JPH071404A - Decorative plate and manufacture thereof - Google Patents

Abstract

PURPOSE:To provide a decorative plate having a curved surface to be used as a surface plate such as a surface material for a furniture, a building material, etc., or particularly a table, etc., and a method for manufacturing the plate by a vacuum press. CONSTITUTION:A decorative plate in which a decorative sheet is laminated in close contact on a base material having a cubic curved surface is manufactured by the steps of placing the base material W having the cubic curved surface and coated at least on an upper surface with adhesive on a lower chamber 19 by using a vacuum press molding machine having an upper chamber 9 and the chamber 19 partitioned by a rubber elastic film 7, so covering the decorative sheet S of a wet state as to cover at least entire coating surface of the material W having the curved surface, then heating the film 7 and applying a differential pressure to the chambers 9, 19.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative plate having a curved surface which is used as a surface material such as furniture and building materials, particularly as a top plate for desks and tables, and a method for producing the decorative plate by vacuum pressing. is there.

[0002]

2. Description of the Related Art Conventionally, as a decorative plate having a curved surface, a flexible thermoplastic resin film is pasted on a substrate, and then the back surface of the substrate is subjected to V-cutting or comb-tooth processing to form a curved surface. Alternatively, a thermoplastic resin film such as a polyvinyl chloride resin or a thin sliced wood veneer is formed on a substrate having a curved surface by a vacuum pressing method. In particular, regarding the lamination of the sheet on the base material by the vacuum press, the molding method and apparatus as disclosed in JP-A-4-368837 and JP-A-5-31743 are considered.

[0003]

However, in the curved surface processing method by V-cutting or comb-tooth processing described above, processing of a cubic curved surface is impossible even if a quadric surface is possible. Further, in the case of a method of sticking to a curved surface portion by a vacuum pressing method, a thermoplastic resin film such as a polyvinyl chloride resin can be adhered and laminated on a cubic curved surface as described in the above publication. However, since it is extremely inferior in strength and heat resistance, it cannot be used as a surface material for furniture, building materials, etc., especially as a top plate for desks, tables, etc., for example, a curable resin is coated on a thermoplastic resin film. However, even if the heat resistance is improved due to the occurrence of cracks due to shrinkage during curing of the curable resin and the fact that there is a flexible film in the inner layer, it cannot be used as a top plate of a desk or table in terms of strength. It is possible. Further, even in the case of a wood veneer, it is difficult to attach it to a cubic curved surface, and there is a problem in that it cannot be diversified in terms of design.

[0004]

In order to solve the above problems, according to the present invention, a decorative board having the following constitution and a method for manufacturing the decorative board are provided. First, the decorative board of the present invention is one in which decorative paper is adhered and laminated on a substrate having a cubic curved surface via an adhesive layer.

Next, as a method of manufacturing the decorative plate, in a vacuum press molding apparatus having an upper chamber and a lower chamber divided by a rubber-like elastic film, an adhesive is applied to at least the upper surface of the lower chamber. A base material having a cubic curved surface is placed, and after covering the base material having the cubic curved surface with at least the adhesive-coated surface in a wet state, the rubber elastic film is heated. At the same time, a differential pressure is applied to the upper chamber and the lower chamber to form the decorative paper in close contact with the base material having a cubic curved surface. Further, in the above manufacturing method, the moisture content of the decorative paper to be coated on the base material having the cubic curved surface is set to be 25 to 40% (JIS standard-P8127) in a wet state so that the base material having the cubic curved surface is coated with the moisture content. Adhesive lamination is more reliable.

[0006]

As described above, the wet state, especially the water content of 25 to
A 40% decorative paper is used to heat the rubber-like elastic film and to apply a pressure difference between the upper chamber and the lower chamber, so-called vacuum press molding is performed, so that a beautiful cubic curved surface without wrinkles or breaks is formed. Since it is possible to obtain a decorative board having the above, it is possible to manufacture a surface material such as furniture or a building material having a cubic curved surface, which has not been a product until now, and particularly a top board such as a desk or a table.

[0007]

Embodiments of the present invention will be described below with reference to the drawings. FIG. 1 shows an example of a vacuum press molding apparatus used to carry out the present invention. The vacuum press molding apparatus has an upper chamber member 3 and a fixed lower chamber member 5 which are vertically driven by a fluid pressure cylinder device 1.

The upper chamber member 3 has a box-like shape with a lower opening, and a heat-resistant rubber-like elastic film 7 is attached to the lower opening so as to close the lower surface opening. As a result, a closed upper chamber 9 is defined inside the upper chamber member 3. A heater 11 is provided on the ceiling surface of the upper chamber member 3.
Is attached. The lower chamber member 5 has a box shape with an upper opening, and the lower chamber 19 is formed by attaching the porous substrate mounting plate 13 to the upper opening of the lower chamber member 5. The base material W is mounted on the central portion via the base material mounting table 15.

