JP2017159577A - Surface decorative panel, decorative panel comprising the same, and method for manufacturing panel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a surface decorative panel in which a decorative surface layer can be thinned while dimensional stability can be improved, and a surface appearance can be improved; to provide a decorative panel including the surface decorative panel; and to provide a method for manufacturing a panel, by which such a surface decorative panel can be effectively manufactured.SOLUTION: In a surface decorative panel 20, a surface layer side resin layer 23 including the same main resin component as a resin composition included in a fiber-reinforced resin layer 26 is interposed between a decorative surface layer 21 forming a decorative surface and the fiber-reinforced resin layer 26. The method for manufacturing a panel is a method for manufacturing the panel 20, including supplying an uncured resin composition included in the surface layer side resin layer 23 to a back surface of a decorative sheet and then forming the fiber-reinforced resin layer 26 so as to be located on a back surface of the surface layer side resin layer.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a surface decorative panel used as a surface material for interior panels and furniture, a decorative panel provided with the same, and a method for manufacturing the surface decorative panel.

Conventionally, as a surface decorative panel used as a surface material for interior panels and furniture, a structure in which a decorative sheet such as a resin film or a veneer is laminated on a woody base material such as MDF (medium density fiberboard) It has been known. In such a thing, there existed a problem that the dimensional change by moisture absorption / release etc. became easy to produce.
For example, Patent Document 1 below discloses a laminated finishing material in which a back sheet obtained by impregnating a glass fiber with a thermosetting resin and curing is attached to the back surface of a decorative material.

JP 10-1114020 A

  However, in the laminated finishing material described in Patent Document 1, the decorative material constituting the decorative surface is thin, or depending on the pressing pressure at the time of molding, slight irregularities due to glass fibers may be formed on the surface. Therefore, further improvement is desired.

  The present invention has been made in view of the above circumstances, and includes a surface decorative panel that can improve the surface appearance while being able to reduce the thickness of the decorative layer while being able to improve dimensional stability. It aims at providing the panel manufacturing method which can manufacture such a decorative panel and such a surface decorative panel effectively.

  In order to achieve the above object, the surface decorative panel according to the present invention includes a resin composition and a resin main component constituting the fiber reinforced resin layer between the decorative layer constituting the decorative surface and the fiber reinforced resin layer. The same surface layer side resin layer is interposed.

  In order to achieve the above object, the decorative panel according to the present invention is provided with a panel core material and bending grooves so as to be positioned according to the corners of the panel core material. And a surface decorative panel according to the present invention to be attached.

  Moreover, in order to achieve the said objective, the panel manufacturing method which concerns on this invention supplies the uncured resin composition which comprises a surface layer side resin layer to the back surface of a decorative sheet, Then, the back surface side of the said surface layer side resin layer A surface-reinforced panel is produced by forming a fiber reinforced resin layer so as to be positioned at the surface.

The surface decorative panel and the decorative panel provided with the same according to the present invention are configured as described above, so that the dimensional stability can be improved, but the decorative layer can be thinned and the surface appearance can be improved. Can be improved. Moreover, the panel manufacturing method which concerns on this invention can manufacture such a surface decorative panel effectively.

(A), (b) shows typically an example of the surface decorative panel which concerns on one Embodiment of this invention, and an example of a decorative panel provided with the same, (a) is X- in FIG. 3 (a). The partially broken schematic cross-sectional view corresponding to the X-ray arrow view, (b) is a partially broken schematic exploded cross-sectional view corresponding to (a). (A)-(e) is a partially broken schematic side view which shows typically an example of the panel manufacturing method which concerns on one Embodiment of this invention. (A) is a schematic front view of the said decorative panel, (b) is a schematic front view which shows typically an example of the panel core material with which the decorative panel is provided. (A), (b) is a schematic longitudinal cross-sectional view which shows typically an example of the surface decorative panel which concerns on other embodiment of this invention. It is a table | surface which shows the Example and comparative example of the surface decorative panel which concern on this invention with the result of an evaluation test.

Embodiments of the present invention will be described below with reference to the drawings.
1-3 is a figure which shows typically an example of the surface decorative panel which concerns on 1st Embodiment, an example of the decorative panel provided with this, and an example of the manufacturing method of a surface decorative panel.

The surface decorative panel 20 according to the present embodiment includes a fiber reinforced resin layer 26 between a decorative layer 21 and a fiber reinforced resin layer 26 that form a decorative surface, as shown in FIGS. The resin composition 24 and the main resin layer 23 having the same resin main component are interposed. In other words, the front surface decorative panel 20 has the fiber sheet 25 included in the resin layers (fiber reinforced resin layers) 23 and 26 on the back surface side of the decorative layer 21 positioned on the back surface side that is the anti-decorative layer side in the thickness direction. It is set as the structure provided so that it may do (it makes uneven distribution). Moreover, in this embodiment, it is set as the structure which provided the bending grooves 27 and 28 in the back surface side of the said surface decorative panel 20 so that a groove bottom may be located in the surface layer side resin layer 23. FIG.
Further, the decorative panel 1 according to the present embodiment has a configuration in which the surface decorative panel 20 is adhered to the panel core member 10 as shown in FIG. Moreover, it is set as the structure which provided the surface decoration panels 20 and 20 in the panel thickness direction both sides of the panel core material 10. FIG.

