JPH05318994A - Decorative sheet having relief engraving pattern and its manufacture - Google Patents

Abstract

PURPOSE:To improve a decorative effect at a low cost by a method wherein in a decorative sheet wherein a sheet for decoration is bonded to a surface of a base material, a profiling mold is laid between the surface of the material and the sheet for decoration, and a projected line pattern along a shape of the profiling mold is formed on a surface of the decorative sheet. CONSTITUTION:A decorative sheet 1 is obtained by bonding a sheet for decoration 4 to a surface of a base material 2. In that case, a projected line pattern 1a along a shape of a profiling mold 6 is formed on a surface of the decorative sheet 1 by laying the profiling mold between the surface 2a of the base material 2 and the sheet for decoration 4. Further, a natural material or artificially formed mold is used as the profiling mold 6. Then, in order to vacuum attract the sheet for decoration 4 to the base material 2 in manufacturing, a vacuum press mold 8 consisting of a drag and a cope 11 is used. Further, a frame 15 and a bed board 16 are used as jigs for vacuum pressing. Then, an interval between the frame 15 and the base material 2 is set to be at least 1.5 times a thickness of the base material 2.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a decorative board having an embossed pattern and a manufacturing method thereof, and more particularly to a decorative board having a precise embossed pattern which can reduce time and cost and a manufacturing method thereof.

[0002]

2. Description of the Related Art Conventionally, this type of decorative board has a surface of a base material coated with an adhesive, and a decorative sheet made of a thin synthetic resin or the like with a wood grain pattern is adhered by vacuum suction and heated under pressure. It is formed by bonding. The veneer thus formed is widely used not only as a material for furniture but also as a building material. Therefore, like the solid board, the surface is engraved with a high decorative effect to improve the appearance and enhance the commercial value.

In such a case, after engraving on the surface of the base material with a numerically controlled NC router or a woodworking engraving machine, a decorative sheet is adhered to form a relief pattern.

[0004]

However, the engraving by the NC router is generally applied to a flat relief with no irregularities, which is convenient when engraving a certain pattern many times, and it is also suitable for cutting. It is necessary to convert all conditions into data according to a certain standard. For this reason, it takes a lot of time and effort to convert a complicated pattern having a high decorative effect into data, and it is often not cost-effective to meet the recent demand for a large number of small quantities.

Further, a woodworking engraving machine or the like can emboss a complicated pattern having irregularities in the pattern, but it requires a high degree of skill and takes a lot of time. Often. Therefore, it is an object of the present invention to provide a decorative board having a complicated relief pattern with a high decorative effect, which saves time and cost, and a method for manufacturing the same.

[0006]

In order to solve the above technical problems, in the present invention, in a decorative plate having a surface of a base material to which a cosmetic sheet is adhered, a conforming mold is provided between the surface of the base material and the cosmetic sheet. A jig including a decorative board having a relief pattern, in which a convex pattern is formed on the surface of the decorative board along the shape of the profile, and a jig including a bedboard and a frame are interposed. In a method for producing a decorative sheet in which a cosmetic sheet is adhered to the surface of a base material by vacuum suction using, a step of arranging a tracing mold on the surface of the base material, And a step of forming a convex pattern on the decorative plate along the shape of the contour type by bonding to the above.

[0007] The base material may be any one suitable for forming a decorative sheet by adhering a decorative sheet, and is formed by molding a peeling board, laminated wood, plywood, wood-based chips or fibers. Plate, synthetic resin and inorganic base material. The cosmetic sheet is a sheet that can be vacuum suction adhered to the surface of the base material via an adhesive, and may have a property of expanding and contracting and adhering along the conforming mold, and has a wood grain pattern. These include transparent materials, transparent materials, and so-called laminated boards formed by slicing wood into a sheet shape. The decorative plate includes a plate material in which the sheet is adhered to the surface of the base material and the surface of the base material is not exposed. The profile pattern has a thickness and may be any pattern having an external shape or a decoration on its surface, for example, a family crest, a picture, a photograph, an artificial shape such as a decorated shape. It is designed and formed, or includes natural materials and processed products such as plants, leaves and branches of plants, flowers, insects and the like.

