WO2017135078A1

WO2017135078A1 - Decorative panel and manufacturing method for same

Info

Publication number: WO2017135078A1
Application number: PCT/JP2017/002083
Authority: WO
Inventors: 遠藤　和志; 中村　晋也; 雅浩平戸
Original assignee: ヤマハファインテック株式会社
Priority date: 2016-02-05
Filing date: 2017-01-23
Publication date: 2017-08-10
Also published as: JP2017136770A; JP6801966B2

Abstract

Provided is a decorative panel on which various patterns with excellent design can be industrially produced without falling off, peeling, or the like. This decorative panel is configured so that an external layer that is partially present on a panel surface and a decoration layer that is exposed in regions of the panel surface not covered by the external layer are bonded to each other in a laminated state via a junction interface, and the junction interface extends to the outer edge of the region of the panel surface not covered by the external layer.

Description

Decorative panel and manufacturing method thereof

The present invention relates to a decorative panel suitable for use on the surface of vehicle interior members, furniture, building materials, electrical equipment, and the like, and a method for manufacturing the same.

Designs such as woodgrain patterns and inlay patterns may be applied to the surfaces of vehicle interior members, furniture, building materials, electrical equipment, and the like. In the field of traditional crafts, techniques such as graining and inlaying have been inherited as techniques for applying such designs. However, since it is difficult to mass-produce products with these technologies, a technology that can be applied to industrial products that are mass-produced is required.

As a technique for decorating a predetermined design pattern on the surface of a metal body or the like, for example, there are techniques described in Patent Document 1 and Patent Document 2.

In Patent Document 1, a window hole is formed so that an inlaying member is exposed at a desired position of the surface decorative material, the inlaying member is loaded into the window hole, and a resin layer is formed on the back surface by injection molding to provide a backing treatment. Techniques for applying are disclosed.

In Patent Document 2, a concave portion having a predetermined pattern shape is formed on the surface of a multilayer metal body formed by laminating and joining a plurality of metal plates of different materials, and the height of the concave portion and the surface of the non-pattern portion A technique for flattening with the same height is disclosed. Specifically, Patent Document 2 discloses a method in which a concave portion is formed by imprinting the surface of a multilayer metal body and shifting it in the thickness direction, and then removing the non-pattern portion to align the height. A part of the surface of the body is removed with a laser or the like to form a recess, and the non-patterned part is pressed to make the height uniform, the surface of the multilayer metal body is engraved and the other side is shifted in the thickness direction A method of forming a convex portion on the surface and removing the convex portion to make the surface flush is described.

JP 2003-326897 A JP 2009-196299 A

However, as described in Patent Document 1, in the method of loading the inlaying member into the window hole of the surface decorative material, a slight gap is likely to be generated between the peripheral edge of the window hole and the surface decorative material. There is a possibility that the inlay member may fall off. On the other hand, although it is considered that the method of Patent Document 2 can prevent a gap from being formed between a pattern portion and a non-pattern portion, it is difficult to repeatedly form a complicated pattern with good reproducibility industrially.

The present invention has been made in view of such circumstances, and is a decorative panel that can be provided with various patterns having excellent design properties and that can be industrially produced without causing dropping or peeling. And a method for manufacturing the same.

In the decorative panel of the present invention, an outer layer partially present on the panel surface and a decorative layer exposed in a region of the panel surface that is not covered with the outer layer are joined in a laminated state via a joining interface. At the same time, the joining interface extends to the outer edge of a region of the panel surface that is not covered by the outer layer. In other words, in the decorative panel of the present invention, an outer layer having an opening and a decorative layer having an exposed portion in the opening are bonded to each other in a stacked state via a bonding interface, and the bonding interface is the opening. Extending to the surface of the outer layer.

In the decorative panel of the present invention, a part of the decorative layer is exposed in a region (open portion) of the panel surface that is not covered by the outer layer. In this respect, the decorative panel is similar to the structure described in Patent Documents 1 and 2. However, the bonding interface between the outer layer and the decorative layer extends to the panel surface at the outer edge of the open portion, that is, the surface of the outer layer at the open portion, and the outer edge of the exposed portion of the decorative layer and the surrounding outer layer Are connected to the panel surface. In this way, the inner peripheral surface of the open portion in the outer layer and the outer peripheral surface of the exposed portion of the decorative layer in the open portion are in a joined state, thereby preventing the peeling and falling off of the exposed portion of the decorative layer. The Moreover, a multiple pattern can be attached | subjected by making a decoration layer into a multilayer structure and exposing each layer to an exposed part.

