JPS6261432B2 - - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method of using a wood decorative board having a metallic appearance.

Generally, in order to manufacture long sashes with a constant cross section from aluminum materials, a pultrusion molding method from an ingot is used. This molding requires a sizing mold, but there is a limit to the drawing cross-sectional area due to the capacity of the molding machine, and it is difficult to create a sizing mold with a diameter larger than 40 cm. Furthermore, depending on the shape, it may be technically difficult to mold. In addition, the material cost becomes considerably high because many processes are required, such as surface polishing and anti-corrosion treatment after molding.

The present invention can be very easily processed using a V-cutting machine for woodworking, and moreover, it can be cut using sashes, plates, or other materials that have the same appearance as metal.
The present invention provides a method of using a decorative board for the purpose of obtaining a next processed product at a much lower cost than metal materials.

An embodiment of the decorative board used in the present invention will be described below with reference to FIGS. 1 and 2. In FIG. 1, a metal foil 1 is a rolled sheet having a thickness of 20 to 80 μm and whose surface has been subjected to surface treatment for decoration such as etching and hair lines.

Materials suitable for decorative purposes include aluminum, stainless steel, copper, and titanium, but the present invention is primarily based on aluminum. Aluminum with a hardness of O to H is used depending on the thickness and surface treatment method.

The paint 2 is a transparent resin that is applied to the surface of the metal foil 1 to prevent corrosion and scratches, but its main purpose is to adjust the metallic luster by adding an erasing agent and to color the metal surface by adding a pigment. .

Resin paints require heat-resistant resin paints that have high transparency, appropriate flexibility, extensibility, and abrasion resistance, and form a strong film with high adhesion to metal surfaces.
Suitable examples of such resin paints include two-liquid mixed polyurethane resins and epoxy resins. Specifically, the coating material 2 is continuously applied to the metal foil 1 using a coater, and the coating material 2 is passed through a dryer oven to be cured to accelerate curing. Appropriate coating amount is about 3 to 8 g/m ² .

Next, a thermoplastic resin sheet 3 is laminated on the back surface of the metal foil 1 whose surface is coated with a resin.

Metal foil 1 is prone to creases, wrinkles, and unevenness due to slight external pressure, making its handling extremely difficult, but handling can be greatly improved by lining it with thermoplastic resin 3 having appropriate elasticity. Also, if the thickness of the metal foil 1 is as thin as 20 to 50μ,
If it is attached directly to the wooden base plate 4, the unevenness on the surface of the wooden base plate or unevenness due to uneven application of adhesive will appear as uneven gloss on the metal foil surface, and the unevenness will be emphasized.
By backing with the resin sheet 3, these irregularities are softened by the resin sheet and the flatness of the metal foil surface is improved.

The thermoplastic resin 3 mainly uses vinyl chloride, but the hardness is 15 to 25%, and the degree of polymerization of the plasticizer blend =
A high molecular weight material of around 1200 is suitable, and the thickness is 100.
It is about ~200μ.

The adhesive used to bond the metal foil 1 and the resin sheet 3 must be a thermoplastic resin adhesive with appropriate viscoelasticity, since there is a large difference in linear expansion coefficient between metal and synthetic resin.

Solvent-diluted dry laminator adhesive is applied to metal foil, passed through an oven to remove the solvent, and then a transparent resin film is layered on the surface and heated to 60-100℃ using a preheater to activate the adhesive. The material is heated to 100°C and then passed between laminating rollers at around 100°C for thermocompression bonding. Figure 2 shows the adhesive processing line, where 6 is a metal foil coil, 7 is an adhesive applicator, 8 is an infrared oven at around 60℃, 9 is an aluminum foil preheating heater, and 10 is a metal foil coil wound into a roll. The vinyl chloride sheet, 11 is a doubling hot roller, and 12 is a winder for winding up the sheet in which the metal foil 1 and the vinyl chloride sheet 10 are bonded together.

Note that if the metal foil 1 is made of aluminum, its interfacial adhesion with the adhesive is poor, so depending on the adhesive used, it may be necessary to treat the surface of the aluminum with an adhesion aid (primer) in advance. There is. As the primer, vinyl chloride or epoxy resin is used.

The dry laminator described above generally does not have very strong adhesive strength, and the peel strength between the metal foil and the resin sheet is about 1 to 1.5 kg/inch (180° peel). A minimum width of 2 kg/inch is required for woodworking materials, but if additional peel strength is required, 2 kg/inch width is required.
Use a liquid reaction curing type urethane adhesive. 2
Liquid-curing urethane adhesives are used by mixing a main ingredient and a curing agent just before coating, but they generally have a high viscosity and do not have good roller applicability, but this can be solved by lowering the viscosity with a small amount of solvent. Two-component reaction-curing adhesives have a disadvantage in that they require a curing period after bonding because polymerization and curing are slow and it takes about four days to complete curing. On the other hand, a photopolymerizable transparent adhesive that reacts and cures with ultraviolet rays is applied to metal foil, and a colorless and transparent thermoplastic resin sheet is used to overlap the adhesive-coated surface and roll-press it using an ultraviolet irradiation device. By passing ultraviolet rays through the transparent sheet, irradiating the sheet side with ultraviolet rays, and curing the adhesive using the ultraviolet rays that have passed through the transparent sheet, it is possible to cure the adhesive in seconds and obtain sufficient adhesive strength. For the photopolymerizable adhesive, urethane-modified acrylic resin or epoxy resin can be used.

