JP2013132838A - Composite panel using paper honeycomb as core, and method of manufacturing the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a composite panel and a method of manufacturing the same which reduces the effort of operation in a step of assembling a frame member and a step of finishing in a final dimension or the like without using wood as the frame member such as a flush structure, achieves excellent productivity even in a small lot, and secures stiffness while reducing a weight.SOLUTION: The composite panel in a rectangular flat plate shape is formed by attaching surface members 4 on upper and lower surfaces of a paper honeycomb 3 which is laid in the size of the surface member 4, and directly attaching a butt end member 2 on an end surface of the panel cut in the final dimension and having a three-layer structure formed of the surface member 4 on the upper surface, the paper honeycomb 3 in the middle, and the surface member 4 on the lower surface.

Description

The present invention relates to a composite panel used for various fittings, furniture, store fixtures, interior panels, and the like.

Conventionally, there is a flash structure as shown in FIG. 5 as a composite panel. The flash structure is a composite that creates a wooden frame material 5 that matches the dimensions of the final product, attaches decorative plates 8 and 8 to the upper and lower surfaces of the frame material 5, and then pastes the wooden material 9 on the wooden surface. It is a panel.

A composite panel made of a flash structure has a hollow portion 7 in the frame material 5, and can be manufactured at a low price because it is considerably lighter and uses less material than using a solid core material. On the other hand, as a manufacturing process, it takes time and labor to cut the wood to be the frame material 5 into an arbitrary size and then assemble the frame material 5, the process of attaching the decorative plates 8 and 8, and the process of cutting to the exact size. At the same time, since there is nothing about the hollow portion 7 that does not contain the frame material 5, the rigidity of the composite panel is partially reduced.

Therefore, when it is necessary to improve the rigidity, by inserting a paper honeycomb 6 or the like into the hollow portion 7 in the frame member 5, the rigidity of the hollow portion 7 is improved while maintaining the light weight. However, there is a problem that the process is diversified and takes time and effort.

Further, as described above, it is necessary to assemble the frame material 5 in advance to a size slightly larger than the size of the final product, and it is also necessary to cut the decorative board 8, so that the production efficiency is low in the case of a small variety of products. Will be very bad.

As a prior art to solve such a problem, as in the panel disclosed in Patent Document 1, the frame material 5 is assembled in accordance with the size of the decorative plate 4 and the decorative plates 8 and 8 are bonded once. However, it is necessary to prepare a frame material 5 having a size close to the final product in advance.

JP 2009-269299 A

  Accordingly, the present invention provides a composite panel that does not use wood as a frame material of such a flash structure, reduces labor, is excellent in productivity, and is lightweight while ensuring rigidity, and a method for manufacturing the same. The task is to do.

In order to solve the above-mentioned problems, the present invention is configured as follows.

First, the invention described in claim 1 is a rectangular flat plate-shaped composite panel, a core material made of a paper honeycomb, a decorative board attached to both upper and lower surfaces thereof, and attached to at least one end face. It is characterized by the fact that it is made of wood.

Next, the invention according to claim 2 is characterized in that, in the composite panel according to claim 1, the density of the paper honeycomb used is 6 g / cm 3 or more.

The invention described in claim 3 is characterized in that, in the composite panel according to claim 1 or 2, the tie material is affixed to the butt face at an adhesive application amount of 200 g / m 2 or more. .

  The invention according to claim 4 is manufactured by pasting a decorative board on both upper and lower surfaces of a paper honeycomb, cutting it into a size to be a final product, and then pasting a mouthpiece material on at least one of the end faces. It is characterized by that.

First, according to the first aspect of the present invention, the composite panel has a rectangular flat plate shape, and is formed of a core material made of a paper honeycomb, a decorative plate attached to both upper and lower surfaces thereof, and attached to at least one end face. It is characterized by the fact that it is made of wood.

Compared with a panel with a flash structure that requires a conventional frame material because it does not use wood as a frame material by attaching decorative panels to the top and bottom surfaces of the paper honeycomb and directly attaching the edge material to the cross section. In addition to the advantage of reducing the weight when using the same decorative panel and wood finish, the inside is filled with paper honeycomb, so no large cavities are generated inside, and the rigidity of the composite panel is improved. ing.

Next, according to the invention described in claim 2, since the paper honeycomb having a density of 6 g / cm 3 or more is used, the minimum adhesion area necessary for performing the end treatment even when cut at any portion is obtained. It can be secured.