In the decorative panel of the present invention, it is preferable that the surface of the exposed portion of the decorative layer and the surface of the outer layer are continuous. That is, the surface of the outer peripheral edge of the exposed portion and the surface of the inner peripheral edge of the open portion of the outer layer are preferably formed on the same plane. According to this configuration, there is no step between the outer layer and the exposed portion of the decorative layer, and the surface at the outer peripheral edge of the exposed portion and the surface of the outer layer at the inner peripheral edge of the open portion are formed on the same surface. Therefore, it is also excellent in design.

In the decorative panel of the present invention, a resin layer may be integrally formed on the surface opposite to the outer layer. According to this structure, the rigidity of the whole decorative panel can be provided by the resin layer, and the occurrence of swell and warpage can be prevented. Thereby, the outer layer and the decorative layer can be made thin, and the molding can be easily performed, which is suitable for industrial production.

The method for producing a decorative panel according to the present invention includes a laminate forming step of forming a laminate in which an outer layer and a decorative layer are joined in a laminated state via a joining interface, and the laminate while deforming the joining interface. A convex portion forming step for forming a convex portion protruding from the decorative layer side to the outer layer side, and removing at least the protruding end portion of the convex portion so that the joint interface in the convex portion is cut. And forming a region (open portion) where the outer layer does not exist on the surface of the panel, and a protruding end portion removing step for exposing the decorative layer within the region where the outer layer does not exist.

The decorative panel manufacturing method of the present invention can be manufactured by a simple process of forming a convex portion on a laminated plate and removing the protruding end portion of the convex portion. Production can be facilitated.

In the method for producing a decorative panel according to the present invention, as a method for forming a convex portion on a laminate, a method of forming the convex portion by press-molding and deforming an outer layer and a decorative layer, a cavity concave portion on the inner surface The laminate is disposed in the injection mold having the cavity facing the cavity recess, and the laminate is placed in the cavity recess by the pressure of resin injected into the injection mold. There is a method of forming the convex portion by pressing and deforming.

According to the present invention, various patterns having excellent design properties can be applied, and industrial production can be performed without causing dropping or peeling of the exposed portion of the decorative layer.

It is sectional drawing of the decoration panel of one Embodiment of this invention. It is a top view of the opening part vicinity of the decorative panel of FIG. It is an expanded sectional view near the open part of the decorative panel of FIG. It is a flowchart which shows the manufacturing method of 1st Embodiment of the decorative panel of FIG. It is sectional drawing which shows the change of the decoration panel manufactured by the manufacturing method of FIG. 4 in order of a process. It is sectional drawing which shows the modification of the manufacturing method of 1st Embodiment in order of a process. It is a flowchart which shows the manufacturing method of 2nd Embodiment of the decorative panel of FIG. It is sectional drawing which shows the change of the decoration panel manufactured by the manufacturing method of FIG. 7 in order of a process. It is sectional drawing which made the decoration layer into multiple layers in the decoration panel of embodiment of this invention. FIG. 10 is a plan view of the vicinity of the opening of the decorative panel of FIG. 9. It is sectional drawing which shows another form of a decoration panel. It is a flowchart which shows the manufacturing method of the decoration panel of FIG. It is sectional drawing which shows the change of the decorative panel manufactured by the manufacturing method of FIG. 12 in order of a process.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.

[First embodiment of decorative panel]
As shown in FIG. 1, the decorative panel 10 according to the first embodiment has a structure in which an outer layer 11, a decorative layer 12, an adhesive layer 13, and a resin layer 14 are sequentially laminated from the panel surface (outer surface) side. Yes. For example, the outer layer 11 can be a layer made of copper having a thickness of 50 μm, and the decorative layer 12 can be a layer made of aluminum having a thickness of 450 μm. As the adhesive layer 13, wood such as birch or dope cement can be used. Here, the dope cement is an adhesive in which a thermoplastic resin is dissolved in a solvent. When wood is used as the adhesive layer 13, an anchor effect is obtained by embedding a part of the resin of the resin layer 14 in the unevenness or micropores on the surface of the wood. In addition, the laminated board which consists of the outer layer 11 except the resin layer 14, the decoration layer 12, and the adhesive material layer 13 is called the laminated board for panels (laminated board of this invention) 10 '.

