EXTRUSION MOLDING ARTICLE WITH EMBOSSING FINISH AND A METHOD FOR PRODUCING THE SAME

ARTICLE MOULE PAR EXTRUSION AVEC FINITION GAUFREE, ET PROCEDE DE FABRICATION ASSOCIE

English Abstract

The present invention provides an art for solving the problems that wood-like
touch is lost due to light and shade stripes when an embossing finish is
applied on the extrusion molding article expected to have wood-like touch. The
glazed portion comprising a glazed face is formed by an extrusion molding
using a resin material containing wood powder in which the resin is blended
with the wood powder. Paint layers are penetrated into embossing grooves after
applying an embossing finish and painting on the glazed face, followed by
brushing.

French Abstract

L'invention permet de résoudre le problème que constitue la perte du toucher de type bois dû aux bandes de lumière et d'ombre quand on applique une finition gaufrée sur un article moulé par extrusion auquel on désire donner ledit toucher. On forme la partie lustrée, présentant une face lustrée, par un procédé de moulage par extrusion, à partir d'un matériau à base de résine contenant de la poudre de bois, dans lequel la résine est mélangée à la poudre de bois. On fait pénétrer les couches de peinture dans les rainures du gaufrage après avoir appliqué sur la face lustrée une finition gaufrée et une peinture, puis on brosse.

Claims

CLAIMS
1. An extrusion molding article of resins formed by an
extrusion molding, characterized in that
the glazed portion comprising at least a glazed face
is formed with a resin material containing wood powder in
which the resin is blended with the wood powder; and
the glazed face thereof being formed, after applying
an embossing finish and painting, by burying a paint in
grooves formed by the embossing finish and brushing the
surface of the buried paint.
2. An extrusion molding article with an embossing
finish according to Claim 1, wherein the glazed portion is
molded by a monolithic extrusion with the other portions.
3. An extrusion molding article with an embossing
finish according to Claim 1 or claim 2, wherein the glazed
portion and the other portions are molded with a resin
material containing wood powder forming the glazed portion.
4. An extrusion molding article with an embossing
finish according to Claim 1, wherein the wood powder in the
resin containing wood powder that forms the glazed portion
is produced by the steps comprising:
grinding the crushed powder obtained by crushing a
cellulose material; and
adhering surface particles having a smaller particle
size and higher hardness than the crushed powder on the
peripheral surface of the crushed powder.
5. A method for producing an extrusion molding article
with an embossing finish comprising:
an extrusion molding step for extrusion molding a
glazed portion that forms at least a glazed face by using a
resin material containing wood powder in which the resin is
mixed with the wood powder;
an embossing step for applying an embossing finish
on the glazed face;
a painting step for painting so as to bury the paint
into grooves formed by the embossing finish; and
a brushing step for brushing the paint layer buried
in the grooves formed by the embossing finish.

Description

CA 02255784 1998-11-23
~ WO 9~437gl - PCT~lP97/0107
I~ESCRIPTION
- ~;2~ Ku~ION MOI.DING ARTICLE WIT~I EMBOSSING FINIS~I
AND A PEl~OD FOR PRODUCING T~; SAME
~echnical Field
The present i~entlon re1ates to an e~trusion
molding article with an embosslng ~ini9h and a method ~or
producing the same. In more detail, the present lnvention
relates to an art ~or applying an embossing ~inish on the
surface o~ an e~trusion ~olding article o~ resins, rollowed
by making the pattern prlnted by the embosslng ~inish clear.
~kground Art
~ ome building components, in which extrusion molding
artlcles o~ re~in materials cont~1n1n~ wood powder are
~requently used, are described below as a related art.
Extrusion molded articles o~ synthetic resins have
been frequently u9ed for highly processed buildlng
components like a door sash ~nstead o~ wooden components
manufactured by natural ti~bers. The materials for these
extrusion molded articles oi synthetic resins are, for
example, a hard vinyl chloride resin with which several tens
percentage o~ wood powder is blended. The e~trusion moldlng
article comprising the a~orementioned materials can be
pre~iously ~ormed into a desired shape while the natural
timbers re~uire several times of p1 ~nl n~ steps. There~ore,
processing steps a~ter the moldlng can be largely reduced ln
addltion to enabling the article to be c~t with a saw or to
be ~i~ed with nails, which makes the construction so easy.
- ~owever, the new article according to the art
described above yet invol~es several problems that lts
speciiic gravity is so large compared with that o~ timbers
and its surface becomes so hard by ~orming skin layers on
the sur~ace that wood-like touch is lost. Moreover, since
its compatibility wlth vinyl acetate based adhesi~es or
paints that are commonly used for the wooden components ls
low, adhesion or painting with the resin was di~iicult.
There~ore, the uses o~ this new article ~ere limited. For
the purpose o~ solving the a~oreme~tioned problems, an
e~trusion ~olding with a low degree ~f ~o~m~ng has been
applied after adding a blowing agent in the resin material
to maXe the specific gra~ity of the molded article nesrly
equal to that of the natural timber components.
Notwithstanding the specific gra~ity o~ the molded

