JP2505321B2 - Core material for panel - Google Patents

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a panel core material containing a mineral fiber as a main component.

[0002]

2. Description of the Related Art Conventionally, a panel core material used for a partition panel or the like is required to be fireproof, thick and lightweight. Therefore, it is possible to use a mineral fiber board.

However, the surface hardness of the mineral fiber board is low, and the surface is likely to be dented by the impact force from the outside. Moreover, the surface of the mineral fiber board is not dense, and when the cloth or the like is stuck, the adhesive penetrates into the mineral fiber board, so that the cloth sticking is troublesome and the finish is not beautiful.

Therefore, gypsum board or calcium silicate board, which does not cause the above-mentioned problems, is generally used as the core material for the panel, but this is heavy and inconvenient for transportation. Moreover, the gypsum board and the like are fragile because the strength is secured only by the sheets adhered to the front and back surfaces, and there is a problem that the strength sharply decreases when the surface is cut out.

In view of the above problems, an object of the present invention is to provide a core material for a panel, which has a hard surface and is dense, is lightweight, and is excellent in shock absorption.

[0006]

In order to achieve the above-mentioned object, a panel core material according to the present invention has a front surface and a back surface of a low-density plate-like intermediate layer containing a mineral fiber as a main component and a lightweight aggregate. In addition to stacking and integrating a high-density surface layer containing mineral powder as a main component and containing inorganic powder, the plate-like intermediate layer is provided with a plurality of cavities each having an opening at a side surface facing each other. It has a formed structure.

[0007]

Therefore, according to the present invention, the front and back surfaces of the intermediate layer, which is lightweight and has excellent shock absorption, are covered with a hard and dense surface layer. Therefore, even if an impact force is applied from the outside, the dent unlike the mineral fiber board does not occur. Moreover, since the surface is dense, the adhesive does not penetrate even when a cloth or the like is stuck, and the finish is beautiful. Furthermore, since the surface layer and the intermediate layer are mainly composed of lightweight mineral fibers, and the intermediate layer has a hollow portion, it is lighter than the gypsum board as a whole and is easy to transport. In addition, the low-density intermediate layer, which is mainly composed of mineral fibers and has cavities, has excellent impact absorption properties and effectively absorbs impact force from the outside, so that the surface layer does not crack. effective.

[0008]

Embodiments of the panel core material according to the present invention will now be described with reference to the accompanying drawings of FIGS. As shown in FIG. 1, the panel core material according to the first embodiment includes a plate-like intermediate layer 1 containing a mineral fiber as a main component and a lightweight aggregate and having a specific gravity of less than 0.3, and a mineral fiber. The intermediate layer 1 has a specific gravity of 0.3 to 0.6 containing an inorganic powder as a main component.
And surface layers 4 and 4 which are laminated and integrated on the front and back surfaces.

Examples of the mineral fibers forming the plate-shaped intermediate layer 1 include rock wool, mineral wool and glass fibers, which may be used alone or in combination with 2
It can be used in combination of two or more species.

The lightweight aggregate is added to reduce the weight while maintaining the compressive strength. For example, perlite,
Examples thereof include inorganic foams such as shirasu balloon, and these can be used alone or in combination of two or more kinds.

The amount of the lightweight aggregate added to the mineral fibers needs to be such that the specific gravity of the mid layer 1 is less than 0.3 for weight reduction. For example, when the lightweight aggregate is an inorganic foam, the weight ratio is 5% by weight or more,
It is preferably 30% by weight or less. 5% by weight
This is because it becomes difficult to reduce the weight of the core material for a panel if it is below. Further, if the weight ratio is 30% by weight or more, the density becomes too small and elastic deformation easily occurs, so that the dimensional accuracy of the thickness deteriorates and the supporting strength for the surface layer becomes low, and the impact force from the outside is reduced. This is because the surface layer is apt to crack.

The mineral fibers of the surface layer 4 can be arbitrarily selected from the mineral fibers of the intermediate layer 1 described above, but a mineral fiber different from that of the intermediate layer 1 may be selected depending on the application.

The inorganic powder is added in order to increase hardness and prevent dents on the surface due to external impact while maintaining the fire resistance of the surface layer. For example, calcium carbonate, aluminum hydroxide and the like are added. These can be used alone or in combination of two or more.

The amount of the inorganic powder added to the mineral fibers is preferably such that the surface layer 4 has a specific gravity of 0.3 or more and 0.6 or less. When the specific gravity is less than 0.3, the hardness of the surface layer is low and it is not possible to sufficiently prevent the dents. When the specific gravity is more than 0.6, the surface layer becomes too hard and the cutting process becomes difficult and heavy. This is because the weight of the panel core material cannot be reduced.

The thickness of the surface layer 4 is preferably 3% to 20% of the total thickness of the panel core material. This is because if the thickness is 3% or less, the thickness of the core material is limited even if the density is high, and if the thickness is 20% or more, the surface layer becomes too hard.

As a method of manufacturing the core material for a panel according to this embodiment, for example, mineral fiber, lightweight aggregate, water and a binder are added and kneaded, and a plate-shaped mineral fiber plate 2 is formed by wet papermaking. Three
After drying it, one side of each of the mineral fiber boards 2 and 3 is cut to form a plurality of parallel grooves, while the remaining one side is covered with the inorganic powder obtained in another step. A plurality of cavities are formed by laminating and integrating the contained mineral fiber boards as the surface layer 4, and then laminating and integrating the one surfaces of the mineral fiber boards 2 and 3 provided with the concave grooves with each other. There is a method of forming 5. Wiring and piping may be provided in the hollow portion 5 of the intermediate layer 1, and a reinforcing crosspiece may be inserted.

Further, the manufacturing method is not limited to the above-mentioned one, and for example, the intermediate layer 1 as in the second embodiment shown in FIG.
It is also possible to form the hollow portion 5 by providing a concave groove only on one of the mineral fiber boards 7 forming the above, and by bonding the other mineral fiber board 6 without forming a concave groove. Further, it goes without saying that the mineral fiber board of the intermediate layer 1 may be formed by extrusion molding as in the third embodiment shown in FIG. In addition, as a method of forming the mineral fiber board for forming the intermediate layer 1 and the surface layer 4,
The present invention is not limited to wet papermaking and extrusion molding, and other existing methods may be used. In particular, the surface layer 4 is formed by applying a kneaded material of mineral fibers containing inorganic powder to the front and back surfaces of the intermediate layer 1. You may form.

[Brief description of drawings]

FIG. 1 is a partial cross-sectional view of a panel core material according to a first embodiment.

FIG. 2 is a partial cross-sectional view of a panel core material according to a second embodiment.

FIG. 3 is a partial cross-sectional view of a panel core material according to a third embodiment.

[Explanation of symbols]

 1 ... Plate-shaped intermediate layer 4 ... Surface layer 5 ... Cavity

Claims (1)

(57) [Claims] 1. A high-density surface layer containing mineral powder as a main component and inorganic powder on the front and back surfaces of a low-density plate-like intermediate layer containing a mineral fiber as a main component and containing a lightweight aggregate. A core material for a panel, characterized in that a plurality of cavities having openings at opposite side end surfaces are formed in the plate-shaped intermediate layer while being laminated and integrated.