JPH01253441A - Decoration plate, method and apparatus for manufacturing the same - Google Patents

Abstract

PURPOSE:To reduce the deforming malfunction of a decoration plate which occurs as a stress distortion due to the contraction of a decorative layer by molding a board in a state that a warpage deformation is so applied so to form its rear face recess, and laminating and integrating the layer of synthetic resin with uneven pattern on the surface of the board. CONSTITUTION:An uneven pattern molding die plate 4 is placed on the recess face 5 of a recess die 6, the flexibly formed plate 4 is so warpage-deformed along the face 5 as to become recess, preheated, for example at approx. 120-180 deg.C in an atmosphere, and a synthetic resin molding material 10 is melted. A board 1 is superposed on the material 10, and a protrusion die 8 in which its lower molding face becomes a protrusion face 7 is superposed on the upper face (rear face side) of the board 1. The curvature of the protruding curve of the face 7 is substantially equal to that of the recess curve of the face 5, they are set and placed on a lower hot platen 16 of a press 9 to be molded to laminate and integrate a decorative layer 3 with an uneven pattern 2 on its surface layer on the board 1 by the plate 4.

Description

[Detailed description of the invention] [Industrial application field] The present invention relates to decorative laminates used as interior materials for buildings. [Conventional technology]

2. Description of the Related Art As a decorative board A used for construction, etc., a board formed by providing a decorative layer 3 of synthetic resin on the surface of a substrate 1 has been known. This decorative board is provided by spraying or coating a synthetic resin molding material on the surface of the substrate 1, and is then heated and pressure molded while pressing the surface of the synthetic resin molding material layer with a template for molding an uneven pattern. , is formed by providing the uneven pattern 2 on the surface of the decorative layer 3.

[Problem to be solved by the invention]

However, in the decorative board A obtained by molding the decorative layer 3 of synthetic resin in this way, &t! Since molding shrinkage occurs in fN during curing and solidification, there is a risk that warping deformation in which the back side of the substrate 1 becomes convex as shown in FIG. However, there was a problem in that the incidence of deformation defects was extremely high. The present invention has been made in view of the above points, and it is an object of the present invention to provide a decorative board, a method for manufacturing the same, and an apparatus for manufacturing the same, which are free from the risk of warping or deformation defects.

[Means for Solving the Problems] - The decorative board according to the present invention includes a synthetic resin decorative layer 3 provided with an uneven pattern 2 on the surface of a substrate 1 which is subjected to warping stress so that the back side is concave. It is characterized by being formed by laminating and integrating. In addition, the method for manufacturing a decorative board according to the present invention includes stacking a flexibly formed concave-convex pattern molding plate 4, a synthetic resin molding material 10, and a substrate 1 in this order, so that the back side of the substrate 1 is concave. The present invention is characterized in that heating and pressure molding is performed in a state where the substrate 1 and the uneven pattern molding plate 4 are warped and deformed. Furthermore, the manufacturing f & installation of the decorative board according to the present invention includes a concave mold 6 having four pressure surfaces 5, and a convex mold 8 having a convex surface 7 as the pressure surface and disposing the convex surface 7 opposite to the concave surface 5 of the concave mold 6. and a concave-convex pattern molding plate 4 formed flexibly from the concave mold 6 side between the concave mold 6 and the convex mold 8, a synthetic resin molding material 10, and a substrate 1.
With the layers set in this order, the concave mold 6 and the convex mold 8
The present invention is characterized in that it is equipped with a press machine 9 for compressing the parts.

[For use]

In the present invention, the substrate 1 is molded in a warped state so that the back side is concave, and the synthetic resin decorative layer 3 provided with the uneven pattern 2 is laminated and integrated on the surface of the substrate 1. By doing so, the warp deformation imparted to the substrate 1 and the warp caused by shrinkage of the decorative layer 3 during molding can be canceled out, and occurrence of deformation defects in the decorative board A due to warp can be reduced.