[0008]

The decorative board having the relief pattern described above becomes a decorative board having a relief pattern having subtle irregularities and peripheral shapes, which has a high decorative effect and can be provided at a low cost. Further, according to the above manufacturing method, conventionally, in order to form an embossed pattern on a decorative plate, it was necessary to engrave the base material surface, but between the base material surface coated with the adhesive and the cosmetic sheet. By vacuum-suction bonding with a follow-up mold interposed, it is possible to easily emboss a complicated shape with subtle unevenness, and to significantly reduce the time and cost required for manufacturing.

[0009]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described below with reference to FIGS. The decorative board 1 having an embossed pattern according to the present invention includes a base material 2, a mold 6 and a decorative sheet 4. The base material 2 is formed of a wood fiber board in which wood chips are compression-molded and prepared to have a predetermined size. The thickness of the cosmetic sheet 4 is about 0.1.
It is 5 mm in length and made of vinyl chloride having a grain pattern on its surface and has elasticity. Further, as the adhesive 5 for adhering the base material 2 and the decorative sheet 4, the adhesive 5 developed for vacuum pressing is good, and in this embodiment, the main component composed of urethane emulsion is composed of polyisocyanate. A thermosetting adhesive 5 is used, which is used by blending a predetermined amount of a curing agent and which is adhered by heating and curing. Note that the adhesive 5 is not limited to this, and an adhesive having the most appropriate properties can be selected depending on the types of the base material 2, the cosmetic sheet 4, the tracing mold 6, and the like.

In the present embodiment, the tracing die 6 is obtained by cutting the tip of a tree branch into a suitable length. That is, a state in which a plurality of leaves were attached to a branch, which was cut from a raw tree and then dried was used. The drying is not always necessary, and may be used as it is depending on the tracing mold 6. In addition, it is preferable that those having a large amount of water be dried in consideration of the modification of the tracing mold 6 after the adhesion of the cosmetic sheet 4 or subjected to the anti-corrosion treatment.

Further, in order to adhere the decorative sheet 4 to the base material 2 by vacuum suction, a vacuum press die 8 comprising a lower die 9 and an upper die 11 is used. An upper surface of the lower die 9 is formed in a flat shape, and a mounting surface 10 on which the base material 2 can be mounted is formed. Also,
A large number of suction holes 10a are formed on the surface of the lower mold 9
It is formed so as to be able to suck below the mounting surface 10 of the lower die 9 by a vacuum suction device installed or connected therein.

The upper die 11 is disposed so as to face the lower die 9 and is movable up and down.
A pressing surface 12 having a size corresponding to 0 is formed. A sheet 12a made of silicon is attached to the pressing surface 12, and the cosmetic sheet 4 is well adapted to the surface 2a of the base material so that the pressing surface 12 can be pressed. The sheet 12a is not particularly required to be made of silicon, and may be any sheet that has a predetermined flexibility and can press against the base material surface 2a. Also,
Both the upper and lower molds 11 and 9 are pressed by the heaters on the pressing surface 1
2 and the mounting surface 10 are formed so that they can be heated to a predetermined temperature.

Further, a vacuum press jig 14 is required for vacuum-bonding the cosmetic sheet 4 to the base material 2 using the vacuum press die 8. The jig 14 referred to here is for positioning the base material 2 and the cosmetic sheet 4 so as to be applicable to the vacuum press die 8. Jig 1
4 is composed of a frame 15 and a bed board 16, the bed board 16 and the frame 15 have substantially the same height, the bed board 16 is a plate having a predetermined thickness, and is slightly larger than the base material 2. It is formed to be small so that the base material 2 can be placed thereon. The frame 15 is a frame that is formed in an elongated rod shape and is installed so as to surround the periphery of the base material 2 placed on the bedboard 16.

