JPH10119131A - Surface decorative product covered with vacuum-formed plastic film layer and its production - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a surface decorative product wherein a required pattern is expressed under an excellent surface lustrous condition on the surface of a base material with a complicated uneven curved face and a method for producing it. SOLUTION: In this product, the surface of a base material with a complicated uneven curved face is covered with a plastic film layer formed by vacuum forming and surface decoration is applied with the plastic film layer. In addition, to prepare the product, a plastic sheet 8 for surface decoration with a size being enough for covering the surface of the base material 1 and made of a vacuum-formable substance is positioned by an interval above the base material 1 with a complicated uneven curved face and after the sheet 8 is softened by heating, vacuum forming is performed by making vacuum so as to reach vacuum pressure as fast as possible without using a membrane and the surface of the base material 1 is covered by a film layer being vacuum-formed from the sheet 8.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a surface-decorated product whose surface is covered with a plastic film layer formed by vacuum forming, particularly furniture, building interior / exterior furnishings, office furnishings, etc. having a complicated curved surface. The present invention relates to a surface-decorated product and a method for manufacturing the same.

[0002]

2. Description of the Related Art At present, decorating furniture, interior / exterior furniture, office furniture, etc. having a complex uneven curved surface is generally performed by spraying or dipping. In order to supply the raw materials, raw materials or compressed materials having a rough substrate surface must be used. However, it is desired that the surface of the final product has smoothness and a design with a design from the viewpoint of its product value. In order to finish a product with a certain pattern, the painting process,
There is a problem that painting and polishing must be repeated at least 3 to 4 times, and more often at least 6 times. Products whose surfaces are decorated by spraying or dipping and whose surfaces are decorated are poor in the expressiveness of the decorated surface, and it has been considered that it is impossible to express, for example, a high-grade wooden bark. . Further, the coating process that is currently widely performed is in an unfavorable state when considering the environmental health in the future.

On the other hand, a vacuum forming apparatus is widely known as an apparatus used for forming a plastic film into various three-dimensional shapes. However, when it is intended to coat a surface of a substrate having a complicated uneven surface with a vacuum forming film using such an existing membrane type vacuum forming apparatus which has been conventionally used, as shown in FIG. In addition, in order to perform molding by positioning the membrane sheet 14 for pressurization and decompression on the outer surface of the plastic sheet 8 for vacuum molding, the bending rate of the coating film after vacuum molding depends on the characteristics of the membrane sheet. However, there is a problem that it is not suitable for a substrate (object to be coated) having a very complicated uneven surface. In other words, this membrane sheet must be an elastic substance (elastic body) that does not undergo plastic deformation, and therefore has a certain physical thickness, and cannot increase the maximum flexural modulus extremely. However, the surface shape of the product was greatly restricted.

[0004]

DISCLOSURE OF THE INVENTION The present invention solves the above-mentioned problems and provides a method for forming a substrate having a complicated uneven surface on a surface thereof.
It is an object of the present invention to provide a surface-decorated product in which a desired pattern has excellent surface smoothness, or has a design pattern and fine irregularities corresponding to the pattern. Another object of the present invention is to provide a method capable of producing such a surface-decorated product. The present inventor has conducted various studies and found that, in an existing membrane-type vacuum forming machine, without using a membrane sheet, the decorative plastic sheet was positioned at an interval from the substrate surface to which the adhesive was applied, Vacuum forming is performed at a large decompression speed without applying pressure, and the decoration plastic sheet is coated on the object to be coated with only decompression force, so that even the object to be coated having any complicated uneven surface can be detailed. They found that the seat could be fitted and completed the present invention.

[0005]

According to the surface-decorated product of the present invention, the surface of a substrate having a complicated uneven surface is covered with a plastic film layer formed by vacuum forming, and the surface is decorated with the plastic film layer. It is characterized by being decorated. The present invention is also a method for producing a surface-decorated product having the above configuration,
In this method, a plastic sheet for surface decoration having a size large enough to cover the surface of the base material and made of a vacuum moldable material is provided above the base material having a complex uneven curved surface. After heating and softening the plastic sheet for surface decoration, without using a membrane sheet,
The space formed between the sheet and the base material was vacuum-formed by reducing the pressure to reach the vacuum pressure as quickly as possible, and the surface of the base material was vacuum-formed from the surface-decorating plastic sheet. It is characterized by being covered with a plastic film layer. Furthermore, the present invention relates to the above production method,
The vacuum forming is performed by reducing the pressure in the space formed between the sheet and the base material so as to reach the vacuum pressure within 10 seconds.

