Wood-based decorative article and method of manufacturing the same

• US 20020031620A1
• Filed: 05/23/2001
• Published: 03/14/2002
• Est. Priority Date: 05/24/2000
• Status: Active Grant

• Current Assignee: Kabushiki Kaisha Kawai Gakki Seisakusho
• Original Assignee: Kabushiki Kaisha Kawai Gakki Seisakusho
• Inventors: Sano, Yoshiaki, Yuzawa, Satoshi, Imai, Shigeto
• Granted Patent: US 7,097,913 B2
• Time in Patent Office: Days
• US Class Current: 428/1.1
• CPC Class Codes: B27D 1/00 Joining wood veneer with any material; Forming articles thereby in conjunction with moulding of wood particles or fibres B27N3/06; Preparatory processing of surfaces to be joined, e.g. scoring
• CPC Class Codes: B29C 45/14811 Multilayered articles B29C45/14827 takes precedence
• CPC Class Codes: B29K 2711/14 Wood, e.g. woodboard or fibreboard
• CPC Class Codes: B29K 2713/00 Use of textile products or fabrics for preformed parts, e.g. for inserts B29K2105/06 takes precedence
• CPC Class Codes: B29K 2715/006 Glues or adhesives, e.g. hot melts or thermofusible adhesives
• CPC Class Codes: B32B 21/08 of synthetic resin
• CPC Class Codes: B44C 5/043 containing wooden elements
• CPC Class Codes: B44C 5/0453 produced by processes involving moulding
• CPC Class Codes: C09K 2323/00 Functional layers of liquid crystal optical display excluding electroactive liquid crystal layer characterised by chemical composition
• CPC Class Codes: Y10T 428/24066 Wood grain
• CPC Class Codes: Y10T 428/31989 Of wood

Abstract

There is provided a method of manufacturing a wood-based decorative article, which can fully ensure the effect of coating a veneer e.g. to achieve a beautiful finish with an enhanced grain of the veneer by coloring or dyeing. A predetermined coating process is performed on a veneer formed by slicing wood. Then, a veneer sheet is prepared by bonding a reinforcing member onto the coated veneer by an adhesive. Then, injection molding is carried out by injecting a molten synthetic resin onto a rear surface of the prepared veneer sheet, to thereby integrate the veneer sheet and the synthetic resin with each other and at the same time mold the wood-based decorative article.

Claims

1. A method of manufacturing a wood-based decorative article, comprising the steps of:

performing a predetermined coating process on a veneer formed by slicing wood;

preparing a veneer sheet by bonding a reinforcing member to said coated veneer by an adhesive; and

carrying out injection molding by injecting a molten synthetic resin onto a rear surface of said prepared veneer sheet, to thereby integrate said veneer sheet and said synthetic resin with each other.

2. A method of manufacturing a wood-based decorative article, according to claim 1, wherein a colored adhesive is used as said adhesive.

3. A method of manufacturing a wood-based decorative article, according to claim 1, wherein a dimensional stabilization process by using a dimensional stabilizer is performed on said veneer subjected to said predetermined coating process, before preparing said veneer sheet.

4. A method of manufacturing a wood-based decorative article, according to claim 3, wherein said dimensional stabilizer is colored by a coloring agent.

5. A method of manufacturing a wood-based decorative article, according to claim 1, wherein one of a coating process and an impregnation process is performed on said prepared veneer sheet before said injection molding.

6. A method of manufacturing a wood-based decorative article, according to claim 1, wherein top coating is performed on a front surface of said veneer after said injection molding.

7. A method of manufacturing a wood-based decorative article, comprising:

a veneer sheet-preparing step of preparing a veneer sheet by bonding a fibrous sheet having transparent and air permeable properties onto a front surface of a veneer by using one of an adhesive having a transparent property and a coating material having transparent and adhesive properties; and

a substrate-joining step of joining a substrate to a rear surface of said veneer sheet.

8. A method of manufacturing a wood-based decorative article, according to claim 7, wherein said substrate-joining step includes a molding step of introducing a molten synthetic resin onto said rear surface of said veneer sheet to mold said synthetic resin into a predetermine shape and at the same time joining said synthetic resin to said rear surface of said veneer sheet, as said substrate.

9. A method of manufacturing a wood-based decorative article, according to claim 8, wherein a hot melt adhesive is provided on said rear surface of said veneer sheet in advance before said molding step.

10. A method of manufacturing a wood-based decorative article, according to claim 7, wherein a rear fibrous sheet is further bonded to said rear surface of said veneer sheet at said veneer sheet-preparing step.

11. A method of manufacturing a wood-based decorative article, according to claim 10, wherein said substrate-joining step includes

a step of setting said veneer sheet in a mold having a predetermined shape,

a step of arranging a molten synthetic resin on said rear surface of said veneer sheet set in said mold, and

a molding step of joining said synthetic resin to said rear surface of said veneer sheet, as said substrate, by molding said veneer sheet and said molten synthetic resin by using said mold.

12. A method of manufacturing a wood-based decorative article, according to claim 11, wherein a hot melt adhesive is provided on said rear surface of said veneer sheet in advance before said molding step.

13. A method of manufacturing a wood-based decorative article, according to claim 7, wherein top coating is performed on a front surface of said veneer sheet.

14. A method of manufacturing a wood-based decorative article, according to claim 7, wherein said veneer is colored before said veneer sheet-preparing step.

15. A method of manufacturing a wood-based decorative article, according to claim 7, wherein at least one of said fibrous sheet and said adhesive or said coating material is colored in advance in a state of said transparent property thereof being preserved.

17. A wood-based decorative article according to claim 16, wherein a transparent reinforcing member for reinforcing said veneer is interposed between said veneer and said substrate.

18. A wood-based decorative article according to claim 17, wherein at least one of said veneer and said reinforcing member is impregnated with a transparent synthetic resin.

19. A wood-based decorative article according to claim 16, wherein a design layer for increasing variation of a design of said veneer is arranged on at least one of front and rear surfaces of said substrate.

20. A wood-based decorative article according to claim 19, wherein said design layer is removably attached to said rear surface of said substrate.

21. A wood-based decorative article according to claim 16, wherein a light source for illumination is provided on a rear surface side of said substrate.

22. A wood-based decorative article according to claim 21, wherein at least one of a color and an amount of light emitted from said light source is variable.

23. A wood-based decorative article according to claim 21, wherein a light guide plate for making uniform said light from said light source is interposed between said light source and said substrate.

24. A wood-based decorative article according to claim 21, wherein a display member for displaying predetermined information is provided on a front surface of said veneer.

25. A wood-based decorative article according to claim 16, wherein an indicator for giving a predetermined indication by using at least one of a liquid crystal device and an LED device is provided on a rear surface side of said substrate.

26. A wood-based decorative article according to claim 16, wherein part of said substrate is formed of an opaque synthetic resin.

27. A wood-based decorative article according to claim 16, wherein a topcoat is applied to a front surface of said veneer.

16. A wood-based decorative article comprising:

a veneer formed by slicing wood; and

a substrate formed of a transparent synthetic resin and joined to a rear surface of said veneer.