JP2018145679A - Ceiling panel material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a ceiling panel material capable of providing high rigidity to a construction as well as ensuring fire retardancy.SOLUTION: A ceiling panel material is configured with: a base layer in a flat plate shape composed of fire retardant resin foams; a first surface layer made of an aluminum alloy sheet and deposited on a surface of the base layer; a first adhesion layer intermediately arranged between the base layer and the first surface layer; a second surface layer deposited on an opposite surface of the base layer opposite to the surface and made of an aluminum alloy sheet; and a second adhesive layer intermediately arranged between the base layer and the second surface layer. A thickness of the aluminum alloy sheet is in the range of 30 μm or more to 50 μm or less.SELECTED DRAWING: Figure 2

Description

  The present invention relates to a ceiling panel material applied to a ceiling of a building or the like, and particularly relates to a ceiling panel material that is lightweight and has desired rigidity and flame retardancy.

  Conventionally, a decorative panel in which paper or the like is laminated on a design surface of a gypsum board is used for a ceiling in a building such as an office building or a large store. These decorative panels are hard and high rigidity as a building structure is obtained, but on the other hand, since the cracks and chips are likely to occur in the screwing parts, etc., the decorative panels in which such cracks and chips are generated become brittle. Repair and reuse become difficult. Moreover, if the decorative panel that has become brittle is left unattended, there is a risk of breaking and dropping when an impact such as an earthquake is applied.

  In consideration of such problems, for example, in Patent Document 1, a ceiling decorative panel in which a surface material and a back material are attached to both surfaces of a board made of a synthetic resin foam, the surface material and the back material are An aluminum foil that prevents warping, a paper layer that ensures rigidity, and a transparent plastic layer that covers the surface are disclosed. Patent Document 2 discloses a flat heat insulating material having flame retardancy, a metal foil such as an aluminum foil laminated on at least one surface of the heat insulating material, and a matte coated on the surface of the laminated metal foil. A ceiling board including a layer is disclosed.

JP-A-11-247352 Japanese Patent Laid-Open No. 2006-61108

  The ceiling decorative panel described in Patent Document 1 has a board made of a synthetic resin foam as a main component, and thus is lighter than a conventional gypsum board, but is attached to the front and back surfaces of the board. Since the surface material and the back material to be attached are both composed of a laminate composed of an aluminum foil, a paper layer, and a plastic layer, it takes time and effort to manufacture these surface material and back material. The effect is not enough.

  On the other hand, although the ceiling board described in the above-mentioned patent document 2 can obtain a desired flame retardancy by a heat insulating material as a base, as a specific embodiment, the ceiling board is thin with a matte layer formed on the surface. Only an example of obtaining an effect that the aluminum foil is excellent in design by adhering to one side of the heat insulating material is disclosed, and it can be said that the point of obtaining high rigidity as a single ceiling board is considered. Absent.

  Then, the objective of this invention is providing the ceiling panel material which can acquire the high rigidity as a structure, ensuring a flame retardance.

  In order to solve the above problems, a ceiling panel according to the present invention includes a flat base layer made of a flame-retardant resin foam and a first surface layer made of an aluminum alloy sheet and laminated on one surface of the base layer. A first adhesive layer interposed between the base layer and the first surface layer, and a second surface layer made of an aluminum alloy sheet and laminated on a surface facing the one surface of the base layer And a second adhesive layer interposed between the base layer and the second surface layer, wherein the aluminum alloy sheet has a thickness in the range of 30 μm to 50 μm. And

  According to this invention, since the aluminum alloy sheets capable of obtaining sufficient rigidity are laminated on both sides of the base layer made of the flame-retardant resin foam, rather than a mere aluminum foil having a small thickness, it is difficult as a ceiling panel. High rigidity can be obtained while ensuring flammability.

  In the above invention, the flame retardant resin foam may be a foam made of a melamine resin or a phenol resin. Moreover, the 3rd surface layer which covers the side surface of the said base layer may be formed by folding and adhering the edge part of the said 1st surface layer or the said 2nd surface layer. Furthermore, at least one of the first adhesive layer or the second adhesive layer may be partially formed on the entire surface of the base layer.