[0006]

DESCRIPTION OF THE PREFERRED EMBODIMENTS First, an example of a surface-decorated product of the present invention is shown in the drawings to explain the present invention. FIG. 2 is a diagram showing a longitudinal sectional structure of an example of the surface-decorated product of the present invention. As can be seen from this figure, in the product of the present invention,
The entire surface of the substrate 1 having a complicated uneven surface, excluding the bottom surface, is covered with a plastic film layer 8 'formed by vacuum forming a plastic sheet for vacuum forming. The plastic film layer 8 'may be printed, colored or transparent (the printed layer is not shown), and if printed, it may be white or black. A single color may be printed, but a pattern such as a grain pattern or a marble pattern is preferable, and it is more preferable that the surface is embossed corresponding to the pattern. Further, the layer 8 'and the substrate 1 may be firmly adhered in a state of being in close contact with each other via an adhesive layer, or may be adhered without an adhesive layer. The material of the substrate 1 in the present invention is not particularly limited, and various types of plywood, plastic plates, and the like can be used. Further, the material of the plastic film layer 8 'in the present invention is not particularly limited, either.
The layer 8 'is generally formed from a vinyl chloride resin sheet, an amorphous polyester sheet, an acrylic sheet, a polycarbonate sheet, etc., which are widely commercially available as suitable for vacuum forming.

[0007] By using such a surface-decorated product of the present invention, it is possible to produce various kinds of furniture, interior and exterior furniture, office furniture and the like having excellent surface smoothness and design. Note that the “complex uneven surface” of the substrate 1 in the product of the present invention means that the opening surface of the substrate surface gradually increases toward the inside of the substrate as in the substrate 1 shown in FIGS. A concave / convex surface including a concave portion (a dent), a general U-shaped groove or a U-shaped groove having an open top, and a rounded ant as shown in FIG. Concave surfaces such as grooves are also included, and convex surfaces corresponding to such concave surfaces are also included. In the present invention, the “complex concave-convex curved surface” refers to, for example, in a longitudinal cross-sectional shape as shown in FIG. The angle (depression angle) between the line of sight and the surface of the substrate when viewed from the front side θ
Is 60 ° or less.

Next, a manufacturing method of the present invention for manufacturing the above-described surface-decorated product will be described with reference to the drawings.
FIG. 1 is a cross-sectional structural view of a vacuum processing apparatus used when carrying out the manufacturing method of the present invention. In the manufacturing method of the present invention, the surface of a substrate 1 having a complicated uneven surface is decorated. When coating and decorating with the plastic sheet 8 for use, the adhesive 2 is generally applied to the entire surface of the substrate 1 except for the bottom surface, but the adhesive 2 is applied to the back surface of the sheet 8. Is also good. In the present invention, when the adhesive 2 is applied to the substrate 1,
Although it is preferable to use a hot-melt type adhesive, a thermosetting or light-curing adhesive may be used. If the adhesiveness of the sheet 8 to the substrate 1 is sufficient, the adhesive may be used. It is not necessary to apply the agent. In the present invention, the material and thickness of the plastic sheet 8 for surface decoration are considered according to the shape of the uneven curved surface of the substrate 1.

Then, as shown in FIG. 1, the metal screen 3 is placed on the upper surface of a decompression box 7 on which a perforated plate 5 having a decompression path 4 (a vacuum pump is not shown) is disposed. Then, the substrate 1 is placed thereon.
In the apparatus shown in FIG. 1, a support 6 for improving the flatness of the perforated plate 5 is provided in a decompression box 7. The metal screen 3 only needs to be one size smaller than the inner peripheral surface of the frame to be installed later, for example, about 1 cm smaller. 5 without adhesion to substrate 1
The ventilation holes of the perforated plate 5 located below the bottom surface of the base material are not blocked (see FIG. 1), and the ventilation holes located on the outer periphery of the base material are not blocked by the plastic sheet 8 for surface decoration. Therefore, decompression is performed smoothly and steeply, and a large decompression speed can be obtained. If the pressure is reduced after heating in the absence of the metal screen 3, the sheet 8 closes the holes of the perforated plate 5, so that a steep pressure reduction cannot be obtained. At this time, according to the present invention, as shown in FIG.
It is preferable to provide a spacer 15 of an arbitrary thickness between 5 mm and 20 mm at the center of the base material, and the spacer 15 is adjusted so that the gap between the surface of the base material 1 and the plastic sheet 8 for surface decoration is about 1 cm. This is effective for covering the side surface of the substrate 1 with the plastic sheet 8 for surface decoration.

