JPS6254658B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for producing a decorative board having a three-dimensional pattern on its surface, which is used for furniture and various other building boards.

Conventionally, various methods for obtaining three-dimensionally molded decorative sheets using molds have been developed, and the applicant of the present application previously proposed a method for forming a decorative sheet from the inner bottom surface to the top surface of the mold in Japanese Patent Application No. 54616/1983. After bonding, the foamed resin liquid and the substrate are sequentially inserted into the mold, and then the foamed resin liquid is foamed and hardened to form a three-dimensional foamed resin layer covered with a decorative sheet on the surface of the substrate. We have invented a method for manufacturing decorative boards, but this method requires a large amount of foamed resin liquid to be used and a thick layer to create a three-dimensional pattern by forming a foamed resin layer of an appropriate thickness on the entire surface of the board. Not only is this large and uneconomical, but it also has poor dimensional stability against temperature changes.Furthermore, the substrate surface is completely covered with a foamed resin layer of an appropriate thickness, which makes it difficult to change. When attaching by nailing, the foamed resin layer is damaged, which limits the range of use.

In order to eliminate such drawbacks, the present invention has been developed by applying a thermoplastic synthetic resin decorative film to the mold from the inner bottom surface of the patterned recess to the substrate mounting surface, which is made up of a patterned recess and a substrate mounting surface. A foaming resin liquid is injected into the patterned recesses of the mold, and an adhesive is applied to the decorative film surface of the substrate mounting surface, and the bottom surface of the substrate to be placed in the mold is placed in close contact with the adhesive. A three-dimensional molded decorative board in which the substrate, the foamed resin, and the decorative film are integrated by foaming and curing the foamable resin liquid in the mold, and the foamed resin layer is not provided on the surface of the substrate except for the three-dimensional patterned portion. A manufacturing method is provided.

To explain an embodiment of the present invention with reference to the drawings, a thermoplastic synthetic resin decorative film 2 is placed on the upper surface of a female mold 1.
The decorative film 2 is placed with its printed surface facing upward, and the four side ends of the decorative film 2 are clamped by appropriate clamping devices (not shown) and stretched over the female mold 1.

A pattern recess 3 corresponding to the convex pattern of the decorative board to be obtained is carved on the inner bottom surface of the female mold 1, and a smooth substrate mounting surface 1a is provided on the four sides of the upper opening edge of the pattern recess 3. Furthermore, a plurality of small exhaust holes 4 are provided at the bottom to connect and communicate with a suitable vacuum generator (not shown).

After the decorative film 2 is stretched over the female mold 1, the decorative film 2 is heated from above with warm air, an infrared lamp, an infrared heater, or other suitable heating means to soften it. While holding the air, the vacuum generator is operated to suction and remove the air inside the female mold 1 through the small exhaust hole 4, and the decorative film 2 is removed from the female mold 1 by the exhaust.
The patterned recesses 3 are brought into close contact along the four circumferential substrate mounting surfaces 1a from the inner bottom surface.

Next, an adhesive 5 such as ethylene-modified vinyl acetate emulsion is applied to the upper surface of the four peripheries of the decorative film 2 that is in close contact with the substrate placement surface 1a of the female mold 1, and an adhesive 5 such as ethylene-modified vinyl acetate emulsion is applied to the inner bottom of the female mold 1. A foaming resin liquid 6 such as a hard urethane foam stock solution is injected in an amount necessary to fill the pattern recesses 3 of the female mold 1, and then the female mold 1 is closed and molded with plywood, hardboard, etc. A rectangular substrate 7 made of particle board, gypsum board, etc. is placed on the four circumferential substrate mounting surfaces of the female mold 1, and the four peripheral edges of the lower surface are tightly attached to the adhesive layer 5 of the decorative film 2. let

Next, the female mold 1 is placed on the lower press plate 9 of the upper and lower press plates 8 and 9, and the upper press plate 8 is moved down to press the substrate 7 against the female mold 1, and in this state, the foaming The resin liquid 6 is foamed and hardened to fill the pattern recesses 3 of the female mold 1 with the foamed resin, thereby obtaining a three-dimensional molded decorative board in which the substrate 7, the foamed resin layer 6a, and the decorative film 2 are integrated.