The resin layer 14 is formed by injection molding as described later, and can be integrated with the panel laminate 10 ′ by insert molding in which the panel laminate 10 ′ is placed in a mold. By integrating the resin layer 14 and the panel laminate 10 'in this way, the entire decorative panel 10 is given strength, and the decorative panel 10 has a function of holding a desired three-dimensional shape such as a plate shape. . As the material of the resin layer 14, a synthetic resin suitable for injection molding such as polyethylene, polypropylene, polycarbonate, polyethylene terephthalate is used, and is set to an appropriate thickness in accordance with requirements such as strength required for the decorative panel 10. The

In the decorative panel 10 having such a laminated structure, the outer layer 11 is partially present on the panel surface, and 12 decorative layers are exposed in a region of the panel surface that is not covered by the outer layer 11. In other words, the open portion 15 is formed in a part of the outer layer 11, and the exposed portion 16 is formed in the open portion 15 by exposing a part of the decorative layer 12 that is a layer below the outer layer 11. Yes. In this case, the bonding interface 17 between the outer layer 11 and the decorative layer 12 extends to the surface of the outer layer 11 at the inner peripheral edge 15. That is, the bonding interface extends to the outer edge of the region of the panel surface that is not covered by the outer layer 11.

As will be described later, the opening 15 can be formed by cutting and removing a part of the laminated panel 10 ′ that has been deformed. For this reason, as shown in the enlarged sectional view of FIG. 3, the bonding interface 17 between the outer layer 11 and the decorative layer 12 extends to the surface of the outer layer 11 in the opening portion 15, and as shown in FIG. 2, the opening portion The cut end face 11 a of the outer layer 11 is exposed together with the cut end 17 a of the bonding interface 17 between the outer layer 11 and the decorative layer 12. And it is preferable to form in the same surface so that the decoration layer 12 in the open part 15 and the surface of the outer layer 11 of the circumference | surroundings may continue. In other words, the inner peripheral edge of the open portion 15 on the surface of the outer layer 11 is formed by the cut end 17a of the bonding interface 17 between the outer layer 11 and the decorative layer 12, and is approximately equal to the thickness of the outer layer 11 around the periphery. It is preferable that the cut end face 11a of the outer layer 11 is exposed in width. Note that “formed on the same surface” means that there is no step between the surface of the exposed portion 16 of the decorative layer 12 and the surface of the outer layer 11 around it, and the exposed of the decorative layer 12. The surface of the portion 16 and the surface of the outer layer 11 around it may be curved.

[First Embodiment of Method for Manufacturing Decorative Panel]
There are typically two methods for manufacturing the decorative panel 10 described above. First, the first embodiment which is one of the methods will be described.

In the manufacturing method of this embodiment, as shown in the flowchart of FIG. 4, the decorative panel 10 is manufactured by performing a laminated plate forming step, a convex portion forming step, a protruding end portion removing step, and a resin integration step in this order. .

FIG. 5 shows the change of the cross section by the manufacturing method in order. Hereinafter, it demonstrates in order of a process.

(Laminated plate forming process)
First, as shown to Fig.5 (a), the outer layer 11, the decoration layer 12, and the adhesive material layer 13 are laminated | stacked, and panel laminated board 10 'is manufactured. At this stage, all of them are flat and are joined in a laminated state by, for example, adhesive, fusion, brazing, plating, sputtering, vapor deposition, or the like. When the outer layer 11 is made of copper and the decorative layer 12 is made of aluminum, the outer layer 11 can be joined by diffusion bonding.

