JP2015157431A - Method of manufacturing original stock product - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method of manufacturing an original stock product, which wholly assumes a three-dimensional shape, in which a synthetic resin base material layer is formed in the state of being superposed on the backside of a sliced veneer by an injection molding operation, and which enables the front side of the sliced veneer to be formed as a three-dimensional excellent design surface by relief working.SOLUTION: A synthetic resin injection molding operation makes a base material layer formed in the state of being superposed on the backside of a sliced veneer, and an insert molding is formed. Subsequently, the insert molding is subjected to humidification treatment for swelling of the sliced veneer constituting the insert molding. After that, the sliced veneer of the insert molding swollen by the humidification treatment is dried, and relief working is applied to a surface of the dried sliced veneer of the insert molding to form an uneven design surface.

Description

  The present invention relates to a method of manufacturing a main wood product, and in particular, a base layer made of synthetic resin is formed on the back side of the veneer, and exhibits a three-dimensional shape as a whole, and the surface of the veneer is excellent in three dimensions. The present invention relates to a method that can advantageously produce a genuine wood product having excellent design properties.

  Conventionally, in automobiles and the like, so-called genuine wood products using real wood have been used as design panels for interior parts such as armrest bases, clusters, and console boxes in order to produce a high-class interior. Yes. Such main wood products are generally made of synthetic resin on the back side of a thin wood (projection board) whose surface is a design surface from the viewpoint of product shape, physical properties, etc. in addition to the availability and economy of wood. It is manufactured in the form of a laminated structure in which the base materials are integrally laminated.

  For example, in Japanese Patent Application Laid-Open No. 11-309745 (Patent Document 1), etc., a main wood product having a laminated structure as described above and having at least a part of a design surface constituted by a three-dimensional curved surface Using a molding die having a molding cavity having a shape corresponding to the core material (base material), a relatively thin wooden board (projection board) is placed on the design surface in the molding cavity of the molding die. After being arranged in a three-dimensional curved shape so as to correspond to a three-dimensional curved surface, a resin material is injected and filled into the molding cavity, and the core material (base material) is integrated with the back side of the wooden board (projection board). It is manufactured by laminating and forming.

  On the other hand, a so-called floating process is known as one process for improving the design of the surface of such genuine wood. For example, as disclosed in Japanese Patent Application Laid-Open No. 5-77210 (Patent Document 2), Japanese Patent Application Laid-Open No. 2008-55719 (Patent Document 3), etc., natural woody materials are Alternatively, it is made up of the fact that it is composed of a part that is also referred to as spring wood and a winter eye (also referred to as late or autumn wood) part. That is, the Natsume part is a part that grows from spring to autumn, and since the growth is fast, the organization is rough and relatively soft, and the winter part is from autumn to the end of winter. Since the growth is slow, and the growth is slow, the structure is dense and relatively hard, so the floating process is the surface of the Natsume part among the Natsume and Winter eyes. Is selectively removed by a brushing process or the like to form a concave portion having a predetermined depth, thereby creating a three-dimensional and excellent design of the concave-convex pattern on the surface of the wood. The wood that has been subjected to such floating processing is widely used in the ceiling boards and flooring of temples and shrines.

  By the way, in general, such float processing is performed on the surface of a relatively thick plate-like wood (projection plate) in order to obtain a desired three-dimensional effect, and thus exhibits a three-dimensional shape. When manufacturing a real wood product that has a three-dimensional and excellent design surface by subjecting the surface of the veneer to float processing as a real wood product, using such a thick veneer makes it easy to apply it to a three-dimensional shape. Therefore, when injection molding a base material on the back side of such a veneer, it is difficult to place the veneer in a three-dimensionally curved manner in the molding cavity of the molding die. Cause problems.

  Therefore, in order to solve such a problem, the projecting plate has a relatively thin plate thickness, that is, a plate that can be curved and arranged in a three-dimensional shape in the molding cavity to maintain such a shape. Thickness is considered. However, when the base material is laminated by injection molding operation, since the injection pressure of the molten resin material injected into the molding cavity is high, the projecting plate has such a high pressure molten resin material and cavity surface. Is pressed between the two and compressed in the plate thickness direction, the plate thickness of the protruding plate is further reduced. As a result, when a relatively thin plate is used, it becomes impossible to secure a plate thickness for obtaining a sufficient three-dimensional effect by performing a float process. In the worst case, when the removal process of the Natsume part is performed, there is a possibility that a problem that the resin base material is exposed in such a processing part may be caused. In addition, since the Natsume part becomes hard due to such compression, it is possible to selectively remove the Natsume part by utilizing the difference in hardness between the Natsume part and the Winter eye part in the float process. Therefore, there is an inherent problem that it is difficult to perform the floating process itself.