  As shown in FIG. 3A, the decorative panel 1 has a substantially rectangular flat plate shape that is long in one direction. This decorative panel 1 is used as a partition panel, a partition panel or the like for opening / closing an entrance / exit or a storage opening, a furniture constituent member, etc. when both sides in the thickness direction are decorative surfaces as in this embodiment. It is good. Moreover, it is good also as a structure which provided the surface decorative panel 20 only in the panel thickness direction one side of the panel core material 10 instead of the aspect which used the thickness direction both sides as a decorative surface in this way. Also in this case, it can be used for the same purpose as described above. Further, the decorative panel 1 may be used so as to constitute a part of the panel, for example, a collar part or a panel part of a bowl-shaped panel. In addition, the decorative panel 1 has a ceiling panel, a wall panel (partition wall panel), a waist wall panel, a floor panel, a baseboard panel, a marginal panel, an opening frame panel, etc., with the anti-decorative surface side facing the mounting base side. It may be used as

Further, the length dimension (vertical dimension, height dimension), width dimension, thickness dimension, and the like of the decorative panel 1 may be appropriate dimensions depending on the use of the decorative panel 1 and the like.
For example, when the decorative panel 1 is used as a joinery panel, the vertical dimension (door height dimension) of the decorative panel 1 is set to about 1800 mm to 3000 mm, the door width dimension is set to about 600 mm to 1200 mm, and the door thickness dimension. May be about 20 mm to 40 mm. In this case, a handle or a handle for opening and closing, a lock device, a rotation connecting member such as a hinge, a running member such as a runner or a door wheel, a guide groove, etc. are provided at an appropriate position of the decorative panel 1. Or you may.

As shown in FIG. 3B, the panel core material 10 is configured such that the core material 16 is accommodated in a space surrounded by the frame body 11 including the four-circumference frames 12, 13, 13, and 14.
The frame 11 includes an upper horizontal frame 12, a pair of left and right vertical frames 13 and 13, and a lower horizontal frame 14 that constitute the four-circumferential frames 12, 13, 13, and 14. In addition, the frame body 11 includes a plurality of horizontal rails 15 and 15 provided at intervals in the vertical direction so as to be spanned between the left and right vertical frames 13 and 13. Further, in the illustrated example, the lower horizontal frame 14 is illustrated as having a configuration in which a plurality (two in the illustrated example) are stacked vertically. Moreover, the example which laminated | stacked the crosspiece member used as the process base of the attachment hole of driving | running | working members, such as a doorwheel, is shown on the upper side of the right and left (longitudinal direction) both ends of the lower horizontal frame 14. Depending on the use of the decorative panel 1, a running member such as a runner such as the above, a handle, or a lock device is provided below the left and right ends of the upper horizontal frame 12 or on the inner side of one vertical frame 13. It is good also as a structure which provided the processing foundation | substrate of attachment holes, such as these, and an attachment foundation | substrate. Similarly, the upper horizontal frame 12 may have a configuration in which a plurality of upper horizontal frames 12 are stacked one above the other. Moreover, it is good also as a structure which provided the vertical crosspiece long in the up-down direction instead of the aspect which provided the horizontal crosspiece 15 in the frame 11 or in addition.

Further, these quadrilateral frames 12, 13, 13, 14 and the horizontal rail 15 are formed in a substantially quadrangular prism shape, and the dimensions along the panel thickness direction are substantially the same so that both surfaces in the panel thickness direction are substantially the same plane. It is a dimension. Further, in the illustrated example, the width dimensions orthogonal to the dimension and the length dimension along the panel thickness direction of the four circumferential frames 12, 13, 13, and 14 and the horizontal rail 15 are shown as substantially the same dimensions. .
These four-circumferential frames 12, 13, 13, 14 and the cross rail 15 are made of wood laminates such as plywood and LVL (single laminate), wood boards such as PB (particle board), MDF (medium density fiber board), It is good also as what was formed from woody materials, such as wood fiber boards, such as a hard board. The wood material may be a wood powder / plastic composite (WPC) in which a synthetic resin material contains wood powder, an inorganic filler, a compatibilizing agent, a colorant and the like in a predetermined content ratio. Moreover, the frame 11 is not limited to the one formed from such a wood-based material, and may be formed from a synthetic resin-based material or a metal-based material.

  Moreover, in this embodiment, as shown in FIG.1 (b) and FIG.3 (b), the difference of the surface decoration panels 20 and 20 mentioned later on the outer surface which faces the panel width direction outer side of both the vertical frames 13 and 13 is shown. It is set as the structure which provided the insertion grooves 13a and 13a in which the insertion piece parts 20c and 20c are inserted over the full length. The insertion grooves 13a and 13a on both sides in the panel width direction are provided so as to open toward the outside in the panel width direction. In addition, the insertion grooves 13a and 13a are provided so as to be positioned approximately at the center of the vertical frames 13 and 13 in the panel thickness direction. The groove depth dimension along the panel width direction and the groove width dimension along the panel thickness direction of these insertion grooves 13a, 13a are the insertion property and retaining property of the insertion piece portions 20c, 20c of the surface decorative panel 20, 20. It is good also as an appropriate dimension from such viewpoints.

  As shown in FIG. 3B, the core material 16 of the panel core material 10 is accommodated so as to fill a space surrounded by the frame body 11. In the present embodiment, as described above, the spaces in the four-circumferential frames 12, 13, 13, and 14 that are vertically divided by the plurality of horizontal rails 15 and 15 that are spaced apart in the vertical direction (panel longitudinal direction). The core material 16 is accommodated in each of the above. The dimension of the core material 16 along the panel thickness direction is substantially the same as the dimension of the frame body 11 along the panel thickness direction. Such a core material 16 may be made of a foam molded body formed from a foamed resin material such as urethane foam, but in this embodiment, a large number of hollow cylindrical cells open on both sides in the panel thickness direction. The honeycomb core material 16 is made of an aggregate of the above. That is, the core material 16 is a so-called paper core. In addition, the core material 16 may be formed by stacking and bonding paper materials such as corrugated cardboard paper and kraft paper with an adhesive. Further, the core material 16 may be such a paper material that is further impregnated with a reinforcing resin such as an epoxy resin. In addition, a metal material such as an aluminum material, a hard polyvinyl chloride resin, or a polypropylene resin. It may be formed from a synthetic resin material such as.

