JP2019173537A - Interior panel and manufacturing method of interior panel - Google Patents

Abstract

To provide an interior panel capable of improving fire retardancy of at least one side end part in addition to fire retardancy in indoor side and a manufacturing method of the interior panel capable of manufacturing such interior panel suitably.SOLUTION: An interior panel 1 is provided that a rear surface side is constructed toward an interior substrate 5 side and a foam resin layer 20, a fire retardancy layer 12 arranged on indoor side of the foam resin layer and a decorative layer 11 arranged on indoor side of the fire retardancy layer are provided, a front surface layer is arranged on an end surface 3 of a one-side end part 2, folded at a site of a folding groove 22, 25 arranged at least on a rear surface side of the one-side end part so that the front surface layer 10 including said fire retardancy layer and said decorative layer is present on a groove bottom side.SELECTED DRAWING: Figure 1

Description

  The present invention relates to an interior panel constituting a ceiling, a wall, and the like of a building and a method for manufacturing the interior panel.

Conventionally, an interior panel constituting a ceiling or a wall of a building has been required to have flame retardancy (nonflammability).
For example, Patent Document 1 below discloses a non-combustible laminated material in which a non-combustible reinforcing layer including a decorative layer and a metal layer is provided on a heat insulating base material made of a resin foam.

JP 2013-99864 A

  However, the non-combustible laminate as described above has a problem that the heat insulating base material is exposed at the end face.

  The present invention has been made in view of the above circumstances, and suitably manufactures an interior panel that can improve the flame retardancy of at least one side end in addition to the flame retardance on the indoor side, and such an interior panel. It aims at providing the manufacturing method of the interior panel to obtain.

  In order to achieve the above object, an interior panel according to the present invention is an interior panel constructed with the back side facing the interior base side, and is provided on the interior side of the foamed resin layer and the foamed resin layer. A flame retardant layer and a decorative layer provided on the indoor side of the flame retardant layer, and at least one side such that the surface layer including the flame retardant layer and the decorative layer exists on the groove bottom side It is characterized in that the surface layer is provided on the end surface of the one side end portion by being bent at the portion of the bent groove provided on the back surface side of the end portion.

  Moreover, in order to achieve the said objective, the manufacturing method of the interior panel which concerns on this invention is a manufacturing method of the interior panel constructed | assembled with a back surface side facing an interior foundation side, Comprising: A decorative layer and a flame retardant layer are included. Forming a folded groove on the back surface side of at least one side end of the panel body provided with the foamed resin layer on the back surface side of the surface layer so that the surface layer exists on the groove bottom side; and And a step of bending the surface of the groove to provide the surface layer on the end surface of the one side end.

  Since the interior panel according to the present invention is configured as described above, it is possible to improve the flame retardancy of at least one side end portion in addition to the flame retardance on the indoor side. Moreover, the manufacturing method of the interior panel according to the present invention can suitably manufacture such an interior panel by adopting the above-described configuration.

It is a partially broken schematic longitudinal cross-sectional view which shows typically an example of the interior panel which concerns on one Embodiment of this invention. (A)-(d) is a partially broken schematic longitudinal cross-sectional view which shows typically an example of the manufacturing method of the interior panel which concerns on one Embodiment of this invention. (A)-(c) shows an example of the manufacturing method of the interior panel typically, (a) is a partially broken schematic plan view, (b), (c) is a partially broken schematic longitudinal section. FIG. (A) is a partially broken schematic longitudinal cross-sectional view which shows typically an example of the manufacturing method of the same interior panel, (b) is a partially broken schematic plan view of the same interior panel. (A) is a partially broken schematic longitudinal cross-sectional view which shows typically an example of the interior panel which concerns on other embodiment of this invention, (b) is the manufacturing method of the interior panel which concerns on other embodiment of this invention. It is a partially broken schematic longitudinal cross-sectional view which shows typically an example. (A) is a partially broken schematic longitudinal sectional view schematically showing an example of an interior panel according to still another embodiment of the present invention, and (b) to (d) are still another embodiment of the present invention. It is a partially broken schematic longitudinal cross-sectional view which shows typically an example of the manufacturing method of the interior panel which concerns.

Embodiments of the present invention will be described below with reference to the drawings.
In some of the drawings, some of the detailed reference numerals attached to other drawings are omitted.
Further, in the following embodiments, directions such as the vertical direction will be described with reference to a state in which a ceiling panel as an example of an interior panel according to each embodiment is constructed.
1 to 4 are diagrams schematically illustrating an example of an interior panel according to the first embodiment and an example of a method for manufacturing the interior panel according to the first embodiment.

The interior panel which concerns on this embodiment comprises the ceiling panel 1, and as shown in FIG. 1, it is constructed toward the ceiling base | substrate 5 side by making a back surface side into an interior base | substrate. The ceiling panel 1 includes a foamed resin layer 20, a flame retardant layer 12 provided on the indoor side of the foamed resin layer 20, and a decorative layer 11 provided on the indoor side of the flame retardant layer 12. Yes. With such a configuration, it is possible to reduce the weight and to improve the flame retardance on the indoor side as compared with the wooden board and the gypsum board.
The ceiling base 5 to which the ceiling panel 1 is fixed may be a wooden ceiling base or a steel ceiling base. The ceiling base 5 may be a so-called light ceiling base using a light iron material. In the illustrated example, the ceiling base 5 is an example of a so-called suspended ceiling in which a field edge 7 is suspended from a suspension member 6 such as a suspension tree or a suspension bolt. Good.
Moreover, this ceiling panel 1 was fixed so that the end surfaces 3 and 3 of the one direction both ends 2 and 2 of adjacent ceiling panels 1 and 1 faced each other, and these side ends 2 and 2 were penetrated. It may be fixed to the field edge 7 of the ceiling base 5 by the stoppers 8, 8. Thus, if it is set as the structure which fixes the ceiling panel 1 with the fastener 8, compared with what needs to construct using joining members, such as a joiner, workability can be improved.

Further, the ceiling panel 1 may be constructed as a ceiling of a relatively small building such as a residence or an office, and may be used for various relatively large buildings such as a gymnasium, a hall, a shopping mall, a factory, and a school. It may be constructed as a ceiling.
The ceiling panel 1 may have a mass per unit area (1 m ² ) of 2.0 kg or less. Further, the mass of the ceiling panel 1 may be set such that the mass of the entire ceiling system including the ceiling base 5 made of the light ceiling as described above is 2.0 kg / m ² or less. In addition, as an interior panel which concerns on this embodiment, it is not restricted to what comprises the ceiling panel 1, A wall panel may be comprised. In this case, what is necessary is just to grasp | ascertain wall bases, such as a stud and a stud, as an interior base.

  Further, as shown in FIG. 4B, the ceiling panel 1 has a substantially rectangular shape in plan view (as viewed in the thickness direction). The ceiling panel 1 may have a substantially square shape in plan view or may have a substantially rectangular shape. The size of the ceiling panel 1 in a plan view may be an appropriate size from the viewpoint of handleability, workability, and the like. For example, the length of one side may be 0.3 m or more, It may be 2.0 m or less. Moreover, in the ceiling panel 1 made into the substantially rectangular shape, the length of the short side may be 0.3 m or more and the length of the long side may be 2.0 m or less. Moreover, in the ceiling panel 1 made into the substantially square shape, the length of one side may be 0.6 m or more and 1.5 m or less, and may be about 0.9 m to 1.2 m. . Moreover, although the thickness of this ceiling panel 1 is based also on a layer structure etc., it may be about 2.5 mm-15.0 mm, for example, Preferably, you may be about 3.0 mm-12.0 mm, More preferably May be about 3.0 mm to 6.0 mm.