Japanese Patent Laid-Open No. 11-309745 JP-A-5-77210 JP 2008-55719 A

  Here, the present invention has been made against the background of such circumstances, and the solution to the problem is that it exhibits a three-dimensional shape as a whole, and a base layer made of synthetic resin is provided on the back side of the protruding plate. An object of the present invention is to provide a manufacturing method of a wood product that is formed by injection molding operation and that can make the surface of such a veneer plate into a three-dimensional and excellent design surface by float processing. It is.

  In the present invention, in order to solve such a problem, a floating process is applied to the surface of a wooden veneer that gives a design surface, and on the back side of the veneer, a synthetic resin base material is provided. A method of manufacturing a wood product in which layers are laminated by an injection molding operation, wherein (a) the projecting plate is housed in a molding cavity of a mold capable of molding the base material layer, and the projecting plate A process of forming an insert-molded product by laminating the base material layer by an injection molding operation of a synthetic resin on the back surface side of the projecting plate in a state where the surface is opposed to the cavity surface of the molding cavity; (B) a step of humidifying the insert molded product to swell the veneer constituting the insert molded product, and (c) drying the veneer of the insert molded product swollen by the humidification process. Process and ( ) Is subjected to 浮造 Ri machining respect dried veneer surface of the insert-molded article, a step of forming a design surface having irregularities, a manufacturing method of the present wood including one in which the gist thereof.

  In addition, in this invention, it is employ | adopted suitably to perform the humidification process with respect to the said insert molded product from the surface side of the said protrusion plate which comprises this insert molded product.

  Further, according to one of the desirable embodiments of the method for producing a main wood product according to the present invention, the humidification treatment for the insert molded product is performed using dilute hydrochloric acid, and the float processing is performed by baking float processing. Will be.

  Furthermore, according to another one of the desirable aspects of the present invention, preferably, a clear layer made of a transparent synthetic resin is further laminated on the surface side of the projecting plate subjected to the float processing by a coating operation. Will be.

  Thus, in the manufacturing method of the main wood product according to the present invention, such an insert molded product in which a base layer made of a synthetic resin is laminated on the back side of the veneer is obtained by an injection molding operation. Even if the veneer is thinned by injection molding pressure, the resulting insert molded product is humidified so that the veneer constituting the insert molded product can be swollen. It is possible to effectively secure a plate thickness that can produce a sufficient three-dimensional effect, which makes it possible to float the surface of such a veneer and effectively create a three-dimensional and excellent design surface with irregularities. It will be possible to form. That is, the plate thickness necessary for forming the concave portion of a predetermined depth by the float processing will be advantageously ensured, and thereby, the base material layer is exposed by the removal of the Natsume portion, The problem of seeing through can be effectively eliminated.

  Moreover, because the veneer is swollen by the humidification treatment for such an insert molded product, the Natsume portion of the veneer that has been compressed and hardened by the injection molding operation of the base material layer becomes soft, The advantage that the removal process (floating process) of the Natsume part can be performed more easily also occurs.

  Furthermore, in the manufacturing method of the main wood product according to the present invention, the veneer swollen by the humidification process is dried prior to the floating process, and is floated on the surface of the dried veneer. Since the surface is processed, it is possible to effectively improve the surface condition of the processed veneer plate, thereby advantageously preventing or suppressing surface roughness or damage of the veneer plate. Is possible.

  In the manufacturing method of the main wood product according to the present invention, the protruding plate is accommodated in the molding cavity of the mold that can mold the base material layer, and the surface of the protruding plate is opposed to the cavity surface of the molding cavity. Under the condition, since the base material layer is laminated and formed on the back surface side of the veneer by an injection molding operation, there is an advantage that the main wood product exhibiting a three-dimensional shape as a whole can be advantageously manufactured. is there.

It is sectional explanatory drawing which shows an example of the main wood product manufactured according to this invention method, Comprising: (a) shows this whole main wood product, (b) shows the one part expanded. It is. It is longitudinal cross-sectional explanatory drawing which shows the veneer sheet | seat which comprises some main tree products shown by FIG. FIG. 2 is a cross-sectional explanatory view showing an example of a process for forming an injection-molded product when the main wood product shown in FIG. 1 is manufactured according to the method of the present invention, and is one side of an injection-molding mold that is opened. The state which accommodated and arrange | positioned the veneer sheet | seat in the shaping | molding cavity of this type | mold is shown. FIG. 4 is a cross-sectional explanatory diagram illustrating an example of a process performed subsequent to FIG. 3, showing a state in which a molten resin material is injected and filled in a molding cavity in which a veneer sheet is accommodated. It is the A section enlarged explanatory view in FIG. FIG. 5 is a cross-sectional explanatory view showing an example of a process performed subsequent to FIG. 4, and after the molten resin material injected and filled in the molding cavity is solidified, the injection molded product is opened from the mold for injection molding The removed state is shown. It is the B section enlarged explanatory view in FIG. FIG. 7 is a partially cutaway explanatory view showing an example of a process carried out subsequent to FIG. 6, showing a state where the injection molded product is humidified. FIG. 9 is an enlarged explanatory diagram of a portion C in FIG. FIG. 9 is a partially cutaway explanatory view showing an example of a process carried out subsequent to FIG. 8, showing a state in which a floating process is performed on a protruding plate of an injection molded product. It is D section expansion explanatory drawing in FIG.