The material of the outer layer 11, the decorative layer 12, and the adhesive layer 13 is not limited to the combination of the embodiments, and any combination of wood, metal, and resin is possible. As a joining means for the decoration layer 12 and the adhesive layer 13, an adhesive, fusion, brazing, plating, sputtering, vapor deposition, or the like can be used. Moreover, in order to improve the designability, it is preferable that the material of the outer layer 11 and the material of the decorative layer 12 are different. However, for example, the grain direction of wood, the extending direction of metal, and the like may be different. Further, the adhesive layer 13 may be omitted by performing a surface treatment such as anodization for improving the adhesion with the resin layer 14 on the back surface of the decorative layer 12.

(Projection forming process)
Next, as shown by a two-dot chain line in FIG. 5A, the concave mold 52 in which the molding concave portion 51 is formed is brought into contact with the surface of the outer layer 11, and the molding convex so as to face the molding concave portion 51. By pressing the convex mold 56 formed with the portion 55 to the adhesive layer 13 and pressing the convex mold 56 from the adhesive layer 13 side to the outer layer 11 side in the plate pressure direction (stacking direction). As shown in FIG. 5B, the concave portion 21 on the adhesive layer 13 side and the convex portion 22 on the opposite outer layer 11 side are formed. At this time, it is not engraved as in Patent Document 2 described above and the respective layers are not shifted on the boundary surface along the plate thickness direction, but the panel laminated plate 10 ′ is formed so as to be deformed unevenly. Thereby, the joining interface 17 of the outer layer 11 and the decoration layer 12 will be in the state by which uneven | corrugated deformation was carried out. For this reason, the outer peripheral side surface of the convex portion 22 is also formed by the surface of the outer layer 11. Preferably, the convex portion 22 is shaped such that the protruding height H is equal to or greater than the thickness t 1 of the outer layer 11.

(Projection end removal process)
Next, at least the protruding end portion 22a of the convex portion 22 formed on the surface of the outer layer 11 is removed by milling or the like, so that the decorative layer 12 is partially exposed. Preferably, as shown in FIG.5 (c), the whole convex part 22 is removed so that it may become the same surface as the outer surface of the outer layer 11 of the circumference | surroundings.

As shown in an enlarged view in FIG. 3, when this convex portion 22 is removed, an open portion (region where the outer layer 11 does not exist) 15 is formed in the outer layer 11, and a decorative layer of a lower layer is formed in the open portion 15. 12 is exposed. Moreover, in the previous convex part formation process, since the convex part 22 was formed so that the outer peripheral side surface of the convex part 22 was also formed by the surface of the outer layer 11, it follows the surface of the outer layer 11 around the convex part 22. When the entire convex portion 22 is removed from the position indicated by the solid line arrow, the outer layer 11 is cut and the bonding interface 17 between the outer layer 11 and the decorative layer 12 is also cut. Therefore, the cut end surface 11 a of the outer layer 11 and the cut end 17 a of the bonding interface 17 are exposed on the surface of the outer layer 11.

About the decoration layer 12, when the height H of the convex part 22 formed in a convex part formation process is the same height as the thickness t1 of the outer layer 11, the convex part 22 is made into a protrusion end part cutting process. If it removes so that it may become the same surface as the outer surface of the surrounding outer layer 11, only the outer layer 11 which covered the upper surface of the decoration layer 12 in the open part 15 will be removed, and the surface of the decoration layer 12 will be exposed. Further, the height H of the convex portion 22 formed in the convex portion forming step is a height exceeding the thickness t1 of the outer layer 11, and the convex portion 22 is separated from the outer surface of the surrounding outer layer 11 by the protruding end portion removing step. When removing the whole height of the convex part 22 so that it may become the same surface, the decoration layer 12 is also cut | disconnected in the middle position of thickness, and the cut surface of the decoration layer 12 is in the open part 15. Exposed. FIG. 3 shows this latter case, and therefore the exposed portion 16 of the decorative layer 12 is also a cut end surface of the decorative layer 12.