The decorative layer 11 and the flame retardant layer 12 are provided on the indoor side of the ceiling panel 1 and constitute the surface layer 10.
The decorative layer 11 has a thin sheet shape with a thickness of about 0.1 mm to 0.5 mm, and constitutes a decorative surface of the ceiling panel 1. In this embodiment, this decorative layer 11 is a glass fiber sheet. With such a configuration, the rigidity and flame retardancy can be improved as compared with the case where the decorative layer 11 is a printing paper or a veneer. As the decorative layer 11 may also nonwoven glass fabric (glass paper) may be those having a basis weight is between ^20g / ^{m 2 ~250g} / m 2, preferably about, basis weight ^30g / ^{m 2 ~100g} / m 2 about It may be what was said.
Further, the decorative layer 11 may be one in which an appropriate surface decorative treatment such as printing or painting is performed on the surface of the glass fiber sheet. The decorative layer 11 is not limited to a glass fiber sheet, and may be another sheet material that has been subjected to an appropriate surface cosmetic treatment such as printing or painting, or may be formed by printing, painting, or the like. Moreover, it is preferable that the pigment, additive, etc. which are contained in the coating material used for printing of the decorative layer 11 are inorganic based from the viewpoint of ensuring flame retardancy.

The flame retardant layer 12 may have an appropriate configuration so that the ceiling panel 1 satisfies technical standards related to performance required for non-combustible materials and the like specified in the Building Standard Law. For example, the ceiling panel 1 may be configured to satisfy the standard of “flame retardant material” in the technical standard, and preferably may be configured to satisfy the standard of “quasi-incombustible material”, More preferably, it may be configured to satisfy the standard of “non-combustible material”. As the flame retardant layer 12, for example, a foil-like aluminum sheet formed into a thin sheet may be used. The thickness of the aluminum sheet constituting the flame retardant layer 12 may be about 5 μm to 50 μm, preferably about 7 μm to 40 μm, and more preferably about 10 μm to 30 μm.
The flame retardant layer 12 is not limited to the above-described configuration, and various other configurations can be employed. For example, it is good also as a resin impregnation glass fiber nonwoven fabric board containing an endothermic metal hydroxide.
The decorative layer 11 and the flame retardant layer 12 may be laminated and integrated with an appropriate adhesive or the like.

In the present embodiment, as shown in FIG. 1, the surface layer 10 includes a glass fiber reinforced resin layer 13 provided on the flame retardant layer 12 on the foamed resin layer 20 side. With such a configuration, the glass fiber reinforced resin layer 13 functions as a reinforcing layer, and the bending rigidity and dimensional stability of the entire ceiling panel 1 can be improved. Thereby, while aiming at weight reduction, the dripping after construction can be suppressed more effectively and it becomes suitable as the ceiling panel 1.
The glass fiber reinforced resin layer 13 has the same resin main component as the resin main component of the foamed resin layer 20. With such a configuration, the familiarity in each layer is improved, and boundary peeling or the like can be made difficult to occur.

The glass fiber sheet 14 which constitute the glass fiber reinforced resin layer 13, the basis weight is a glass cloth ^{50g / m 2 ~300g / m 2} . With such a configuration, it is possible to ensure an appropriate bending rigidity while reducing the weight. Basis weight of the glass fiber sheet 14 preferably ^may even ^{50g / m 2 ~150g / m 2} , more ^preferably, may be ^{50g / m 2 ~100g / m 2} . The glass fiber sheet 14 may be a thin sheet having a thickness of about 0.1 mm to 0.5 mm. The glass fiber sheet 14 is preferably a glass fiber woven fabric, and may be a glass cloth which is a woven fabric such as a plain weave or a woven fabric woven using glass roving for warp and weft. By using glass cloth, thermal deformation can be made difficult to occur. The glass fiber sheet 14 is not limited to such a glass cloth, and may be glass paper or a glass mat.

  In the present embodiment, the glass fiber reinforced resin layer 13 is formed by impregnating the glass fiber sheet 14 with the resin composition constituting the foamed resin layer 20. That is, the glass fiber reinforced resin layer 13 is integrally provided on a part of the foamed resin layer 20. With such a configuration, it is possible to make boundary peeling and the like less likely to occur as compared to a sheet in which a separately formed sheet constituting a glass fiber reinforced resin layer is laminated on the foamed resin layer 20. Moreover, manufacturing efficiency can be improved. The glass fiber reinforced resin layer 13 may be configured to include bubbles by foaming of the resin composition.

  In addition, the composite sheet in which the glass fiber sheet 14 is laminated and integrated with an appropriate adhesive on the ceiling base 5 side of the decorative layer 11 and the flame retardant layer 12 laminated and integrated as described above constitutes the foamed resin layer 20. The resin composition may be laminated and integrated with the foamed resin layer 20. In this case, the flame retardant layer 12 may be at least partially bonded to the resin composition that has passed through the glass fiber sheet 14 constituting the glass fiber reinforced resin layer 13. That is, even if the resin composition constituting the foamed resin layer 20 bleeds out from the glass fiber sheet 14 whose basis weight is reduced and the gap is increased as described above, even if it is partially adhered to the flame retardant layer 12 Good. Further, the adhesive for laminating and integrating the flame retardant layer 12 and the glass fiber sheet 14 allows the glass fiber sheet to exude from the glass fiber sheet 14 of the resin composition constituting the glass fiber reinforced resin layer 13. 14 may be applied. With such a configuration, it is possible to suppress peeling compared to the case where the flame retardant layer 12 is laminated through an adhesive or the like, and it is difficult to form wrinkles and the like, which can improve manufacturing efficiency. it can.

Moreover, in this embodiment, it is set as the structure which provided the glass fiber reinforced resin layer 17 which comprises the base | substrate side layer 15 in the ceiling base | substrate 5 side of the foamed resin layer 20. FIG. That is, the foamed resin layer 20 is sandwiched between the glass fiber reinforced resin layers 13 and 17 constituting the reinforcing layers on both sides in the thickness direction. With such a configuration, the bending rigidity and dimensional stability can be improved more effectively. Thereby, while aiming at weight reduction, the dripping after construction can be suppressed more effectively, and it becomes more suitable as the ceiling panel 1.
In the glass fiber reinforced resin layer 17 on the base side, the resin main component and the resin main component of the foamed resin layer 20 are the same as the glass fiber reinforced resin layer 13 constituting the surface layer 10 described above. Similarly to the above, the glass fiber reinforced resin layer 17 on the base side is formed by impregnating the glass fiber sheet 18 with the resin composition constituting the foamed resin layer 20. The glass fiber reinforced resin layer 17 on the base side may be configured to include bubbles by foaming the resin composition, as described above.