  Hereinafter, in order to clarify the present invention more specifically, embodiments of the present invention will be described in detail with reference to the drawings.

  First, FIG. 1A schematically shows a main wood product 10 used as an automobile interior part as an example of a main wood product manufactured according to the method of the present invention in a vertical cross-sectional form. The main wood product 10 has a three-dimensional shape of a shallow box as a whole by being bent so that the peripheral portion rises at a predetermined height. Specifically, as clarified in FIG. 1 (b), the main wood product 10 has a reinforcing layer 14 and a bonding layer on the back side of the protruding plate 12 [the lower side in FIG. 1 (b)]. 16 has a veneer sheet 18 formed by laminating. Moreover, the base material layer 20 is laminated and formed by injection molding on the back surface [the lower surface in FIG. 1 (b)] of the protruding plate sheet 18, while the front surface [in FIG. 1 (b)]. On the upper surface: design surface 22], a clear layer 24 made of a transparent synthetic resin is laminated and formed with a predetermined thickness by a painting operation. In other words, here, the main wood product 10 is configured by a laminated structure in which the bonding layer 16, the reinforcing layer 14, the protruding plate 12, and the clear layer 24 are laminated in that order on the base material layer 20. Has been. In the following, for the sake of convenience, the upper side (surface) in FIG. 1B of the main wood product 10 on the design surface 22 side of the protruding plate 12 is referred to as the front surface side (surface), and the opposite side (surface). Is called the back side (back side). Further, in FIG. 1 and FIGS. 2 to 11 described later, in order to facilitate understanding of the structure of the main wood product 10 of the present embodiment, the thickness of each layer including the protruding plate 12 is set to the clear layer 24 and the base layer. It should be understood that the exaggerated size is different from the actual size compared to the thickness of the material layer 20.

  Here, as shown in FIG. 1B, an uneven design surface 22 is formed on the surface of the protruding plate 12 in the main wood product 10 by a float process. That is, the protruding plate 12 has a coarse texture and a relatively soft portion Natsume portion 26 and a winter portion 28 that is a dense and relatively hard portion [the diagonal lines in the protruding plate 12 in FIG. 1B. The concave portion 30 is formed in the Natsume portion 26, and thereby a three-dimensional and excellent design of the uneven pattern is created on the design surface 22 of the protruding plate 12.

  In the present invention, the main wood product 10 having such a structure is manufactured according to the following procedure.

  That is, first, a veneer sheet 18 having a structure as shown in FIG. 2 is prepared. When preparing the projecting plate sheet 18, the flat projecting plate 12 is prepared by cutting out from a predetermined piece of wood. When the protruding plate 12 is cut out from a predetermined piece of wood, desired grain (Natsume part 26 and Winter eye part 28) such as a grain, a grid, a grid, etc. appears on the surface (design surface 22). The And the well-known drying process is given to the protruding board 12 cut out from the predetermined | prescribed wood as needed. Further, the plate thickness (t1) of the protruding plate 12 ensures the flexibility of the protruding plate sheet 18 that can be formed into a three-dimensional shape, and also secures the plate thickness that can form the concave portion 30 with a desired depth by floating processing. For this reason, the thickness is preferably about 0.5 mm to 1.0 mm.

  Such a veneer 12 is provided to give a realistic wood texture. For example, the grain of Obankor, Bubinga, Birdseye Maple, Curly Maple, White Ash, Sappelima Hogany, Tamo, Sugi, Hinoki, Cherry, Teak, etc. Made of various beautiful natural wood. It should be noted that, since the surface of the projecting plate 12 is subjected to a floating process, a material in which the grain of the natural wood appears relatively clearly, in other words, the Natsume portion 26 and the winter. It is preferable to use a material having a clear contrast with the eye portion 28. For example, a material having a large hardness difference between the summer eyes and the winter eyes such as cedar is preferably used.

  On the other hand, an aluminum thin plate having a rectangular flat plate shape substantially the same size as the protruding plate 12 constituting the reinforcing layer 14 is prepared by cutting out from a predetermined blank or the like by press molding or the like. The reinforcing layer 14 has a rigidity that can impart a desired rigidity to the veneer sheet 18 and is not damaged by pressure or heat during injection molding of the base material layer 20. Thus, the material of the projecting plate sheet 18 is not limited as long as it does not hinder the placement and placement of the projecting plate sheet 18 in the molding cavity (42) of the injection mold (36) in a three-dimensional shape. For example, other metal thin plates such as iron and copper, hard resin sheets such as polypropylene and ABS resin, or non-woven fabrics, and fiber sheets such as glass fibers and carbon fibers are replaced with aluminum thin plates. Any of them can be adopted.

