JPH09300494A - Curved decorative panel and its manufacture - Google Patents

Abstract

PROBLEM TO BE SOLVED: To improve design properties and productivity of a curved decorative panel and to make decoration of both surface possible and to decrease aging deformation by bonding a surface decorative material or/and a back face reinforcing material on a curved face prepd. by filling and bonding a resin in a part or the whole of narrow channels provided in the thickness direction of a sheet-like base sheet. SOLUTION: Reinforcing materials 2 each consisting of a kraft paper are bonded on both faces of a sheet-like base sheet 1 consisting of a particle board and narrow channels 3 are provided in a comb-like shape so as to make them reach from the surface side to the position just before the kraft paper on the back face side to form a sheet-like base sheet 1 which can be curved. In addition, an injection channel 4 for injection of a resin is provided in the right angles direction to the narrow channels 3 and then, under a condition where the sheet-like base sheet 1 is curved inward to the surface side provided with the narrow channel 3, an ambient temp.-curable adhesive resin 5 is injected from the injection channel 4 and it is cured to form a curved sheet-like base sheet. Thereafter, surface decorative materials 6 consisting of a melamine decorative sheet are bonded on both faces to prepare a curved decorative panel.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a curved decorative panel which is light in weight and has little deformation over time, and a method for manufacturing the curved decorative panel.

[0002]

2. Description of the Related Art Decorative boards and decorative panels are widely used in housing equipment, furniture, building materials, etc. because of their excellent design and heat resistance, abrasion resistance and stain resistance. As the number of cases in which curved surfaces have become higher has become higher and the number of cases where curved surfaces have been used has increased, bending of decorative boards and decorative panels has become more frequent.

As an example of these bending methods, a post-form processing method has been adopted in which a substrate is previously bent by an NC router or the like and a high-pressure melamine decorative board or the like that is heat-softened is bonded with an adhesive. There is. in this case,
There was a problem in productivity because the production speed of NC router processing of the substrate was slow.

As another example, a so-called comb processing method, V
There is a cutting method, and a composite decorative board obtained by laminating a vinyl chloride decorative film on a wooden board is often used for cabinets and the like. However, these processing methods are used only for a composite plate to which an extremely thin decorative film is attached, and have not been applied to a composite plate to which a thick decorative plate is attached.

Therefore, after forming a groove on the plate-shaped base material side of a composite plate in which a surface layer plate material that can be bent under heating and a plate-shaped base material that cannot be bent under heating are laminated, A method for manufacturing a curved panel has also been proposed in which the surface layer plate material is heated and softened before the injection of the adhesive or the filler, and the plate-shaped base material is bent inside. In this case, it could not be applied to a composite board in which surface layer board materials were laminated on both sides.

[0006]

SUMMARY OF THE INVENTION It is an object of the present invention to solve the above-mentioned problems and to provide a curved decorative panel which is excellent in design and productivity and can be double-sided with less deformation over time, and a method for producing the same. .

[0007]

According to the present invention, a surface decorative material and / or a back surface reinforcing material is adhered to a curved surface obtained by filling and adhering a part or all of fine grooves formed in the thickness direction of a plate-like substrate with a resin. It is a curved makeup panel characterized by being.

Further, a reinforcing material made of a flexible sheet is adhered to a plate-shaped substrate, and a plurality of narrow grooves are formed so as to reach the reinforcing material on the back surface side from the front surface side of the substrate, and the plate shape is bendable. A method of manufacturing a curved decorative panel, which comprises forming a substrate, injecting a resin into a narrow groove on one side in a curved state of the substrate to cure the resin into a curved substrate, and then bonding a surface decorative material thereto.

The present invention will be described below with reference to the drawings. FIG. 1 shows a partially exploded perspective view of a curved decorative panel of the present invention. The plate-like substrate 1 used in the present invention is usually a wood plate having a thickness of 5 to 30 mm (muk wood), plywood, MDF (medium density wood fiber board), particle board, fiber board, or other wood board or other base material. Is mentioned.

The reinforcing material 2 made of a flexible sheet attached to one or both sides of the plate-like substrate 1 is made of kraft paper, resin-impregnated kraft paper, woven cloth or non-woven cloth made of natural fibers or synthetic fibers, etc. In addition, a porous sheet that is strong enough not to cause the substrate 1 to scatter even when the fine groove 3 is formed in the next step and has such a strength that the liquid resin to be injected into the fine groove 3 is in close contact and does not flow out is suitable. Then, the sticking to the plate-shaped substrate 1 is performed by using a commercially available synthetic resin-based or rubber-based adhesive.