Through the above steps, the decorative sheet 5 made of metal foil and synthetic resin is completed, but from now on, the decorative sheet can be attached to the wooden base plate 4 in the same steps as for general PVC decorative boards.

However, the distinctive features compared to PVC decorative boards are:
Since the decorative sheet has a metallic luster, slight irregularities due to the surface properties of the wooden base plate 4, uneven application of adhesive, etc. become extremely accentuated as uneven gloss on the surface of the decorative sheet. Therefore, it is necessary to finish the surface of the wooden base plate 4 to have a smooth finish, especially in order to apply it smoothly.

As the wooden base plate 4, plywood, particle board,
This includes hardboards, etc. In addition to wood materials, wood materials using an inorganic matrix can also be processed in the same manner. As the inorganic material, gypsum MgO, cement, etc. can be used. Other inorganic foamed materials can also be processed in the same way as wood materials.

Sanding is generally performed to flatten the surface of the wooden baseboard 4, but especially when the surface of the baseboard is rough or there is a plywood conduit, it is necessary to fill in the recesses with polyester resin putty. Also, since highly water-absorbent materials can cause uneven absorption of adhesive, a sealer (filler) is applied and then sanded to give a smooth finish.

Furthermore, when adhering to a rough surface, it is possible to increase the thickness and hardness of the resin sheet 3 lining the metal foil 1 so that the unevenness does not affect the metal foil surface. Although unevenness can be reduced by increasing the thickness, it is not preferable because it increases the product cost.

An ethylene-vinyl acetate emulsion adhesive is used to bond the resin sheet 3 and the wooden base plate 4, but if a particularly smooth surface is required or hardness is desired to be given to the surface of the decorative board, an epoxy-based adhesive 2 may be used. Use liquid-curing adhesive. In this case, the curing period after pasting is 3 to 4 days.
It takes days.

The decorative board having a metallic luster obtained through the above steps can be processed using the same wood processing method as that of a general decorative board pasted with a PVC sheet.

However, it differs from general resin sheets in that the decorative sheet contains metal foil with poor extensibility, and special consideration must be given to the V-cut method when bending the V-groove cut.

Next, a method of using the decorative board of the present invention, particularly a V-cut folding method, will be explained.

Parts 3a and 3b show conventionally known bending methods. Generally, when such processing is performed, a considerably strong tensile stress is applied to the corners of the decorative sheet. PVC sheet can withstand this tensile stress because of its high elongation, but metal foil exceeds its elongation limit and breaks. That is, as shown in FIG. 4, the elongation rate between the sheet surfaces A and A' at the corners is πt/2, which increases in proportion to the thickness t of the sheet 5. The tensile stress A-A' becomes an internal stress and is concentrated at the corner B of the wooden base plate 4.

Therefore, as shown in FIGS. 5a, b, c and 6, the first and second saw blades 14 of the V-groove cutter,
Adjust the left and right pitch of No. 15 so that a width of √2 ² remains at the bottom of the groove and cut it, making a two-step corner C with a 45° angle as shown in Figure 7 a and b when bent. , C' are formed, then C~D,
The elongation of the decorative sheet at each corner between C' and D' is πt/4, which is 1/2 of the elongation between A and A' in FIG. 4, πt/2.

Also, the elongation between C and D or C' and D' between D and D' is 1/4 of that in Figure 4, so C...
The elongation rate between D and between C' and D' is 1/8 of that between A and A', making it possible to significantly reduce tensile stress. Therefore, V-cut holding processing of decorative sheets using metal foil becomes possible.

Figures 8a and b show other processing methods,
As shown in Figure 8a, the first and second V-groove cutters
After cutting the first V-shaped groove with a saw blade, cut a second groove with a width of ^√2 at the intersection of the first groove, and bend it around this second groove. According to the 8th
As shown in Figure b, the adhesive surfaces of the wooden base plates 4 are bonded together leaving a triangular space. In this way, the bent adhesive surfaces of the wooden base plate are non-parallel in the case of FIGS. 6 and 7, but the adhesive surfaces can be made parallel, improving adhesive properties. At the same time, C ~ at the corner part
It is possible to create an isosceles triangular space with C' as the base and use this space as a pool for the adhesive.
Furthermore, the shape of the corner between D and D' can be kept uniform.