CA 02255784 1998-11-23
product nearly identical with that o~ the natural timber
components, problems as described belo~ has still remained
~or applying an embossing finlsh.
In the embcssing finish, a cylindrical roller
pro~ided with a lot o~ conve~ities on lts suriace is pressed
on the suriace o~ the molded article to iorm many tiny
grooves on it, therebr printing grain patterns on the
surrace o~ the molded article ~ollowed by painting on it.
However, since the painting is applied onl~ by a
spray-coating, the paint layer so hardly-penetrates into the
grooved portions iormed by the embossing finish that ~ood-
like touch is lost due to light and shade stripes on lts
surrace .
Disclosure o~ Invention
Accor~n~ly, the ob~ect of the present invention is
to solve the problems described hitherto that arise aiter
applying an embossing finish to the e~trusion moldlng
article that is e~pected to have wood-like touch. Paints
are allowed to pe~etrate i~to the patterns formed by the
embossing iinish ~or emphasizing its color tone, thereby
making the grain patterns clear and enha~cing wood-like
touch.
The present invention comprises the steps Or
e~trusion molding a molded article havi~g a cross section
with a desired shape, applying an embossing ~inish aiter
removing skin layers iormed on the surface, spray-coating a
paint on the sur~ace, allowing to penetrate the paint layer
lnto patterns formed by the embossing iinish by rubbing with
an elastic block and fl~lly re~oving the light and shade
stripes iormed by rubbing with a brush.
(E~planation o~ Claim 1)
The present invention according to Claim 1 provides
an e~trusion molding article oi resins rormed by ~n
e~trusion molding, characterized in that the glazed portion
comprising at least a glazed iace is ~ormed with a resin
material cont~ln~n~ wood powder ln which the resin is
blended wlth the wood powder; the glazed ~ace thereo~ being
iormed, aiter applying a~ embosslng iinlsh and paintl~g, by
buryi~g a paint i~ grooves ~ormed by the embossing ~inis~
and brnsh1 ng the sur~ace Or the burled paint.
The foregoing "glazed portlon" denotes a ~islble
port~on when the molded artic~e of resins formed by the
e~trusion molding according to the present i~vention is
brought in a circumstance where their inherent functions can
be e~hibited.

CA 02255784 l998-ll-23
WO g~43791 ~ iJ~/~1075
(Explan~tion o~ Claim 2)
The present invention according to Claim 2 ls
provided to technically limlt the extrusion mDlding article
with an embossing ~inish according to Claim 1, wherein the
glazed portion ls molded by a monolithlc extrusion wlth the
other portions.
~ hen the glazed portion and the other portions are
composed oi di~erent material9 with each other, both
portions are molded by a monollthlc extrusion molding.
(E~planation o~ Claim 3)
The present lnvention according to Claim 3 is
pro~ided to technically limit *he glazed portion of the
e~trusion molding article with an embossing iinish according
to Claim 1 or Claim 2, wherein the glazed portion and the
other portlons are molded ~ith a resin materlal cont~1n~ng
wood po~der rorming the glazed portion.
When the glazed portion and the other portions are
composed o~ an identlcal material, the whole portion is
produced by using the material oi the glazed portion.
(Explanation of Clalm 4)
The present lnvention accordlng to Claim 4 is
characterized by producing the wood powder in the resin
cont~ nl nr wood powder that ~orms the glazed portion by the
steps comprising: grinding the crushed powder obtained by
cr~qh~n~ a cellulose material; and adherlng sur~ace
particles having a smaller particle slze and higher hardness
than the crushed powder on the peripheral sur~ace o~ the
crushed powder.
"Cellulose materials~ described herein denotes
natural woods as well as such mater~als including sawdust,
rice straws and bagasse.
~ Resins~ includes hard resins, ~or example, such as
pol~inyl chloride resin, foamed poly~inyl chloride res~n,
polyethylene resin, polypropylene resin, phenol resin.
polyurethane resin, ABS resin and polystylene resin. So~t
type resin may be also used depending on the molded bodies
required.
~ Suriace particles~ correspond to titanium oxide,
aluminum, nickel, silver, ierrites, thermoplastic reslns or
ceramics.
The proportion oi the wood powder to be mi~e~ wlth
the resin to the total molded body i9 ad,~usted not to e~ceed
30X by weight since molding processes ~ay be interfered with
a low iluidity during the molding.
"Pigments~ denote colored pigments, exnmples oi them
bei~g inorganic pigments such as iron oxide, cadmium yellow

