Method for producing wooden decorative articles

• US 4,890,656 A
• Filed: 10/23/1987
• Issued: 01/02/1990
• Est. Priority Date: 10/25/1986
• Status: Expired due to Fees

• Current Assignee: Yamaha Corporation
• Original Assignee: Yamaha Corporation
• Inventors: Ohsumi, Hisayoshi, Ikeya, Taichi
• Primary Examiner(s): BRAY, WAYMOND D
• Application Number:
  US07/112,820
• Time in Patent Office: 802 Days
• Field of Search: 144/348, 144/350, 144/351, 156/283, 156/298, 156/300, 427/185
• US Class Current: 144/350
• CPC Class Codes: B27M 3/18 of furniture or of doors B27D5/003 takes precedence
• CPC Class Codes: Y10T 156/109 Embedding of laminae within face of additional laminae
• CPC Class Codes: Y10T 156/1093 with covering of discrete laminae with additional lamina

Abstract

In production of a decorative article from piece board of a decorative plywood, a decorative sheet for the decorative plywood is formed by heat pressing a powdery sheet on a material sheet in order to simplify coating process.

Claims

1. An improved method for producing a decorative plywood, said method comprising the steps of:

forming a powdery resin sheet on a material sheet;

heatpressing said powdery resin sheet with said material sheet to form a decorative sheet; and

attaching said decorative sheet to a base board to form a decorative plywood.

2. An improved method as claimed in claim 1 further comprising

the step of forming one or more decorative layers on said material sheet before formation of said powdery resin sheet, said decorative layers being subsequently fully covered by said powdery resin sheet.

3. An improved method as claimed in claim 1 further comprising the steps of

forming one or more decorative layers on said powdery resin sheet, and

covering said decorative layers with a further powdery resin sheet before heat pressing.

4. An improved method as claimed in claim 1 further comprising the steps of

forming one or more decorative layers on a material cloth, and

attaching said material cloth to said material sheet before formation of said powdery resin sheet.

5. An improved method as claimed in claim 1 further comprising the steps of

placing one or more inlay pieces on said powdery resin sheet, and

covering said inlay pieces with a further powdery resin sheet before heat pressing.

6. An improved method as claimed in any one of claims 1 to 4 in which

said powdery resin sheet contains one of epoxy resin, unsaturated polyester resin, epoxy polyester resin, epoxy phenol resin, thermosettable acrylic resin and acrylic resin.

7. An improved method as claimed in any one of claims 1 to 4 in which

the unit weight of said powdery resin sheet is in a range from 100 to 300 g/m².

8. An improved method as claimed in any one of claims 1 to 4

in which heat pressing is carried out at a temperature of 120°

to 140°

C.

9. An improved method as claimed in any one of claims 1 to 4

in which heat pressing is carried out under a pressure of 0.2 to 1.5 MPa.

10. An improved method as claimed in any one of claims 1 to 4

in which heat pressing is carried out for a period of 5 to 10 min.

11. An improved method as claimed in any one of claims 1 to 4

in which attachment of said decorative sheet to said base board is carried out with a bond containing one of EVA resin, vinyl acetate resin, a mixture of vinyl acetate resin with urea resin and melamine resin.

12. An improved method as claimed in claim 11

in which bonding is carried out at a temperature of 100°

to 120°

C.

13. An improved method as claimed in claim 11

in which bonding is carried out under a pressure of 0.1 to 1 MPa.

14. An improved method as claimed in any one of claims 1 to 4 in which

the thickness of said material sheet is in a range from 0.2 to 0.8 mm.

15. An improved method for producing a decorative article, said method comprising the steps of:

forming a decorative plywood according to claim 1;

cutting said decorative plywood into piece boards; and

assembling said piece boards to form a decorative article.

16. An improved method as claimed in claim 15, further comprising the steps of:

forming one or more decorative layers on said powdery resin sheet; and

covering said decorative layers with a further powdery resin sheet before heating.

17. An improved method as claimed in claim 16, in which the thickness of said material sheet is in a range from 0.2 to 0.8 mm.

18. An improved method as claimed in claim 16, in which said powdery resin sheet contains one of epoxy resin, unsaturated polyester resin, epoxy polyester resin, epoxy phenol resin, thermosettable acrylic resin and acrylic resin.

19. An improved method as claimed in claim 16, in which the unit weight of said powdery resin sheet is in a range from 100 to 300 g/m².

20. An improved method as claimed in claim 16, in which heat pressing is carried out at a temperature of 120°

to 140°

C.

21. An improved method as claimed in claim 16, in which heat pressing is carried out under a pressure of 0.2 to 1.5 MPa.

22. An improved method as claimed in claim 16, in which heat pressing is carried out for a period of five to ten minutes.

23. An improved method as claimed in claim 16, in which attachment of said decorative sheet to said baseboard is carried out with a bond containing one of EVA resin, vinyl acetate resin, a mixture of vinyl acetate resin with urea resin and melamine resin.

24. An improved method as claimed in claim 23, in which bonding is carried out at a temperature of 100°

to 120°

C.

25. An improved method as claimed in claim 23, in which bonding is carried out under a pressure of 0.1 to 1 MPa