  Further, separately from the projecting plate 12, a rectangular flat plate-shaped wood board that is substantially the same size as the projecting plate 12 and that constitutes the bonding layer 16 is prepared by cutting out from predetermined wood. Note that, when cutting a wooden board from a predetermined wood, the direction of the grain is not limited, but as such wood, there are those having coarser grain than the wood from which the protruding board 12 is cut, for example, Claro walnut, Manga shirono, etc. Can be selected. And the well-known drying process is given to the wooden board cut out from the predetermined | prescribed timber as needed.

  Next, after forming the adhesive layer 32 on the back surface of the protruding plate 12 using a known adhesive capable of firmly bonding wood and metal, the prepared aluminum thin plate is passed through the adhesive layer 32. Then, it adheres so that the whole back surface of the protrusion 12 may be covered. Thereby, the reinforcing layer 14 is laminated on the back surface of the protruding plate 12 to increase the rigidity of the protruding plate 12.

  Thereafter, the adhesive layer 34 is formed on the back surface of the reinforcing layer 14 by using an adhesive similar to the adhesive constituting the adhesive layer 32, and then the previously prepared wooden board is passed through the adhesive layer 34. Then, bonding is performed so as to cover the entire back surface of the reinforcing layer 14. As a result, the bonding layer 16 is laminated on the back surface of the protruding plate 12 via the reinforcing layer 14. Thus, the protruding plate sheet 18 is obtained.

  In the method of the present invention, the resin material constituting the base material layer 20 is not always selected to have excellent bondability or adhesion to a metal material. Therefore, here, the bonding layer 16 having excellent bonding property or adhesion to the base material layer 20 is laminated on the back surface of the reinforcing layer 14.

  Next, as shown in FIGS. 3 to 7, an injection molding operation (insert molding) is performed by performing an injection molding operation of the target base material layer 20 using an injection molding die 36 having a known structure. Product) (54) will be formed. Here, the injection mold 36 includes a fixed mold 38 and a movable mold 40, and the molding cavity 42 is formed by matching them.

  In such an injection molding operation, as shown in FIG. 3, the previously prepared protruding plate sheet 18 is accommodated in the cavity forming recess 44 of the movable mold 40. At this time, the protruding plate 12 is disposed in a state where the surface thereof is opposed to the inner surface (cavity surface) of the cavity forming recess 44 of the movable mold 40. That is, the entire projecting plate sheet 18 is accommodated in the molding cavity 42 in a three-dimensional shape corresponding to the inner shape of the cavity forming recess 44 of the movable mold 40. Although not shown, the injection mold 36 used in the present embodiment is provided with a mechanism capable of holding the protruding plate sheet 18 in a predetermined shape.

  Then, as shown in FIG. 4, the mold 36 for injection molding is clamped and from a nozzle 46 of an injection molding machine (not shown), a molten resin material made of an opaque ABS resin that is a material for forming the base material layer 20. 48 is injected, and the molten resin material 48 is filled into the molding cavity 42 through the sprue 50 and the sub sprue 52.

  In addition, as a forming material of the base material layer 20, in addition to a general-purpose ABS resin, it is generally used as a forming material for automobile interior parts. For example, polycarbonate / ABS resin, ABS resin containing glass fiber, polypropylene, polyethylene Further, thermoplastic resins such as polyamide, polybutylene terephthalate, and noryl resin can be appropriately used.

  At this time, as shown in FIG. 5, the projecting plate sheet 18 is formed between the molten resin material 48 filled with a high injection pressure in the molding cavity 42 and the inner surface of the cavity forming recess 44 of the movable mold 40. By being pinched, the protruding plate 12 is pressed against the inner surface of the cavity forming recess 44 with a large force based on the injection pressure of the molten resin material 48 (see the white arrow in FIG. 5). Here, the state of the protruding plate sheet 18 before filling with the molten resin material 48 is indicated by a two-dot chain line.

  Thereafter, the molten resin material 48 filled in the molding cavity 42 is cooled and solidified to form the base material layer 20. At this time, since there are many recesses such as minute holes and minute grooves on the surface of the bonding layer 16 facing the base material layer 20, the molten resin material 48 enters the recesses. Alternatively, the anchor effect is exhibited by permeating into the fiber, and thus the adhesion between the bonding layer 16 and the base material layer 20 is effectively enhanced. Thus, as shown in FIG. 6, an injection molded product 54 in which the base layer 20 made of a synthetic resin is formed on the back surface side of the protruding plate 12 via the reinforcing layer 14 and the bonding layer 16 is an insert molded product. Is taken out from the injection mold 36.

  By the way, as described above, when the base material layer 20 is formed by the injection molding operation, the injection pressure of the molten resin material 48 injected into the molding cavity 42 is high. The high pressure molten resin material 48 and the inner surface (cavity surface) of the cavity forming recess 44 are sandwiched and compressed in the plate thickness direction, so that the plate thickness of the protruding plate 12 becomes thin. That is, as shown in FIG. 7, after the formation of the base material layer 20, the thickness (t2) of the protruding plate 12 of the injection molded product 54 taken out from the injection mold 36 is indicated by a two-dot chain line in FIG. This is a decrease by Δt (mm) from the state before the base material layer 20 is formed (plate thickness: t1).