Note that it is actually impossible to make a width of √2 ² using a cutter with an extremely thin blade. To avoid this, as shown in Figure 9a,
6 must be made into a trapezoidal shape, but even if this is done, the same effect can be obtained, only the shape of the isosceles triangle is different, as shown in FIG. 9b.

The shape of the corner shown above is t=0.1~0.2
This is an enlarged display of minute dimensions in mm.
In reality, the corners D and D' of the two stages in Figure 7 a and b are also 1
It is visually observed as two curved surfaces.

In addition, the folding process shown in Figures 5 to 9 reduces the elongation of the metal foil, so the expansion force due to bending is small. It can be easily held even in the case of sashimi etc.

In general, the glass frame shown in Figure 11 is made of aluminum and is formed into a sash shape using a drawing die, then the surface is treated with hairline processing and anti-rust treatment, each side of the frame is cut, and the four corners are cut. They must go through a complicated process of assembling them with screws.

However, if the decorative board of the present invention is used, the 12th
As shown in the figure, after performing primary V-cut folding processing in the axial direction and forming into a sash shape,
It can be made in a very simple way by bending the three corners E ₁ , E ₂ , and E ₃ of the diagram using a secondary V-cut, gluing the remaining corner E ₄ with wood glue, and securing it with wood screws 17. It is possible to mold even small lots. As a result, there is no need for a mold, making it possible to obtain a product that is much cheaper than using aluminum material.

In addition, large hollow sashes such as the one shown in Figure 13 require extremely sophisticated techniques, size limitations, and expensive molds when drawing aluminum materials.
If the decorative board of the present invention is used, it can be made extremely easily by only wood processing.

FIGS. 14a and 14b show comb-like grooves cut into the back surface of a decorative board to form a curved surface. Note that 18 indicates a base to which the wooden base plate 4 is attached.
Even in this manner, the metal foil can be bent without breaking.

As described above, in the present invention, a transparent resin paint is applied to the surface of metal foil, a base resin sheet is attached to the back side to create a decorative sheet, and this decorative sheet is attached to a wooden or inorganic base plate. Using a decorative board manufactured by , the metal foil inside the decorative sheet can be folded beautifully without breaking.

[Brief explanation of the drawing]

Fig. 1 is a sectional view showing one embodiment of the decorative board of the present invention, Fig. 2 is a side view showing the manufacturing equipment thereof, and Figs. 3a and b are diagrams for explaining how to use a general decorative board. Cross-sectional views, Fig. 4, Fig. 5 a, b, c, Fig. 6
Figures 7a and 7b are diagrams for explaining the first usage method of the present invention, Figures 8a and b are diagrams for explaining the second usage method of the invention, and Figure 9a is a diagram for explaining the second usage method of the invention. , b is a diagram for explaining the third usage method of the present invention, the first
Figure 0, Figure 11, Figure 12, and Figure 13 are diagrams showing products manufactured by the above usage method, and Figures 14a and b are diagrams for explaining the fourth usage method of the present invention. It is. 1... Metal foil, 2... Resin paint, 3... Resin sheet, 4... Wooden base plate, 5... Decorative sheet.

Claims (1)

[Scope of Claims] 1. A decorative sheet is created by coating the surface of a metal foil with a transparent resin paint and pasting a thermoplastic resin sheet on the back surface, and the resin sheet surface of the decorative sheet is coated with a wooden or inorganic base plate. Using a decorative board attached to the surface, a groove having a substantially V-shaped cross section is formed from the back side of the base plate toward the resin sheet, and between the intersection lines of each wall surface of the groove and the resin sheet. A predetermined gap is provided between the intersection lines, and a portion of the base plate is left with a substantially triangular cross section between the lines of intersection.
A method for using a decorative board, characterized in that the decorative board is bent at a predetermined angle around this remaining portion. 2 A decorative sheet is created by coating the surface of metal foil with transparent resin paint and pasting a thermoplastic resin sheet on the back side, and pasting the resin sheet side of the decorative sheet on the surface of a wooden or inorganic base plate. A first groove having a substantially V-shaped cross section is formed from the back surface of the base plate toward the resin sheet using a plate, and is substantially perpendicular to the resin sheet at the intersection of two wall surfaces of the first groove. A method for using a decorative laminate, characterized in that a second groove is provided with a wall surface that is curved, and the decorative laminate is bent at a predetermined angle around the second groove. 3 A decorative sheet is created by coating the surface of metal foil with transparent resin paint and pasting a thermoplastic resin sheet on the back side, and pasting the resin sheet side of the decorative sheet on the surface of a wooden or inorganic base plate. Use of a decorative board characterized in that a comb-shaped groove is provided from the back side of the base plate toward the resin sheet, and the decorative board is bent at a predetermined angle around the groove. Method.