  According to this invention, in addition to the above effects, it is possible to ensure the rigidity on the side surface of the base layer and to obtain flame retardancy between the base layer and the first and second surface layers.

It is a fragmentary perspective view which shows the outline of the concrete structure of the ceiling panel material by Example 1 of this invention. It is the partial side view seen from the direction of arrow A shown in FIG. It is a fragmentary sectional view showing the outline of the attachment structure to the ceiling of the ceiling panel material by Example 1, and Drawing 3 (a) shows the state before attachment, and Drawing 3 (b) shows the state after attachment. . FIG. 4A is a partial cross-sectional view showing a specific structure of a ceiling panel according to Embodiment 2 of the present invention, in which FIG. 4A shows a state before the side wall portion is formed, and FIG. The state after doing. It is a fragmentary sectional view which shows the specific structure of the ceiling panel by Example 3 of this invention.

  Hereinafter, the specific example of the ceiling panel material by this invention is demonstrated using drawing.

<Example 1>
FIG. 1 is a partial perspective view showing an outline of a specific configuration of a ceiling panel material according to Embodiment 1 of the present invention. FIG. 2 is a partial side view seen from the direction of arrow A shown in FIG. As shown in FIG. 1, a ceiling panel material 100 according to the present invention includes a flat base layer 110 made of a flame-retardant foam and a first surface layer laminated on one surface (upper surface) side of the base layer 110. 120 and a second surface layer 130 stacked on the other surface (lower surface) side of the base layer 110. As shown in FIG. 2, a first adhesive layer 140 is interposed between the base layer 110 and the first surface layer 120, and between the base layer 110 and the second surface layer 130. The second adhesive layer 150 is interposed. Here, as an example of the specifications of the ceiling panel 100, the overall thickness (see reference symbol T in FIG. 4A) is 10 to 15 mm, and the weight per unit area is 700 g / m ³ or less.

  The base layer 110 is made of a foamed material such as a melamine resin, a phenol resin, or a nonflammable hard polyurethane resin, and is made of a material having a low density and sufficient flame retardancy. As an example, the base layer 110 can be applied by cutting a resin foam lump as a raw material into a flat plate having a predetermined shape.

  The first surface layer 120 and the second surface layer 130 are both made of an aluminum alloy sheet material. At this time, as an example of the aluminum alloy sheet, a plate-like material such as a commercially available pure aluminum alloy, an Al-Mn alloy having formability, or an Al-Mg alloy used as a structural material is available. It can be illustrated. Here, the thickness T1 of the first surface layer 120 and the thickness T2 of the second surface layer 130 shown in FIG. 2 are each 30 μm in order to achieve weight reduction while ensuring the rigidity of the entire ceiling panel material 100. The lower limit is preferably set to 50 μm. The thicknesses T1 and T2 may be the same or different. In addition, when one of the first surface layer 120 and the second surface layer 130 is used as a design surface of the ceiling, a sheet material such as paper on which a predetermined pattern is printed is additionally attached to the design surface. You may comprise.

  The first adhesive layer 140 and the second adhesive layer 150 are layers that surface-bond the base layer 110 that is a resin material and the first surface layer 120 or the second surface layer 130 that is a metal layer. Any resin-based, acrylic resin-based, vinyl acetate-based, silicone-based, or rubber-based material that has good adhesion to the base layer 110 can be used. Note that both the first adhesive layer 140 and the second adhesive layer 150 may be disposed on the entire adhesive surface of the base layer 110, or may be partially disposed.