  Therefore, in the method of the present invention, a humidification process is performed on the injection molded product 54 obtained as described above. Here, as shown in FIG. 8, the humidifier 56 used for the humidification process includes a conveyor 58 for conveying the injection molded product 54 and a plurality of nozzles 60 arranged in the conveying direction. Yes. The injection molded product 54 is placed on the conveyor 58 with the protruding plate 12 facing upward, and is sequentially transferred (see the white arrow in FIG. 8). Then, water vapor (steam) 62 is blown out from the nozzle 60, and the water vapor 62 is blown toward the protruding plate 12 of the injection molded product 54. In this way, the thickness of the protruding plate 12 that has been compressed and reduced during the formation of the base material layer 20 is effectively increased by causing the protruding plate 12 to absorb water (absorb moisture) and swell the protruding plate 12. (Restoration).

  In addition, in such a humidification process, in order to obtain the target increase (restoration) effect of the plate thickness, for example, it is effective to control the moisture content of the protruding plate 12 during or immediately after the humidification process. . If the moisture content is too low, the effect of increasing the plate thickness cannot be obtained sufficiently, and if the moisture content is too high, the effect of increasing the plate thickness can not be obtained. And the subsequent drying takes time. In addition, the moisture content of the veneer 12 immediately after the humidification process is generally about 18% to 30%.

  Further, in the case of using the humidifier 56 as in the present embodiment, the temperature of the water vapor (steam) 62 and the humidification treatment time are appropriately set in order to control the moisture content within the above-described range. become. Here, if the temperature of the water vapor 62 is too low, it becomes difficult for the protruding plate 12 to swell, so it takes a long time to swell the protruding plate 12, or the plate thickness may be increased to a desired thickness. It becomes difficult. On the other hand, even if the temperature of the water vapor 62 is too high, the swelling of the protruding plate 12 does not favorably proceed in proportion thereto, and the energy efficiency is deteriorated. Furthermore, excessive rise in the temperature of the protruding plate 12 or the injection-molded product 54 may cause warpage or damage to the product. For this reason, the temperature of the water vapor 62 is preferably in the range of 40 ° C to 60 ° C.

  Further, regarding the humidifying time, if the humidifying time is too short, the protruding plate 12 cannot be sufficiently swollen and it is difficult to increase the plate thickness to a desired thickness. On the other hand, if the humidifying time is too long, the cycle time is extended and the production efficiency is reduced, or the protruding plate 12 absorbs water more than necessary, and the subsequent drying takes time. Accordingly, generally, the humidifying treatment time is about 5 to 20 minutes.

  Then, as shown in FIG. 9, the thickness of the protruding plate 12 is increased by Δt ′ (mm) by the swelling of the protruding plate 12 by the humidification process as described above, whereby the protruding plate 12 after the humidifying process is increased. The plate thickness is t3 (mm). Here, the state (plate thickness: t2) of the protruding plate 12 before the humidification treatment is indicated by a two-dot chain line. Further, in order to advantageously form an uneven design surface 22 by a floating process described later, it is desirable that the thickness (t3) of the protruding plate 12 after the humidification process is at least about 0.5 mm or more. .

  Next, the protruding plate 12 of the injection molded product 54 swollen by the humidification process is dried. Here, the drying of the protruding plate 12 is performed by leaving the humidified injection-molded product 54 in a drying chamber in which the temperature and humidity are controlled. By drying the protruding plate 12 in this manner, the characteristics such as the hardness of the protruding plate 12 that have been lowered by the humidification treatment (moisture absorption, water absorption) can be advantageously improved. In other words, by such drying, excess water contained in the protruding plate 12 is discharged, and the swelling state of the protruding plate is eliminated.

  Even in this drying operation, it is effective to control the moisture content after drying of the protruding plate 12 in order to obtain the target characteristic improvement effect of the protruding plate 12. If the moisture content is still high, the effect of improving the characteristics cannot be obtained sufficiently, and the hardness of the veneer 12 is low, so that the surface of the veneer (design surface 22) is roughened by the subsequent floating process, Problems such as poor adhesion to the clear layer 24 and coating unevenness occur. Further, even if the moisture content is lowered more than necessary, it is not possible to obtain the effect of improving the characteristics corresponding to it, and only the time and cost required for drying are wasted. As is well known, when wood is left in an environment adjusted to a certain temperature and humidity, when the moisture content is reached, the moisture absorption and moisture release of the wood become the same speed, and the appearance is apparent. Moreover, wood does not absorb and release moisture. Such a moisture content is called an equilibrium moisture content, and this state is called an air-dry state. Generally, the moisture content in an air-dried state when wood is left in the atmosphere is around 15%. Here, the moisture content of the veneer 12 after drying is preferably in the range of 5% to 15% including such an air-dried state.