  Further, in the illustrated example, a hollow cylindrical cell of the core material 16 is schematically shown, and an example in which a corrugated portion (corrugated portion) is provided between thin sheets along the thickness direction in the panel width direction is illustrated. However, it is not limited to such a mode. As the core material 16, the hollow cylindrical cell has various shapes such as a honeycomb shape (hexagonal shape), a rectangular shape, a cylindrical shape, etc. It may be what was said. Further, the core material 16 may be fixed to the frame body 11 with a stopper such as a staple or an adhesive. In addition, the cell size (cell diameter, cell width) of the hollow cylindrical cell of the core material 16 may be an appropriate size from the viewpoint of weight reduction or strength, and may be 1 mm or more and 25 mm or less. Preferably, it is good also as 5 mm or more and 15 mm or less.

The surface decorative panel 20 has a thin plate shape. The surface decorative panel 20 has a thickness similar to that of a surface material based on a wood-based material such as MDF conventionally used as a surface material constituting the decorative surface of various decorative panels 1 (for example, about 3 mm). ), But may have an appropriate thickness depending on the application. For example, the thickness of the surface decorative panel 20 may be about 0.5 mm to 5.0 mm, preferably 3.0 mm or less.
The decorative layer 21 constituting the surface decorative panel 20 is a decorative sheet 21 in the form of a thin sheet in the present embodiment. As the decorative sheet 21, a veneer (decorative veneer) such as a veneer formed from natural wood (named wood), a decorative printing paper printed with various patterns (patterns) such as a wood grain pattern, or a synthetic resin type It is good also as a resin sheet (film) etc. Examples of the resin film include a vinyl chloride resin film, a polyethylene resin film, a polyethylene terephthalate resin film, a polypropylene resin film, a polycarbonate resin film, an acrylic resin film, and a urethane resin film. The thickness of the resin film is, for example, 0.02 mm to 1.0 mm, preferably 0.05 mm to 0.2 mm, and more preferably 0.06 mm to 0.12 mm.

  Moreover, as a thickness of the decorative veneer which comprises the decorative sheet 21, the range of 0.2 mm-1.0 mm is illustrated, for example. When the decorative sheet 21 is a decorative veneer, a backing material such as a nonwoven fabric may be attached to the back surface of the decorative veneer via an adhesive. The adhesive in this case is preferably exemplified by a water-insoluble adhesive that hardly transfers moisture to the decorative veneer. Examples of water-insoluble adhesives include, for example, solution-type acrylic copolymers, synthetic rubber adhesives, hot-melt adhesives that are thermoplastic synthetic resins, or a combination of two or more types. can do. Examples of the hot melt adhesive include ethylene vinyl acetate (EVA) and urethane hot melt (PUR). Moreover, what used the epoxy resin type | system | group, urethane type, vinyl chloride type, the vinyl acetate type adhesive agent etc. individually or in combination of 2 or more types can be illustrated.

  The surface layer side resin layer 23 constituting the front decorative panel 20 is provided over substantially the entire back surface side of the decorative sheet 21. The surface layer side resin layer 23 may have an appropriate thickness from the viewpoint of improving the surface appearance including the folded corner appearance of the surface decorative panel 20, dimensional stability, and productivity. For example, the thickness of the surface layer side resin layer 23 is in the range of 0.01 mm to 1.5 mm, preferably 0.03 to 1.0 mm, and more preferably 0.05 mm to 0.5 mm. If the thickness of the surface layer side resin layer 23 is too small, the surface appearance tends to be lowered. If the thickness of the surface layer side resin layer 23 is too large, the influence of thermal expansion by the surface layer side resin layer 23 is large. Or the productivity tends to decrease.

In addition, the surface layer side resin layer 23 has a configuration that does not substantially include fibers (a configuration that does not substantially include fibers) as included in the fiber reinforced resin layer 26. In addition, the structure which does not contain a fiber substantially includes the case where a fiber is slightly mixed in the surface layer side resin layer 23 in a manufacturing process or the like.
Further, the resin composition 22 (see FIG. 2A) constituting the surface layer side resin layer 23 is the resin composition 24 (see FIG. 2C) constituting the fiber reinforced resin layer 26 described later by the resin main component. ) Resin main component. Examples of these resin compositions 22 and 24 include non-foaming or low-foaming resins. For example, examples of the resin main components of these resin compositions 22 and 24 include those in which urethane (polyurethane) resin, polystyrene resin, polyethylene resin, polypropylene resin, phenol resin and the like are used alone or in combination of two or more.

  In the present embodiment, the expansion ratio of the resin composition 22 constituting the surface layer side resin layer 23 is set to be equal to or less than the expansion ratio of the resin composition 24 constituting the fiber reinforced resin layer 26. That is, the expansion ratio of the resin composition 22 constituting the surface layer-side resin layer 23 is the same as or smaller than the expansion ratio of the resin composition 24 constituting the fiber reinforced resin layer 26. When these resin compositions 22 and 24 are foamed resins, they may have low foaming properties with a foaming ratio of 7 times or less, more preferably 5 times or less, depending on the type. In addition, as the resin compositions 22 and 24, urethane resins are exemplified as suitable ones. In this case, the foaming ratio is 1 to 5 times, more preferably 1 to 3 times, and still more preferably 1 It may be double or double. When the resin compositions 22 and 24 are made of such a urethane resin, they are excellent in adhesion to the decorative sheet 21 and excellent in impregnation into a fiber sheet 25 (see FIG. 2D) described later. It will be a thing. Moreover, as a urethane resin, the ether type and castor oil type urethane resin which has water resistance is illustrated preferably. Various additives such as a curing agent and a flame retardant can be added to the resin compositions 22 and 24.