Next, a method of manufacturing the decorative plate 1 having a relief pattern by using the vacuum press die 8 and the jig 14 will be described. First, the adhesive 5 is applied to the surface 2a of the base material 2.
Is applied by a spray gun or the like. As the adhesive 5, a mixture of urethane emulsion and polyisocyanate which is a curing agent in a ratio of 100: 5 or 100: 10 is used. The coating amount is preferably 100 to 150 g / m ² . It should be noted that the amount is appropriately adjusted depending on the water absorption state of the base material 2.

After the adhesive 5 is uniformly applied to the surface 2a of the base material 2, it is left at room temperature for about 30 minutes or slightly dried and cured by an electric heater or the like. This is for the purpose of evaporating the water in the adhesive 5 to obtain good adhesion and for facilitating the adjustment of the disposition of the tracing mold 6. Then, following the pattern of the relief pattern 1a to be formed on the surface 2a of the base material to which the adhesive 5 has been applied, the leaf pattern 6 of the leaves
To place.

The base material 2 having the above-described structure is used as the bed board 16 on the mounting surface 10 of the lower mold 9 of the vacuum press mold 8.
Placed on. At this time, as shown in FIG. 3, the base material 2 is accurately placed so that the bed board 16 is located at the center of the lower surface of the base material 2, and the frame 15 is three times as thick as the base material 2 from the peripheral edge of the base material 2. It is installed on the mounting surface 10 around the base material 2 at intervals.

Then, the heater of the vacuum press die 8 is operated so that the temperature of the mounting surface 10 becomes 20 to 60 ° and the temperature of the pressing surface 12 becomes 55 to 80 °. The temperature of the pressing surface 12 is set in consideration of the range of adhesive hardening of the adhesive 5 and the heat resistant temperature of the cosmetic sheet 4. That is, 5
This is because there is a possibility that the cosmetic sheet 4 will not be bonded at a temperature lower than 5 ° and that the cosmetic sheet 4 will be deteriorated at a temperature higher than 80 °. Further, since the mounting surface 10 is applied so that the base material 2 does not warp due to the heating of the pressing surface 12, the temperature may be such that the warpage is suppressed, and is particularly limited to the present embodiment. Not something to do.

With the placing surface 10 and the pressing surface 12 thus heated, the base material 2 and the frame 15 are covered with the cosmetic sheet 4. At this time, the seat 4 has a frame 15
A space over which the cosmetic sheet 4 can be sucked by vacuum suction is formed between the frame 15 and the base material 2 so as to cover the outer circumference.

Then, the upper mold 11 is moved downward to press the base material 2 and the cosmetic sheet 4 at a predetermined pressure. Although a 4 kg / m ² in view of the stretchability of the decorative sheet 4 in this example, is usually carried out in 1-5 kg / m ^2, the decorative sheet 4 and the base material 2 type and shape of the copying type 6 Can be adjusted by The pressing surface 12a having appropriate flexibility of the upper mold 11 and the base material surface 2a for a predetermined time, 14 seconds in this embodiment, after the pressurization by the upper mold 11 is started. Air between the cosmetic sheet 4 and the cosmetic sheet 4 is extruded to preliminarily bring the base material 2 and the cosmetic sheet 4 into close contact with each other. In this way, the extra air is discharged in advance by the suction performed next.
The purpose is to complete the close contact with the conforming die 6 arranged on the surface 2a of the base material, and to help improve the adhered state.

Next, the vacuum suction device connected to the lower mold 9 is operated to perform vacuum suction from the suction holes 10a on the mounting surface 10. At this time, the pressing surface 1 which is heated and has flexibility
The cosmetic sheet 4, the tracing die 6 and the base material 2 are pressed by 2 and the cosmetic sheet 4 is sucked below the outer periphery of the base material 2 in the suction operation, so that the cosmetic sheet 4 is stretched and expanded. The material 2 and the base material surface 2a are closely adhered to each other along the shape of the conforming die 6 arranged on the surface. Also, the base material 2
The cosmetic sheet 4 between the cosmetic sheet 4 and the cosmetic sheet 4 is the base material 2
The outer peripheral edge of is closely adhered. Then, the cosmetic sheet 4 is adhered along the base material surface 2a and the peripheral edge thereof by the adhesive agent 5 which has started adhesive curing by heating.