  When the injection molded product 54 is left in the drying chamber to dry the protruding plate 12 as in this embodiment, the moisture content of the protruding plate 12 is set to a desired value. It is necessary to appropriately control temperature, humidity, and standing time. Here, if the temperature in the drying chamber is too low, drying is difficult to proceed, and if too high, drying of a part (particularly the surface) of the protruding plate 12 proceeds rapidly and uniform drying becomes difficult. The temperature is preferably in the range of 60 ° C. to 80 ° C. because the temperature of the injection molded product 54 is excessively increased, which may cause warpage or damage to the product.

  In addition, if the humidity in the drying chamber is too low, problems such as cracking of the protruding plate 12 occur, and if it is too high, the drying of the protruding plate 12 is difficult to proceed. Therefore, the humidity is preferably in the range of 5% to 20%. It is said. Furthermore, the standing time is preferably in the range of 30 minutes to 1 hour in order to shorten the cycle time as much as possible and to dry the entire protruding plate 12 uniformly. Even if the protruding plate 12 (injection-molded product 54) is dried in this manner, the thickness (t3) of the protruding plate 12 that has once increased due to the humidification process hardly decreases again.

  Subsequently, a floating process is performed on the dried surface of the protruding plate 12 of the injection molded product 54. Here, by using a float processing apparatus 64 as shown in FIG. 10, a rotating thin metal wire brush 68 is brought into contact with the surface of the protruding plate 12 of the injection molded product 54 conveyed on the conveyor 66. Then, the Natsume portion 26 on the surface of the protruding plate 12 is scraped off. That is, as shown in FIG. 11, the surface of the relatively soft summer eye portion 26 of the summer eye portion 26 and the winter eye portion 28 (the hatched portion in FIG. 11) constituting the protrusion 12 is brushed. By removing, the concave portion 30 having a predetermined depth (d) is formed in the Natsume portion 26. In FIG. 11, the surface of the protruding plate 12 before the floating process is shown by a two-dot chain line. Here, in order to obtain a three-dimensional and excellent design surface 22 with unevenness, the depth (d) of the recess 30 is preferably about 0.3 mm to 0.5 mm. Thereby, the uneven design surface 22 is effectively formed on the surface of the protruding plate 12 of the injection molded product 54.

  A clear layer 24 is laminated and formed on the design surface 22 of the projecting plate 12 that has been floated as described above. Here, this coating operation is performed by so-called spray coating, in which an acrylic resin-based paint is sprayed onto the design surface 22 of the projecting plate 12 with a paint gun. As a result, a clear layer 24 made of a transparent acrylic resin is laminated on the design surface 22 with a predetermined thickness, and the main wood product 10 having a three-dimensional effect and excellent in design properties as shown in FIG. 1 described above. Can be made.

  As is clear from the above description, in this embodiment, the base layer 20 is laminated and formed by injection molding operation, so that the compressed and thinned protruding plate 12 is humidified and swollen. From the point where the plate thickness is increased, the plate thickness necessary to form the concave portion 30 of a predetermined depth is advantageously ensured in the floating process. The three-dimensional and excellent design surface 22 having unevenness can be effectively formed. Moreover, the problem that the base material layer 20 is exposed or can be seen through due to the removal process of the Natsume portion 26 can be effectively solved.

  Moreover, the Natsume portion 26 of the protruding plate 12 that has been compressed and hardened by the injection molding operation of the base material layer 20 is made soft by swelling the protruding plate 12 by the humidification treatment on the injection molded product 54. Therefore, there is an advantage that the removal process (floating process) of the Natsume portion 26 can be performed more easily.

  Further, in the present embodiment, since the humidification process is performed from the surface side of the projecting plate 12 constituting the injection-molded product 54, the projecting plate 12 is effectively humidified and advantageously swelled. And the swelling (moisture absorption) of the base layer 20 made of the synthetic resin formed on the back side of the protruding plate 12 can be suppressed. Can be advantageously avoided.

  In the present embodiment, prior to the floating process, the protruding plate 12 swollen by the humidification process is dried, and the floating process is performed on the surface of the dried protruding plate 12. The Rukoto. For this reason, when the surface state of the protruding plate 12 is effectively improved, it is possible to advantageously prevent or suppress roughening, flaking, damage, or the like of the design surface 22 of the protruding plate 12. Furthermore, the state of the design surface 22 of the protruding plate 12 is improved, so that there is an advantage that the subsequent coating operation of the clear layer 24 becomes easy.

  In the present embodiment, in consideration of the thinning of the protruding plate 12 due to the formation of the base material layer 20, it is not necessary to increase the thickness of the protruding plate 12 in advance. The flexibility of the veneer sheet 18) can be ensured, and the main wood product 10 having a three-dimensional shape as a whole can be advantageously manufactured.

