JP2913256B2 - Panel with corrugated cardboard structure and method of manufacturing the same - 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 having a cardboard structure and a method of manufacturing the same.

[0002]

2. Description of the Related Art Conventionally, panels having a corrugated cardboard structure have been used as interior and exterior materials of buildings and vehicles, and various structural materials. This device has a structure in which an exterior plate or a surface plate also made of a metal plate or the like is bonded to both surfaces of a core material obtained by bending a metal plate into a corrugated shape by an adhesive (for example, Japanese Patent Application Laid-Open No. 3-314412). 56-958
No. 28, and Japanese Utility Model Laid-Open No. Sho 62-173495). These corrugated cardboard panels have features such as lighter weight and superior heat insulation properties as compared to muku materials and the like.

[0003]

The conventional corrugated cardboard panel has a problem in that it takes time and effort to bond the corrugated core member and the surface plate, and the bonding strength is low. An object of the present invention is to provide a cardboard structure panel which is easy to manufacture and has high bonding strength.

[0004]

According to the present invention, there is provided a panel having a corrugated cardboard structure, comprising: a corrugated core made of a laminate obtained by laminating a thermoplastic resin film on both surfaces of a metal base;
It comprises a surface plate bonded to both surfaces thereof, wherein the peaks and valleys of the core material and the surface plate are bonded by thermal fusion of the thermoplastic resin film.
In such a panel, at least one of the surface plates is a laminated plate obtained by laminating a thermoplastic resin film on one surface of a base material, and the surface plate and a core material,
It is preferable that the thermoplastic resin films are joined by heat fusion. Further, it is preferable to adopt, as the core material, a material having a polygonal cross-sectional shape in which rectangular or trapezoidal shapes are alternately and continuously arranged in opposite directions. Further, the core material may be provided in two or more stages.

According to the method of manufacturing a panel having a corrugated cardboard structure of the present invention, a laminate is prepared by laminating a thermoplastic resin film on both sides of a metal base material into a corrugated sheet to produce a core material. It is characterized in that the entire surface is heated while pressing the three members. In that case, a laminated plate obtained by laminating a thermoplastic resin film on one side of the base material is adopted as the surface plate, and the surface plate is arranged so that the film becomes the inner surface, and the whole is heated while pressing the three members. Is preferred.

[0006]

In the cardboard structure panel of the present invention, since the corrugated core is made of a metal plate laminated with a thermoplastic resin film, the surface plate, the core material, and the surface plate are stacked in this order, and a load is applied to them. When heating is performed as a whole while heating, the thermoplastic resin film on the surface of the core material is melted or softened, and further cooled, the core material and the surface plate are joined via the film. Therefore, the operation is greatly simplified as compared with the case of joining with an adhesive, and automation is also easy. Also, the joining strength is significantly improved as compared with the case of joining with an adhesive. Furthermore, since the assembly work and the joining work are separate,
At the time of assembling, the positional relationship between the core material and the surface plate can be easily corrected, so that the overall combination accuracy is high. Furthermore, since the core material is laminated with a resin film,
High durability. When using a laminate plate for the surface plate,
Since the film of the face plate and the film of the core material are joined,
The joining strength is further increased.

The above-described effects of improving the bonding strength and simplifying the manufacturing process can be more effectively exerted in the case of a panel in which a plurality of core members are stacked and interposed. In this case, by forming a plurality of cores all in the same shape and alternately stacking them one by one in the opposite direction, the ridges and valleys of the cores that are in contact with each other are brought into contact with each other. It can be easily assembled.

According to the method for manufacturing a panel having a cardboard structure of the present invention, the assembling step and the joining step are separate, so that the assembling step is particularly simplified, and the assembling accuracy is increased. Can be manufactured well. When using a plurality of cores, the top and bottom parts of the cores that are in contact with each other are brought into contact with each other by overlapping them one by one alternately while aligning both side edges with a guide. It can be easily assembled.

[0009]

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is an exploded perspective view of a panel having a cardboard structure according to the present invention. FIG. 1 is a partially cutaway perspective view showing an embodiment of a panel having a cardboard structure of the present invention, FIGS. 2a and 2b are partially enlarged front views of the panel of FIG. FIG. 4 is a main part process diagram showing one embodiment of a method of manufacturing the panel of FIG.
5 and FIG. 5 are front views of essential parts showing another embodiment of the panel having the cardboard structure of the present invention, and FIG. 6 is a partially cutaway perspective view showing still another embodiment of the panel having the cardboard structure of the present invention.