As described above, in order to adhere the cosmetic sheet 4 to the base material surface 2a faithfully along the shape of the tracing mold 6, the thickness of the base material 2 is set between the peripheral edge of the base material 2 and the frame 15. At least 1.5 times or more is required, preferably 2.5 times or more, and more preferably 3 times. That is, the base material 2
When the distance between the periphery of the frame and the frame 15 is less than 1.5 times, it may be possible to form the contour mold 6 having a simple shape, but when the contour mold 6 having a complicated shape is used, The makeup sheet 4 does not closely adhere to the conforming die 6 and is adhered in a state where air enters the outer periphery of the conforming die 6. As a result, the three-dimensional shape of the tracing die 6 cannot be expressed on the decorative board 1. The interval is 2
Even if doubled, it is in the same state.

When the distance is 2.5 times, the adhesive force of the cosmetic sheet 4 increases, and the air around the outer periphery of the conforming mold 6 having a complicated shape is almost completely discharged, and the cosmetic sheet is It becomes possible to represent the three-dimensional shape of the tracing type 6 by 4. However, it is impossible to obtain a stable adhesion state and expressiveness. Further, if the distance is tripled, the adhesive force is further increased, the expressiveness of the mold 6 is improved, and it becomes possible to obtain a good bonded state and a relief shape.

As described above, as the area surrounded by the frame 15 becomes larger, the adhesiveness and expressiveness of the cosmetic sheet 4 increase, but on the other hand, the cosmetic sheet 4 must be larger than the area surrounded by the frame 15. Since this is not necessary, widening this interval wastefully uses the cosmetic sheet 4. Therefore, it is desirable that the amount is about three times as high as a product that is stable in terms of cost can be obtained.

Now, suction is continued for 14 seconds after the lapse of a predetermined pressurizing time, and after this suction is finished, the upper die 11 is moved upwards, and precisely along the three-dimensional shape of the profile die 6. The decorative plate 1 having the formed relief pattern 1a is taken out. Hereinafter, the decorative plate 1 having the relief pattern 1a is manufactured by the same procedure.

As shown in FIGS. 1 and 2, the decorative plate 1 formed in this manner has the shape of the leaves of the model 6 as a contour and is clearly and three-dimensionally formed. Is becoming That is, the original complicated leaf shape is embossed as it is. Such a relief pattern 1a can be achieved only by engraving the outer periphery of the shape to be embossed when a router or an engraving machine is used. It was also very difficult to make the relief pattern 1a itself uneven.
For this reason, it is very time-consuming and labor-intensive, and also requires technical skill, which has been impossible in the past in terms of cost.

Since the surface of the conforming die 6 is not coated with the adhesive 5, the makeup sheet 4 and the conforming die 6 are not directly adhered to each other, but the conforming die 6 and the substrate surface 2a are adhered to each other, and The makeup sheet 4 is adhered to the base material surface 2a so as to press the tracing die 6. Therefore, the embossed state is not broken by the deviation of the tracing die 6 from the substrate surface 2a. Further, when the tracing die 6 having a delicate three-dimensional shape is used, it is possible to faithfully represent the shape of the tracing die 6 on the decorative plate 1 if the adhesive 5 is not applied to the substrate surface 2a. In some cases. However, in the case of using the tracing die 6 having a large area or the tracing die 6 having a large wall thickness, it may be necessary to apply the adhesive 5 not only on the base material surface 2a but also on the tracing die 6 surface. In such a case, the back surface of the cosmetic sheet 4 to which the adhesive 5 is applied may be used.