In any case, the bonding interface 17 between the outer layer 11 and the decorative layer 12 is formed so as to extend to the surface of the outer layer 11 at the inner peripheral edge of the opening 15, and the bonding interface 17 is formed at the inner peripheral edge of the opening 15. The cut end surface 11a of the outer layer 11 is exposed together with the cut end 17a, and the cut end surface 11a of the outer layer 11 and the surface of the exposed portion 16 of the decorative layer 12 in the open portion 15 are formed on the same plane. In other words, the inner peripheral edge of the open portion 15 on the surface of the panel laminate 10 ′ is formed by the cut end 17 a of the bonding interface 17 between the outer layer 11 and the decorative layer 12. Thus, the cut end surface 11a of the outer layer 11 is exposed with a width substantially equal to the thickness t1 of the outer layer 11. If necessary, the outer surface of the panel laminate 10 ′ may be polished or painted.

In this protruding end portion removing step, the entire convex portion 22 is removed at the surface position of the outer layer 11 so as to match the surface of the outer layer 11 around the convex portion 22, but the convex portion formed in the convex portion forming step. The height H of 22 may be set to a height exceeding the thickness t1 of the outer layer 11, and may be cut at a position halfway along the height H of the convex portion 22 at a position indicated by a one-dot chain line arrow in FIG. That is, you may make it leave the part by the side of the decoration layer 12 of the convex part 22 by excising the protrusion edge part 22a more than thickness t1 among the convex parts 22. FIG. In that case, the outer layer 11 is formed in a state where the outer layer 11 is raised around the open portion 15, the top is the cut end surface 11 a of the outer layer 11, and the exposed portion 16 of the decorative layer 12 is exposed inside. The cut end surface 11a of the outer layer 11 and the surface of the exposed portion 16 of the decorative layer 12 are formed on the same plane.

(Resin integration process)
Next, as shown in FIG. 5 (c), the panel laminate 10 ′ is placed in the injection mold 60 so that the outer layer 11 contacts the inner surface of the injection mold 60. When the resin is injected and the resin layer 14 is formed so as to be laminated on the adhesive layer 13 of the panel laminate 10 ′, the decorative panel 10 in which the resin layer 14 is integrated is formed as shown in FIG. In this case, the resin layer 14 is integrated with the adhesive layer 13 so as to fill the concave portion 21 of the adhesive layer 13.

Finally, the outer surface of the decorative panel 10 may be polished or painted as necessary.

The decorative panel 10 manufactured in this manner is deformed in an uneven state in a state where the outer layer 11 and the decorative layer 12 are joined in the convex portion forming step, and in the protruding end portion removing step, the outer layer 11 and the decorative layer 12 are formed. The convex portion 22 including the bonding interface 17 is cut, and not only the decorative layer 12 but also the cut end surface 11 a of the outer layer 11 is exposed to the inner peripheral edge of the open portion 15 together with the cut end 17 a of the bonding interface 17. . Therefore, the bonding interface 17 between the outer layer 11 and the decorative layer 12 is formed to extend to the surface of the outer layer 11 at the periphery of the opening 15, and the inner peripheral surface of the outer layer 11 and the decoration at the inner periphery of the opening 15. The bonding state between the exposed portion 16 of the layer 12 and the outer peripheral surface of the layer 12 is maintained, and peeling and dropping of the exposed portion 16 of the decorative layer 12 are prevented.

In this case, since the cut end surface 11a of the outer layer 11 and the surface of the exposed portion 16 of the decorative layer 12 in the open portion 15 are arranged in the same plane, the peripheral portion of the open portion 15 is formed into a flat surface. Also excellent in properties.

In addition, since the resin layer 14 is provided in the backing state, the rigidity of the decorative panel 10 as a whole can be increased, and the occurrence of swell and warpage can be prevented. For this reason, the outer layer 11 and the decorative layer 12 can be made thin, and the molding thereof can be easily performed, which is suitable for industrial production.

In the process shown in FIG. 5, the height H of the convex portion 22 is formed larger than the thickness t1 of the outer layer 11, and the convex portion 22 is removed. However, as shown in FIG. It is also possible to form the height H of the portion 22 smaller than the thickness t1 of the outer layer 11, and in this case, as shown in FIG. 6 (b), the surface of the outer layer 11 around the convex portion 22 Since the decorative layer 12 is not exposed even if the convex portion 22 is removed at the position, as shown in FIG. 6C, the outer layer 11 of the convex portion 22 is completely removed by laser processing or the like, and the decorative layer 12 is exposed. Therefore, in this case, a surface recess 23 having a slight depth is formed with respect to the outer layer 11 around the open portion 15, and the decorative layer 12 is exposed so as to form a bottom surface of the surface recess 23.