  Moreover, in this embodiment, the clear layer 24 is laminated | stacked directly on the design surface 22 of the protrusion 12 by coating operation. As a result, it is possible to form the clear layer 24 without crushing the irregularities of the design surface 22 formed by floating processing, in other words, without filling the concave portions 30. Therefore, the design surface 22 can be protected without impairing the three-dimensional effect, and a deeper design property can be imparted to the design surface 22. The material for forming the clear layer 24 may be a transparent synthetic resin, and is not limited to an acrylic resin, and a polycarbonate resin or the like can also be used. In addition, examples of the paint for forming the clear layer 24 include clear paints such as polyurethane resin paints, acrylic resin paints, amino alkyd resin paints, and the like. A clear layer 24 may be formed. In the present invention, the clear layer 24 is not essential and may be omitted.

  The exemplary embodiments of the present invention have been described in detail above. However, the embodiments are merely examples, and the present invention is limited in any way by specific descriptions according to such embodiments. It should be understood that it is not interpreted.

  For example, the projecting plate sheet 18 is pre-shaped into a shape corresponding to the inner shape of the cavity forming recess 44 of the injection molding die 36 (movable mold 40), and then placed in the cavity forming recess 44 (molding cavity 42). You may make it accommodate. By doing so, the surface of the projecting plate sheet 18 (projecting plate 12) is brought into close contact with the inner surface of the cavity forming recess 44, so that the injection filling of the molten resin material 48 forming the base material layer 20 into the molding cavity 42 is performed. At times (see FIG. 4), the molten resin material 48 can be advantageously prevented from wrapping around the surface of the protruding plate sheet 18 (the protruding plate 12).

  Further, the humidification treatment can be carried out by various known methods that can swell the protruding plate 12 constituting the injection molded product 54. For example, in a room (tank) in which temperature and humidity are controlled. Alternatively, the injection molded product 54 may be left unattended. In addition, you may implement this humidification process under pressure reduction or a pressurization state. However, such humidification treatment suppresses the moisture absorption of the synthetic resin constituting the base material layer 20, and suppresses the dimensional change of the base material layer 20, so that the surface of the protruding plate 12 constituting the injection-molded product 54. It is desirable to do from the side.

  Further, in the case where the humidification process is performed from the surface side of the projecting plate 12 constituting the injection molded product 54 as described above, it is not limited to the above-described mode of spraying water vapor. For example, a liquid such as water is used. It can be carried out in various modes such as spraying, dropping a liquid, dipping in a liquid, or contacting with a medium holding the liquid.

  Various known methods can be employed as the float processing method, for example, a method of removing the Natsume portion 26 by blasting or the like, or a removal treatment of the Natsume portion 26 after carbonizing the surface of the protruding plate 12. A so-called baked float crafting method or the like that performs the above may be employed as appropriate. Note that these methods can be combined.

  Furthermore, the humidification process can be performed using dilute hydrochloric acid instead of water, and the float process can be performed by a baked float process. Conventionally, it is known that the unevenness to be formed can be advantageously increased by applying dilute hydrochloric acid to the surface of the protruding plate 12 in the baking process, and the unevenness of baking in the baking process is reduced. Thereby, it is possible to advantageously form the design surface 22 with a beautiful contrast between the grain (Natsume 26 and Winter 28). Therefore, by performing the humidification process using dilute hydrochloric acid, it is possible to swell the veneer 12 with moisture in the dilute hydrochloric acid, and the application process of dilute hydrochloric acid can be performed simultaneously with the humidification process. The step of applying dilute hydrochloric acid can be omitted. In this case, it is more desirable to perform the humidification process from the surface side of the protruding plate 12 in order to prevent the adverse effect of the diluted hydrochloric acid on the base material layer 20.

  Further, the method for forming the clear layer 24 on the design surface 22 of the projecting plate 12 is not limited to the spray coating by the illustrated coating gun, and other methods such as a coating method by a roll coater or a flow coater, and a coating by wiping. Etc. can also be employed as appropriate.

  It is more desirable that the reinforcing layer 14 is composed of a thin metal plate having high heat conductivity among the materials described above. In that case, in the injection molding of the base material layer 20, the heat of the molten resin is taken away by both the injection molding die 36 and the reinforcing layer 14, and thereby the discoloration of the design surface 22 of the projecting plate 12 due to the thermal effect. The occurrence of problems such as these can be effectively prevented. The reinforcing layer 14 is not essential in the present invention and can be omitted.

  The material of the bonding layer 16 is not particularly limited as long as the bonding layer 16 has higher bonding property or adhesion to the synthetic resin base material layer 20 than the reinforcing layer 14. Therefore, when the reinforcing layer 14 is made of a thin metal plate, as the bonding layer 16, for example, a natural woven fabric made of cotton, or a fiber sheet knitted with glass fiber or carbon fiber, or various nonwoven fabrics, It can be used instead of a wooden board. In addition, when the reinforcing layer 14 is composed of various woven fabrics, nonwoven fabrics, or the like, or when the reinforcing layer 14 is not provided, the bonding layer 16 can be omitted. Of course, you may comprise the joining layer 16 with a well-known adhesive agent.

