JPS5818217B2 - Method for producing sheet overlay decorative material - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION When manufacturing a sheet overlay decorative material by a so-called vacuum forming method in which a thermoplastic resin decorative sheet is attached to the top and side surfaces of a suitably shaped base material by air suction, The present invention relates to a method for producing a sheet overlay decorative material that can completely cover up to 100% of the sheet with a sheet.

Conventionally, in the manufacturing method of sheet overlay decorative materials,
The vacuum forming method is widely used in the manufacturing field of various furniture parts and electrical equipment cabinets because it can cover the decorative sheet along the surface shape of the base material and covers five sides of the base material except the bottom surface with one sheet. It is used.

In such a vacuum forming method, a secondary film such as a rubber sheet or a thermoplastic resin sheet is used to seal the container containing the acid base material and the base material, and the inside of the container is evacuated. The sheet is attached to the surface of the base material, and in order to seal the open end of the container with the sheet, a clamp method, a method of applying pressure from above, etc. are used.

Among these methods, in the method using a secondary film such as a rubber sheet, it is difficult to cover the thermoplastic resin sheet to the lower end of the side surface of the base material, and the sheet is heated and plasticized through the secondary film. Because it takes a large amount of heat and requires long periods of heat to form a thermoplastic resin sheet, in the production of decorative laminates, etc., when covering a base material with a thermoplastic resin sheet, a box-shaped container is generally used. A method is used to seal the edges with a decorative sheet.

In this case, methods using clamps or applying pressure from the top are used to stretch and fix the decorative sheet over the open end of the box-shaped container, but these methods only make the process complicated. However, devices such as pressurizing devices become larger, and since they are often integrated with the heating unit, it is necessary to attach a moving device, and the heating unit may break due to vertical movement of the pressurizing device. be.

In addition, since the base material covered with the sheet is placed directly on the top surface, such as the inner bottom surface of the box-shaped container, if the side surface or end surface of the base material is vertical or inclined inward, The sheet that is in close contact with the base material due to suction contacts the placement surface at the lower end of the side surface of the base material and is bent into an arc shape, and since the bent portion cannot come into close contact with the lower end of the base material, the lower end surface of the product is Peeling of the sheet may occur.

As a countermeasure to this problem, a method of repairing the sheet using a jig or the like during vacuum forming, or a method of protecting the sheet edge using a joiner or the like has been used, but both methods require time and effort and are expensive.

Furthermore, when a plurality of decorative materials are manufactured simultaneously using one container, if sufficient attention is not paid to the placement position of the base materials, the occurrence of defective products and increased loss of sheets will occur.

The present invention eliminates these drawbacks, and makes it possible to reliably stretch and fix a thermoplastic resin sheet to the upper opening of a box-shaped container by using the suction force of a vacuum pump, and to place the thermoplastic resin sheet inside the container. To provide a method for producing a sheet overlay decorative material, which allows the sheet to be completely applied to the lower end of the side surface of a base material.

To explain an embodiment of the present invention with reference to the drawings, a box-shaped container 1
A rectangular peripheral frame 6 having a large number of suction holes 5 formed on the upper end surface 4 is fixed to the outer periphery of the upper surface of a rectangular bottom plate 3 having a large number of suction holes 2 formed therein, and a hollow chamber 7 on the lower side of the bottom surface 3. A vacuum pump 8 is provided inside the hollow chamber 7 and the surrounding frame 6.
, 9 are connected and communicated with each other.

Note that this vacuum pump may be combined into one and connected to the peripheral frame 6 and the hollow chamber 7 via a switching valve.

A wire mesh 10 is placed on the bottom plate 3 of the box-like container 1 formed in this manner, and then a sheet of plate-like body 12 having a large number of through holes 11 is placed on the wire mesh 10.

Instead of the wire mesh 10, other spacers such as protrusions may be provided at appropriate locations on the bottom plate 3, or may be provided integrally with the bottom plate 3.

You can leave it there.

On the upper surface of the plate-like body 12, a plurality of supports 1 are arranged at regular intervals.
3 is for rigging and fixing.

The base material mounting surface of each of these supports 13 is the base material 14 to be placed.
It needs to be the same as or smaller than the bottom shape of
If the size is too small, the sheet 15 will be rolled up on the lower surface side of the base material 14, so it is necessary to determine the size appropriately according to the shape of the product.

Further, this support 13 is arranged so that the sheet 15 hangs downward from the support 13 when coating the base material, and is brought completely close to the bottom end of the base material without being bent at the bottom end of the base material. However, when a plurality of base materials 14 are placed in the container 1 at the same time, the sheets 15 must be completely covered with the base materials 14. Since it is necessary to take sufficient consideration of the spacing between the supports,
By attaching it to the plate-shaped body 12 in advance, such trouble is eliminated.

In this way, the base material 14 is placed on each support 13 on the plate-like body 12 arranged inside the box-like container 1, and then a thermoplastic resin sheet 15 such as a vinyl chloride sheet is placed on the container 1. The lower surface of the outer periphery is covered with the peripheral frame 6 so as to close the upper end opening.
The sheet 15 is brought into close contact with the upper end surface 4 of the peripheral frame 6, and in this state, the vacuum pump 9 is operated to remove the air inside the hollow of the peripheral frame 6 to reduce the pressure, and the sheet 15 is transferred to the upper end surface of the peripheral frame 6 through the suction hole 5. The inside of the box-shaped container 1 is completely sealed.