Then, when the decorative layer 12 is arranged so as to form the bottom surface of the surface recess 23 in this way, a cavity that fits into the surface recess 23 so that the surface recess 23 is not deformed in the next resin integration step. A protrusion (not shown) may be formed on the inner surface of the injection mold, and the resin may be injected with the cavity protrusion and the surface recess 23 fitted together, or the surface recess 23 may be flat. The exposed portion 16 of the decorative layer 12 is pushed out by the resin pressure by pressing against the cavity surface with a resin pressure so that the surface of the exposed portion 16 of the outer layer 11 around the open portion 15 is pressed. You may shape | mold so that it may become the same surface as the surface.

Also in the decorative panel formed in this way, the joint interface 17 between the outer layer 11 and the decorative layer 12 is formed to extend to the surface of the outer layer 11 in the open portion 15, and the periphery of the open portion 15 is the cut of the joint interface 17. Formed by edges.

[Second Embodiment of Manufacturing Method of Decorative Panel]
Next, a second embodiment of the method for manufacturing the decorative panel in FIG. 1 will be described.

Referring to the flowchart of FIG. 7, the manufacturing method of this embodiment manufactures the decorative panel 10 in the order of the laminated plate forming step, the resin integration and protruding portion forming step, and the protruding end removing step. FIG. 8 shows changes in cross section by the manufacturing method in the order of steps. Hereinafter, it demonstrates in order of a process.

(Laminated plate forming process)
In the laminated plate forming step, the panel laminated plate 10 ′ is formed in the same manner as in the manufacturing method of the first embodiment described above.

(Resin integration and convex formation process)
In the resin integration and projection forming step of the second embodiment, an injection mold 60 having a cavity recess 61 formed on the inner surface thereof is used, and the panel recess 10 ′ is formed by the cavity recess 61. The convex part 22 is formed in

The depth of the cavity recess 61 is formed to be equal to or greater than the thickness t1 of the outer layer 11 of the panel laminate 10 ′. 8A, the surface of the outer layer 11 of the panel laminate 10 ′ is brought into contact with the inner surface of the injection mold 60, and a part of the outer layer 11 is opposed to the cavity recess 61. To place. In this state, as shown in FIG. 8B, the resin is injected to the adhesive layer 13 side of the panel laminate 10 ′, and the panel laminate 10 ′ is placed in the cavity recess 61 by the injection pressure at that time. The concave portion 21 is formed on the side of the adhesive layer 13 of the panel laminate 10 ′, and the convex portion 22 is formed on the opposite outer layer side. The resin is integrated with the adhesive layer 13 so as to fill the recess 21 while deforming the panel laminate 10 ′. The protrusion height H of the protrusion 22 is equal to or greater than the thickness t 1 of the outer layer 11, and can be adjusted by the depth of the cavity recess 61 formed in the injection mold 60.

In this way, after the resin integration and the convex portion forming step, the convex portion 22 is formed on the outer layer 11 side and the resin layer 14 is integrally formed on the opposite surface of the panel laminate 10 ′. Has been.

The cavity recess 61 formed on the surface of the injection mold 60 may be formed by cutting the surface of the injection mold 60, or a metal thin plate or a thin plate provided with an opening in a resin film may be used as the injection mold. You may form simply by inserting between the flat inner surface of 60, and panel laminated board 10 '.

(Projection end removal process)
As shown by the arrow in FIG. 8C, at least the protruding end 22a of the convex portion 22 formed on the surface of the outer layer 11 is formed on the panel laminate 10 ′ having the convex portion 22 formed in this way. By removing so as to be cut by milling or the like, the open portion 15 is formed in the outer layer 11, and the cut end of the bonding interface 17 between the outer layer 11 and the decorative layer 12 is formed on the inner peripheral edge of the open portion 15. The cut end surface 11a of the outer layer 11 is exposed in both the layers 17a, and the decorative panel 10 is formed in which the cut end surface 11a of the outer layer 11 and the surface of the decorative layer 12 in the opening 15 are formed on the same plane.