  FIG. 3 is a partial cross-sectional view showing an outline of the structure for attaching the ceiling panel material to the ceiling according to Example 1, FIG. 3 (a) shows a state before attachment, and FIG. 3 (b) is after attachment. Shows the state. As shown in FIG. 3, the ceiling panel member 100 according to the first embodiment is fixed to a beam-shaped fixing member 160 provided on the ceiling of a building via a fastening member 170 such as a nail. At this time, each of the first surface layer 120 and the second surface layer 130 formed on both surfaces of the base layer 110 has such a thickness that the fastening member 170 can be penetrated and a minimum rigidity can be obtained on both surfaces. It is said that. In addition, although the case where a nail is used as the fastening member 170 is illustrated in FIG. 3, as long as it can be detachably fixed according to the material of the fixing member 160, for example, a bolt with a screw or a vise is used. Any method such as a mechanical fastening means or an adhesive structure can be adopted.

  With this configuration, the ceiling panel material 100 according to the first embodiment of the present invention is formed of an aluminum alloy sheet on both sides of the flat base layer 110 made of a flame retardant resin foam and laminated on one surface of the base layer. Adopting a structure in which the first surface layer 120 and the second surface layer 130 made of an aluminum alloy sheet and laminated on the opposite surface of the base layer facing the one surface are used. By making the thickness of the surface layer 120 and the second surface layer 130 in the range of 30 μm or more and 50 μm or less, the surface layer on both the front and back surfaces is not a mere aluminum foil with a small thickness, but an aluminum alloy sheet that can obtain sufficient rigidity. Since it is comprised, high rigidity can be acquired, ensuring the flame retardance as a ceiling panel.

<Example 2>
FIG. 4 is a partial cross-sectional view showing a specific structure of the ceiling panel according to the second embodiment of the present invention, in which FIG. 4 (a) shows a state before the side wall portion is formed, and FIG. The state after forming a side wall part is shown. As shown in FIG. 4, the ceiling panel 200 according to the second embodiment includes a flat base layer 210 made of a flame retardant foam and a first surface layer laminated on one surface (upper surface) side of the base layer 210. 220, a first adhesive layer 240 interposed between the base layer 210 and the first surface layer 220, a second surface layer 230 laminated on the other surface (lower surface) side of the base layer 210, and a base A second adhesive layer 250 interposed between the layer 210 and the second surface layer 230. Here, the base layer 210, the first surface layer 220 and the second surface layer 230, and the first adhesive layer 240 and the second adhesive layer 250 are all the same as those exemplified in the first embodiment. Can do.

  As shown in FIG. 4A, in the ceiling panel 200 according to the second embodiment, as one example, one end of the second surface layer 230 is in the longitudinal direction (perpendicular to the paper surface in the drawing) with respect to the end of the base layer 210 The protruding portion 230a is formed over the entire surface in the direction). At this time, the overhang length L from the end E of the base layer 210 of the overhang portion 230a is set to be substantially the same as the total thickness T of the ceiling panel 200 as a laminate. 4B, the overhanging portion 230a is bent at the bent portion 230b, and the overhanging portion 230a is disposed along the end portion E of the base layer 210 via the side surface side adhesive layer 250a. Adhere and fix. Thereby, a side wall portion (third surface layer 230 a) made of an aluminum alloy sheet is formed on the side surface of the base layer 210. In FIG. 4, the case where the protruding portion 230 a is formed at one end of the second surface layer 230 is illustrated, but the protruding portion may be formed at one end of the first surface layer 220. At this time, it is preferable to provide the above-described overhanging portion on the surface layer of the first surface layer 220 or the second surface layer 230 on the side facing the design surface of the ceiling (that is, the room side).

  With this configuration, the ceiling panel material 200 according to the second embodiment of the present invention forms an overhang portion (reference numeral 230a) at one end of the surface layer laminated on the base layer 210, and the bent portion (reference numeral 230b) is bent. In addition to the effect obtained by the ceiling panel according to the first embodiment, the third surface layer (side wall portion) has a predetermined rigidity in the thickness direction of the ceiling panel 200. Therefore, higher rigidity can be obtained as a building structure.

