JP2008001096A - Method for manufacturing decorative board, and decorative board - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To simplify the step of forming a resin layer on the surface of a base material and stabilize the quality of the resin layer. <P>SOLUTION: Firstly, the base material 11 is fixed in a cavity 24 so as to generate a gap S corresponding to the thickness of the resin layer 12 between the inner face of the cavity 24 of a molding die 20 and the surface of the base material 11. In the second place, a resin material is flowed into the gap S through an opening part 28. Thereafter, the resin layer 12 is formed on the surface of the base material 11 by curing or hardening the resin material and released from the molding die, which result in manufacturing a resin decorative board 10 provided with the resin layer 12 on the surface of the base material 11. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a decorative plate manufacturing method and a decorative plate, and more particularly, to a decorative plate manufacturing method and a decorative plate capable of easily forming a resin layer on the surface of a substrate.

Conventionally, in a kitchen door or the like, a decorative board is used in which a predetermined resin material is applied to the surface of a base material such as MDF to form a coating film. In such a decorative board, in order to maintain the smoothness of the surface well over a long period of time, the substrate is subjected to a heat treatment and a pressure treatment (hereinafter referred to as “conventional step 1”). Or a step of forming a thick coating film (hereinafter referred to as “conventional step 2”).
JP 2000-210619A

However, in the conventional process 1, in order to obtain a stable finish, it takes time and effort to set and manage conditions such as heating, which in turn disadvantageously increases the cost burden. In particular, when the base material is made of a wood material, the inconveniences appear because the strength, hardness, and the like vary from base material to base material.
Further, in the conventional process 2, in order to form a coating film thickly, a resin material is applied to form a thin coating film of about 0.3 to 0.5 mm, and after the coating film is dried, the surface of the coating film is formed. It is indispensable to perform this cycle a plurality of times, with the step of polishing the substrate as one cycle. For this reason, the process becomes complicated and requires a long time, and this also causes a disadvantage of increasing the cost. Furthermore, when coating is performed, it is difficult to form a coating film uniformly, for example, the resin material applied to the vertical surface is easily dripped during drying.

[Object of invention]
The present invention has been devised by paying attention to such inconveniences, and its purpose is to stabilize the quality of the resin layer while simplifying the process of forming the resin layer on the surface of the substrate. It is providing the manufacturing method of a decorative board which can be manufactured, and a decorative board.

In order to achieve the above object, the present invention provides a decorative board manufacturing method in which a resin layer is provided on the surface of a plate-like substrate.
After fixing the substrate in the cavity so that a gap according to the thickness of the resin layer is generated between the cavity inner surface of the mold and the surface of the substrate,
Pour the resin material into the gap from the opening formed in the mold,
A method is adopted in which the resin material is cured or solidified to form a resin layer on the surface of the substrate, and then demolded.

  In this invention, the said base material is fixed in a cavity using the shaft member connected with a shaping | molding die, This shaft member is taken through the recessed part formed in the surface of a base material. Is preferred.

  The base material may be fixed in the cavity using positioning means connected to the mold, and the positioning means may be inserted into a recess formed on the surface of the base material. Good.

  Moreover, the method of arrange | positioning the surface which becomes the largest area among each surface of the said base material along the substantially perpendicular direction at the time of pouring of the said resin material is employable.

  Furthermore, the shaft member or the positioning means is preferably made of the same material as the resin material.

  Further, after the demolding, it is preferable to remove only a portion protruding from the surface of the shaft member or the resin layer of the positioning means.

Furthermore, the present invention provides a decorative board in which a resin layer is provided on the surface of a base material having a plate shape,
A configuration in which the resin layer is formed by pouring a resin material into the cavity in a state where the base material is disposed in the cavity of the mold and curing or solidifying the resin layer is employed.

  Moreover, it is preferable that the thickness of the resin layer is 1 mm to 5 mm.

  According to the present invention, the resin layer can be formed so as to cover the base material by pouring the resin material into the cavity and then curing or solidifying the resin material. Thereby, the smoothness of the resin layer surface can be obtained well without performing the process as in the conventional process 1, and the manufacturing cost can be reduced through the simplification of the process and the shortening of the time compared to the conventional process 2. It becomes possible to plan. That is, the present invention can obtain a special effect of simultaneously achieving rationalization of the process of forming the resin layer and stabilization of the finish of the resin layer. Moreover, for example, when a large number of fine irregularities are formed on the inner surface of the cavity, it is possible to easily form an irregular shape on the surface of the resin layer corresponding to the irregularities, and to reveal a pattern composed of irregularities difficult to form by painting. A design rich in variations can be imparted.