Moreover, in this embodiment, it is set as the structure which provided the exudation suppression layer 16 which comprises the base side layer 15 in the ceiling base 5 side of the glass fiber reinforced resin layer 17 of this base side. With such a configuration, the glass fiber reinforced resin layers 13 and 17 and the sheet-like member (the flame retardant layer 12 and the exudation suppressing layer 16) are provided on both sides in the thickness direction of the foamed resin layer 20, and bending rigidity and Dimensional stability can be improved more effectively. In addition, since the structure is generally symmetric, it can be expected to suppress warpage.
The exudation suppressing layer 16 may be any material that can suppress the exudation of the resin composition constituting the glass fiber reinforced resin layer 17, and may be a resin sheet or a metal sheet. If the exudation suppression layer 16 is a metal sheet, flame retardancy can be improved, and improvement in heat shielding properties and electromagnetic wave shielding properties can be expected.
For example, the exudation suppressing layer 16 may be an aluminum sheet similar to the flame retardant layer 12 described above, or may be a sheet thinner than the flame retardant layer 12. For example, the thickness of the exudation suppressing layer 16 may be about 2/5 to 3/5 of the thickness of the flame retardant layer 12.

  In addition, a composite sheet in which the glass fiber sheet 18 constituting the glass fiber reinforced resin layer 17 is laminated and integrated on the exudation suppressing layer 16 with an appropriate adhesive is formed into a foamed resin layer by the resin composition constituting the foamed resin layer 20. 20 may be laminated and integrated. In this case, the leaching suppression layer 16 may be at least partially adhered to the resin composition that has passed through the glass fiber sheet 18 constituting the glass fiber reinforced resin layer 17. That is, even if the resin composition constituting the foamed resin layer 20 oozes out from the glass fiber sheet 18 whose basis weight is reduced and the gap is increased as described above, it is partially adhered to the exudation suppressing layer 16. Good. Further, the adhesive for laminating and integrating the exudation suppressing layer 16 and the glass fiber sheet 18 allows the glass fiber sheet to exude from the glass fiber sheet 18 of the resin composition constituting the glass fiber reinforced resin layer 17. 18 may be applied.

  With the configuration as described above, it is possible to suppress peeling compared to a layer in which the exudation suppressing layer 16 is laminated via an adhesive or the like, and it is difficult to form wrinkles or the like, thereby improving manufacturing efficiency. Can do. Moreover, if the basis weight of the glass fiber sheet 18 is reduced as described above, the gap increases, and the resin composition constituting the glass fiber reinforced resin layer 17 oozes out during molding, so that the glass fiber sheet 18 has a resin composition. It is conceivable to be buried in the material layer. If it is set as the structure which laminated and integrated the glass fiber sheet 18 in the bleed suppression layer 16 as mentioned above, the burying of the glass fiber sheet 18 at the time of shaping | molding can be suppressed.

  The foamed resin layer 20 occupies most of the ceiling panel 1. The thickness of the foamed resin layer 20 is preferably 80% to 99% of the thickness of the ceiling panel 1, and more preferably 85% to 95%. The thickness of the foamed resin layer 10 may be, for example, about 2.3 mm to 14.8 mm, preferably about 2.5 mm to 11.5 mm, and more preferably 2.5 mm to 5.5 mm. It is good also as a grade. Moreover, the resin composition which comprises this foamed resin layer 20 is made into the foaming polyurethane resin whose foaming magnification is 10 times-30 times in this embodiment. With such a configuration, the weight can be reduced. Further, one or both of the surface layer 10 and the base side layer 15 on both sides in the thickness direction of the foamed resin layer 20 are laminated and integrated with the foamed resin layer 20 by the resin composition constituting the foamed resin layer 20 as described above. Manufacturing efficiency can be improved. The expansion ratio of the resin composition constituting the foamed resin layer 20 may preferably be about 15 to 25 times.

  Moreover, in this embodiment, the resin composition which comprises the foamed resin layer 20 is made into the flame-retardant polyurethane resin composition. If it is set as such a structure, a flame retardance (nonflammability) can be improved more combined with having set it as the above expansion ratios. That is, since the amount of the organic material contained in the foamed resin layer 20 is relatively small, the total calorific value can be reduced. As such a flame retardant polyurethane resin composition, a composition containing a polyisocyanate compound, a polyol compound, a catalyst, a foaming agent, a foam stabilizer and an additive may be used. Moreover, such a flame retardant polyurethane resin composition may further contain a flame retardant, a filler, and an inorganic filler. Examples of the resin constituting the foamed resin layer 20 include polyurethane resin, polystyrene resin, polyethylene resin, polypropylene resin, phenol resin, epoxy resin, and the like.

  Further, the ceiling panel 1 has at least the bent grooves 22 and 25 provided on the back surface side of the one end portion 2 so that the surface layer 10 including the flame retardant layer 12 and the decorative layer 11 exists on the groove bottom side. The surface layer 10 (end surface layer 10c) is provided on the end surface 3 of the one side end portion 2 by being bent at the site. If it is set as such a structure, the flame retardance in the end surface 3 of the at least one side edge part 2 of the four side edge parts 2, 2, 2, 2 can be improved. Thereby, even when a fire occurs on the indoor side in a state where the end surfaces 3 and 3 of the one side end portions 2 and 2 of the adjacent ceiling panels 1 and 1 are abutted to each other, the foamed resin layer 20 can be used. Combustion from the end surface 3 can be delayed as compared with the one exposed at the end surface 3. Moreover, the bending rigidity in the one side edge part 2 can be improved. In addition, since the surface layer 10 is provided in a continuous manner from the indoor side surface on the end surface 3 of the one side end portion 2, for example, compared with a case in which an edge sheet is attached and the end surface 3 is covered. The appearance of the inner edge can be improved. Moreover, in this embodiment, since it is set as the structure which included the glass fiber reinforced resin layer 13 in the surface layer 10 as mentioned above, the bending rigidity of the one side edge part 2 can be improved more effectively.

  Moreover, in this embodiment, it is set as the structure which provided the several bending groove | channels 22 and 25 so that the chamfering part 4 may be formed in the indoor side edge part of the one side edge part 2. FIG. With such a configuration, it is possible to make the step difference between the indoor side surfaces inconspicuous when construction is performed by abutting the end surfaces 3 and 3 of the one side end portions 2 and 2 of the adjacent ceiling panels 1 and 1. Further, since the surface layer 10 is provided in a continuous manner on the end surface 3 of the one side end portion 2 including the chamfered portion 4 from the indoor side surface, a seam is not formed, and the appearance can be improved. That is, in this embodiment, the surface layer 10 includes the indoor side surface layer 10a that forms the indoor side surface of the ceiling panel 1, the chamfered surface layer 10b that forms the chamfered portion 4, and the end surface layer 10c that forms the end surface 3. It is equipped with.

  In the present embodiment, the end layer back surface layer 10d that constitutes an extended portion that extends from the end surface layer 10c to cover the back surface of the one end portion 2 is provided on the surface layer 10 of the one end portion 2. It has a configuration. If it is set as such a structure, in addition to the end surface 3, the flame retardance of the back surface of the one side edge part 2 can be improved. Moreover, compared with what provided the surface layer 10 only in the indoor side surface and the end surface 3, the bending rigidity in the one side edge part 2 can be improved more, and peeling of the surface layer 10 can be suppressed. Further, as shown in FIG. 1, if the fastener 8 such as a screw is fastened to the portion where the end portion back surface layer 10 d is provided on the back surface of the one side end portion 2, the stopper holding force is increased. Can be improved.