This manufacturing method is excellent in productivity because, when the resin layer 14 is integrally formed on the back surface of the decorative panel 10, the formation of the convex portions 22 and the integration of the resin can be performed simultaneously.

In the above-described embodiment, the decorative layer 12 is formed of a single plate material (aluminum plate), and the single decorative layer 12 is exposed in the open portion 15 of the outer layer 11. The decorative layer 12 may have a multilayer structure in which a plurality of plate members are joined in a laminated state, and the multilayer structure of the decorative layer 12 may be exposed in the open portion 15 of the outer layer 11.

The decorative panel 100 shown in FIGS. 9 and 10 includes a decorative layer 12 having a first decorative layer 12E bonded to the outer layer 11 and a second decorative layer 12F bonded to the first decorative layer 12E. In the convex portion forming step, the second decorative layer 12F that is separated from the outer layer 11 is formed so as to protrude from the surface of the outer layer 11, and the protruding end of the convex portion 22 is formed. By removing the portion 22a so as to cut at the surface position of the outer layer 11, the first decorative layer 12E and the second decorative layer 12F are exposed in this order from the outside in the open portion 15. In this case, the cut end surface 11a of the outer layer 11 is disposed outside the open portion 15, the cut end 17a of the bonding interface 17 between the outer layer 11 and the first decorative layer 12E, and the exposed portion of the first decorative layer 12E inside thereof. 16E, the cut end 18a of the bonding interface 18 between the first decorative layer 12E and the second decorative layer 12F, and the exposed portion 16F of the second decorative layer 12F are sequentially exposed. In the example shown in FIG. 9, these exposed

portions

16E and 16F are also cut end surfaces of the

decorative layers

12E and 12F. By setting it as this structure, a multiple pattern is formed in the open part 15 by the decorating layer 12, and design nature can be improved further. Also in the case of the decorative panel 100 shown in FIGS. 9 and 10, as shown in FIG. 7, the resin integration and the convex portion formation may be performed simultaneously.

In addition, when forming a decoration layer in three or more layers, in the convex part formation process, the board | plate material of the lowest layer (layer most distant from an outer layer) in a decoration layer protrudes from the surface of the outer layer 11. Molded (molded so that the bonding interface between each plate in the decorative layer also deforms unevenly), and in the protruding end removal process, the convex part is removed by cutting it at the surface position of the outer layer, for example, to open Each decoration layer can be exposed including the cut end of the bonding interface of each layer of the decoration layer in the part.

[Another form of decorative panel]
In the decorative panel 10 of the first embodiment described above and the decorative panel 100 of FIG. 9, the cut end 17 a of the bonding interface 17 between the outer layer 11 and the decorative layer 12 is also formed so as to be exposed to the open portion 15. You may do it.

As shown in FIG. 11, the decorative panel 110 in another form has a part of the decorative layer 12 under the exposed portion 15 exposed in a part of the outer layer 11, Although the surface of the outer layer 11 around the open part 15 and the surface of the exposed part 16 of the decorative layer 12 in the open part 15 are formed in the same plane, the same as the first embodiment, The bonding interface 17 with the decorative layer 12 extends to the inner peripheral edge of the back surface of the open portion 15 of the outer layer 11, and is decorated at the lower edge of the open portion 15 (the back surface side of the outer layer 11). The layer 12 is bent and formed so as to protrude into the open portion 15. For this reason, the surface of the decoration layer 12 is arrange | positioned facing, without joining to the internal peripheral surface of the open part 15 of the outer layer 11. FIG.

[Method of manufacturing another form of decorative panel]
As shown in the flowchart of FIG. 12, the decorative panel 110 of this embodiment is manufactured in the order of a laminated plate forming step, an opening portion forming step, a resin integration, and a decorative layer deformation step. FIG. 13 is a sectional view in the order of steps.

(Open part forming process)
Part of the outer layer 11 of the panel laminate 10 ′ is removed by laser processing or the like to form the opening 15. The laser output is set so that the outer layer 11 is removed but the decorative layer 12 is not processed.