As described above, in the present embodiment, the profile mold 6 is arranged after the adhesive is applied to the base material surface 2a. However, the relief pattern 1a to be formed on the base material surface 2a. After arranging the tracing die 6 along the surface of the tracing die 6, the adhesive 5 is applied to the surface 2a of the base material and the surface of the tracing die 6 to produce the embossed decorative plate 1 having the same expressive power. You can In particular, when the adhesive 5 must be applied on the surface 2a of the base material and then the adhesive 5 is also applied to the surface of the conforming die 6, the adhesive 5 is placed on the base material after the conforming die 6 is arranged. With the configuration in which the adhesive is applied to the surface 2a, it is possible to save the labor of applying the adhesive 5 and reduce the amount of the adhesive 5 used. At this time, if a tracing die 6 having adhesiveness or tackiness provided on the back surface in advance or before the arrangement is used, it is easy to secure the adhesion between the substrate surface 2a and the tracing die 6.

Although the present embodiment has been described using the relatively thin profile mold 6, the shape and material of the sheet 12a attached to the pressing surface 12 of the upper mold 11, the bonding conditions, the material of the cosmetic sheet and the bonding thereof. By appropriately changing the type of the agent, it is possible to apply it to the thick and three-dimensional profile mold 6. Further, in the present embodiment, the case where the follower die 6 having a relatively complicated shape is used has been described. However, when the follower die 6 has a simple shape, a thin one, or a small one, the jig 14 is used. It is possible to form the shape and bond it without it. In addition, particularly when using a transparent cosmetic sheet 4, in order to enhance the decorative effect of the base material surface 2a and the conforming die 6, the base material surface 2a on which the conforming die 6 is arranged
It is also possible to adhere the cosmetic sheet 4 after applying a suitable paint or the like to the cosmetic sheet 4.

[0029]

As described above, according to the present invention, a decorative three-dimensional pattern that is faithful to the conforming mold is formed by placing the conforming mold on the base material and then adhering the decorative sheet by vacuum suction. It can be formed on a decorative board. As a result, it is possible to easily and quickly manufacture a decorative plate having an embossed pattern, which has been difficult with the conventional technique, and it is possible to provide a decorative plate having an embossed pattern with a reduced manufacturing cost. In addition, this embossed pattern is formed faithfully and precisely in the shape of the tracing type, and has the expressive power that was difficult to achieve by the conventional embossing method by engraving.

[Brief description of drawings]

FIG. 1 is a cross-sectional view of a decorative board having a relief pattern in the vicinity of the relief pattern.

FIG. 2 is a perspective view of a decorative plate having a relief pattern.

FIG. 3 is a view in which a top view and a cross-sectional view of arrangement of a base material, a tracing die, and a jig are combined.

FIG. 4 is a cross-sectional view showing a step of setting a cosmetic sheet on a base material and performing vacuum suction from a lower mold.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 ... Decorative plate 1a ... Convex pattern (relief pattern) 2 ... Base material 2a ... Surface of base material 4 ... Makeup sheet 6 ... Tracing type 14 ... Jig 15 ... Frame 16 ... Bedboard

Claims (5)

[Claims] 1. A decorative plate having a cosmetic sheet adhered to the surface of a base material, wherein a conforming mold is interposed between the surface of the base material and the cosmetic sheet, and the shape of the conforming mold is provided on the surface of the decorative plate. A decorative board with a relief pattern, characterized in that a convex pattern is formed along the edges. 2. The embossed decorative plate according to claim 1, wherein the profiled pattern is a natural material. 3. The embossed decorative plate according to claim 1, wherein the profile pattern is artificially formed. 4. A method for producing a decorative plate in which a cosmetic sheet is adhered to the surface of a base material by vacuum suction using a jig composed of a bedboard and a frame, and the surface of the base material is followed. A relief pattern characterized by comprising a step of arranging a mold and a step of adhering a decorative sheet to the surface of a base material and forming a convex pattern on the decorative plate along the shape of the profile mold. A method for manufacturing a decorative board. 5. The distance between the frame of the jig installed around the base material and the base material is 1.5 times or more the thickness of the base material when the cosmetic sheet is vacuum-adhered to the surface of the base material. 5. The method for manufacturing a decorative board having a relief pattern according to claim 4.