  The amount of the resin composition 22 constituting the surface layer side resin layer 23 may be an appropriate amount so that the surface layer side resin layer 23 has the above thickness. The surface layer side resin layer 23 may be one obtained by curing the resin composition 22 applied to the back surface (anti-decorative surface) of the decorative sheet 21 with a spray or a roller. Also, the resin composition 24 and the fiber sheet 25 constituting the fiber reinforced resin layer 26 to be described later may be arranged in a state where the resin composition 22 constituting the surface layer side resin layer 23 is semi-cured (uncured). Good.

As shown in FIGS. 2D and 2E, the fiber reinforced resin layer 26 has a configuration in which the fiber sheet 25 is impregnated with the uncured resin composition 24, and can also be referred to as a resin-impregnated fiber sheet layer. The thickness of the fiber reinforced resin layer 26 may be an appropriate thickness according to the type, basis weight, thickness, and the like of the fiber sheet 25 selected according to the use of the surface decorative panel 20 (decorative panel 1). Good. The thickness of the fiber reinforced resin layer 26 may be, for example, about 0.1 mm to 1.0 mm, or about 0.2 mm to 0.6 mm. In the present embodiment, the thickness of the fiber reinforced resin layer 26 is larger than the thickness of the surface layer side resin layer 23. For example, the thickness of the fiber reinforced resin layer 26 may be about 2 to 10 times the thickness of the surface layer side resin layer 23.
Examples of the fiber sheet 25 include woven fabrics, nonwoven fabrics, mats, and the like of reinforcing fibers such as glass fibers, carbon fibers, and mineral fibers. Examples of the woven fabric of glass fiber include glass cloth which is a woven fabric such as plain weave and entangled weave using glass roving for warp and weft. As a glass fiber nonwoven fabric, for example, a glass fiber having a length of about 10 mm is dispersed in water, then scooped by a wet papermaking method, dehydrated and formed into a sheet, and an adhesive such as an epoxy resin or an acrylic resin is applied. The glass paper etc. which are are illustrated. As a glass fiber mat, a glass strand cut into a long fiber shape (for example, around 30 mm in length, preferably around 50 mm in length) is uniformly dispersed in a non-direction, and a mat is used using a binder such as a polyester binder. Examples thereof include a glass mat formed into a shape.

Moreover, as thickness of the fiber sheet 25, the range of 0.1 mm-0.5 mm is illustrated, for example. When the fiber sheet 25 is a glass mat, the thickness may be about 0.3 mm to 0.5 mm. When the fiber sheet 25 is a glass cloth, the thickness is about 0.1 mm to 0.3 mm. It is good. Moreover, as a density of a glass cloth, a 30-120 piece / 25mm thing is illustrated, for example. Moreover, as a count (thickness) of the glass yarn which comprises a glass cloth, the range of 67-135 tex (g / 1000m) is illustrated, for example.
The basis weight of the fiber sheet 25, for example, 150 g / ^{m 2} or more 700 g / ^{m 2} or less ranges are exemplified. If the fabric weight of the fiber sheet 25 is too small, the strength tends to decrease, while if too large, the fiber sheet 25 tends to be heavy. When a glass cloth is used as the fiber sheet 25, the basis weight may be 200 g / m ² or more. Moreover, when using glass paper as the fiber sheet 25, it is good also considering a fabric weight as 50 g / m < ² > or more. Further, when a glass mat is used as the fiber sheet 25, the basis weight may be 300 g / m ² or more. Moreover, as the fiber sheet 25, a glass mat or a glass cloth is preferable among such glass fiber sheets.

  Further, as the fiber sheet 25, a laminate of a plurality of glass fiber woven fabrics, nonwoven fabrics or mats (glass fiber sheets), a glass fiber sheet and vegetable fiber woven fabrics, nonwoven fabrics, films, papers or mats are used. And may be laminated. The plant fiber is not particularly limited as long as it is a plant fiber used in a plant fiber mat or papermaking. However, considering the strength, durability, dimensional stability, etc. of the fiber sheet 25, hemp natural fiber, palm fiber, or agricultural waste It is preferable that it is any 1 or more types of physical fiber.

The amount of the resin composition 24 impregnated in the fiber sheet 25 is appropriately determined from the viewpoint of the thickness of the fiber sheet 25, the desired thickness of the fiber reinforced resin layer 26, the strength and dimensional stability of the surface decorative panel 20, and the cost. It is good also as the quantity. For example, the amount of the resin composition 24 impregnated in the fiber sheet 25 may be 100 g / m ² or more, and preferably 150 g / m ² or more. From the viewpoint of cost and the like, the amount of the resin composition 24 impregnated in the fiber sheet 25 may be 300 g / m ² or less, and preferably 250 g / m ² or less.
Further, the impregnation of the fiber sheet 25 with the resin composition 24 may be performed by squeezing the excess after the fiber sheet 25 is immersed in a container for storing the resin composition 24, It is good also as an aspect applied with a roller etc. Or like the preferable manufacturing method mentioned later, the resin composition 22 which comprises the above-mentioned surface layer side resin layer 23 was hardened or semi-hardened, and the resin composition apply | coated to the anti-decorative sheet side with a spray, a roller, etc. By laminating the fiber sheet 25 on 24, the fiber sheet 25 may be impregnated with the resin composition 24 as a result.

In the present embodiment, the surface decorative panel 20 configured as described above is provided in a paired manner on both sides of the panel core material 10 in the panel thickness direction so that the seams are located on both end faces in the panel width direction. It is said. That is, it is set as the structure which provided the two surface decorative panels 20 and 20. FIG. Further, the two surface decorative panels 20, 20 are formed on the four peripheral surfaces (panel thickness) of the panel core 10 so that the four peripheral surfaces of the decorative panel 1 (both surfaces in the thickness direction and both end surfaces in the width direction) are decorative surfaces. Both sides in the direction and both end faces in the panel width direction).
These front decorative panels 20 and 20 have the same configuration as each other, and bend grooves (corner bent grooves) 27, 27, 27 on the back side so as to be positioned according to the corners of the panel core 10. , 27 are provided. Moreover, in this embodiment, in addition to the corner bending grooves 27, 27, 27, 27, both opening edges of the insertion grooves 13 a, 13 a of the panel core member 10 are formed on the back surfaces of the surface decorative panels 20, 20. It is set as the structure which provided the edge part bending groove | channels 28,28,28,28 so that it might become a position according to.