On the other hand, a surface decoration plastic sheet 8 made of a material which can be vacuum formed is simply bonded or clamped to the upper surface of a frame 10 provided with a sealing rubber sheet 9 on the lower surface. At this time, the method of fixing to the frame may be any method, and a method with good mass productivity can be selected. When a plastic sheet having a low elongation after heating and softening is used as the surface-decorating plastic sheet 8, a function of creeping while maintaining a vacuum state in the sheet so as not to be broken during vacuum molding. It is preferable to use a clamp having a structure in which the outer edge of the sheet can move slightly toward the center of the frame. The frame 10 thus arranged is positioned so that the surface decorative plastic sheet 8 covers the base material 1. In the manufacturing method of the present invention, it is important to perform vacuum forming in a state where the plastic sheet 8 is located at a certain distance from the surface of the substrate 1, for example, about 1 cm, and the plastic sheet 8 In a case where vacuum molding is performed with the substrate 8 placed thereon, the sheet cannot be formed in a shape in which it is in close contact with the details of the uneven curved surface of the base material. Then, the masking film 11 is coated on the perforated plate 5 located on the outer peripheral portion of the frame 10 to close the ventilation holes (see FIG. 1). Thus, the suction force decompressed from the decompression path 4 can be efficiently applied to the surface decoration plastic sheet 8. The sealing rubber sheet 9 attached to the lower surface of the frame 10 is also intended to effectively apply the suction force to the surface decoration plastic sheet 8.

After preparing for vacuum forming in this way,
A heating hood having a hood 12 for holding a temperature and having a heater 13 disposed therein is placed on the decompression box 7, and the surface-decoration plastic sheet 8 is heated and softened at a constant temperature and time. By reducing the pressure through the pressure reducing path 4, the gap between the plastic sheet 8 for decorative surface and the substrate 1 becomes a vacuum, and a difference from the outside air pressure is generated. It is molded into a shape that is in close contact. At this time, the heating time must be minimized, and the pressure reduction rate must be controlled so as to reach the vacuum pressure in a short time. In the present invention, it is preferable that the time to reach a vacuum pressure of, for example, about 10 Torr is controlled to 10 seconds or less. If it takes a long time to reach the vacuum pressure, the surface decorative plastic sheet 8 may not adhere to the details of the surface irregularities of the substrate 1. Further, if the heating is performed for a long time, the plastic sheet 8 for decorating the surface may be broken, which is not preferable. The heating time at this time is appropriately selected according to the softening characteristics (softening temperature and the like) of the plastic sheet 8 for surface decoration, and is also appropriately selected according to the material of the sheet 8. After molding, setting is performed under vacuum pressure. The setting time varies depending on the type of the plastic sheet 8 for surface decoration and the adhesive 2 and the like, but is generally preferably about 30 seconds. In the present invention, at the same time as the vacuum forming, the plastic film layer formed by the vacuum forming and the substrate 1 are bonded together, and the adhesive 2
Is applied, the adhesive 2 activated by heating
, The plastic film layer formed under vacuum and the substrate 1 are firmly bonded to each other.

In the present invention, the surface of the plastic sheet for surface decoration 8 to be adhered to the substrate 1 is finished to be rough,
It is possible to prevent the gas from being left without being sucked during the decompression, and to prevent the decorative plastic sheet 8 after vacuum molding on the base material 1 from causing adhesion failure without becoming familiar. Generally, since the roughness of the substrate surface of the base material 1 is large, even if a general plastic sheet for decorating is used in the production method of the present invention, no major problem occurs. In the manufacturing method of the present invention, the ultimate pressure, as well as the pressure reduction rate during the above-described pressure reduction, greatly affects the finished product, and the final pressure is preferably 10 Torr or less.

The surface of the substrate of the surface-decorated product of the present invention may be coated on a surface of a substrate such as a special UV paint sheet described in JP-A-7-125496 for the purpose of improving surface physical properties and surface gloss. The transfer plastic sheet material may be coated, and when the surface is coated with the UV paint sheet, a product having very excellent surface hardness is obtained.

[0014]

EXAMPLE A commercially available plastic sheet for vacuum forming (made of vinyl chloride resin, 0.3 mm thick) was prepared, and the manufacturing method of the present invention was carried out using a vacuum processing apparatus having an internal structure shown in FIG. . First, a frame (600 x 600 mm, pipe section 40
A metal screen (500 × 500 mm, made of stainless steel, 10 mesh / inch) smaller than the inner diameter of (mm × 35 mm in height) is placed in the center of a vacuum box (2400 mm in width × 1200 mm in depth × 50 mm in height), A spacer (285 mm wide x
195 mm deep x 10 mm high). Then, an aqueous urethane-based thermoplastic resin is applied to the surface of a base material (310 mm in width × 210 mm in depth × 20 mm in height) having a surface shape shown in FIG. Put on. On the other hand, a plastic sheet for surface decoration was adhered and fixed to the surface of the frame with a heat-resistant double-sided tape, and this was set so that the metal screen placed on the vacuum box was the center. Then, a masking film was covered on the upper surface of the perforated plate that was not covered with the frame to which the surface decoration plastic sheet was fixed.

