[0001] The present invention relates to a wooden decorative laminated sheet, and more particularly
to a wooden decorative laminated sheet having an embroidery pattern such that a small-sized,
patterned veneer processed into the form of a natural product or the like is laminated
on a large-sized veneer, and an embroidery finish is provided therefor, including
the small-sized veneer as well.
[0002] Conventionally, decorative laminated sheets in which a very thin sheet called veneer
that is cut from natural decorative timber is attached and laminated onto a baseplate
are used for furniture, such as high-quality chests of drawers and sideboards, as
well as building materials.
[0003] These decorative laminated sheets produce naturally wrought patterns having the grain,
curly grain, burls, etc. of natural timber. Wooden decorative laminated sheets are
known in which decorative patterns are embroidered on this veneer with various types
of fibrous yarn so as to reinforce and conceal the defects of the veneer such as back
cracking and holes and to cause a variety of patterns to be revealed on the natural
grain.
[0004] This conventional wooden decorative laminated sheet in which the veneer is embroidered
and is attached to the baseplate has drawbacks in that only planar embroidery patterns
can be created, and that molten resin permeates and stains the embroidery yarn at
the time of processing with resin for surface protection. In addition, a resin layer
having substantially the same thickness as an embroidery yarn layer projecting from
the rear surface of the veneer is provided on a portion of the rear surface of the
veneer where the embroidery yarn is not provided, and the veneer is attached to the
baseplate after the rear surface thereof is thereby flattened. Accordingly, there
has been another drawback in that the pre-attaching process is complicated, resulting
in poor processing efficiency.
[0005] A wooden decorative laminated sheet which overcomes these drawbacks is already known
and is disclosed in Japanese Utility Model Laid-Open No. 117200/1985 proposed by the
present applicant.
[0006] This prior art is arranged as follows: A small-sized veneer processed into a particular
configuration is partially and provisionally attached to one surface of a large-sized
veneer, a liner being attached to the other (rear) surface of the large-sized veneer
with a thermoplastic adhesive. Then, after the two veneers are embroidered with an
oil-repellant embroidery yarn, the large-sized veneer is attached to a baseplate,
and the small-sized veneer is attached to the large-sized veneer. A synthetic resin
layer which has a sufficiently greater thickness than that of the embroidery yarn
is provided on the two veneers, and the surface of that layer is ground and polished
so as to be smoothened.
[0007] In this prior art, as shown in Fig. 23, at the time of attaching a liner 2 to a large-sized
veneer 1, an adhesive 3 is sprayed onto the liner 2, and when an attempt is made to
attach the liner 2 to the veneer 1, the adhesive 3 which has penetrated the liner
2 adheres to the press dies, thereby making processing extremely difficult. In addition,
since a large amount of adhesive penetrates the cloth of the liner 2, it is necessary
to increase the amount of the adhesive sprayed. Hence, there is the problem that it
is very uneconomical.
[0008] For this reason, it is conceivable to spray the adhesive 3 onto the rear surface
of the veneer 1, as shown in Fig. 24, so as to attach the liner 2 thereto. With this
process, however, the large-sized veneer 1 becomes warped, as shown in Fig. 25, so
that there is the problem that it is extremely difficult to apply the liner 2 to the
veneer 1. Moreover, there is a mutually incompatible drawback that, if the amount
of the adhesive 3 sprayed is too small, the liner 2 will attach incompletely, while,
if it is excessive, the adhesive oozes out to the surface of the veneer, with the
result that the surface of the veneer is liable to show a pitted pattern and the defective
fraction becomes large.
[0009] Accordingly, an object of the present invention is to provide a wooden decorative
laminated sheet with a decorative embroidery pattern which is capable of substantially
improving the process of bonding between the large-sized veneer and the liner and
of being produced at low cost and with a good yield on a mass-production basis.
[0010] To this end, according to one aspect of the present invention, there is provided
a wooden decorative laminated sheet with an embroidered pattern, comprising: a large-sized
veneer; a liner bonded to the rear surface of the large-sized veneer via a thermoplastic
sheet through heating and compression; a small-sized decorative veneer having a specific
configuration and provisionally attached to a surface of the large-sized veneer; embroidery
provided on both of the veneers with oil-repellant embroidery yarn; a baseplate to
which the large-sized veneer is attached with the liner placed therebetween; and a
transparent protective layer formed on the both veneers, the thickness of the transparent
protective layer being greater than the size of the oil-repellant embroidery yarn.
[0011] According to another aspect of the present invention, there is provided a method
of manufacturing a wooden decorative laminated sheet with an embroidered pattern,
comprising the steps of: bonding a liner onto the rear surface of a large-sized veneer
via a thermoplastic sheet by means of heating and pressurization; provisionally attaching
a small-sized decorative veneer, processed into a specific configuration, to a surface
of the large-sized veneer; providing embroidery on both of the veneers with oil-repellant
embroidery yarn; attaching the large-sized veneer to the baseplate with the liner
placed therebetween; and forming a transparent protective layer on the both veneers,
the thickness of the transparent protective layer being greater than the size of the
oil-repellant embroidery yarn.
[0012] In accordance with the present invention, since the wooden decorative laminated sheet
with an embroidered pattern is arranged as described above, it is possible to provide
the wooden decorative laminated sheet with an embroidered pattern having a beautiful
appearance at low cost on a mass-production basis through automation.