CA 02255784 1998-11-23
W098J437Yq ~ tJ~
and carbon blac~.
(E~planation o~ Claim 5)
The present inventlon according to Claim 5 provideq
a method ~or producing an e~trusion molding article wlth a~
embossing ~inish comprising: an e~truslon moldi~g step ~or
extr~sion molding a glazed pcrtion that ~orms at least a
glazed ~ace by using a resin material cont~n~ng wood powder
in which the resin is mi~ed with the wood powder; an
embossing step ~or applying an embossing rinish on the
glazed race; a paintlng step ~or painting so as to bury the
paint into grooves ~ormed by the embossing ~inish; and a
br~ch~n~ step rOr brllch~ng the paint layer buried in the
grooves ~ormed by the embosslng finish.
Brier Description of Drawings
Fig. 1 is an lllustrative drawing representing a
production process according to the prese~t invention. and
Fig. 2 is a perspective view showing an example Or the
molded article.
.,.
Best Mode ior Carrying ~ut the Invention
The present invention ~ill now be described by way
Or embodied illustrations. However, the invention ls not
limited thereto.
In Fig. 1, 1 is an extrusion moldlng machine ror
synthetic resins, 2 is a cooler a~d 3 is sn extrusion guide.
These parts are commonly found in the conventio~al e~truder.
A molding die 4 is attached to the e~trusion molding machine
1 ~or continuously moldlng a molding article having a cross
section with a desired shape.
A molded article A having a cross section as shown
in Fig. 2 is rormed, rOr e~mple, by supplying a molding
~aterial Or a synthetic resin to the extruder 1, with ~hich
several tens percentage o~ wood powder, several percentage
oi blowing agent, stabilizer and rein~orcing material,
respectively, are blended. A s~ ng machine 5 is provided
in ~ront oi the extrusion molding machine to remove skln
layers ~ormed on the surface o~ the mo}ded article A and ~or
applyinF a satin finish on the surface, thereby e~posinF
countless smal} pores produced by wood powder and blowing
agents ~or emphasizing wood~ e touch of the molded article
A as ~ell as ~or enhancing a compatibility with paints. An
embossing machi~e 6 is also provided i~ ~ront o~ the S~n~i n~
machine 5 to appl~ an embossing ~inish on the suriace o~ the
molded artlcle arrlved at this posltion. The embossing
machine 6 is provlded with a press roller on the suriace oi

CA 02255784 1998-11-23
WO9~ PCT~J~n~1~s
which a lot o~ conve~ities are protruded ~onming a grain
pattern. A grain pattern having thin grooves is printed by
pressing this press roller on and penetrating the
convexities into the sur~ace o~ the molded article A.
A spray coating machlne 7, rubbing ~achine 8 and
brush 9 are ~urther provided, respecti~ely, in ~ront of the
embossing machlne 6 ~or spray coating a prescribed amount of
paint on the sur~ace o~ the molded article A prevlously
subJ ected to an embossing ~inish, ~ollowed by rubbing the
coated surface with a gentle touch o~ the sur~ace with an
elastic bloc~ like an urethan ~oam, thereby penetrat~ng the
palnt layer into the thin grooves ~ormed by the embossing
finish. Then, light and shade stripes appeared on the
palnted sur~ace of the molded article A are retouched by
using the brush 9 to ~orm an uni~or~ painted surface. The
molded article is ~inally rinished by drying the coated
layer by a con~entional method ~ollowed by painting a clear
lacquer.
According to the a~orementioned process, a pattern
by the embossing finish clearly appears since the coated
paint can penetrate into the thin grooves where it is
di~icult by the spray coating. Llght and shade stripes
appeared on the s~riace of the processed material are erased
by rubbing to ~orm an uni~ormly palnted surface, thereby
making it possible to obtain a product having a beauti~ul
appearance with highly wood-like touch.
The block used ~or rubbing the painted sur~ace
absorbs few paints since it has an appropriate degree of
elasticity. Therefore, an eifectlve painting is made
possible since few amount o~ the paint coated on the ~hole
painting sur~ace comprising the groove part and the other
parts is lost ~hile enabling to penetrate the paint into
every thin grooves.
The painted sur~ace on which light and shade stripes
appear arising from the palnted sur~ace other than the thin
grooves can be e~fectively turned into an uni~orm surface ~y
brll~h~ng after rubbing with an elastic block. Thus, it is
possible to make the embossing pattern clear by emphasizlng
the color tone on the thin grooves, ~urther enhancing wood-
like touch as a bac~ground on the substrate even when both
the thln groove portion and the other portions on the
sur~ace are simultaneously coated with a paint.
Industrial Applicability
As disclosed herein, the present in~ention provides
an art ~or solving the problems that wood-like touch is lost

CA 02255784 1998-11-23
WO gU~
due to light and shade stripes ~hen an em~ossing ~lnish is
applied an the extrusion molding. article e~pected t~ ha~e
- wood-like touch.

Representative Drawing