  In the present embodiment, the back surface of the one side end 2 is provided with a portion where the end back layer 10d and the base layer 15 are overlapped. If it is set as such a structure, the bending rigidity in the one side edge part 2 can be improved more. It is good also as a structure by which the fastener 8 is fixed to the site | part overlapped in this way. The dimension (width dimension) along the extending direction of the end back layer 10d may be an appropriate dimension from the viewpoint of the strength of the one side end 2, the viewpoint of suppressing peeling, the viewpoint of weight reduction, and the like. . For example, the width dimension of the end back layer 10d may be about 1 to 15 times the thickness dimension of the ceiling panel 1, and preferably about 3 to 10 times.

  The end face layer 10c as described above (in this embodiment, in addition to the end face layer 10c, the chamfered surface layer 10b and the end back surface layer 10d) are preferably formed on both side edges 2, 2 in one direction of the ceiling panel 1. It may be provided. If it is set as such a structure, the flame retardance in the end surfaces 3 and 3 of the both-sides edge parts 2 and 2 of the one direction of the ceiling panel 1 can be improved. In the present embodiment, the end face layer 10c (in this embodiment, the chamfered surface layer 10b and the end back surface layer 10d in addition to the end face layer 10c) is provided on the side edges 2, 2, 2, and 2 of the four circumferences of the ceiling panel 1. It is set as the structure provided (refer FIG.4 (b)). If it is set as such a structure, the flame retardance in the end surface 3, 3, 3, 3 of the side edge part 2,2,2,2 of the four circumferences of the ceiling panel 1 can be improved. Since the side end portions 2, 2, 2, and 2 have the same configuration, the details will be described below by taking one side end portion 2 as an example.

The chamfered portion 4 provided at the side end portion 2 is provided at a corner portion between the indoor side surface of the ceiling panel 1 and the end surface 3. The dimension (depth dimension) along the panel thickness direction from the boundary portion with the indoor side surface of the chamfered portion 4 to the boundary portion with the end surface 3 is a viewpoint that makes the step between adjacent ceiling panels 1 and 1 inconspicuous. It is good also as an appropriate dimension from these. The depth dimension of the chamfered portion 4 may be, for example, about 0.5 mm to 3.0 mm. In the present embodiment, an example in which the depth dimension of the ceiling panel 1 is about ½ is shown. .
In the present embodiment, the two bent grooves (the first bent groove 22 and the second bent groove 25) 22 and 25 are arranged on the side so that the chamfered portion 4 becomes a C-chamfered inclined surface. The structure is provided at the end 2.

  The dimensions along the panel thickness direction of the groove bottom side portions of the bent grooves 22 and 25 may be appropriate dimensions from the viewpoint of the bendability and the appearance on the surface side after the bending, and at least the decorative layer. 11 and the thickness of the flame retardant layer 12 may be equal to or greater than the total dimension. The dimension along the panel thickness direction of the groove bottom side portions of these bent grooves 22 and 25 may be, for example, about 0.05 mm to 0.3 mm, and preferably about 0.1 mm to 0.2 mm. In the illustrated example, a part of the foamed resin layer 20 is left on the groove bottom side of the bent grooves 22 and 25 (see FIG. 2D). That is, an example in which the dimension along the panel thickness direction of the groove bottom side portions of the bent grooves 22 and 25 is equal to or larger than the thickness dimension of the surface layer 10 including the glass fiber reinforced resin layer 13 is shown.

  Further, as shown in FIG. 2 (d), the bent grooves 22 and 25 are not bent at the portion where they are provided (deployed state), and are on one side in the panel thickness direction (on the ceiling base 5 side). ) And is provided to extend along the side end 2 (2A). Further, these bent grooves 22 and 25 are provided substantially in parallel with each other, and are substantially V-shaped when viewed in the longitudinal direction of the groove in the developed state. The first bent groove 22 located on the inner side of the panel in the unfolded state (the panel center side in the direction along the groove width direction) is directed toward the outer side of the panel (the panel outer side in the direction along the groove width direction). Both sides in the groove width direction are partitioned by the first groove wall 23 and the second groove wall 24 facing the inner side of the panel. The second bent groove 25 located on the panel outer side in the unfolded state is partitioned on both sides in the groove width direction by the first groove wall 26 facing the panel outer side and the second groove wall 27 facing the panel inner side. ing.

  Between these bent grooves 22 and 25, a chamfered resin layer 20a is provided which is located on the back side of the chamfered surface layer 10b and constitutes the indoor side portion of the side end portion of the foamed resin layer 20. In addition, on the outer side of the panel of the second bent groove 25 in the unfolded state, there is a base resin layer 20b that is located on the back side of the end surface layer 10c and constitutes a base side portion of the side end portion of the foam resin layer 20. Provided (see also FIG. 4A). Further, an end back surface layer 10d is provided so as to extend toward the panel outer side than the base resin layer 20b in the developed state. This end back surface layer 10d may be composed of only the surface layer 10 including the glass fiber reinforced resin layer 13, but may be provided with a part of the foamed resin layer 20 on the back surface side, and at least a decorative layer. 11 and the flame retardant layer 12 may be used.

  The chamfered resin layer 20a protrudes toward one side in the panel thickness direction in the unfolded state, and has a substantially right-angled isosceles triangle shape when viewed in the groove longitudinal direction. In other words, the first bent groove 22 and the second bent groove 25 are provided adjacent to each other so that a substantially right-angled isosceles triangular chamfered resin layer 20a is formed therebetween. The chamfered resin layer 20 a is provided so that the width dimension of both side portions is approximately the depth dimension of the chamfered portion 4. Further, both side portions of the chamfered resin layer 20 a constitute the second groove wall 24 of the first bent groove 22 and the first groove wall 26 of the second bent groove 25. That is, the second groove wall 24 of the first bent groove 22 and the first groove wall 26 of the second bent groove 25 are provided so as to be substantially orthogonal to each other. The angle formed by the second groove wall 24 of the first bent groove 22 and the first groove wall 26 of the second bent groove 25 may be, for example, about 85 to 95 degrees.

  Further, the first groove wall 23 of the first bent groove 22 and the second groove wall 27 of the second bent groove 25 are provided in a substantially parallel shape so as to face each other, and the ceiling panel 1 of the ceiling panel 1 in the unfolded state is provided. It is provided so as to be substantially orthogonal to both surfaces in the thickness direction. The width dimension along the panel thickness direction in the developed state of the first groove wall 23 of the first bent groove 22 and the second groove wall 27 of the second bent groove 25 is the both sides of the chamfered resin layer 20a. The width is approximately the same as the width of the part. In other words, the width dimension of the first groove wall 23 of the first bent groove 22 and the second groove wall 27 of the second bent groove 25 is approximately ½ of the thickness dimension of the ceiling panel 1. Yes.

  The base-side resin layer 20b protrudes toward one side in the panel thickness direction in the unfolded state, and has a substantially inverted right-angled trapezoidal shape when viewed in the groove longitudinal direction. In the unfolded state, the surface of the base-side resin layer 20b facing the inner side of the panel forms the second groove wall 27 of the second bent groove 25, and the surface of the base-side resin layer 20b facing the outer side of the panel is bent. In this state, a base side surface 29 facing the ceiling base 5 is configured (see also FIG. 4A). Further, the front end surface of the base-side resin layer 20b in the protruding direction is an inclined surface 28 that inclines so as to descend toward the inner side of the panel in the unfolded state. The base side layer 15 may be provided at the leading end in the protruding direction on the base side surface 29 side of the base side resin layer 20b. That is, the protrusion direction front end portion of the base side resin layer 20b on the base side surface 29 side may be provided so as to be positioned substantially coincident with the base side layer 15 in the panel thickness direction in the developed state.