The corner bent grooves 27 and the end bent grooves 28 are provided on the back surfaces of the front decorative panels 20 and 20 so that at least the decorative sheet 21 remains.
In each surface decorative panel 20, 20, at least the part of the decorative sheet 21 remaining in the corner bent groove 27 and the end bent groove 28 functions as a hinge part (bent part). It can be bent at the site.
Moreover, in this embodiment, it is set as the structure which provided these corner | angular part bending grooves 27 and the edge part bending grooves 28 so that a groove bottom may be located in the surface layer side resin layer 23 (refer FIG.1 (b)). That is, the corner bent groove 27 and the end bent groove 28 are formed so that the groove bottom remains on the surface layer side resin layer 23 and does not reach the decorative sheet 21 and the entire fiber reinforced resin layer 26 in the thickness direction. It is set as the structure provided over.

The thickness of the surface layer side resin layer 23 in the portion where the corner bent groove 27 and the end bent groove 28 are provided, that is, the remaining thickness on the groove bottom side functions as a hinge portion as described above. In addition, an appropriate thickness may be used according to the thickness of the decorative sheet 21 and the thickness of the surface layer side resin layer 23. In the example shown in the figure, the remaining thickness on the groove bottom side of the surface layer side resin layer 23 is set to about ½ of the total thickness of the surface layer side resin layer 23. However, the thickness is limited to such a thickness. Absent.
Further, the corner bent grooves 27, 27 are provided along the surface side piece 20 a of the surface decorative panel 20 that is provided along one surface in the thickness direction of the panel core member 10 and the respective end surfaces in the width direction of the panel core member 10. It is provided so that it may be located in the boundary part of the side end surface piece parts 20b and 20b.
Further, the end bent grooves 28, 28 are located at the boundary between the side end face pieces 20 b, 20 b and the insertion pieces 20 c, 20 c inserted into the insertion grooves 13 a, 13 a of the panel core member 10. It is provided as follows. The insertion piece portions 20c, 20c, 20c, 20c of the surface decorative panels 20, 20 on both sides in the panel thickness direction are stored so as to be fitted into the insertion grooves 13a, 13a of the panel core member 10.

Moreover, in this embodiment, the back surface side of the surface decorative panel 20 is formed so that the corner portions formed by bending the corner portion bent grooves 27, 27 at the corner portion bent grooves 27, 27 are substantially perpendicular. It is set as the structure provided in. In the illustrated example, the corner bent grooves 27, 27 are formed of a single groove having a substantially V-shaped groove when viewed in the groove longitudinal direction. Instead of such a mode, the corner bent grooves 27, 27 are formed so that the corners formed by bending in the corner bent grooves 27, 27 have an R chamfered shape or a C chamfered shape. Each of these may be composed of a plurality of grooves. Further, the end bent grooves 28, 28 are provided on the back surface side of the front decorative panel 20 so that the corners formed by being bent in the end bent grooves 28, 28 are substantially perpendicular. .
The surface decorative panels 20 and 20 on both sides in the panel thickness direction having the above-described configuration are attached to the four-round surface of the panel core member 10 so that the four-round surface of the decorative panel 1 is a decorative surface. The surface decorative panels 20 and 20 may be attached to the panel core member 10 by using the same appropriate adhesive as described above.

Next, an example of a panel manufacturing method for manufacturing the surface decorative panel 20 according to the present embodiment will be described with reference to FIG.
In this embodiment, after supplying the uncured resin composition 22 constituting the surface layer side resin layer 23 to the back surface of the decorative sheet 21, the fiber reinforced resin layer 26 is disposed so as to be positioned on the back surface side of the surface layer side resin layer 23. It is set as the structure which forms and manufactures the surface decorative panel 20. FIG.
Moreover, in this embodiment, it is set as the structure which manufactures the surface decorative panel 20 using the upper and lower shaping | molding die 2 and 3 by which the surface which mutually faces was a flat surface. Such molds 2 and 3 depend on the types of the resin compositions 22 and 24, but when heating is required for curing, a heater or a medium flow path through which a heat medium is circulated may be provided. Good. That is, the molds 2 and 3 may be hot pressed.

  First, as shown in FIG. 2A, the decorative sheet 21 is placed on the upper surface of the lower mold 2 of the upper and lower molds 2 and 3 so that the decorative surface faces each other. That is, the decorative sheet 21 is placed on the lower mold 2 with the back surface (anti-decorative surface) facing upward. And the resin composition 22 which comprises the surface layer side resin layer 23 is apply | coated to the back surface of this decorative sheet 21. FIG. The resin composition 22 may be applied to the decorative sheet 21 using a spray or a roller with a uniform application amount so that the surface-side resin layer 23 has the desired thickness as described above. Good. The resin composition 22 constituting the surface layer side resin layer 23 is supplied with the lower mold 2 heated to an appropriate temperature (for example, a relatively low temperature of about 40 ° C. to 80 ° C.) and cured or semi-cured. You may do it. At this time, in addition to the heating by the lower mold 2, the heating may be performed from the upper side by an appropriate radiant heater such as a far infrared heater. Further, the curing (semi-curing) time at this time depends on the type and amount of the resin composition 22, but may be about 1 to 30 minutes, preferably 15 minutes or less.