The panel A in FIG. 1 has a corrugated cardboard structure composed of a corrugated core material 1 and front plates 2 and 3 joined to the front and back sides, respectively. That is, FIG.
As shown in a, the core material 1 has a cross-sectional shape of a continuous curved line or a wavy line alternately folded at substantially the same pitch, and the top plates 4 and the valley portions 5 are brought into contact with the surface plates 2 and 3, Are joined. As shown in FIG. 2B, the core material 1 is made of a metal base material 6.
And a laminated metal plate composed of thermoplastic resin films 7, 7 laminated on both sides of the base material 6,
It is bent into a corrugated shape, and the surface plates 2 and 3 and the core material 1 are joined by fusion of the thermoplastic resin films 7 and 7.

Examples of the substrate 6 include a steel sheet such as a cold-rolled steel sheet, a surface-treated steel sheet whose surface is subjected to various surface treatments such as galvanization to enhance durability, and a light metal sheet such as an aluminum alloy. Various metal plates can be employed. On the other hand, as the thermoplastic resin, polyethylene, polypropylene, ethylene-propylene copolymer,
Olefinic resins such as ethylene-vinyl acetate copolymer, ethylene-acrylic ester copolymer, and ionomer; polyesters such as polyethylene terephthalate, polyethylene naphthalate, polybutylene terephthalate, and ethylene terephthalate / isophthalate copolymer; nylon 6, nylon Examples include polyamide resins such as 6.6, nylon 11, and nylon 12, and polyvinyl chloride, polyvinylidene chloride, and the like. Films made of these resins may be uniaxially or biaxially stretched or unstretched. The joining of the resin film to the metal plate may be any of heat fusion, adhesion using an adhesive, and heat fusion via a low melting point thermoplastic resin film.

The surface plates 2 and 3 may be metal plates such as a steel plate or an aluminum plate, and may be various boards such as paper, wood, and plaster. That is, if strength is required, a steel plate may be adopted, and aluminum may be selected for weight reduction according to the purpose of the panel.
In any case, if a thermoplastic resin film similar to that used for the core material 1 is laminated on one surface of the surface plates 2 and 3, the core material 1 and the surface plates 2 and 3 are heat-sealed. There is an advantage that the joining strength is increased when performing.

Next, a method of manufacturing the panel A having the cardboard structure constructed as described above will be described. First, a thermoplastic resin film is laminated on both sides of a strip-shaped metal plate by a laminating roll or the like to produce a laminated metal plate. Then, the laminated metal plate is cut into a predetermined size and bent into a corrugated plate by a press or the like to manufacture the core material 1. Then, as shown in FIG.
Laminate the surface plates 2, 3 of the same size as the core material 1,
After the load W is placed on the upper surface, the heating is performed in the heating furnace F. The heating temperature is a temperature at which the thermoplastic resin film melts or softens. As the heating furnace, any of a high-frequency heating furnace and a heating furnace using energy such as electric heating or gas combustion can be used.

Further, the film can be melted by applying a soldering iron or blowing hot air without using a heating furnace. In addition, when it puts in a heating furnace, one set of the material of the panel A is piled up in three stages and a large number of panels can be joined at a time, and one or several sheets are continuously flowed and heated. You can also. Further, the continuous strip-shaped laminated metal sheet is formed into a corrugated sheet shape by roll processing or the like, and is passed through a heating furnace while sequentially stacking strip-shaped surface plates on both sides thereof, thereby continuously forming a panel having a corrugated cardboard structure. It can also be manufactured.

In the embodiment shown in FIG. 1, the core material 1 has a gently curved curved cross-sectional shape, but as shown in FIG.
A core material 8 having a polygonal cross-sectional shape with a continuous trapezoid can also be employed. Since the peaks 4 and the valleys 5 of the core material 8 each have a constant width b, the contact area with the surface plates 2 and 3 is large. Therefore, there is an advantage that the joining strength is further improved.

As shown in FIG. 5, the core material 1 can be formed in a corrugated cardboard structure by stacking two or more layers. In this case, for example, guides 9 are provided on the left and right in accordance with the lower surface plate 2, and a core 1b, which is upside down, is placed on the first core 1a. If the core 1c oriented in the same direction as the eyes is superimposed on the third stage, the peaks 4 of the first stage core 1a and the valleys 5 of the second stage core 1b abut, and similarly. Crest 4 of second stage core 1b and third stage core 1
The valley 5 of c contacts. Therefore, in this state, the upper surface plate 3 may be further stacked and heated in a heating furnace.