  Further, by using the shaft member or the positioning means, the gap between the cavity inner surface and the surface of the base material is stably maintained, and the region where the resin layer is not formed is suppressed to the minimum only as the position of the shaft member. Can do. And when using a decorative board as a door, it becomes possible to utilize the recessed part of a base material as a screw hole for connecting members, such as a hinge.

  In addition, by pouring the resin material with the maximum surface area of the base material facing in a substantially vertical direction, the resin material can be easily spread throughout the gap, and air bubbles in the cavity can be prevented from remaining. It becomes.

  Moreover, when the shaft member or the positioning means is made of the same material as the resin material, the recess, the shaft member or the positioning means on the resin layer surface can be made inconspicuous. In addition, the thermal expansion coefficients of the shaft member or positioning means and the resin material can be made substantially equal, and it is possible to prevent the appearance defect around the recess due to non-uniform shrinkage thereof.

  Furthermore, when only the part which protrudes from the resin layer surface of a shaft member or a positioning means is removed, the resin layer surface can be easily finished substantially flush.

  Moreover, by setting the thickness of the resin layer within the above-described range, it is possible to avoid sink marks when the resin decorative board is used for a long time.

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

[First Embodiment]
FIG. 1 is a schematic longitudinal sectional view of a decorative board according to the first embodiment. In this figure, a resin decorative board 10 has a basic configuration including a plate-like base material 11 and a resin layer 12 provided on the surface of the base material 11. Here, as the resin decorative board 10, the panel material used for a kitchen, furniture, a fitting, etc., especially the door material of a cabinet used for a kitchen etc., and a surface decorative board can be illustrated.

  Although the said base material 11 is not specifically limited, In this embodiment, it consists of woody materials, such as MDF. As shown in FIG. 2, the base material 11 includes a decorative surface 11 </ b> A and a back surface 11 </ b> B that are substantially square in front view, and a front end surface 11 </ b> C that is located on the outer edge side of the decorative surface 11 </ b> A and the back surface 11 </ b> B. Of the surfaces 11A, 11B, and 11C, the areas of the decorative surface 11A and the back surface 11B are maximized. In the vicinity of each corner of the back surface 11B, there are provided recesses 13 through which screw members described later are inserted.

  The resin layer 12 is provided on the entire surface of the substrate 11 and has a thickness of 1 mm to 5 mm. If the thickness of the resin layer 12 is less than 1 mm, sink marks at the time of long-term use or variations in thickness at the time of molding occur, which affects the design properties. Further, if the thickness of the resin layer 12 exceeds 5 mm, the overall weight increases, and the heat generated by the resin during molding increases, causing uneven gloss on the surface of the resin layer 12 and increasing the burden on the finishing process. . The thickness of the resin layer 12 is more preferably about 1.5 mm to 3 mm. This can provide a design effect with a sense of depth, is excellent in long-term smoothness of the surface, and can be easily repaired by polishing against scratches during use. Furthermore, the resin material can be easily poured during molding, which will be described later.

  The resin material for forming the resin layer 12 is preferably a transparent thermosetting resin, and examples thereof include unsaturated polyester resins, acrylic resins, and epoxy resins. Further, it is desirable that the resin has a small shrinkage rate, and the volume shrinkage rate is 4% or less, preferably 2.5% or less. Thereby, even if thickness unevenness arises in the resin layer 12, it becomes difficult to generate | occur | produce a curvature in the resin decorative board 10. FIG. The thickness ratio of the resin layer 12 on the front and back surfaces, the resin layer 12 on the front surface / the resin layer 12 on the back surface is preferably 0.5 to 1.5, and more preferably 0.8 to 1.2. Preferably, 1 is the most preferable. This also prevents the resin decorative board 10 from being warped.

  As shown in FIGS. 2 and 3, the resin decorative board 10 is manufactured using a mold 20. The molding die 20 has a first die 21 located on the decorative surface 11A side of the base material 11, a second die 22 located on the back surface 11B side, and a frame shape located between these die 21 and 22. And a cavity 24 is formed inside.

  The inner surfaces of the first and second molds 21 and 22 and the spacer 23, that is, the inner surface of the cavity 24 are polished so as to be smooth. In the vicinity of each corner of the second mold 22, holes 26 are respectively provided at positions corresponding to the recesses 13, and screw members 27 as shaft members are inserted into the recesses 13 through the holes 26, whereby the cavities 24. The base material 11 can be positioned inside. The size and shape of the spacer 23 are determined between the inner surface of the cavity 24 and the decorative surface 11A, the back surface 11B, and the end surface 11C of the base material 11 when the base material 11 is fixed in the cavity 24 using the screw member 27. The gap S is set to be substantially the same as the thickness of the resin layer 12. In addition, an opening 28 that communicates the outside of the mold 20 and the cavity 24 is provided on the spacer 23.