[Example 1] The present invention will be explained in detail below using examples. The uneven pattern molding plate 4 is flexibly formed of an elastic material such as silicone rubber. In creating this uneven pattern molding template 4, a two-component mixture consisting of a base material and a hardening agent, for example, This can be done by applying room-temperature curing silicone resin to an appropriate thickness, curing it, and then releasing it from the model mold.It is created as having an uneven surface 15 for flexible and precise uneven molding. can do. When manufacturing 9I decorative board A using the uneven pattern molding plate 4 formed as shown in 2, first preheat the uneven pattern forming plate 4 to about 120°C to 150°C. A synthetic resin molding material 10 is spread on the uneven surface 15 of the plate 4 and supplied to a thickness of 3-4+ui as shown in FIG. Here, as the synthetic resin molding material 10, it is preferable to use a material whose main component is a powder coating. Since liquid paint flows, it is not possible to make the thickness thicker, and it is not possible to form the decorative layer 3 with the uneven pattern 2.However, when powder paint is used, the uneven pattern 2 can be formed with a sufficient thickness. It is possible to form Cosmetic N3.Powder coatings are made by blending fillers such as calcium carbonate, hardening agents, color pigments, etc. with thermosetting resins such as epoxy resins, polyester resins, and cross-linked acrylic resins. A mixture of thermoplastic resins such as polypropylene resin, polyethylene resin, and polyamide resin with fillers such as calcium carbonate and pigments can be used.
A thickness of about 100 microns is preferable. And this powder paint with silica sand and Lass M! The synthetic resin molding material 10 can be obtained by blending with Lm. Silica sand is blended to prevent the synthetic resin molding material 10 from flowing out from the ends during pressing during molding, and 5
It is preferable to use Nos. 7 to 7. The 7y lath fiber is blended to ensure the strength of the decorative layer 3 against bending, etc., and preferably has a fiber length of about 3 to 61. The blending amounts of these materials are desirably set at 30 to 100 parts by weight of silica sand and 4 to 7 parts by weight of plus fiber per 100 parts by weight of the powder coating. As mentioned above, the synthetic resin molding material 1 is placed on the uneven pattern molding plate 4.
0, the concavo-convex pattern molding plate 4 together with the synthetic resin molding material 10 is placed on a concave mold 6 whose upper molding surface is a concave surface 5, as shown in FIG. 2(b). The concave surface 5 is formed as a concave curved surface that becomes progressively deeper from the periphery to the center. The concave mold 6 is preheated to about 150°C, and when the concave-convex pattern molding plate 4 is placed on the concave surface 5 of the concave mold 6 in this way, the concave-convex pattern molding plate 4 is formed into a flexible shape. The uneven surface 15gA is warped and deformed along the concave surface 5 so that it becomes concave.8 Next, in this state, 120
℃ to 180℃ for about 2 to 6 minutes to preheat and melt the synthetic resin molding material 10. After confirming that the synthetic resin molding material 10 has melted, The substrate 1 is stacked on the molding material 10. The substrate 1 is not particularly limited (wooden plates such as plywood and particle board, metal plates such as iron plates and aluminum plates, calcium silicate plates and slate plates, etc.). An inorganic board such as an asbestos-cement board can be used.Of course, in the present invention, the thickness of these boards is such that warp deformation occurs due to stress caused by shrinkage of the decorative layer 3. After overlapping the substrate 1 on the plywood resin molding material 10, the convex mold 8 whose lower molding surface is the convex surface 7 is placed on the upper surface (back @) of the substrate 1.The curvature of the convex curve of the convex surface 7 is as described above. The curvature of the concave curve of the concave surface 5 is equal to tr.Then, as shown in FIG. A plant gear 18 is attached to the main body 17 formed as a main body 17 so as to be movable up and down, and a tie bar 19 is provided upright on the main body 17, and a fixed plate 20 is attached to the upper end of the tie bar 19.
At the same time, a movable platen 21 which is movable up and down along the tie bar 19 can be attached to the upper end of the planter 18, and the movable platen 2
An upper heating plate 16 is placed on the upper surface of 1, and an upper heating plate 2 is placed on the lower surface of the fixed plate 20.
2 are provided respectively. Then, the movable platen 21 is raised by moving the planter 18 upward using a hydraulic mechanism or the like, and the movable platen 21 and the fixed platen 20 are pressed together via the upper and lower heating plates 16 and 22 to perform heating and pressure forming. The heating temperature and pressure applied vary depending on the type and composition of the synthetic wood 11wl1c shaped material 10, but are generally about 130°C to 180'C.
It can be carried out at a low pressure of about 1 to 5 kg/em2. In addition, it is generally good for the molding time to be about 2 to 5 minutes per thickness II of the synthetic resin molding material 10.6 By molding as described above, the uneven pattern 2 is formed on the surface layer with the uneven pattern molding plate 4. The decorative layer 3 is applied to the substrate 1.
At this time, molding is performed with the substrate 1 and the uneven pattern molding plate 4 being warped and deformed by the action of the concave surface 5 of the concave mold 6 and the convex surface 7 of the convex mold 8. As a result, the decorative board A is obtained in a state where the substrate 1 is warped and deformed so that the back side of the substrate 1 becomes concave, as shown in FIG. Then press the decorative board A.
When the decorative board A is removed from the substrate, stress is generated in the decorative board A to cause it to warp in the opposite direction from the warped state as shown by the imaginary line in Figure @1 due to the molding shrinkage of the decorative board 13. This will be canceled out by the warping stress applied to the
As a result, the decorative board A is finished without any undesirable deformation as shown by the solid line in FIG. Therefore, if the concave surface 5 of the concave mold 6 and the convex surface 6 of the convex mold 7 are formed so as to warp the substrate 1 by the same amount and in the opposite direction to the amount of warp that occurs as stress distortion due to molding shrinkage of the decorative layer 3, It is possible to manufacture 91 decorative boards A while reducing the occurrence of warping defects. [Effects of the Invention] As described above, in the present invention, the back side of the substrate is warped and deformed so that the back side is concave, and the decorative layer of synthetic resin with the uneven pattern is applied to the surface of the substrate. Since it is laminated and integrated, it is possible to cancel out the warping deformation imparted to the substrate and the warpage caused by shrinkage of the decorative layer during molding, and eliminate the stress distortion caused by shrinkage of the decorative layer. This makes it possible to reduce deformation defects. In addition, since the uneven pattern molding template that molds the surface of the synthetic resin molding material to give the decorative layer an uneven pattern is formed in a flexible manner, even when the substrate is warped, the uneven pattern will follow the warp. The molding plate can be deformed, and an uneven pattern can be easily and accurately formed on the decorative layer.