Then, the hood in which the heated heater is installed is placed on the decompression box, and heating is performed at a heating temperature of 120 ° C. After 30 seconds, the sheet starts to soften, and at the same time, the pressure is reduced through the decompression path. Suction was performed. At this time, an exhaust pump having an exhaust capacity of 3700 l / min and an ultimate pressure of 5 × 10 ⁻³ Torr is used. The final ultimate pressure after the reduced pressure suction is 10 Torr. Reached 5.5 seconds. Then, after leaving under vacuum pressure for 30 seconds, the hood 12 is raised and the substrate 1
Was taken out. By the above process, even in the form of a complicated uneven surface as shown in FIG. 3, the plastic sheet for surface decoration can be easily coated, and a beautiful surface design is added to the base material surface, thereby adding value. , The surface-decorated product (furniture panel) of the present invention having a high value can be manufactured at a low price. Similarly, an amorphous polyester sheet (thickness of 0.5) was used as a plastic sheet for surface decoration.
mm), the same result was obtained.

[0016]

According to the production method of the present invention, it is possible to obtain a product in which a desired beautiful surface design is provided on the surface of a substrate having a complicated uneven surface, and the production method uses a membrane sheet. It is relatively easy to carry out, and can provide a rich expression of the decorative surface as compared with conventional painting, and the product manufacturing process is excellent in terms of environmental impact.

[Brief description of the drawings]

FIG. 1 is a sectional structural view of a vacuum processing apparatus used when performing a method of the present invention.

FIG. 2 is a diagram showing a vertical cross-sectional structure of an example of the surface-decorated product of the present invention.

FIG. 3 is a diagram showing an example of a surface unevenness shape in the surface-decorated product of the present invention.

FIG. 4 is a diagram showing a state in which a substrate 1 is covered with a plastic sheet 8 for surface decoration when a conventional membrane-type vacuum forming apparatus is used.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Base material 2 Adhesive 3 Metal screen 4 Decompression path 5 Perforated plate 6 Support 7 Decompression box 8 Plastic sheet for surface decoration 8 'Plastic film layer 9 Rubber sheet for sealing 10 Frame 11 Masking film 12 Food 13 Heater 14 Membrane Sheet 15 Spacer

 ────────────────────────────────────────────────── ─── Continued on the front page (71) Applicant 592066723 Nakanuma Art Screen Co., Ltd. 23-8, 23 Uzumasui Yasushi Okuhatacho, Ukyo-ku, Kyoto-shi, Kyoto (72) Inventor Yoshihisa Miyasaka 14 Saganakadoricho, Ukyo-ku, Kyoto-shi, Kyoto No. 4 Inside Miyasaka Furniture and Crafts Co., Ltd. (72) Inventor Tadao Yamamoto 98 Kagamiba Pagoda Mori Higashi-cho, Minami-ku, Kyoto, Kyoto 1 1 Yamamoto Wood Industry Co., Ltd. (72) Inventor Shin Hayashi, Fushimi-ku, Kyoto, Kyoto 43-2 Takeda Koya Nonai-cho 2 Teishin Shoji Co., Ltd. (72) Inventor Osamu Nakanuma 23-8 Uzumasa Yasui Okuhata-cho, Kyoto, Kyoto, Japan 8 Nakanuma Art Screen Co., Ltd.

Claims (3)

[Claims] 1. The surface of a substrate having a complex uneven curved surface,
A surface-decorated product, which is covered with a plastic film layer formed by vacuum forming, and surface-decorated by the plastic film layer. 2. A method for producing a surface-decorated product having a surface covered with a vacuum-formed plastic film layer, comprising: forming a surface of a substrate above a substrate having a complicated uneven surface; After having a sufficient size to cover and positioning the surface decoration plastic sheet made of a material that can be vacuum formed at intervals, and heating and softening the surface decoration plastic sheet, a membrane sheet is used. Instead, the space formed between the sheet and the base material is reduced in pressure to reach a vacuum pressure and vacuum-formed, and the surface of the base material is formed by vacuum-forming the plastic from the surface-decorating plastic sheet. A method for producing a surface-decorated product, characterized by coating with a film layer. 3. The surface-decorated product according to claim 2, wherein the space formed between the sheet and the base material is reduced in pressure so as to reach a vacuum pressure within 10 seconds and vacuum-formed. Production method.