  An inclined surface 21 that is inclined so as to descend from the base side surface (panel back surface) toward the panel outer side is provided on the base side edge of the first bent groove 22 of the side end 2 on the inner side of the panel. Yes. The inclined surface 21 is provided to be bent with respect to the first groove wall 23 so as to be continuous with the first groove wall 23 of the first bent groove 22. That is, the inclined surface 21 and the inclined surface 28 of the base-side resin layer 20b are provided so as to expand toward the one side in the panel thickness direction in the unfolded state. These inclined surfaces 21 and 28 are provided so that the width dimension along the inclination direction is substantially the same as each other and substantially orthogonal to each other. The angle formed by these inclined surfaces 21 and 28 may be, for example, about 85 to 95 degrees.

  When the side end portion 2 (2A) having the above-described configuration is bent at the portions of the bent grooves 22 and 25, as shown in FIGS. 3 (c) and 4 (a), the first bent groove 22 is provided. The both side groove walls 23, 24 abut against each other or face each other. Similarly, the both side groove walls 26 and 27 of the second bent groove 25 are brought into contact with each other or in close proximity to each other, and the inclined surfaces 21 and 28 are brought into contact with each other or in close proximity to each other. As a result, the chamfered portion 4 is formed at the indoor side edge of the side end portion 2, and the base side surface 29 of the base side resin layer 20b and the base side surface of the base side layer 15 are substantially flush. Further, when the end back layer 10d extended as described above is bent so as to cover the base resin layer 20b and the base layer 15, the end back layer 10d is provided on the base side of the side end 2. It is done. In addition, it is good also as a structure which provided the recessed step part which receives this edge part back surface layer 10d in the base | substrate side of the side edge part 2. FIG. Such a concave step portion may be formed by being cut by cutting or the like, or may be formed by compression.

Moreover, in this embodiment, it is set as the structure which provided the site | part bend | folded above in each of the side edge part 2,2,2,2 of 4 circumferences. Therefore, as shown to Fig.3 (a), it is set as the structure which provided the notch-shaped recess 19 which reduces the overlap of the site | part bent at the corner part.
This notch-shaped recess 19 is provided so as to open toward the diagonally outer side in the unfolded state. Further, the notch 19 is formed in the first bent grooves 22 and 22 so as to reduce the overlap between the chamfered surface layers 10b and 10b and the chamfered resin layers 20a and 20a of the adjacent side end portions 2 and 2. Proximal end portions on both side edges are partitioned by first edge portions 19a, 19a provided in an expanded form from a portion where the groove bottoms intersect each other. If these first edge portions 19a and 19a are bent as described above at the portions where the bent grooves 22 and 25 are provided, the first edge portions 19a and 19a come into contact with each other or face each other, and the chamfered portion The corner part where 4 and 4 cross | intersect is comprised. Moreover, in the example of a figure, it is set as the structure which provided the inclined surface which suppresses mutual interference in the edge part of the 1st edge part 19a, 19a side of chamfering resin layer 20a, 20a.

  Further, the notch 19 is further expanded from the first edge portions 19a and 19a so as to reduce the overlap between the end face layers 10c and 10c of the adjacent side end portions 2 and 2 and the base resin layers 20b and 20b. The intermediate portions of both side edges are partitioned by the second edges 19b, 19b provided in an open shape. If these second edge portions 19b and 19b are bent as described above at the portions where the bent grooves 22 and 25 are provided, the second edge portions 19b and 19b come into contact with each other or face each other, and end faces 3, Consists of a corner where three intersect. Further, in the example shown in the drawing, inclined surfaces that suppress mutual interference are provided at the ends of the base side resin layers 20b, 20b on the second edge portions 19b, 19b side. In addition, it is good also as a structure which does not provide such an inclined surface in the base | substrate side resin layers 20b and 20b and above-mentioned chamfering resin layers 20a and 20a. Even in such a configuration, the mutual interference portions of the base side resin layers 20b and 20b and the chamfered resin layers 20a and 20a are compressed and crushed, so that a bulge due to interference is hardly formed in the corner portion.

Moreover, the opening side site | part of the both-sides edge of the notch-shaped recess 19 continues to 2nd edge part 19b, 19b so that the overlap of the edge part back surface layers 10d and 10d of the adjacent side edge parts 2 and 2 may be reduced. The third edge portions 19c and 19c are provided as described above. If these third edge portions 19c and 19c are bent as described above at the portions where the bent grooves 22 and 25 are provided, the third edge portions 19c and 19c come into contact with each other or face each other, and the back surface of the end portion. A corner portion where the layers 10d and 10d intersect with each other is formed (see FIG. 4B). In other words, the third edge portions 19c and 19c of the end portion back surface layers 10d and 10d of the adjacent side end portions 2 and 2 are butted together in a spear shape.
In addition, as a structure which reduces the overlap of the site | part bent in the corner part, it is not restricted to the above structures, In addition, various deformation | transformation are possible.

Further, in the above-described example, the example in which the inclined surfaces 21 and 28 are provided on the base side edge portion and the base side resin layer 20b on the inner side of the panel of the first bent groove 22 of the side end portion 2 is shown. It is good also as a structure which does not provide such inclined surfaces 21 and 28. FIG. For example, a flat surface portion that is flush with the first groove wall 23 of the first bent groove 22 is provided on the base side portion of the side end portion 2, and the front end surface in the protruding direction of the base side resin layer 20 b is formed on this flat surface portion. It is good also as a flat surface which contact | abuts or adjoins closely. Or it is good also as an aspect which provided the recessed step part which receives the protrusion direction front-end | tip part of the base | substrate side resin layer 20b in the base | substrate side edge part of the side edge part 2. As shown in FIG. The configuration for reducing the overlap between the base side edge portion of the first bent groove 22 of the side end portion 2 and the base side resin layer 20b on the inner side of the panel is not limited to the above-described mode, and various other configurations are also possible. Deformation is possible.
In the above example, the chamfered portion 4 is an example of a C chamfered inclined surface, but may be an R chamfered protruding curved surface. In this case, the shape and number of the bent grooves 22 and 25, the shapes of the chamfered resin layer 20a and the base side resin layer 20b, and the like may be appropriately modified.

Next, an example of a method for manufacturing an interior panel according to the present embodiment will be described with reference to the drawings. In addition, although this embodiment demonstrates the method of manufacturing the above-mentioned ceiling panel 1 as an interior panel, it is also possible to manufacture other interior panels, such as a wall panel.
In the manufacturing method, as shown in FIG. 2, the back side of at least one side end 2A of the panel body 1A in which the foamed resin layer 20A is provided on the back side of the surface layer 10A including the decorative layer 11 and the flame retardant layer 12 is used. And a step of forming the bent grooves 22 and 25 so that the surface layer 10A exists on the groove bottom side. Further, in the manufacturing method, as shown in FIG. 3C and FIG. 4A, a step of providing the end surface layer 10c on the end surface 3 of the one side end portion 2A by bending at the bent grooves 22 and 25. I have. With such a configuration, the ceiling panel 1 as described above can be suitably manufactured.