BRIEF DESCRIPTION OF THE DRAWINGS:
[0013]
Figs. 1 to 21 illustrate an embodiment of the present invention, in which
Figs. 1 to 4 are perspective views illustrating the procedure of processing a large-sized
veneer;
Figs. 5 to 7 are partially expanded cross-sectional views illustrating the procedure
of processing the large-sized veneer;
Fig. 8 is a schematic top plan view of the large-sized veneer;
Fig. 9 is a top plan view of a state in which pattern contour stitching is provided;
Figs. 10 and 11 are diagrams illustrating the process of fixing a decorative veneer
laminate on the large-sized veneer laminate;
Figs. 12 to 15 are diagrams illustrating the process of embroidering the large-sized
veneer and decorative veneer laminates;
Fig. 16 is a cross-sectional view of the decorative veneer laminate on which embroidery
has been completed;
Fig. 17 is a cross-sectional view in which this decorative veneer laminate is attached
to a baseplate;
Figs. 18 to 21 are diagrams illustrating the proces of processing a protective layer
on the decorative veneer laminate;
Fig. 22 is a cross-sectional view illustrating another embodiment of the present invention;
and
Figs. 23 to 25 are cross-sectional views illustrating examples of the prior art.
DESCRIPTION OF THE PREFERRED EMBODIMENTS:
[0014] Referring now to the accompanying drawings, a description will be given of the embodiments
of the present invention.
[0015] As shown in Figs. 1 and 5, a very thin thermoplastic sheet 14 and a liner 15, such
as soft cloth or Japanese paper, are consecutively superposed on the rear surface
of a large-sized veneer 13. Then, as shown in Figs. 3 and 6, this laminate is placed
on a provisional processing plate D, such as the one shown in Fig. 2. Subsequently,
this assembly is pressed by a press base P2 and a pressing plate P1 while it is being
heated. As a result, the liner 15 is made to adhere to the rear surface of the large-sized
veneer 13 via the thermoplastic sheet 14, thereby obtaining a substrate A, as shown
in Figs. 4 and 8.
[0016] Subsequently, as shown in Fig. 9, contour stitching is performed for the surface
of the above-described large-sized veneer 13 with oil-repellant yarn 17 in such a
manner as to trace the contour of a decorative veneer laminate 16 processed into a
specific configuration, as will be described later.
[0017] Then, the decorative veneer laminate 16 is provisionally attached to the large-sized
veneer 13, as shown in Figs. 10 and 11.
[0018] In other words, this decorative veneer laminate 16 is arranged as follows: A liner
22 is attached to the rear surface of a large-sized veneer 21 having a specific configuration
corresponding to the portion of the above-described contour stitching, using a thermoplastic
adhesive 23. An adhesive 24, which is the same as the aforementioned one, is applied
to the other surface of the liner 22 where the adhesive had not been previously applied.
This decorative veneer laminate 16 is processed into a specific configuration (the
trunk of a pine tree in this embodiment), and is fixed to the surface of the large-sized
veneer 13 by being partially heat-compressed by means of a heating tool, as shown
in Fig. 11.
[0019] Subsequently, as shown in Figs. 12 to 16, a ground surface portion, a trunk, branches,
and leaves are embroidered at portions 18 by using an embroidery sewing machine with
an oil-repellant embroidery yarn (gold and silver threads) 17.
[0020] As shown in Fig. 17, a decorative laminated sheet 25 with an embroidered pattern
thus processed is placed on a baseplate 19 formed of plain timber, plywood, a tile,
or the like and is then subjected to heating so as to cause the veneer 13 to adhere
to the baseplate 19 by means of a thermoplastic adhesive 26 with the liner 15 placed
therebetween.
[0021] After this lamination process is completed, an adhesion aiding agent (sealer) 71
is sprayed onto the decorative laminated sheet 25 a plurality of times to make the
surface thereof less uneven, as shown in Fig. 18. Subsequently, a solvent 72 formed
of a polyester resin is applied thereto a plurality of times with a brush to make
the surface even less uneven, as shown in Fig. 19.
[0022] Thus, a transparent protective layer 20 is formed on the decorative laminated sheet
25 having an embroidered pattern, and after this protective layer 20 is smoothed by
being polished with sandpaper, as shown in Figs. 20 and 21, a finish spray is provided
on this protective layer 20.
[0023] It should be noted that the decorative veneer laminate 16 may be directly bonded
to the large-sized veneer 13 by means of the adhesive 23 without applying the liner
22 onto the rear surface of the decorative veneer laminate 16.
[0024] Since the present invention is arranged as described above, the present invention
produces the following advantages.
[0025] With the wooden decorative laminated sheet in accordance with the present invention,
the liner can be readily bonded to the large sized veneer by means of a very thin
thermoplastic sheet, and since no adhesive is applied to the large-sized veneer, the
large-sized veneer is prevented from warping. In addition, since no adhesive is applied
to the liner, stamping can be facilitated, and the wasteful adhesive resulting from
the permeation of the adhesive can be eliminated, and the permeation of the adhesive
through the large-sized veneer can be eliminated. Hence, there is the advantage that
it is possible to obtain a beautiful wooden decorative laminated sheet which is free
of pitted patterns.
[0026] In addition to the above-described advantage, by virtue of the above-described transparent,
flat protective layer, the uneven surface patterns of the decorative veneer and the
embroidery yarn layer can be expressed three-dimensionally. In addition, since the
molten resin does not permeate the oil-repellant embroidery yarn at the time of formation
of the protective layer, it is possible to obtain three-dimensional embroidery of
a beautiful appearance. The uneveness of the rear-surface yarn is absorbed by an adhesive
layer for bonding the veneer laminate onto the baseplate, while the surface uneveness
can be absorbed by a protective layer formed thereon. Accordingly, there are additional
advantages in that a three-dimensional pattern exhibiting a beautiful and gorgeous
appearance can be obtained with good processing efficiency, and that, since mass production
through automation is facilitated, it is possible to provide the wooden decorative
laminated sheets at low cost.