  In the method for manufacturing the decorative resin board 10 of the present invention, a predetermined pretreatment is performed on the base material 11, and before and after this, a mold release treatment is performed on the inner surface of the cavity 24. Next, the screw members 27 are inserted into the holes 29 and the recesses 13 of the base material 11, and the first and second molds 21 and 22 and the spacer 23 are combined (see FIG. 2). As a result, as shown in FIG. 3, a closed cavity 24 is formed, and the base material 11 is formed so that a gap S corresponding to the thickness of the resin layer 12 is generated between the inner surface of the cavity 24 and the base material 11. Fixed. Thereafter, the resin material is poured into the gap S from the opening 28 in a state where the decorative surface 11A and the back surface 11B of the base material 11 are arranged along the substantially vertical direction. Then, after the resin layer 12 is formed on the surface of the base material 11 by allowing the resin material to cure or solidify for a predetermined time, the screw member 17 is removed, and the first and second molds 21 and 22 and the spacer 23 are removed. Is demolded. After demolding, the recess 13 is filled with a resin material or the like as necessary to smooth the back surface 11B of the substrate 11, and a predetermined finishing process is performed on the surface of the resin layer 12.

Therefore, according to the first embodiment, it is possible to easily and quickly form the resin layer 12 having the above thickness without repeating the same process a plurality of times as in the case of painting.
In addition, since the inner surface of the cavity 24 is polished, the surface smoothness of the resin layer 12 can be obtained satisfactorily and the labor required for the finishing process can be reduced.
Further, since the base member 11 is fixed using the screw member 17, the gap S is kept constant, and the thickness of the resin layer 12 can be made uniform.

[Second Embodiment]
Next, a second embodiment of the present invention will be described with reference to FIGS. In the following description, the same reference numerals are used for the same or equivalent components as in the first embodiment, and the description is omitted or simplified.

  The mold 30 according to the second embodiment includes an upper mold 31 located on the side of the top end 11C of the base material 11, a lower mold 32 located on the side of the bottom face 11C of the base material 11, and the upper mold 31 and the lower side. A cylindrical intermediate mold 33 provided between the molds 32 and surrounding the substrate 11 is provided, and a cavity 34 is formed therein.

  Two recesses 36 are provided on the cavity 34 side of the upper mold 31 and the lower mold 32. Further, the upper and lower end surfaces 11C of the substrate 11 are provided with recesses 11D at positions corresponding to the recesses 36, respectively. A dowel or a pin 38 as a positioning means is inserted into the recesses 36 and 11D that face each other at the time of molding, and the base material 11 is positioned in the cavity 34. The dowel or pin 38 is formed of the same material as the resin material forming the resin layer 12. The upper mold 31 is provided with an opening 39 for injecting a resin material.

  In 2nd Embodiment, when manufacturing the resin decorative board 10, the base material 11 is connected to either one of the upper mold | type 31 and the lower mold | type 32 using the dowel or the pin 38. FIG. Next, after the base material 11 is inserted into the intermediate mold 33, the base material 11 is connected to one of the upper mold 31 and the lower mold 32 via a dowel or a pin 38, and the upper mold 31 and the lower mold 32 are connected. And the intermediate mold 33 is combined. At this time, the base material 11 is fixed via a dowel or a pin 38 so that a gap S corresponding to the thickness of the resin layer 12 is generated between the inner surface of the cavity 34 and the base material 11. Next, a resin material is poured into the gap S to cure or solidify the resin material, thereby forming the resin layer 12. The dowels or pins 38 are removed from the recesses 36 of the upper mold 31 and the lower mold 32, and the upper mold 31, the lower mold 32, and the intermediate mold 33 are disassembled and removed. After demolding, the dowel or pin 38 protrudes from the surface of the resin layer 12, and this protruding portion (portion indicated by the dotted line in FIG. 8) is removed by grinding to remove the surface of the resin layer 12 and the dowel or pin 38. Finish so that and are almost flush with each other.

  Therefore, according to the second embodiment, by performing the grinding process, it is possible to eliminate the work of filling the recess 11D of the base material 11, and it is possible to simplify the finishing work. In addition, since the dowels or pins 38 and the resin material forming the resin layer 12 are made of the same material, their colors are the same and the concavity 11D can be made inconspicuous. It is possible to avoid appearance defects such as irregularities.