  In the manufacturing method, as shown in FIG. 2 (a), a resin composition constituting the foamed resin layer 20A is supplied between the surface layer 10A and the base layer 15A to mold the panel body 1A. May be. At this time, the surface layer 10A is a composite sheet in which the decorative layer 11, the flame retardant layer 12, and the glass fiber sheet 14 (see FIG. 1) are laminated and integrated, and the supplied resin composition impregnates the glass fiber sheet 14. The glass fiber reinforced resin layer 13 may be formed. Further, the base side layer 15A is a composite sheet in which the exudation suppressing layer 16 and the glass fiber sheet 18 (see FIG. 1) are laminated and integrated, and the glass fiber sheet 18 is impregnated with the supplied resin composition to reinforce the glass fiber. The resin layer 17 may be formed. At this time, the resin composition constituting the foamed resin layer 20A is supplied (applied) to one back side of the surface layer 10A and the base layer 15A so as to cover the supplied resin composition. You may make it shape | mold by arrange | positioning the other and foaming, regulating thickness. In this case, for example, continuous molding may be performed by a double belt press device or a press device provided with an endless track band in which a plurality of crawler plates are connected.

Then, as shown in FIG. 2B, the four turns are cut so that the panel body 1A has an appropriate size. Thus, the dimension of each side (dimension along one direction and the other direction) of the panel body 1A having four cuts is set to the dimension of each side of the ceiling panel 1 to be manufactured, as described above. , 25, and the dimension of the end back surface layer 10d may be taken into account for the appropriate dimensions.
Moreover, as shown in FIG.2 (c), the bending grooves 22 and 25 and the inclined surfaces 21 and 28 are formed in the side edge part 2A. The bent grooves 22 and 25 and the inclined surfaces 21 and 28 may be formed by appropriately cutting and cutting the base side layer 15A and the foamed resin layer 20A. At this time, the base side layer of the portion where the bent grooves 22 and 25 and the inclined surfaces 21 and 28 on the back surface side of the panel body 1A are formed (or the portion where the end back layer 10d is formed in addition thereto). At least the exudation suppressing layer 16 of 15A may be peeled off. With such a configuration, even when the exudation suppressing layer 16 is made of a metal sheet such as an aluminum sheet as described above, the occurrence of sparks or the like during cutting can be suppressed.

  Further, as shown in FIG. 2D, the end back layer 10d is formed so as to extend the surface layer 10A by cutting off the foam resin layer 20A on the panel outer side of the base resin layer 20b. When the foamed resin layer 20A on the outer side of the panel of the base resin layer 20b is cut off, the cutout 29A (FIG. 6B) as in the third embodiment described later is formed and then cut off. It may be. Further, after the foam resin layer 20A on the panel outer side of the base resin layer 20b is cut away, the foam resin layer 20 remaining on the back surface side of the end back layer 10d is appropriately removed by polishing or the like as necessary. May be. In addition, a bending crease such as a crease or the like may be applied to each groove bottom of the bending grooves 22 and 25 and a boundary portion between the base resin layer 20b and the end back surface layer 10d with a spatula jig or the like. . Note that a part of the foamed resin layer 20A may remain on the groove bottoms of the bent grooves 22 and 25 and the back surface side of the end back layer 10d. That is, it is good also as a structure which provided the bending grooves 22 and 25 and the edge part back surface layer 10d so that 10 A of surface layers might remain at least. Further, from the viewpoint of strength and the like, the surface layer 10A including the glass fiber reinforced resin layer 13 may be left as the groove bottoms and end back layer 10d of the bent grooves 22 and 25, but the glass fiber reinforced resin layer Part of 13 may be removed.

Further, as shown in FIG. 3A, a notch-shaped recess 19 is formed in the corner portion. The notch 19 may be formed after the bent grooves 22 and 25 are formed, or may be performed before the bent grooves 22 and 25 are formed.
And as shown in FIG.3 (b), the suitable adhesive agent 9 is apply | coated to the back surface of the edge part back surface layer 10d. In addition, you may make it apply | coat an adhesive agent also to the groove walls 23,24,26,27 and the inclined surfaces 21 and 28 of each bending groove | channel 22,25.
Then, as shown in FIGS. 3 (c) and 4 (a), folding is performed at the respective bent grooves 22 and 25 by appropriate guide rollers, and the end back layer 10 d is overlaid on the base layer 15. And the adhesive 9 is cured.
Through such steps, the ceiling panel 1 is manufactured as shown in FIGS. 1 and 4B.

In addition, the said manufacturing process is only an example and can deform | transform suitably.
In the present embodiment, the glass fiber reinforced resin layers 13 and 17 on both sides in the thickness direction of the foamed resin layer 20 are formed by impregnating the glass fiber sheets 14 and 18 with the resin composition constituting the foamed resin layer 20. However, the present invention is not limited to such an embodiment. One or both of the glass fiber reinforced resin layers 13 and 17 on both sides in the thickness direction of the foamed resin layer 20 are formed separately from the foamed resin layer 20 and laminated and integrated with an appropriate adhesive. It is good. Similarly, both or one of the flame retardant layer 12 and the exudation suppressing layer 16 may be laminated and integrated with an appropriate adhesive with respect to the glass fiber reinforced resin layers 13 and 17.

Next, another embodiment according to the present invention will be described with reference to the drawings.
In the following embodiments, 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. Also, the description of the same configuration for the manufacturing method will be omitted or briefly described.

FIGS. 5A and 5B are diagrams schematically illustrating an example of a ceiling panel as an interior panel according to the second embodiment and an example of a manufacturing method for manufacturing the ceiling panel.
As shown in FIG. 5A, the ceiling panel 1B according to the present embodiment is mainly different from the first embodiment in that the chamfered portion is not provided in the side end portion 2B. That is, in the present embodiment, the end surface 3A of the side end portion 2B has a flat surface shape over the entire panel thickness direction. Moreover, it is set as the structure which provided the one bending groove 22B in the side edge part 2B. Further, the surface layer 10 is provided so that the indoor side surface layer 10a and the end surface layer 10c on the indoor side of the foamed resin layer 20B are connected substantially orthogonally.

As shown in FIG. 5B, the bent groove 22B is substantially V-shaped when viewed in the longitudinal direction of the groove in the expanded state. The bent groove 22B is partitioned on both sides in the groove width direction by a first groove wall 21B facing the panel outer side and a second groove wall 28B facing the panel inner side. In the present embodiment, both the groove walls 21B and 28B are provided from the groove bottom to the base side surface. The first groove wall 21B and the second groove wall 28B are provided so as to be substantially orthogonal to each other. The angle formed by both the groove walls 21B and 28B may be, for example, about 85 to 95 degrees as described above.
In addition, on the outside of the panel of the bent groove 22B in the unfolded state, a base resin layer 20c is provided which is located on the back side of the end surface layer 10c and constitutes a base portion of the side end of the foam resin layer 20B. (See also FIG. 5 (a)). Further, in the unfolded state, the end back surface layer 10d is provided so as to extend toward the panel outer side than the base-side resin layer 20c.