In the present embodiment, after the resin composition 22 constituting the surface layer side resin layer 23 is cured or semi-cured, an uncured resin composition 24 constituting the fiber reinforced resin layer 26 is supplied, and this fiber reinforced resin is provided. The fiber sheet 25 is impregnated with the resin composition 24 constituting the resin layer 26.
That is, as shown in FIGS. 2B and 2C, when the resin composition 22 constituting the surface layer side resin layer 23 is cured or semi-cured, the uncured resin composition constituting the fiber reinforced resin layer 26 is obtained. 24 is applied so as to be overcoated. And as shown in FIG.2 (d), the fiber sheet 25 is laminated | stacked so that this resin composition 24 may impregnate. Under the present circumstances, after the resin composition 22 which comprises the surface layer side resin layer 23 is semi-hardened or completely hardened so that the fiber sheet 25 may not move substantially in the surface layer side resin layer 23, it is uncured which comprises the fiber reinforced resin layer 26 The resin composition 24 and the fiber sheet 25 may be arranged.

Then, as shown in FIG. 2 (e), the upper and lower molds 2, 3 are pressed. At this time, an appropriate release agent may be applied to the lower surface of the upper mold 3. Moreover, you may make it clamp with an appropriate press pressure. Moreover, you may make it heat the resin composition 22 and 24 as needed, and to make it harden | cure.
The surface decorative panel 20 is manufactured through the steps as described above. And when using this surface decorative panel 20 as a surface material of the decorative panel 1, the above-mentioned corner part bending groove 27 and the end part bending groove 28 are suitably provided in the back surface side, and the panel core material 10 is provided. The decorative panel 1 may be manufactured by sticking to the panel.

According to the manufacturing method as described above, the surface decorative panel 20 with improved dimensional stability and surface smoothness can be effectively manufactured. That is, after forming the fiber reinforced resin layer 26 and the surface layer side resin layer 23, the manufacturing efficiency can be improved as compared with the case where the decorative sheet 21 is adhered to the surface of the surface layer side resin layer 23. The appearance deterioration of the decorative sheet 21 on the surface due to the adhesive component can be made difficult to occur.
In the present embodiment, when the resin composition 22 constituting the surface layer side resin layer 23 is cured or semi-cured, the resin composition 24 constituting the fiber reinforced resin layer 26 is supplied prior to the fiber sheet 25. Yes. Therefore, compared with the aspect which supplies and impregnates the resin composition 24 which comprises the fiber reinforced resin layer 26 with respect to the fiber sheet 25 mounted on the resin composition 22 which comprises the surface layer side resin layer 23, surface layer Separation of the boundary between the side resin layer 23 and the fiber reinforced resin layer 26 can be effectively prevented.

In addition, it replaces with the above aspects, the aspect which laminates | stacks the fiber sheet 25 impregnated with the resin composition 24 on the surface layer side resin layer 23, and the state which laminated | stacked the fiber sheet 25 on the surface layer side resin layer 23, resin It is good also as an aspect etc. which apply | coat the composition 24 to the fiber sheet 25. FIG. Further, a prepreg-like fiber sheet 25 (or fiber reinforced resin layer 26) containing the resin composition 24 and a decorative sheet 21 having a surface layer side resin layer 23 formed on the back surface are laminated and integrated (including adhesion). Thus, the surface decorative panel 20 may be manufactured.
Moreover, the order of each process of the panel manufacturing method which concerns on this embodiment mentioned above is only an example, and may be made in another order, and various deformation | transformation are possible.

Since the surface decorative panel 20 according to the present embodiment has the above-described configuration, the decorative layer (decorative sheet) 21 can be thinned while the dimensional stability can be improved, and the surface appearance can be improved. Can be improved.
That is, a configuration in which the resin layer 24 constituting the fiber reinforced resin layer 26 and the surface resin layer 23 having the same resin main component are interposed between the decorative sheet 21 constituting the decorative surface and the fiber reinforced resin layer 26. It is said. Therefore, as compared with a surface material using a wooden board such as a conventional MDF as a base material, a dimensional change due to moisture absorption / release is less likely to occur, and dimensional stability can be improved. Moreover, since it is set as the structure which provided the surface layer side resin layer 23 in the back surface side of the decorative sheet 21, when the decorative sheet 21 is made thin, the unevenness | corrugation by the fiber contained in the fiber reinforced resin layer 26 becomes difficult to produce on the surface, Surface smoothness can be improved and the appearance of the surface can be improved. In addition, since the resin composition 24 constituting the fiber reinforced resin layer 26 and the resin main component are the same as the surface layer side resin layer 23, the conformability in each layer can be improved, and boundary peeling or the like is less likely to occur. it can.

  In the present embodiment, the expansion ratio of the resin composition 22 constituting the surface layer side resin layer 23 is set to be equal to or less than the expansion ratio of the resin composition 24 constituting the fiber reinforced resin layer 26. Therefore, the strength of the surface side resin layer 23 can be relatively improved. Further, by appropriately adjusting the expansion ratio of the resin composition 24 constituting the fiber reinforced resin layer 26, it is possible to efficiently increase the thickness of the surface decorative panel 20 or to reduce the weight. It becomes.

  Moreover, in this embodiment, it is set as the structure which provided the bending grooves 27 and 28 in the back surface side of the said surface decorative panel 20 so that a groove bottom may be located in the surface layer side resin layer 23. FIG. Therefore, even when there is a corner on the surface to which the surface decorative panel 20 is attached, the surface decorative panel 20 can be bent and covered in a series at the bent grooves 27 and 28. Thereby, the appearance in a corner | angular part can be improved compared with what makes a plurality of surface decorative panel 20 face | match in the corner | angular part of attachment object. Further, since the bent grooves 27 and 28 are provided so that the groove bottom is located on the surface layer side resin layer 23, unevenness or the like due to the fibers contained in the fiber reinforced resin layer 26 is less likely to occur at the bent corners. The appearance of the corner surface can be improved.

