothness, and dimensional stability due to temperature and humidity. , A material part such as resin is provided to form a low moisture permeable material layer Surface decorative veneer in which a possible adhesion without the occurrence of blisters and punk surface.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view illustrating a manufacturing process according to an example of an embodiment of the present invention.

FIGS. 2A and 2B are cross-sectional views illustrating a panel.

FIG. 3 is a sectional view for explaining a manufacturing process of another example of the embodiment.

[Explanation of symbols]

 A Panel 1 Low moisture permeable material layer 2 Base material 3 Surface decorative veneer 5 Mold 6 Moisture permeable layer

Continuation of front page (72) Inventor Hiroaki Usui 1048 Odakadoma, Kadoma City, Osaka Prefecture Matsushita Electric Works, Ltd.

Claims (4)

[Claims] When manufacturing a panel in which a decorative veneer is laminated on a surface of a base material having at least a low moisture permeable material layer on a surface, a laminate of the decorative surface veneer and the low moisture permeable material layer is laminated. A method of manufacturing a panel, characterized in that a mold having a moisture permeability function is provided to allow moisture to escape to the mold during lamination. 2. The method for manufacturing a panel according to claim 1, wherein the mold has a moisture-permeable layer by providing a moisture-permeable layer. 3. The panel manufacturing method according to claim 1, wherein the mold has a porous structure, and the mold has a moisture permeability function. 4. The panel manufacturing method according to claim 1, wherein the low moisture permeable material forming the low moisture permeable material layer is a wood powder resin composite.