(Resin integration and decorative layer deformation process)
The surface of the outer layer 11 on which the open portion 15 is formed is brought into contact with the inner surface of the injection mold 65, and resin is injected to the adhesive layer 13 side of the panel laminate 10 ′ to be integrated with the panel laminate 10 ′. Turn into. At this time, the inner surface of the injection mold 65 at a portion facing the opening portion 15 is formed as a flat surface, but since the opening portion 15 is formed in the outer layer 11, the portion of the opening portion 15 becomes a space. . When the resin is injected, the decorative layer 12 of the panel laminate 10 ′ is deformed so as to be pushed into the open portion 15 of the outer layer 11 by the injection pressure. The adhesive layer 13 is formed with a recess 21 so as to correspond to the deformation of the decorative layer 12.

By this resin integration and decoration layer deformation process, a part of the decoration layer 12 is exposed in the opening portion 15 of the outer layer 11, and the surface of the outer layer 11 around the opening portion 15 and the inside of the opening portion 15 are exposed. The exposed portion 16 surface of the decorative layer 12 is formed on substantially the same plane.

In addition, the resin integration and the decoration layer 12 are not performed in this manner, but the resin integration and the decoration layer 12 are deformed in separate steps. You may do it. For example, in the decorative layer deformation step, the surface around the open portion 15 of the outer layer 11 is brought into contact with the flat surface of the mold by press molding after the open portion forming step, and the opposite side of the open portion 15 is punched. By pressing in the plate thickness direction, the concave portion 21 is formed in the adhesive layer 13 and at the same time, a part of the decorative layer 12 is pushed into the open portion 15. Then, in the resin integration step, the decorative panel 110 may be manufactured by injecting and integrating the resin to the adhesive layer 13 side.

The present invention is not limited to the above-described embodiments, and various modifications can be made without departing from the spirit of the present invention.

For example, in any of the embodiments, the open portion formed in the outer layer has a closed peripheral edge, but is formed as an open portion formed by cutting out the side edge of the panel including the side edge. It is also possible.

Further, an uneven pattern may be further formed on the surface of the exposed portion of the decorative layer in the open portion.

DESCRIPTION OF SYMBOLS 10,100,110 ... Decoration panel, 10 '... Panel laminated board (laminated board), 11 ... Outer layer, 11a ... Cutting end surface, 12, 12E, 12F ... Decorating layer, 13 ... Adhesive layer, 14 ... Resin layer , 15 ... open part, 16, 16E, 16F ... exposed part, 17 and 18 ... joint interface, 17a and 18a ... cut end, 21 ... concave part, 22 ... convex part, 22a ... projecting end part, 23 ... surface concave part, 51 ... molding concave part, 52 ... concave mold, 55 ... convex part for molding, 56 ... convex mold, 60, 65 ... injection mold, 61 ... cavity concave part

Claims

The outer layer partially present on the panel surface and the decorative layer exposed in the region of the panel surface that is not covered by the outer layer are joined in a laminated state via the joining interface,
The decorative panel, wherein the joining interface extends to an outer edge of a region of the panel surface that is not covered with the outer layer.
The decorative panel according to claim 1, wherein the surface of the exposed portion of the decorative layer and the surface of the outer layer are continuous.
3. The decorative panel according to claim 1, wherein a resin layer is integrally formed on a surface opposite to the outer layer.
A laminated plate forming step of forming a laminated plate in which an outer layer and a decorative layer are joined in a laminated state via a joining interface; and the outer layer side from the decorative layer side to the laminated plate while deforming the joining interface And forming a region where the outer layer is not present by removing at least the protruding end of the convex portion so that the joint interface in the convex portion is cut. And a protruding end removing step of exposing the decorative layer in a region where the outer layer does not exist.
5. The method for manufacturing a decorative panel according to claim 4, wherein, in the projecting portion forming step, the projecting portion is formed by pressing and deforming the outer layer and the decorative layer.
In the projection forming step, the laminated plate is placed in an injection mold having a cavity recess formed on the inner surface with the outer layer facing the cavity recess, and injected into the injection mold. The method for manufacturing a decorative panel according to claim 4, wherein the convex portion is formed by pressing and deforming the laminated plate into the cavity concave portion with a resin pressure.