In the present embodiment, the base-side resin layer 20c protrudes toward one side in the panel thickness direction in the unfolded state, and has a substantially right triangle shape when viewed in the groove longitudinal direction. In the unfolded state, the surface of the base resin layer 20c facing the panel inward side constitutes the second groove wall 28B of the bent groove 22B, and the surface of the base resin layer 20c facing the panel outer side is bent. A base side surface 29 facing the ceiling base 5 side is formed.
When the side end portion 2B having the above-described configuration is bent at the portion of the bent groove 22B, the both side groove walls 21B and 28B of the bent groove 22B come into contact with each other or face each other.
Moreover, the manufacturing method which manufactures such a ceiling panel 1B is equipped with the process of forming the bending groove 22B in the side edge part 2C of the panel body 1C as shown in FIG.5 (b) like the above. As described above, the panel body 1 </ b> C may be formed by supplying a resin composition constituting the foamed resin layer 20 </ b> C between the surface layer 10 and the base layer 15. In addition, the manufacturing method includes a step of providing an end surface layer 10c on the end surface 3A of the side end portion 2B by bending at the bent groove 22B.
Also in the present embodiment, when the end surface layer 10c is provided on the end surface 3A of the four side end portions 2B, the above-described notched recess may be provided at the corner portion in the unfolded state.
Also in the ceiling panel 1B according to the present embodiment, there are substantially the same effects as in the first embodiment.

6A to 6D are diagrams schematically showing an example of a ceiling panel as an interior panel according to the third embodiment and an example of a manufacturing method for manufacturing the ceiling panel.
As shown in FIG. 6A, the ceiling panel 1E according to the present embodiment has a configuration in which a chamfered portion 4 is provided at the indoor side edge of the side end portion 2E as in the first embodiment described above. . Further, as shown in FIG. 6 (d), the ceiling panel 1E has inclined surfaces 21A, 28A and bent grooves 22A, which are substantially the same as those in the first embodiment, on the back surface side of the side end 2E (2D). 25A is provided. In the present embodiment, unlike the first embodiment, the inclined surfaces 21A, 28A and the both side groove walls 23A, 24A, 26A, 27A of the bent grooves 22A, 25A are constituted by the base side layer 15C. That is, in the first embodiment, the foamed resin layer 20 is exposed at the inclined surfaces 21 and 28 formed by cutting or the like and the both side groove walls 23, 24, 26 and 27 of the bent grooves 22 and 25. Is different in this embodiment.

That is, a series of from the base side surface on the inner side of the panel to the inclined surface 21A, the both side groove walls 23A, 24A of the first bent groove 22A, the both side groove walls 26A, 27A of the second bent groove 25A, and the inclined surface 28A. A base side layer 15C is provided in a shape.
Moreover, in this embodiment, unlike the said 1st Embodiment, it is set as the structure which provided the edge part foamed resin layer 20E in addition to the edge part back surface layer 10d which comprises the surface layer 10 in the extension part. Further, in addition to the end back surface layer 10d and the end foamed resin layer 20E, an end base layer 15B is provided in the extended portion. That is, although the detailed illustration of the extended portion is omitted, the decorative layer 11, the flame retardant layer 12 and the glass fiber reinforced resin layer 13 constituting the end back layer 10d, the end foamed resin layer 20E, The glass fiber reinforced resin layer 17 and the exudation suppression layer 16 which comprise the edge part base layer 15B are provided. Also, the base side surface 29B of the base side resin layer 20b and the base side surface of the base side layer 15C of the side end portion 2E, the end base side layer 15B, the end foamed resin layer 20E, and the end back surface layer 10d face the base side. Are arranged in this order. With such a configuration, it is possible to more effectively improve the rigidity and the holding force of the side end portion 2E as compared with the first embodiment.

Moreover, in this embodiment, it is set as the structure which provided the resin layer in which the foamed resin layer 20A was compressed in the site | part on the groove bottom side of bending groove 22A, 25A. In other words, in the foamed resin layer 20, the groove bottom side portions of the bent grooves 22A and 25A have a higher density than other portions. With such a configuration, it is possible to improve the strength of the corners on the surface side formed by bending the bent grooves 22A and 25A, that is, the portions on the groove bottom side of the bent grooves 22A and 25A. . In addition to the foamed resin layer 20A, the glass fiber reinforced resin layers 13 and 17 may also be compressed at the groove bottom side portions of the bent grooves 22A and 25A.
Also, the end foamed resin layer 20E has a higher density than other portions. That is, the end foamed resin layer 20E constitutes a resin layer in which the foamed resin layer 20D is compressed. Further, the glass fiber reinforced resin layers 13 and 17 at the extending portions may also be compressed. Here, the other part of the foamed resin layer 20 refers to a part that is not compressed and made dense, such as the part of the end foamed resin layer 20E or the groove bottom side of the bent grooves 22A and 25A. This refers to an uncompressed uncompressed portion of the panel center side portion or the like (a portion on the inner side of the panel with respect to the inclined surface 21A) in the viewed state. That is, the groove bottom portions of the bent grooves 22A and 25A and the end foamed resin layer 20E (and the glass fiber reinforced resin layers 13 and 17) are compressed so that bubbles are crushed and higher than the uncompressed portions. It is said to be density. The groove bottom side portions of the bent grooves 22A and 25A and the end foamed resin layer 20E (and the glass fiber reinforced resin layers 13 and 17) are pressed (hot pressed) as will be described later to form so-called skin layers. Thus, a resin layer substantially free of bubbles may be used, or a resin layer in which some of the bubbles remain may be used.
As shown in FIG. 6B, the bent grooves 22A and 25A and the inclined surfaces 21A and 28A are formed by pressing the groove forming mold 30 from the back side to the portions where they are formed. That is, the bent grooves 22A and 25A and the inclined surfaces 21A and 28A are formed by compressing the foamed resin layer 20A. With such a configuration, it is possible to prevent the generation and adhesion of cutting scraps, etc., compared to those formed by excision, cutting, etc. as in the first embodiment. Can be prevented. In addition, there is no fear of occurrence of sparks or the like even when the exudation suppressing layer 16 that is a metal sheet such as the above-described aluminum sheet is provided on the back surface side without being peeled off.

  The groove forming mold 30 is provided so as to project from the inclined surfaces 31 and 38 on both sides forming the inclined surfaces 21A and 28A on the panel inner side and the panel outer side, and the adjacent end portions of the inclined surfaces 31 and 38. Groove-forming projections 32 and 35. The groove forming protrusions 32 and 35 include a first groove forming protrusion 32 that forms the first bent groove 22A and a second groove forming protrusion 35 that forms the second bent groove 25A. A first side surface 33 of the first groove forming protrusion 32 facing the panel inward side forms a first groove wall 23A facing the panel outward side of the first bent groove 22A, and the panel of the first groove forming protrusion 32 The second side surface 34 facing outward forms the second groove wall 24A facing the panel inward side of the first bent groove 22A. The first side surface 36 facing the panel inward side of the second groove forming protrusion 35 forms the first groove wall 26A facing the panel outward side of the second bent groove 25A, and the panel of the second groove forming protrusion 35 The second side surface 37 facing outward forms the second groove wall 27A facing the panel inward side of the second bent groove 25A. In addition, you may make it make the front-end | tip of the groove | channel formation protrusion 32, 35 into an acute angle rather than an example so that the corner | angular part of each bending groove 22A, 25A may become comparatively sharp.