As shown in FIG. 4, the thus obtained three-dimensionally molded decorative board A has a foamed resin layer 6a having a convex pattern at the center of the surface of the substrate 7, and extends from the surface of the foamed resin layer 6a to the periphery of the surface of the substrate 7. Since the entire surface of the substrate 7 is covered with the decorative film 2, and therefore no foamed resin layer is provided on the surface of the peripheral portion of the substrate 7, it is possible to perform nailing using the peripheral portion. It is what it is.

Alternatively, as shown in FIG. 5, a female mold 1 may be used in which patterned recesses 3, 3 are carved on both sides, and substrate mounting surfaces are provided at the same height at the four circumferential ends and the center. In this case, as shown in FIG. 7, the surface of the substrate covered with the decorative film 2 is exposed at the periphery and center, and the pattern recesses 3 of the female mold 1 are formed on the substrate 7 on both sides. A three-dimensional molded decorative board _A1 having foamed resin layers 6a, 6a having the same shape as that of Example 3 is obtained.

As described above, the present invention has a patterned recess formed on the inner bottom surface, and a thermoplastic synthetic resin on the upper surface of the mold, which is formed by forming a smooth substrate mounting surface on all four sides of the upper opening edge of the patterned recess. After the decorative film is stretched, the decorative film is heated to soften it, and after softening, the air in the mold is removed and the decorative film is brought into close contact from the inner bottom surface of the patterned recess of the mold to the substrate mounting surface. Next, an adhesive is applied onto the decorative film that is in close contact with the substrate mounting surface, and a predetermined amount of foaming resin liquid is injected into the patterned recesses of the mold, and then the substrate is placed on the top surface of the decorative film on the substrate mounting surface. The foamed resin liquid is foamed and cured while the inside of the mold is sealed to form a convex pattern of foamed resin covered with a decorative film on the lower surface of the substrate other than the periphery. Since this relates to a method for manufacturing a three-dimensional molded decorative board characterized by bonding and integrating the peripheral portions of the decorative film without using foamed resin, the foamed resin is layered so as to cover the entire surface of the substrate. Unlike the method in which the foamed resin layer is not provided on the periphery of the substrate, a decorative board can be obtained that does not have any foamed resin layer at all on the periphery of the board. The thickness is substantially the same as that of the substrate, and the decorative board can be easily attached using nails or metal fittings using the peripheral part, and there is no risk of damaging the convex pattern part even when nailing. Moreover, since the peripheral part of the substrate and the decorative film are bonded together with an adhesive, it is possible to obtain a decorative board in which the decorative film does not easily peel off. Thus, it is possible to produce a decorative board that is completely covered with a decorative film and has a beautiful appearance.

Further, according to the method of the present invention, a decorative surface with a wide variety of variations can be formed by the exposed surface of the substrate, the uneven pattern of the foamed resin layer, and the decorative sheet, and since the amount of foamed resin used is small, the temperature can be reduced. It is possible to obtain a decorative board with excellent dimensional stability even against changes in .

[Brief explanation of the drawing]

The drawings show examples of the present invention, and FIGS. 1 to 3 are cross-sectional views for explaining the process, FIG. 4 is a cross-sectional view of the obtained decorative board, and FIG. FIG. 6 is a cross-sectional view of a decorative board obtained using the female mold. DESCRIPTION OF SYMBOLS 1... Female mold, 1a... Substrate mounting surface, 2... Thermoplastic synthetic resin decorative film, 3... Pattern recessed part,
5... Adhesive layer, 6... Foaming resin liquid, 7... Substrate.

Claims (1)

[Claims] 1 After a thermoplastic synthetic resin decorative film is stretched on the upper surface of a mold having a patterned recess formed on the inner bottom surface and a smooth substrate mounting surface on all four sides of the upper opening edge of the patterned recessed portion. The decorative film is heated to soften it, and after softening, the air inside the mold is removed and the decorative film is brought into close contact from the inner bottom surface of the patterned recess of the mold to the substrate mounting surface. After applying an adhesive onto the decorative film that is in close contact with the mounting surface and injecting a predetermined amount of foaming resin liquid into the patterned recesses of the mold, the substrate is applied to the adhesive layer on the upper surface of the decorative film on the substrate mounting surface. The periphery of the lower surface of the substrate is placed in close contact with the periphery of the substrate, and while the inside of the mold is sealed, the foaming resin liquid is foamed and cured to form a convex pattern of foamed resin covered with a decorative film on the lower surface other than the periphery of the substrate. A method for manufacturing a three-dimensional molded decorative board, characterized in that the peripheral part of the decorative film is bonded and integrated with the peripheral part of the lower surface of the substrate without using a foamed resin.