Paper honeycombs installed in a composite panel are usually composed of triangles, quadrilaterals, and hexagons when viewed in a plane, and as the density increases, the fineness of the shape becomes smaller in inverse proportion. The larger the density, the more the surface necessary for adhesion, which appears in the cross section, and the adhesive strength of 500 g / cm, which is judged to cause no peeling of the end piece in actual use, can be secured. If a material having a thickness of less than 6 g / cm 3 is used, the adhesive strength cannot be secured.
Table 1 shows data obtained by measuring the adhesive strength for each density of the paper honeycomb.
The material used for the test was a paper honeycomb having a thickness of 20 mm, the end piece having a thickness of 1 mm and a width of 20 mm, and the adhesive used was a hot melt adhesive.
The application amount of the hot melt adhesive was set to 200 g / m 2, and the adhesive strength was measured by pulling in the 180 ° direction at a speed of 300 mm / min.

According to the third aspect of the present invention, the end piece is attached to the end face with an adhesive application amount of 200 g / m 2 or more, but the adherend is a hollow paper paper honeycomb. The cross-section cut at a predetermined place becomes uneven, and the adhesive area is increased by applying a larger amount of adhesive than before so that the adhesive penetrates firmly into the unevenness. It can be secured.
Table 2 shows the adhesive strength of the end piece material and the state of the attached portion depending on the amount of adhesive applied.
The material used for the test was a paper honeycomb with a thickness of 20 mm and a density of 6 g / cm 3, the end piece of 1 mm with a thickness of 20 mm and a hot melt adhesive.
The strength measurement was pulled in the direction of 180 degrees at a speed of 300 mm / min.

  In addition, it becomes possible to use a lip material bonded by using an edge pasting machine or the like used in conventional panel manufacturing from the inventions of claims 2 and 3, and the appearance of a composite panel as a product is also a conventional flash. The equivalent of a composite panel created with a structure will be completed.

  Finally, according to the invention described in claim 4, the decorative board is bonded to the upper and lower surfaces of the paper honeycomb, cut into a size to be the final product, and then the cut end material is bonded to at least one end face. And a method for manufacturing a composite panel.

Since the decorative plates are attached to the top and bottom of the paper honeycomb and the edge material is directly attached to the cross section, the frame material is assembled in advance with dimensions close to the final product as in the conventional flash structure. There is no need to make fine adjustment cuts according to the size of the final product after pasting, it is only necessary to create a composite panel with the size of the decorative board before cutting and cut it to the size that will be the final product. Simplification can be achieved.

  Embodiments of the present invention will be described.

  As shown in FIG. 1, a core material made of a paper honeycomb 3, decorative plates 4 and 4 attached to both upper and lower surfaces thereof, and a mouthpiece material that is attached to at least one end of the mouth using a hot melt adhesive 2. 1 is a composite panel.

  In this embodiment, the paper honeycomb 3 has a thickness of 20 mm and a cell-shaped square density of 6 g / cm 3, the surface materials 4 and 4 have a high-pressure melamine decorative board with a thickness of 2.5 mm, and the adhesive 2 is mainly made of vinyl acetate resin. The hot melt adhesive as a component was applied at 200 g / m 2, and the end piece 1 made of ABS resin having a thickness of 1 mm and a width of 23 mm was used as a composite panel having a width of 900 mm, a depth of 300 mm, and a thickness of 25 mm.

  As shown in FIG. 1, a paper honeycomb 3 having a square cell shape and a density of 6 g / cm 3 is laid down in accordance with a size of 910 mm length and 1820 mm width of the surface material 4, and then the surface materials 4 and 4 are made of ethylene vinyl acetate. Affix with resin adhesive.

  As the surface material 4, a color plywood, a polyester decorative plywood, a printed plywood, a low-pressure melamine decorative board, various resin boards and the like can be used in addition to the high-pressure melamine decorative board.

In consideration of the warp generated after the processing of the composite panel, it is desirable to use the same type of surface materials 4 and 4 used on the upper and lower sides.

  A panel with a three-layer structure consisting of a surface material 4 on the top surface, a paper honeycomb 3 in the middle, and a surface material 4 on the bottom surface, created in a size of 910 mm length and 1820 mm width, is the final product width 900 mm, depth A panel having a three-layer structure having a width of 898 mm and a depth of 298 mm obtained by subtracting 1 mm of the thickness of the end piece 1 from the size of 300 mm is cut.

  In this embodiment, a panel having a three-layer structure of 910 mm in length and 1820 mm in width is cut into one panel, but if it is the same size, 6 sheets can be taken at once, and further, the remaining area can be cut. If there is, it is possible to take a panel of another size, and the processing efficiency is very good.

  At this time, whether or not an area necessary for adhesion can be obtained depends on which part of the paper honeycomb 3 laid inside is cut, and cut at aa ′ as shown in FIG. The number of cross-sections e of the paper honeycomb 3 generated varies between the case of being cut (FIG. 4) and the case of being cut along bb ′ (FIG. 5). By using a material having a density of 6 g / cm 3 or more, the number of cross-sections e required for bonding of the end piece 1 can be secured even when cut at aa ′ where the number of cross-sections e is the lowest. become.