The upper chamber member 3 is provided with an upper port 21 for supplying and discharging air to and from the upper chamber 9, and the lower chamber member 5 is provided with a lower port 23 for supplying and discharging air to and from the lower chamber 19. Upper port 2
1 and the lower port 23, these ports are respectively provided as drain ports 31d and 33d and air pressure supply ports 31s and 33s.
The switching valves 31 and 33 selectively connected to either of the above are connected. Another switching valve 35 is connected to the air pressure supply port 31s of the switching valve 31.
The air pressure supply port 31s is selectively connected to either the air pressure pump 41 or the vacuum pump 43. The air pressure supply port 33s of the switching valve 33 is directly connected to the vacuum pump 43.

It should be noted that this apparatus is only one example, and essentially all conventionally known vacuum press molding apparatuses can be used as they are in the present invention. Next, a method for manufacturing a decorative plate having a cubic curved surface according to the present invention using the vacuum press molding apparatus having the above-described configuration will be described with reference to FIGS. 1 to 3.

First, as shown in FIG. 1, an adhesive is applied on the upper surface of the porous substrate mounting plate 13 in the lower chamber 19 via the substrate mounting base 15, and the decorative paper is coated thereon. A substrate W having a cubic curved surface covered with S is installed. Then, the rubber-like elastic film 7 made of silicon rubber is heated by energizing the heater 11 to generate heat. This heating is appropriately selected depending on the material and thickness of the decorative paper S to be used, but it is usually heated to about 120 to 150 ° C.

Next, the fluid pressure cylinder device 1 lowers the upper chamber member 3 and joins it to the lower chamber member 5 as shown in FIG. 2 to perform so-called mold clamping. As a result, the rubber-like elastic film 7 that has already been softened by heating adheres to the decorative paper S, and the heat of the rubber-like elastic film 7 is conducted to the decorative paper S. Next, the switching valve 33 is switched to switch the lower port 23.
Is connected to the air pressure supply port 33s, and the lower port 23 is connected to the vacuum pump 43. This allows the lower chamber 1
9 is decompressed, the air in the lower chamber 19 is exhausted to the outside, and the lower chamber 19 is brought into a vacuum state. Almost at the same time, the switching valve 31 is switched to connect the upper port 21 to the air pressure supply port 31s and connect the upper port 21 to the air pressure pump 41. As a result, pressurized air is supplied to the upper chamber 9 to pressurize the inside of the upper chamber 9, and a differential pressure is generated between the upper chamber 9 and the lower chamber 19. Due to this pressure difference, the rubber-like elastic film 7 is formed on the outer surface of the base material W via the decorative paper S, as shown in FIG.
Closely wrap it.

Thereafter, by switching the switching valve 31 to connect the upper port 21 to the drain port 31d and switching the switching valve 33 to connect the lower port 23 to the drain port 33d, the upper chamber 9 and the lower chamber 19 are respectively enlarged. By returning to atmospheric pressure, the rubber-like elastic film 7 returns to the original state and is separated from the decorative paper S. As a result, the decorative paper S is brought into close contact with the outer surface of the base material W, and one-time vacuum press molding is completed by performing lamination molding, and the adhesive layer P is formed on the base material W as shown in FIG. A decorative sheet T in which a decorative sheet S having a pattern layer R on its upper surface is closely laminated is obtained.

Here, as the material of the decorative paper S, any material may be used as long as it has printability on the surface and can maintain a wet state due to appropriate water retention, such as titanium paper, overlay paper for impregnation, linter paper, and sizing agent. Examples include thin paper that has a small amount. Particularly in the case of titanium paper, since it is also excellent in hiding power, it is very suitable for the present invention regardless of the surface material of the substrate. Further, as described below, the water content of the decorative paper S is preferably 25 to 40%.

Next, the base material W may be any one capable of processing a three-dimensional curved surface, such as a plywood, a wood base material such as MDF, ABS resin, phenol resin, polystyrene, PV.
Examples include C, synthetic resins such as polypropylene, ceramics, metals such as iron and aluminum, and the like. As the adhesive applied to the surface of the base material W, an arbitrary emulsion type such as polyvinyl acetate type or polyurethane type is used, and the base material mounting table 15 is resistant to the differential pressure applied during vacuum pressing. Any material may be used as long as it has sufficient strength and is of a size and stable shape that can be placed inside the lower end surface of the base material W.

In this embodiment, the decorative paper S is adhered and laminated on the base material W by the pressure difference from the pressure applied from the upper side and the pressure decrease from the lower side. However, it is not always necessary to do so. Depending on the shape, the conditions of the decorative paper S, and the like, it is possible to adhere and laminate even by a pressure difference from only the pressure applied from above without depressurizing from below.