Panel C shown in FIG.
They are shifted one by one and stacked together, and sandwiched between the surface plates 2 and 3 and joined to each other. This has an advantage that the bonding area between the core materials 1 and 1 is small, but it has sufficient bonding strength and has high bending strength in all directions. 5 and 6
In the case where the core members are stacked in multiple stages as in the embodiment shown in (1), the effect of the present invention that the core members are joined together at a high strength and can be joined at once is further exhibited. When cores are provided in multiple stages, a metal sheet or a sheet of another material may be interposed between the cores.

In each of the above embodiments, the inside of the panel having the corrugated cardboard structure is hollow, but a conventionally known heat insulating material or sound insulating material such as glass wool or rock wool may be filled in the inside. The use of the corrugated cardboard structure panel of the present invention is not particularly limited, and is adopted for various uses such as a simple storage room, a structural material such as a shelf, an interior material of a building or a vehicle, a heat insulating panel, and a sound insulating panel. can do.

[0019]

In the panel of the cardboard structure and the method of manufacturing the same according to the present invention, the bonding of the core material to the surface plate and the core material is performed by thermal fusion of a thermoplastic resin film previously laminated on a metal substrate. Since the joining strength is high and the joining can be performed efficiently at one time, the production efficiency is high. Further, since most of the core material is laminated with the resin film except for the cut end face, the corrosion resistance and durability are high. Further, in a panel having a corrugated cardboard structure using a laminate plate as a surface plate and a method of manufacturing the same, bonding strength is higher and durability is higher.

[Brief description of the drawings]

FIG. 1 is a partially cutaway perspective view showing an embodiment of a panel having a cardboard structure of the present invention.

FIGS. 2a and 2b are a partially enlarged front view of the panel of FIG. 1 and an enlarged sectional view of a P portion thereof, respectively.

FIG. 3 is a main part process view showing one embodiment of a method of manufacturing the panel of FIG. 1;

FIG. 4 is a front view of an essential part showing another embodiment of the panel having a cardboard structure of the present invention.

FIG. 5 is a front view of an essential part showing another embodiment of the panel having a cardboard structure of the present invention.

FIG. 6 is a partially cutaway perspective view showing still another embodiment of a panel having a cardboard structure according to the present invention.

[Explanation of symbols]

 A Panel of corrugated cardboard structure 1 Core material 2 Surface plate 3 Surface plate 6 Base material 7 Thermoplastic resin film B Panel of corrugated cardboard structure C Panel of corrugated cardboard structure

──────────────────────────────────────────────────続 き Continuation of the front page (58) Field surveyed (Int. Cl. ⁶ , DB name) E04C 2/36 B32B 1/00-35/00

Claims (6)

(57) [Claims] 1. A corrugated core made of a laminated plate obtained by laminating a thermoplastic resin film on both sides of a metal base material, and a surface plate joined to both sides thereof. A corrugated cardboard panel in which a valley and a surface plate are joined by thermal fusion of the thermoplastic resin film. 2. At least one of the surface plates is a laminated plate obtained by laminating a thermoplastic resin film on one surface of a substrate, and the surface plate and the peaks and valleys of the core material are formed of a thermoplastic resin film. The panel according to claim 1, wherein the panels are joined by heat fusion. 3. A cross-sectional shape of a polygonal line in which the core material has a rectangular or trapezoidal shape that is alternately and continuously arranged in a reverse direction.
Or the panel of 2. 4. The panel according to claim 1, wherein said core material is provided in two or more stages. 5. A core plate is manufactured by molding a laminated plate obtained by laminating a thermoplastic resin film on both surfaces of a metal base material into a corrugated plate, and a surface plate is arranged on both surfaces of the core material. A method of manufacturing a panel with a cardboard structure that heats the whole while clamping the three parties. 6. A core plate is manufactured by molding a laminated plate obtained by laminating a thermoplastic resin film on both surfaces of a metal base material into a corrugated sheet, and a thermoplastic resin film is formed on both surfaces of the core material on one surface. A method of manufacturing a panel having a corrugated cardboard structure in which a laminated face plate is arranged so that a film is on an inner surface, and the whole is heated while pressing the three members.