Thereafter, the stretched sheet 15 is heated and softened from the upper surface using an appropriate heating means such as infrared rays, and then the vacuum pump 8 is operated to expel the air inside the container 1 and reduce the pressure inside the container 1, so that the sheet 15 is It adheres to and covers the top and side surfaces of the base material 14 along the shape of the base material 14.

At this time, the sheet 15 is easily stretched by heating and softened and hangs down inside the container 1, and the sheet 15 is further stretched by the reduced pressure inside the container 1 and brought into close contact with the base material 14 along the shape of the base material 14. The tensile force acting on the sheet 15 is absorbed by the elongation of the sheet 15, and the tensile force does not act greatly on the outer periphery of the sheet that is in close contact with the peripheral frame 6. It can be suctioned and brought into close contact with the upper end surface without shifting.

In addition, when reducing the pressure inside the container 1, it is preferable to apply the sheet almost uniformly to each base material 14. Since it is difficult for bacteria to communicate effectively between the holes 2 and 11, a spacer such as a wire mesh 10 is used to communicate between the holes 2 and 11.

Furthermore, in order to adhere the sheet 15 to the base material 14, an adhesive is naturally required, but this adhesive may be applied to at least either the base material or the bottom surface of the sheet. .

If this adhesive is applied to the underside of the sheet,
Adhesion to the peripheral frame 6 can further prevent the sheet from slipping as described above, and if the sheet is not coated with adhesive, applying adhesive to the top surface of the peripheral frame 6 can prevent the sheet from slipping as described above. effect can be obtained.

After the sheet 15 is adhered to the base material 14 in this manner, the sheet is cut from appropriate portions to take out the sheet overlay decorative material.

At this time, the sheet 15 is recessed into the container 1 and closely adheres to the base material 14, so the state of the sheet 15 is
It can be viewed directly from the opening side, and even if wrinkles or the like occur, it can be repaired as is.

As described above, the present invention provides a spacer such as a wire mesh inside a box-shaped container whose top end is open and has a suction hole connecting and communicating with a vacuum pump on the bottom surface and the top surface of the peripheral frame.

Next, a support is provided on the upper surface of the spacer, and a plate-like body having a large number of through holes is placed on the spacer, a base material is placed on the support, and heat is applied to seal the inside of the box-shaped container. After a plastic resin sheet is attached to the upper surface of the peripheral frame, a vacuum pump is activated to suck the sheet through the suction holes in the peripheral frame to tightly adhere and fix the sheet to the peripheral frame.Then, the sheet is heated and softened, and then placed inside the box-shaped container. This is a manufacturing method for sheet overlay decorative materials, which is characterized by evacuating and reducing pressure to bring the sheet into close contact with the base material.Compared to pressurizing units or clamp methods, air can be removed by simply operating a vacuum pump switch, compared to pressurizing units or clamp methods. The sheet can be easily and firmly fixed to the upper end surface of the box-shaped container by suction force, and the sheet tensioning work on the box-shaped container can be performed smoothly and quickly, and the entire device is simplified, which prevents malfunctions. (This method does not cause any trouble to the heating unit, and compared to conventional methods that use a secondary film such as a rubber sheet or a pressurizing device, the sheet can be visually checked at all times, and wrinkles, etc., can be easily detected. This can be corrected.

Further, according to the present invention, since the support is provided on the plate-like body, even if the shape and dimensions of the product are to be changed, the change can be easily made by simply replacing the plate-like body with the corresponding support. Moreover, by fixing the base to the plate-shaped body, the sheet can be set in the container without considering the placement of the substrate, and in this state, by evacuating and reducing the pressure inside the container, the sheet can be attached to the substrate. It can be adhered from the top surface to the side surface, and can also hang down to the support side to completely adhere to the bottom edge of the base material. Since the sheet can be directly visually inspected and the sheet can be repaired, there is no need for a joiner or the like to protect the sheet edge, and the occurrence of defective products can be greatly reduced.

[Brief explanation of the drawing]

The drawing is a longitudinal sectional front view for explaining an embodiment of the method of the present invention. 1... Box-shaped container, 2... Suction hole, 3.
...Bottom plate, 5...Suction hole, 6...
...Peripheral frame, 8,9...Vacuum pump, 10...
... wire mesh, 11 ... through hole, 13 ...
... Abutment, 14 ... Base material, 15 ... Thermoplastic resin sheet.

Claims (1)

[Scope of Claims] 1. A spacer such as a wire mesh is provided in a box-shaped container with an open top end that is connected to a vacuum pump and has a communicating suction hole on the bottom surface and the top surface of the peripheral frame, and then placed on the spacer. After arranging a plate-like body with an abutment on the top surface and a large number of through holes, a base material is placed on the abutment, and a thermoplastic resin sheet is placed around the box-shaped container so as to seal the inside of the box-shaped container. After the sheet is adhered to the top surface of the frame, a vacuum pump is activated to suck the sheet through the suction holes in the peripheral frame to tightly adhere and fix the sheet to the peripheral frame.Then, after the sheet is heated and softened, the inside of the box-shaped container is evacuated and the pressure is reduced. 1. A method for producing a sheet overlay decorative material, the method comprising: bringing the sheet into close contact with a base material. 2. The method for manufacturing a sheet overlay decorative material according to claim 1, wherein the mounting surface of the support is formed to have the same size as or smaller than the lower surface of the base material. 3. The sheet overlay decorative material according to claim 1 or 2, wherein a plurality of abutments are arranged on the same plate-like body having a large number of through holes at regular intervals. Production method. 4. The method for manufacturing a sheet overlay decorative material according to claim 1, wherein an adhesive is applied to the base material or the thermoplastic resin sheet.