(Experimental Example) Next, the effect of the present invention will be clarified by an experimental example. First, as a base material, an elliptical M having a thickness of about 20 mm shown in FIGS.
Using DF, a polyvinyl acetate-based adhesive diluted with water to 30% and coated with 50 g / m ² on its upper surface is prepared. Next, 80 g / m ^{2 of} titanium paper with an abstract pattern printed on the surface and moisture content of 3.6% with the moisture content adjusted to 10 to 60% evenly over the entire surface. 80
After using g / m ² as a decorative paper and covering it with the entire surface of the base material coated with the adhesive, the base material is placed on a base material mounting table having a thickness of about 20 mm and a diameter slightly smaller than that of the base material. Place on the table of vacuum press machine. Then, vacuum press molding is performed under the conditions of a heating temperature of 130 ° C., a pressure applied to the decorative paper of 2.0 kgf / cm ² , a pressing time of 60 seconds, and a vacuum pressure of 30 cmHg to closely adhere the decorative paper to the substrate. Table 1 shows the evaluation of the degree of adhesion and lamination of the decorative paper to the base material.

[0018]

[Table 1]

From the results shown in Table 1, in the experiments under the above conditions, in No. 4 and No. 5, the adhesion lamination of the decorative paper and the base material was good, and an excellent decorative board was obtained. Others, such as wrinkles, poor adhesion and tear of the decorative paper, were not able to obtain a beautiful decorative board. That is, 25-40
It is judged that the decorative paper, the humidity of which is adjusted to a water content of about%, is well adhered and laminated to the base material.

Using the decorative board obtained in No. 4 or No. 5, a urethane sealer layer D made of solvent-diluted polyester polyol and isocyanate, which is easy to impregnate the surface thereof, is applied at 50 to 100 g / m ² . It is provided by spray painting so that the amount will be adjusted. Next, a UV-curable sanding sealer layer E made of polyester acrylate and urethane acrylate is provided by spray coating so that the coating amount is 50 to 100 g / m ² , and after UV irradiation, the cured surface is sandpaper of # 400. Polished and smoothed,
UV curable resin consisting of urethane acrylate is coated on the surface at a coating amount of 10 to 30 g / m ² , and further UV irradiation is performed to form a cubic curved surface usable as a table top plate as shown in FIG. 7. A surface material U having the above was obtained. Here, the above-mentioned example is given as an example of the post-processing of the decorative plate T obtained in the present invention, but what kind of post-processing can be used as long as the post-processing is capable of providing physical properties usable as a surface material? It goes without saying that processing may be performed.

[0021]

As described above, by moistening the decorative paper such as titanium paper, the conventional vacuum press molding machine can be used in a simple method to form a wrinkle on the substrate having the cubic curved surface. It became possible to make close contact without the occurrence of breaks. Therefore, it has become possible to manufacture surface materials such as furniture and building materials having a cubic curved surface, which has not been obtained until now, and particularly top plates such as desks and tables.

[Brief description of drawings]

FIG. 1 is a diagram showing a first step of a molding method according to the present invention.

FIG. 2 is a diagram showing the next step of the molding method according to the present invention.

FIG. 3 is a diagram showing a final step of the molding method according to the present invention.

FIG. 4 is a cross-sectional view of a decorative board that is an embodiment of the present invention.

FIG. 5 is a plan view of a decorative board which is an embodiment of the present invention.

6 is a cross-sectional view taken along the line AA of the decorative plate shown in FIG.

FIG. 7 is an example of a product obtained by using the decorative board of the present invention.

[Explanation of symbols]

1 Fluid Pressure Cylinder Device 3 Upper Chamber Member 5 Lower Chamber Member 7 Rubber Elastic Membrane 9 Upper Chamber 15 Base Material Mounting Table 19 Lower Chamber 41 Air Pressure Pump 43 Vacuum Pump W Base Material S Decorative Paper T Decorative Plate

Claims (3)

[Claims] 1. A decorative board characterized in that decorative paper is adhered and laminated on a base material having a cubic curved surface via an adhesive layer. 2. A vacuum press molding apparatus having an upper chamber and a lower chamber divided by a rubber-like elastic film, wherein an adhesive is applied to at least the upper surface of the lower chamber so as to cover the entire adhesive application surface. After placing a base material having a cubic curved surface on which the wet decorative paper is covered, the rubber-like elastic film is heated, and a differential pressure is applied to the upper chamber and the lower chamber, whereby A method for manufacturing a decorative board, which comprises closely laminating on a base material having a curved surface. 3. The moisture content of the wet decorative paper is 25 to.
It is 40%, The manufacturing method of the decorative board of Claim 2 characterized by the above-mentioned.