Although the best configuration, method and the like for carrying out the present invention have been disclosed in the above description, the present invention is not limited to this.
That is, the present invention has been particularly shown and described with respect to particular embodiments, but without departing from the scope of the technical idea and purpose of the present invention. Alternatively, various modifications can be made by those skilled in the art in the direction and other detailed configurations.
Therefore, the description limited to the shape disclosed above is an example for easy understanding of the present invention, and does not limit the present invention. The description by the name of the member which remove | excluded one part or all part is included in this invention.

For example, although the shaft member is the screw member 17 in the first embodiment, various modifications such as a round bar or a cylindrical member are possible.
Further, the formation position of the recess 13 may be set so that a metal fitting such as a hinge can be attached in the recess 13 after the resin decorative board 10 is completed. According to this, the work of filling the recess 13 is omitted. can do.
Furthermore, you may form the recessed part 13 by screwing the screw member 17 in the said base material 11 at the time of fixation of the base material 11, without forming the recessed part 13 previously.
Alternatively, a pattern with a three-dimensional effect may be formed on the surface of the resin layer 12 by forming irregularities on the inner surface of the cavity 24 of the mold 20.
Further, the mold 20 is not limited to the illustrated configuration example, and may be changed as long as the resin layer 12 can be formed as described above.

  Further, in the second embodiment, the positioning means is the dowel or the pin 38, but as shown in FIG. 9, various modifications such as a strip or plate 40 are possible, and according to this, The shape of the recesses 11D and 36 may be changed.

  Further, in the first embodiment, the screw member 17 is formed of the same material as the resin material forming the resin layer 12, and the screw member 17 inserted into the recess 13 at the time of demolding is cut while being inserted into the recess 13. The screw member 17 protruding from the surface of the resin layer 12 may be ground and finished.

The schematic longitudinal cross-sectional view of the resin decorative board which concerns on 1st Embodiment. The decomposition | disassembly schematic perspective view of a shaping | molding die and a base material before forming a resin layer (1st Embodiment). The schematic longitudinal cross-sectional view of the shaping | molding die and base material just before forming a resin layer (1st Embodiment). Sectional drawing similar to FIG. 3 after pouring the resin material (first embodiment). The disassembled schematic perspective view of the shaping | molding die before forming the resin layer of the resin decorative board which concerns on 2nd Embodiment, and a base material. The schematic longitudinal cross-sectional view of the shaping | molding die and base material just before forming a resin layer (2nd Embodiment). Sectional drawing similar to FIG. 6 after pouring of the resin material (2nd Embodiment). The schematic longitudinal cross-sectional view of a resin decorative board (2nd Embodiment). The partially disassembled schematic perspective view of the shaping | molding die before forming the resin layer of the resin decorative board which concerns on a modification, and a base material.

Explanation of symbols

  DESCRIPTION OF SYMBOLS 10 ... Resin decorative board, 11 ... Base material, 12 ... Resin layer, 13 ... Recessed part, 20 ... Mold, 24 ... Cavity, 27 ... Screw member (shaft member ), 28 ... opening, S ... gap, 38 ... dowel or pin (positioning means)

Claims (8)

In the method for producing a decorative board, in which a resin layer is provided on the surface of a plate-like substrate,
After fixing the substrate in the cavity so that a gap according to the thickness of the resin layer is generated between the cavity inner surface of the mold and the surface of the substrate,
Pour the resin material into the gap from the opening formed in the mold,
A method for producing a decorative board, comprising: curing or solidifying a resin material to form a resin layer on a surface of a substrate;   The said base material is fixed in a cavity using the shaft member connected with a shaping | molding die, This shaft member is penetrated by the recessed part formed in the surface of a base material. A method for producing a decorative board.   The said base material is fixed in a cavity using the positioning means connected with a shaping | molding die, This positioning means is penetrated by the recessed part formed in the surface of a base material. A method for producing a decorative board.   2. The method for manufacturing a decorative board according to claim 1, wherein when the resin material is poured, a surface having the maximum area among the surfaces of the substrate is arranged along a substantially vertical direction.   5. The method for manufacturing a decorative board according to claim 1, wherein the shaft member or the positioning means is made of the same material as the resin material.   The method for manufacturing a decorative board according to any one of claims 1 to 5, wherein after the demolding, only a portion protruding from the surface of the resin layer of the shaft member or the positioning means is removed. In the decorative board provided with a resin layer on the surface of the base material in the form of a plate,
The decorative board is characterized in that the resin layer is formed by pouring a resin material into the cavity in a state where the base material is disposed in the cavity of the mold, and curing or solidifying the resin material.   The decorative layer according to claim 7, wherein the resin layer has a thickness of 1 mm to 5 mm.

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