<Example 3>
FIG. 5 is a partial cross-sectional view showing a specific structure of the ceiling panel according to the third embodiment of the present invention. As shown in FIG. 5, the ceiling panel 300 according to Example 3 includes a flat base layer 310 made of a flame-retardant foam and a first surface layer laminated on one surface (upper surface) side of the base layer 310. 320, a first adhesive layer 340 interposed between the base layer 310 and the first surface layer 320, a second surface layer 330 stacked on the other surface (lower surface) side of the base layer 310, and a base A second adhesive layer 350 interposed between the layer 310 and the second surface layer 330. Here, the base layer 310, the first surface layer 320, the second surface layer 330, the first adhesive layer 340, and the second adhesive layer 350 are all the same as those exemplified in the first embodiment. Can do.

  As shown in FIG. 5, in the ceiling panel 300 according to the third embodiment, as an example, the first adhesive layer 340 is partially formed only in the region near the outer edge of the base layer 310, and the remainder In this region, a gap (air layer) 342 is formed between the base layer 310 and the first surface layer 320 without an adhesive layer. At this time, the first adhesive layer 340 may be partially arranged in an island shape inside the base layer 310. Thereby, a region where the base layer 310 and the first surface layer 320 are not in direct contact with each other due to the presence of the air layer 342 is formed. In FIG. 5, the case where the gap (air layer) 342 is formed in a part of the first adhesive layer 340 is illustrated, but the second surface layer 350 is also partially arranged so that the gap (air layer) is formed. You may comprise so that it may form. At this time, it is preferable to provide the air layer on the adhesive layer on the side of the first adhesive layer 340 or the second adhesive layer 350 that faces the design surface of the ceiling (that is, the room side).

  With this configuration, in the ceiling panel member 300 according to the third embodiment of the present invention, the first adhesive layer 340 is partially formed, and the gap between the base layer 310 and the first surface layer 320 is not interposed. By forming the (air layer) 342, in addition to the effect obtained by the ceiling panel according to the first embodiment, the air gap 342 between the base layer 310 and the first surface layer 320 also functions as a heat insulating layer. Therefore, it becomes possible to make a ceiling panel material having heat insulation in addition to flame retardancy as a building structure.

  As mentioned above, although the Example by this invention and the modification based on this were demonstrated, this invention is not necessarily limited to these examples. In addition, those skilled in the art will be able to find various alternative embodiments and modifications without departing from the spirit of the present invention or the scope of the appended claims.

  As one aspect thereof, in Example 2 described above, the case where the protruding portion is formed at one end of the base layer is illustrated, but the present invention is not limited to this. For example, in all four sides near the outer edge of the ceiling panel material according to the present invention, a protruding portion may be formed from one surface layer, and these may be bent to form a third surface layer (side wall portion). . In addition, those skilled in the art will naturally understand that the configurations of the ceiling panel materials shown in the first to third embodiments may be used in combination.

100, 200, 300 Ceiling panel material 110, 210, 310 Base layer 120, 220, 320 First surface layer 130, 230, 330 Second surface layer 140, 240, 340 First adhesive layer 150, 250, 350 Second Adhesive layer 160 Fixing member 170 Fastening member 230a Overhang portion 230b Bending portion 342 Gap

Claims (4)

A flat base layer made of a flame-retardant resin foam, a first surface layer made of an aluminum alloy sheet and laminated on one surface of the base layer, and interposed between the base layer and the first surface layer A first adhesive layer formed, an aluminum alloy sheet, a second surface layer that is laminated on an opposite surface of the base layer facing the one surface, and is interposed between the base layer and the second surface layer A ceiling panel material constituted by the second adhesive layer,
The ceiling sheet material, wherein the aluminum alloy sheet has a thickness in the range of 30 μm to 50 μm. The ceiling panel material according to claim 1, wherein the flame retardant resin foam is a foam made of a melamine resin or a phenol resin. The third surface layer covering the side surface of the base layer is formed by folding back and bonding the end portions of the first surface layer or the second surface layer. Ceiling panel material. 4. The device according to claim 1, wherein at least one of the first adhesive layer and the second adhesive layer is partially formed on the entire surface of the base layer. 5. Ceiling panel material.

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