Further, the decorative panel 1 according to the present embodiment is provided with a bent groove 27 so as to be positioned according to the panel core member 10 and the corners of the panel core member 10, and is attached to the panel core member 10. The surface decorative panel 20 is provided. Therefore, like the above, the surface smoothness of the decorative panel 1 can be improved, and the appearance of the surface and the corner surface can be improved.
Moreover, in this embodiment, it is set as the structure which provided the surface decorative panels 20 and 20 in the panel thickness direction both sides of the panel core material 10, respectively. Therefore, the both sides of the panel in the thickness direction can be made into a decorative surface with an improved appearance as described above.
Moreover, in this embodiment, the panel core material 10 is set as the structure by which the core material 16 was accommodated in the space enclosed by the frame 11 containing the surrounding frames 12,13,13,14. Therefore, the strength of the decorative panel 1 can be improved as compared with the case where the panel core member 10 is made of only the core member 16 or a crosspiece provided on three sides or less, and is preferably used as a fitting. Can do. Further, the weight can be reduced as compared with the solid panel core 10.

  Moreover, in this embodiment, the insertion grooves 13a and 13a into which the insertion piece parts 20c, 20c, 20c, and 20c of the surface decorative panels 20 and 20 on both sides in the panel thickness direction are inserted into both end portions of the panel core member 10. It is set as the structure which provided. Therefore, the joint of the surface decorative panels 20 and 20 can be stored with good appearance as compared with the case where the ends of the surface decorative panels 20 and 20 are stored in contact with each other. Instead of such a mode, the surface decorative panel 20 on one side in the panel thickness direction and the surface decorative panel 20 on the other side in the panel thickness direction are butted or overlapped at each end face in the panel width direction. It is good also as an aspect etc. to pay. Moreover, it is good also as an aspect etc. which cover the end surface of a panel width direction only with the surface decorative panel 20 of the panel thickness direction one side. In this case, the surface decorative panel 20 on the other side in the panel thickness direction may not be provided with a bent groove.

  Moreover, it replaces with the aspect which provided the surface decorative panels 20 and 20 in the shape of a separate body in the panel thickness direction both sides, and also as an aspect which covers the surrounding surface of the panel core material 10 with a series of surface decorative panels 20 Good. In this case, it is good also as an aspect which provided the insertion groove 13a only in the one side edge part of the panel core material 10. FIG. Moreover, it replaces with the aspect which provided the bending grooves 27 and 28 in the surface decorative panels 20 and 20, and the decorative sheet | seats 21 and 21 extended so that the width direction both end surfaces of the panel core material 10 may be covered and stuck. Thus, both end surfaces in the width direction of the panel core member 10 may be covered. Further, instead of the aspect in which the four-sided surface of the panel core member 10 is covered with the surface decorative panel 20, only the both sides in the panel thickness direction may be covered with the surface decorative panel 20. In these cases, the surface layer is made of the panel core material 10 by the resin compositions 24 and 24 constituting the fiber reinforced resin layers 26 and 26 of the surface decorative panels 20 and 20 constituting the surface layers on both sides in the thickness direction of the decorative panel 1. It is good also as what was joined and integrated. In this case, each end face in the panel width direction of the panel core member 10 may be covered with a separate edge sheet or the like, and each end face in the panel width direction may be a decorative face without using a decorative face. A mode in which the material 10 is exposed may be employed.

  Moreover, it is good also as a structure which provided the surface decoration panel 20 only in the panel thickness direction instead of the structure which provided the surface decoration panels 20 and 20 in the panel thickness direction both sides of the panel core material 10 as mentioned above. . In this case, the fiber reinforced resin layer 26 or other surface material may be provided on the other side in the panel thickness direction, and the panel core material 10 may be exposed. In the present embodiment, the panel core material 10 is shown as an example in which the core material 16 is accommodated in the space surrounded by the frame body 11. However, the panel core material 10 is configured by only the frame body 11 or only the core material 16. Or a solid plate-like body. The concrete configuration of the decorative panel 1 described above can be variously modified.

Next, an example of a decorative panel according to another embodiment of the present invention will be described with reference to the drawings.
FIG. 4 is a diagram schematically illustrating an example of a surface decorative panel according to the second embodiment.
Note that differences from the first embodiment will be mainly described, and the same components will be denoted by the same reference numerals, and description thereof will be omitted or briefly described.

  Similarly to the above, the surface decorative panel 20A according to the present embodiment has a configuration in which a surface layer-side resin layer 23 that substantially does not include fibers is provided between the decorative sheet 21 and the fiber reinforced resin layer 26 that form the decorative surface. ing. Moreover, this surface decorative panel 20A is set as the structure used as a cover which covers the existing interior building material. In the present embodiment, as shown in FIG. 4B, the base decorative panel 20 </ b> A covers the baseboard-like baseboard 6 disposed along the corners between the wall surface 4 and the floor surface 5. It is set as the structure used as a cover. Moreover, it is set as the structure which provided the bending groove | channel 29 according to the surface side upper end corner | angular part of the baseboard 6 in the back surface side of the surface decorative panel 20A, as shown to Fig.4 (a), (b). The bent groove 29 is provided along the surface side piece 20Aa of the surface decorative panel 20A along the one surface (surface) in the thickness direction of the baseboard 6 and the one end surface (upper end surface) in the width direction of the baseboard 6. It is provided so that it may be located in a boundary part with end face piece part 20Ab to be.

In the illustrated example, the bent groove 29 is a single V-shaped groove as viewed in the longitudinal direction of the groove so that the corners formed by bending the bent groove 29 have a substantially right angle. Although the example which consists of one groove | channel is shown, it is not restricted to such an aspect. The bent groove 29 may be composed of a plurality of grooves so that the corner portion formed by being bent in the bent groove 29 has an R chamfered shape or a C chamfered shape.
Moreover, this surface decorative panel 20A is good also as what is attached to the baseboard 6 with a suitable adhesive agent, an adhesive material, etc.