Similarly, as shown in FIG. 6C, the extended portion is formed by pressing an end forming die 39 at a portion where the extended portion is formed. With such a configuration, it is possible to prevent the generation and adhesion of cutting scraps and the like, and the need for polishing or the like as described above.
The end forming mold 39 has a flat pressing surface so that the foamed resin layer 20D on the panel outer side of the panel body 1D is compressed to form the extended portion as described above.
As will be described later, the groove forming die 30, the end forming die 39, and the press die on which the panel body 1D is placed when pressing them may be pressed in a heated state. The heating temperature in this case may be an appropriate temperature according to the type of the resin composition constituting the foamed resin layer 20A, or may be a temperature at which the foamed resin layer 20A is moderately softened and does not melt. For example, it may be about 80 to 130 degrees.

  Moreover, as shown in FIG.6 (b), the manufacturing method which manufactures the above ceiling panels 1E makes the groove formation type | mold 30 from the back surface side in the site | part which forms the bending grooves 22A and 25A of the panel body 1D. The bent grooves 22A and 25A are formed by pressing. Further, in addition to the bent grooves 22A and 25A, the inclined surfaces 21A and 28A are formed by pressing the groove forming die 30 from the back side at the portions where the inclined surfaces 21A and 28A are formed. Similarly to the above, the panel body 1D may be formed by supplying a resin composition constituting the foamed resin layer 20A between the surface layer 10A and the base layer 15A. Further, before pressing the groove forming mold 30, the cut 29A is formed so as to form the base side surface 29 of the base side resin layer 20b in the side end 2D of the panel body 1D. The cuts 29A may be formed so as to leave at least the surface layer 10A with an appropriate blade member.

Further, as shown in FIGS. 6C and 6D, the extended portion is formed by pressing the end portion forming die 39 from the back side to the portion where the extended portion of the panel body 1D is formed. . When pressing the end portion forming die 39, an appropriate spacer is interposed between the pressing die on which the panel body 1D is placed so that the extension portion has a desired thickness. May be.
Then, in the same manner as described above, an appropriate adhesive is applied to the back surface side of the extended portion and the like, and the end surface layer 10c is provided on the end surface 3 of the side end portion 2E by bending at the bent grooves 22A and 25A. (See FIG. 6A). In the illustrated example, the end forming die 39 is pressed in the unfolded state where the bent grooves 22A and 25A are not bent. However, the present invention is not limited to such an embodiment. The end forming die 39 may be pressed along the thickness direction of the panel body 1D in a state of being bent at the bent grooves 22A and 25A, or the portions that form the extended portions stand upright. In the raised state, the end portion forming die 39 may be pressed along the planar direction of the panel body 1D.

Also in the present embodiment, when the end surface layer 10c is provided on the end surface 3 of the side end 2E of the four circumferences, the above-described notched recess may be provided in the corner portion in the unfolded state.
Further, in the present embodiment, an example in which the inclined surfaces 21A, 28A and the both side groove walls 23A, 24A, 26A, 27A of the bent grooves 22A, 25A are configured by the base side layer 15C is shown. Not limited. The inclined surfaces 21A, 28A and the side groove walls 23A, 24A, 26A, 27A of the bent grooves 22A, 25A may be constituted by the foamed resin layer 20A or the glass fiber reinforced resin layer 17. That is, it is good also as a structure which does not provide at least exudation suppression layer 16 of the site | part in which inclined surface 21A, 28A and bending groove 22A, 25A are formed.
In the present embodiment, the end foamed resin layer 20E and the end foundation side layer 15B are provided at the extended portion, but at least the exudation suppression layer 16 of the end foundation side layer 15B is provided. The end base layer 15B and the end foamed resin layer 20E may not be provided.

Also in the ceiling panel 1E according to the present embodiment, there are substantially the same effects as in the first embodiment. In addition, you may make it apply the structure which mutually differs in the ceiling panels 1, 1B, 1E which concern on each said embodiment by rearranging or combining suitably. For example, in the present embodiment, an example is shown in which the chamfered portion 4 is provided at the side end portion 2E, as in the first embodiment, but the chamfered portion is not provided as in the second embodiment. It is good also as a structure. In this case, the shape or the like of the groove forming die 30 may be appropriately modified according to the shape of the bent groove 22B.
In each of the above embodiments, the end back layer 10d (20E, 15B) that covers the back of the side ends 2, 2B, 2E is shown. However, the end back layer 10d (20E, 15B) is shown. It is good also as a structure which is not provided.
Moreover, in each said embodiment, although the example which set the surface layer 10 as the structure containing the glass fiber reinforced resin layer 13 is shown, what is necessary is just to include the decorative layer 11 and the flame-resistant layer 12 at least.
Moreover, although each said embodiment has shown the example which provided the base | substrate side layers 15 and 15C containing the glass fiber reinforced resin layer 17 and the bleed suppression layer 16 in the ceiling base | substrate 5 side of the foamed resin layers 20 and 20B, It is good also as a structure which does not provide both or one of the glass fiber reinforced resin layer 17 and the exudation suppression layer 16. The configuration of each part described above of the ceiling panels 1, 1B, 1E according to the above embodiments is merely an example, and various other modifications are possible.

1,1B, 1E Ceiling panel (interior panel)
1A, 1C, 1D Panel body 2, 2A to 2E Side end 3, 3A End face 4 Chamfer 10, 10A Surface layer 10a Indoor side layer (surface layer)
10b Chamfered surface layer (surface layer)
10c End face layer (surface layer)
10d End part back layer (surface layer, extended part)
DESCRIPTION OF SYMBOLS 11 Decorative layer 12 Flame retardant layer 13 Glass fiber reinforced resin layer 20, 20A-20C Foamed resin layer 22, 22A First bent groove 22B Folded groove 25, 25A Second bent groove 5 Ceiling base (interior base)
30 groove forming type

Claims (7)

An interior panel constructed with the back side facing the interior base side,
A foamed resin layer, a flame retardant layer provided on the indoor side of the foamed resin layer, and a decorative layer provided on the indoor side of the flame retardant layer,
The end surface of the one side end portion is folded at a portion of the bent groove provided on the back side of at least one side end so that the surface layer including the flame retardant layer and the decorative layer exists on the groove bottom side. The interior panel is provided with the surface layer. In claim 1,
The interior panel according to claim 1, wherein the surface layer of the one side end portion includes an extending portion that extends from a portion provided on the end surface so as to cover a back surface of the one side end portion. In claim 1 or 2,
The interior panel, wherein the surface layer includes a glass fiber reinforced resin layer provided on the foamed resin layer side of the flame retardant layer. In any one of Claims 1 thru | or 3,
The interior panel, wherein a resin layer in which the foamed resin layer is compressed is provided at a groove bottom side portion of the bent groove. In any one of Claims 1 thru | or 4,
An interior panel, wherein a plurality of the bent grooves are provided so that a chamfered portion is formed at an indoor side edge of the one side end. It is a manufacturing method of an interior panel constructed with the back side facing the interior base side,
A bent groove is formed on the back surface side of at least one side end of the panel body in which the foamed resin layer is provided on the back surface side of the surface layer including the decorative layer and the flame retardant layer so that the surface layer exists on the groove bottom side. Forming, and
Providing the surface layer on the end surface of the one side end by bending at the bent groove portion;
A method for producing an interior panel, comprising: In claim 6,
A method for manufacturing an interior panel, wherein a groove forming die is pressed from the back side to a portion of the panel body where the bent groove is formed, to form the bent groove.

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