  In addition, although not listed one by one, the present invention can be carried out in an embodiment to which various changes, modifications, improvements and the like are added based on the knowledge of those skilled in the art. It goes without saying that any one of them falls within the scope of the present invention without departing from the spirit of the present invention.

  Examples of the present invention will be shown below to clarify the present invention more specifically. However, the present invention is not limited by the description of such examples. Needless to say.

  First, cedar natural wood was sliced at a thickness of 0.8 mm (plate thickness: t1) to obtain a flat plate having a length × width of 100 mm × 150 mm. This flat plate was prepared as a veneer. Separately, Manga-Shirono was sliced with a thickness of 0.2 mm to obtain a flat plate material having the same size as the prepared veneer, but with coarser grain. And the flat plate material was prepared as a wooden board which comprises a joining layer. Furthermore, an aluminum thin plate having the same size as the protruding plate and the wooden plate and having a thickness of 0.5 mm was prepared, and the aluminum thin plate was prepared as a metal plate constituting the reinforcing layer.

  And after bonding the prepared aluminum thin plate to the back surface of the prepared protruding plate with a commercially available adhesive, respectively, the prepared wooden plate against the surface opposite to the protruding plate side of the aluminum thin plate, Each was bonded with a commercially available adhesive. As a result, a laminated sheet (projected plate sheet) in which a reinforcing layer made of an aluminum thin plate and a bonding layer made of a rough wood plate were laminated on the back surface of the projected plate was obtained.

  Then, as shown in FIGS. 3 to 7, insert injection molding using such a laminated sheet as an insert product is performed by a known technique, and a base material made of ABS resin is formed on the back surface of the joining layer of the laminated sheet. Layers were stacked. Then, the thickness of the protruding plate of the laminated sheet on which the base material layer taken out from the injection mold was formed was measured. The thickness (t2) of the protruding plate immediately after forming the base material layer was 0.3 mm.

  Next, using a humidifier having a structure as shown in FIG. 8, a humidification process was performed by spraying steam at 60 ° C. for 10 minutes. The plate thickness (t3) of the veneer immediately after the humidification treatment was 0.9 mm. The moisture content of the veneer at that time was 25%.

  Furthermore, the veneer was dried by leaving the humidified insert-molded product in a drying chamber at a temperature of 60 ° C. and a humidity of 10% for 1 hour. The thickness of the veneer after the drying was 0.8 mm, water content The rate was 6%.

  Then, a float process was applied to the surface of the dried veneer of the insert molded product. That is, using the apparatus as shown in FIG. 10, the surface of the protruding plate was polished with a brass wire brush to remove the Natsume portion. Here, the depth (d) of the formed recess was 0.5 mm.

  The main wood product thus produced has a three-dimensional shape as a whole, has an uneven design surface, has a sufficient three-dimensional effect, and has a problem that the base material layer can be seen through. It did not occur.

  It should be noted that the present invention includes various changes and modifications based on the knowledge of those skilled in the art without departing from the spirit of the present invention, in addition to the following examples, and other than the specific description described above. It should be understood that improvements can be made.

DESCRIPTION OF SYMBOLS 10 Honwood product 12 Veneer board 18 Veneer sheet 20 Base material layer 22 Design surface 24 Clear layer 26 Natsume part 28 Winter part 30 Recess 36 Injection mold 42 Mold cavity 44 Mold cavity formation recess 48 Molten resin material 54 Injection molded product 56 Humidifier 62 Water vapor 68 Wire brush

Claims (4)

A method of manufacturing a main wood product in which a floating processing is applied to the surface of a wooden veneer that gives a design surface, and a base layer made of synthetic resin is laminated on the back side of the veneer by an injection molding operation Because
The projecting plate is housed in a molding cavity of a molding die capable of molding the base material layer, and a composite is formed on the back side of the projecting plate with the surface of the projecting plate facing the cavity surface of the molding cavity. In the resin injection molding operation, the base material layer is laminated to form an insert molded product;
A step of humidifying the insert molded product to swell the protruding plate constituting the insert molded product;
Drying the veneer of the insert molded product swollen by the humidification treatment;
Applying a float process to the surface of the dried veneer of the insert molded product to form a design surface with irregularities;
Manufacturing method of Motoki products including   The manufacturing method of the main wood product according to claim 1 which performs humidification processing to said insert molded product from the surface side of said veneer which constitutes said insert molded product.   The method for producing a main wood product according to claim 2, wherein the humidification process is performed on the insert molded product using dilute hydrochloric acid, and the float process is performed by a baked float process. The manufacturing of the main wood product according to any one of claims 1 to 3, wherein a clear layer made of a transparent synthetic resin is further laminated on the surface side of the projecting plate subjected to the float processing by a painting operation. Method.

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