The surface decorative panel 20 </ b> A according to the present embodiment having such a configuration also has substantially the same effect as described above. Moreover, the surface decorative panel 20A according to the present embodiment can be manufactured in substantially the same manner as the above-described panel manufacturing method.
In the present embodiment, the surface decorative panel 20A is an example of a baseboard cover that covers the existing baseboard 6. However, the present invention is not limited to such an embodiment, and the existing opening frame, window frame, and peripheral edge are not limited thereto. It may be used as a cover for covering other existing interior building materials.
Moreover, in each said embodiment, although the example which used the decorative layer as the decorative sheet 21 is shown, it is not restricted to such an aspect, It is good also as a coating-film layer.

Next, an example of a surface decorative panel according to the present invention and a comparative example will be described with reference to FIG.
In each of Examples 1 and 2 and the comparative example, the decorative sheet as the decorative layer was a polyethylene terephthalate resin film having a thickness of 0.06 mm.
In Examples 1 and 2, the resin composition constituting the surface layer side resin layer was a non-foaming polyurethane resin (foaming factor of 1), and the coating amount on the back side of the decorative sheet was 50 g / m ² . Further, the mold temperature was set to 48 ° C. and left for 15 minutes, and then the resin composition constituting the fiber reinforced resin layer was applied. In Example 1, the resin composition constituting the fiber-reinforced resin layer was a non-foaming polyurethane resin (foaming ratio of 1) as in the above, and the coating amount was 150 g / m ² . In Example 2, the resin composition constituting the fiber reinforced resin layer was a polyurethane resin having an expansion ratio of 1.5 times, and the coating amount was 150 g / m ² . In Examples 1 and 2, a glass mat having a basis weight of 200 g / m ² was placed on the resin composition so as to be impregnated with the resin composition, and pressed using upper and lower molding dies for 15 minutes. The resin composition was cured by allowing to stand. In Example 1, the thickness of the surface layer side resin layer was 0.05 mm, and the thickness of the fiber reinforced resin layer was 0.4 mm.

On the other hand, in the comparative example, the resin composition constituting the fiber reinforced resin layer is made of a non-foaming polyurethane resin (foaming factor of 1) without providing a surface layer side resin layer, and the coating amount on the back side of the decorative sheet is 200 g / m ² . That is, the application amount of the resin of the comparative example and the total application amount of the resins of Examples 1 and 2 were the same. Similarly to the above, a glass mat having a basis weight of 200 g / m ² is placed on the resin composition so as to be impregnated with the resin composition, pressed using upper and lower molds, and allowed to stand for 15 minutes. The composition was cured.
Further, at least the decorative sheet is left on the back surface of the decorative panel of each of the examples 1 and 2 and the comparative example so that at least the decorative sheet is left as viewed in the longitudinal direction of the groove (in Examples 1 and 2). And so that the groove bottom is positioned on the surface side resin layer).

Moreover, the following evaluation tests were done with respect to the surface decorative panel of each Example and the surface decorative panel of each Comparative Example.
<Surface appearance evaluation>
The surfaces of the surface decorative panels of Examples 1 and 2 and Comparative Example were visually observed and evaluated. As a result, as shown in FIG. 5, in Example 1 and Example 2, the unevenness due to the glass fiber conspicuous on the surface was not generated, and in the comparative example, the unevenness due to the glass fiber was conspicuous on the surface. <Scratch hardness test>
In accordance with JIS K5600-5-4 (scratch hardness (pencil method)) on the surface of the decorative panel of each of Examples 1 and 2 and Comparative Example, a scratch hardness test is performed using a pencil with a hardness of H, The presence or absence of surface scars was visually observed and evaluated. As a result, as shown in FIG. 5, in Example 1 and Example 2, no noticeable scar was generated on the surface, and in the comparative example, the scar was conspicuous on the surface.

<Corner appearance evaluation>
The surface decorative panels of Examples 1 and 2 and the comparative example were bent at the bending grooves, and the corner surfaces were visually observed. As shown in FIG. 5, in Example 1 and Example 2, there is no noticeable distortion or unevenness on the corner surface, and in the comparative example, the result is that the distortion or unevenness is noticeable on the corner surface. became.
From the above results, each surface decorative panel of Examples 1 and 2 was excellent in surface appearance and surface hardness as compared with the comparative example, and excellent in the corner portion appearance after bending.

DESCRIPTION OF SYMBOLS 1 Decorative panel 10 Panel core material 20,20A Surface decorative panel 21 Decorative sheet (decorative layer)
22 Resin composition (resin composition constituting the surface layer side resin layer)
23 surface layer side resin layer 24 resin composition (resin composition which comprises fiber reinforced resin layer)
26 Fiber reinforced resin layer 27 Corner bent groove (bent groove according to the corner of the panel core)
28 End Bending Groove (Bending Groove)
29 Bending groove

Claims (5)

  Surface makeup characterized by interposing a resin layer constituting the fiber-reinforced resin layer and a resin layer having the same resin main component between the decorative layer constituting the decorative surface and the fiber-reinforced resin layer panel. In claim 1,
The surface decorative panel according to claim 1, wherein a foaming ratio of the resin composition constituting the surface layer side resin layer is equal to or less than a foaming ratio of the resin composition constituting the fiber reinforced resin layer. In claim 1 or 2,
A surface decorative panel, wherein a bent groove is provided on a back surface side of the surface decorative panel so that a groove bottom is positioned on the surface layer side resin layer.   The surface decorative panel according to claim 3, wherein the bent groove is provided so as to be in a position corresponding to a corner portion of the panel core material, and is adhered to the panel core material. A decorative panel characterized by   After supplying the uncured resin composition constituting the surface layer side resin layer to the back surface of the decorative sheet, a fiber reinforced resin layer is formed so as to be positioned on the back surface side of the surface layer side resin layer to produce a surface decorative panel A panel manufacturing method characterized by the above.

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