[Brief explanation of the drawing]

FIG. 1 is a front view showing an embodiment of a decorative board according to the present invention;
Fig. 2(,)(b) is a front view showing each process of one embodiment of manufacturing a decorative board according to the present invention, Fig. 3 is a partially cutaway front view of the same pressing process as above, and Fig. 4 is a FIG. 5 is a front view showing the decorative board during molding, and FIG. 5 is a front view of a conventional example. 1 is a substrate, 2 is an uneven pattern, 3 is a decorative layer, 4 is an uneven pattern molding plate, 5 is a concave surface, 6 is a concave mold, 7 is a convex surface, 8 is a convex mold, 9
1 is a press machine, and 10 is a synthetic resin molding material. Agent Patent Attorney Atsushi Mori Husband 1...Substrate 1 ・Substrate 4...Irregular pattern molding plate 5...Concave surface 6 ・Concave mold 10...F! ! , resin molding material Fig. 2 (b) 1... Substrate 4... Gate-convex arrogant molding plate 5... Concave surface 6... Concave mold 7... Convex surface 8... Convex shape Fig. 4

Claims (3)

[Claims] (1) A decorative board characterized in that a synthetic resin decorative layer with an uneven pattern is integrally laminated on the surface of a substrate which has been subjected to warping stress so that the back side is concave. (2) Layer the flexible patterned molding plate, the synthetic resin molding material, and the substrate in this order, and warp and deform the substrate and the patterned molding plate so that the back side of the substrate is concave. A method for manufacturing a decorative board, which is characterized by performing heating and pressure molding in a given state. (3) A concave mold with a concave pressure surface, a convex mold with a convex pressure surface and the convex surface facing the concave surface of the concave mold, and a flexible structure formed from the concave side between the concave mold and the convex mold. Manufacture of a decorative board characterized by comprising a press machine that presses a concave mold and a convex mold with a concave-convex pattern molding template, a synthetic resin molding material, and a substrate set in a layered structure in this order. Device.