When the plate-shaped substrate 1 to which the reinforcing material 2 is attached is curved to have, for example, a partial shape of a cylinder, that is, an arch-like curved surface shape, first, the groove of the narrow groove 3 corresponding to a desired radius of curvature is formed. The width and the number are calculated, and the narrow groove 3 is formed from the inner bending surface side of the plate-shaped substrate 1 using a saw or the like. Therefore, the groove width, the number and the intervals of the narrow grooves 3 may be selected appropriately. Narrow groove 3
The shape is a rectangular parallel groove, and the depth thereof is such that it reaches the reinforcing material 2 attached to the back surface. Further, the injection groove 4 required at the time of resin injection in the subsequent step is opened in the direction perpendicular to the narrow groove 3.

Then, for example, in a state of being curved like an arch-like curved surface, a room temperature curing type resin 5 is injected from an injection groove 4 into a part of the narrow groove 3, for example, a part of the reinforcing material 2 on the back surface side. The reinforcing material 2 and a part of the narrow groove 3 are filled and adhered with the resin 5, and after the resin 5 is cured, the plate-shaped substrate 1 is formed into a curved shape.

As the resin 5 which is injected into the narrow groove 3 and filled and adhered thereto, a room temperature reaction-curable high solid content (10) such as urethane resin, epoxy resin, unsaturated polyester resin, etc. is used.
0% resin content) liquid resin as it is, or as a filler,
It is used by adding fillers, diluents, foaming agents, etc.

As described above, after the plate-shaped base material is formed into a curved shape, the surface decorative material 6 is adhered to one or both surfaces via an adhesive.

The surface decorative material 6 is a commercially available thermosetting resin decorative plate such as a melamine decorative plate, artificial marble made of acrylic resin or polyester resin, etc., which can be bent at room temperature or by heating. The surface decorative material of can be applied.

[0016]

Example: A reinforcing material 2 made of kraft paper having a thickness of 0.3 mm is attached to both sides of a plate-like substrate 1 made of a particle board having a thickness of 20 mm, so that the reinforcing material 2 reaches from the front surface to just before the kraft paper on the back surface side. Fine grooves 3 having a width of about 3 mm were opened at intervals of 10 mm in a comb shape to form a plate substrate 1 which can be curved. Also,
Injection grooves 4 for injecting resin were formed at intervals of 30 mm and a width of about 5 mm to a depth of 10 mm in a direction perpendicular to the narrow grooves 3.

Next, in a state where the plate-shaped substrate 1 is inwardly bent and curved on the surface side where the narrow groove 3 is formed, a resin 5 made of a urethane resin adhesive of room temperature curing is injected from an injection groove 4 and cured. After forming the substrate in a curved plate shape, a surface decorative material 6 made of a melamine decorative plate having a thickness of 1.2 mm was adhesively processed on both sides via a rubber adhesive to obtain a curved decorative panel.

[0018]

According to the method for manufacturing a curved decorative panel of the present invention, a surface decorative material is adhered to a curved surface by injecting a resin into a narrow groove formed in a plate-like substrate and curing the resin. Curved surface bonding is easy, and there is little change over time in the product.

Further, since the reinforcing material made of a flexible sheet is adhered to the adhesive surface of the substrate, the adhesive force is uniform, the material is less likely to be broken than the base material, and the interface is not peeled off. Is.

Since the fine grooves formed in the substrate are voids, the panel itself is lightweight and the surface strength is maintained by the decorative material.

Therefore, the curved decorative panel of the present invention is useful for doors for buildings, partitions, doors for furniture and the like.

[0022]

[Brief description of drawings]

FIG. 1 is a partially cutaway perspective view showing an embodiment of a curved makeup panel of the present invention.

[Explanation of symbols]

 1 Substrate 2 Reinforcing Material 3 Fine Groove 4 Injection Groove 5 Resin 6 Surface Decorative Material

Claims (2)

[Claims] 1. A curved surface characterized in that a surface decorative material and / or a back surface reinforcing material is adhered to a curved surface in which resin is filled and adhered to a part or all of the fine grooves formed in the thickness direction of the plate-like substrate. Makeup panel. 2. A plate-like substrate which can be bent by adhering a reinforcing material made of a flexible sheet to a plate-shaped substrate and forming a plurality of fine grooves to reach the reinforcing material on the back side from the front side of the substrate. A method for manufacturing a curved decorative panel, which comprises forming a substrate, injecting a resin into a narrow groove on one side in a curved state to cure the substrate to form a curved substrate, and then bonding a surface decorative material.