  Furthermore, since the cell size c is reduced by using the paper honeycomb 3 having a density of 6 g / cm 3 or more, the depths d1 and d2 generated when the paper honeycomb 3 is cut are also reduced. The amount of adhesive material that is wasted even if it is digging in is reduced, and as a result, the adhesive strength of the end piece 1 of the end piece 1 is ensured.

  In particular, it is rare that the wire is cut exactly along the line aa ′ in FIG. 3, and in most cases, it is cut along the line bb ′, and the generated cross-sectional shape is as shown in FIG. In this case, the triangular cavity portion f generated in the c2 portion is filled with the adhesive 2, and the adhesive strength of the end piece 1 is sufficient.

As the sticking material 1 to be attached, paper, a veneer, a cut piece of various decorative plates, etc. can be used in addition to resinous mouthpieces such as PVC, ABS, PET, acrylic and PS.

In particular, when using the resin wood end material 1, it is preferable to use a material having a thickness of 0.7 mm or more so that the unevenness of the underlying paper honeycomb does not appear on the surface.

When manually attaching the lip material 1, use adhesive 2 mainly composed of urethane resin, ethylene vinyl acetate resin, acrylic resin, polyester resin, silicon rubber, nitrile rubber, etc. on both sides of the lip material and the panel lip part. In addition, it is desirable to apply and apply a total coating amount of 200 g / m 2 or more, and to fill the cavity portion f generated in the cross section of the panel lip portion with the adhesive 2 as much as possible.

When using an automatic edge pasting machine, use a hot melt adhesive 2 or the like, and secure a coating amount of 200 g / m 2 or more on the panel end.

  The cell shape of the paper honeycomb used in the present invention can be applied to any of a triangular shape, a rectangular shape, and a hexagonal shape.

  Finally, data comparing and verifying the weight and rigidity of the composite panel shown in this embodiment and the composite panel having a flash structure will be described.

The outer dimensions of both composite panels were 900 mm wide, 300 mm deep, and 25 mm thick.
The composite panel with flash structure uses a high-pressure melamine decorative board with a thickness of 2.5mm as the surface material, the inner core material is combined with a particle board of 40mm x 20mm so that it becomes an eye shape, and the edge material is made of ABS thickness A 1 mm one bonded to four sides was used.

  In the test, the weight was measured with a platform scale, and the results are shown in Table 3.

As can be seen from the table, the weight was reduced by about 30%.

For evaluation of rigidity, a composite panel was placed on a bracket set at a pitch of 800 mm, a weight serving as a load was placed near the center of the composite panel, and the amount of deflection of the panel was measured.
The results are shown in Table 4.

As can be seen from the table, it was possible to reduce the amount of deflection of the composite panel at each load by about 20%.

With the invention of the flash structure, it is now possible to produce lighter and cheaper composite panels than panels using past particle boards, MDFs, etc. as they are, but the flash structure has various processes in the manufacturing process and has a wide variety of sizes Not suitable for production.
By using this technology, productivity can be improved even in a small variety of products as compared with a composite panel having a flash structure, and a light-weight composite panel having excellent rigidity can be provided.

It is a typical figure of this invention. It is the figure which looked at the paper honeycomb from the upper part. It is sectional drawing of a paper honeycomb when cut | disconnecting by the aa 'line of FIG. It is sectional drawing of a paper honeycomb when cut | disconnecting by the bb 'line of FIG. It is a typical figure of the composite panel of flash structure.

DESCRIPTION OF SYMBOLS 1, 9 Wood end material 2 Adhesive 3 Paper honeycomb 4, 8 Surface material 5 Wooden frame 6 Paper honeycomb 7 put in flash structure Cavity aa 'of flash structure Panel cutting position bb Panel cutting position c Paper Honeycomb cell dimensions d1 and d2 Depth of hollow portion generated when cutting e Cross section of paper honeycomb f Hollow portion generated when cutting

Claims (4)

  A rectangular flat plate-shaped composite panel comprising a core material made of a paper honeycomb, a decorative plate attached to both upper and lower surfaces thereof, and a mouthpiece material attached to at least one end surface. Composite panel.   The composite panel according to claim 1, wherein the paper honeycomb has a density of 6 g / cm 3 or more.   3. The composite panel according to claim 1 or 2, wherein the end piece is affixed to the end face with an adhesive application amount of 200 g / m 2 or more.   A method for manufacturing a composite panel, comprising: a decorative sheet is bonded to both upper and lower surfaces of a paper honeycomb, cut into a size to be a final product, and then a cut end material is bonded to at least one end face.