JP3310406B2 - Curved sandwich panel and manufacturing method thereof - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a curved sandwich panel used for furniture having a curved surface, a concrete formwork, and the like, and a method for producing the same.

[0002]

2. Description of the Related Art In recent years,
In Japan, the spread of Western-style architecture has been remarkable, and furniture has been westernized accordingly. Many of these Western-style furniture emphasize the decorativeness by using many curved surfaces unlike Japanese-style chests and the like. Conventionally, curved furniture has a large number of thin plates (for example, veneer or plywood having a thickness of 2 to 4 mm).
A curved panel formed by laminating and bonding between male and female molds was mainly used. However, this method requires a large compressive force, which increases the size of the pressing device. In addition, it is necessary to prepare a mold in accordance with the required shape each time. Was slightly unsuitable. What has been devised is a curved sandwich panel in which a honeycomb-shaped or corrugated paper core is used as a core material and thin surface materials are adhered to both surfaces thereof. This curved sandwich panel has high utility value if it is narrowed down because of its low manufacturing cost. Since it cannot be turned around, it is particularly unsuitable for producing furniture and concrete formwork.

[0003] It is an object of the present invention to provide a curved sandwich panel capable of performing a dowel and screw effect and a turning process, and of appropriately changing the strength as required, and a method of manufacturing the same.

[0004]

SUMMARY OF THE INVENTION In order to achieve the above object, the present invention provides a plurality of wooden rods arranged in a predetermined curved surface and a plurality of rods connected to each other. A first core having a flexible connection member, a curved paper second core disposed adjacent to the first core, and a curved surface corresponding to the respective curved surfaces of the first core and the second core. And a curved sandwich panel comprising a first core and a surface material adhered to one or both surfaces of the second core.

[0005] The present invention also provides a step of arranging a plurality of wooden rods in parallel, a step of connecting the rods with a flexible connecting member to form a first core, Is disposed at an appropriate location on the first surface material and is attached, and a second core made of paper is disposed adjacent to the first core at a vacant location on the first surface material, and is provided on one side. A method for producing a curved sandwich panel, comprising: a step of forming a sandwich panel; and a step of clamping a single-sided sandwich panel between upper and lower molds of a pressing device having a predetermined curved surface to form a predetermined curved surface. .

[0006]

FIG. 1 is a perspective view of a curved sandwich panel according to a first embodiment of the present invention.
Its internal structure is specifically shown. In the embodiment shown in FIG. 1, the curved sandwich panel 10 includes four sets of a plurality of wooden rods 12, a flexible connecting member 14 for interconnecting the rods 12 of each set, and a rod 12. It is mainly composed of a paper core 16 disposed at the center of the frame, and a surface material 18 (only one side is shown) adhered to both sides thereof.

As the material of the rod-shaped body 12 constituting the first core together with the connecting member 14, a parallel plywood excellent in workability is used. However, other than the parallel plywood, an appropriate wood fiber board can be used. The gap between the adjacent rods 12 may be appropriately set according to the height of the core and the radius of curvature of the curved surface. However, considering the strength of the sandwich panel as a finished product, the gap between the adjacent rods 12 inside the curved surface is considered. Is preferably as close as possible. However, in that case, the thickness of the connecting member 14 needs to be reduced. If it is made thin, the flexible connecting member 14 enters the gap between the adjacent rods when the connecting member is curved, and the surface material 18
There is no need to worry about creating irregularities. The connecting member 14 is preferably a nonwoven fabric made of synthetic fiber such as rayon, polyester, nylon, or the like. If the rod used is small and lightweight, a thickness of about 0.1 mm is sufficient.

On the other hand, the paper core 16, which is the second core, is formed by laminating a plurality of the most common corrugated cardboard paper. However, the internal structure is not limited to the illustrated embodiment. For example, a wing-shaped paper core or Japanese Patent Publication No. 5-45221 disclosed in Japanese Patent Publication No. 4-46221.
No. 414, a round paper core,
Alternatively, they can be used in appropriate combination.

[0009] The arrangement relationship between the first core and the second core is as follows: a place where a certain degree of strength is required, a place where dowels and screws need to be applied, a place where cutting is required, and a place where water resistance is required. What is necessary is just to set and change appropriately according to the above. Of course, where they are required, a first core consisting of a wooden rod is provided to meet that requirement, while where there is no need, the second core is a paper core. The weight and the manufacturing cost may be reduced by disposing a core made of steel.

As the material of the surface material 18, a rawan plywood is used in consideration of workability, but a melanin resin board or a wood fiber board, which is also flexible and rich in elasticity, may be used. Further, not only wood-based materials but also thin plates made of aluminum or steel can be used.

Next, a method for manufacturing a curved sandwich panel according to a first embodiment of the present invention will be described in detail with reference to FIGS.

First, a plurality of rods 12 are arranged in parallel as shown in FIG. 2, and a nonwoven fabric (connecting member) 14 is adhered to both sides thereof to form a space between adjacent rods 12. Hold. In the illustrated embodiment, the non-woven fabric is stuck on both sides of the rod-shaped body 12. However, this non-woven fabric is used only for temporary fixing, so that only one side may be used. However, it is needless to say that when a thick rod is used, it is preferable to stick it on both sides. In FIGS. 1 and 2, the edges 12a of the rods 12 are substantially perpendicular to each other. However, when the surface material 18 to be used is soft or a thin plate material of 2 mm or less, FIG. If the edges of the rods 12 are chamfered and rounded (12b), so-called "burrs" on the surface material can be effectively prevented.

Next, as shown in FIG. 4, a first core, which is a rod-shaped body 12 connected by a non-woven fabric 14, is attached to each side of the surface material 18 using an appropriate adhesive (in FIG. The rods located on the sides are in a state before sticking). Then, a second core (paper core), which is a corrugated cardboard paper, is inserted into a central portion surrounded by a rod. At this time, it is advantageous in terms of strength to arrange the ridge line of the corrugated second core so as to extend in the thickness direction of the sandwich panel 10. In the first embodiment, the reason why the first core was attached to the side is
This is because a higher strength is required in this portion than in the central portion, and a part of the portion is later cut and processed to be provided with a handle or the like.

When the adhesive used for the attachment is cured, another surface material 18 is attached to one side of the side on which the surface material is not attached using an adhesive made of a thermosetting resin, and a double-sided sandwich panel is provided. And At this point, the sandwich panel is flat and the thermosetting resin remains uncured. Then, from this state, the double-sided sandwich panel is placed on the concave portion of the lower die 20a of the pressing device 20, as shown in FIG. Further, a flexible auxiliary pressing means 22 (for example, a round core disclosed in Japanese Patent Publication No. 5-45414) in which a plurality of cardboards are stacked is placed on the upper surface of the sandwich panel as shown in FIG. I do.

Thereafter, the upper die 20b of the pressing device 20 is lowered to press the double-sided sandwich panel between the upper die 20b and the lower die 20a as shown in FIG. When pressed,
The central portion of the curved sandwich panel curves into the recess of the lower mold 20a, and the whole is deformed into an arc shape. At this time, the both sides of the auxiliary pressurizing means 22 are considerably compressed, but the center portion transmits the compressive force of the upper mold 20b to the center portion of the curved sandwich panel while keeping the substantially original state. This auxiliary pressurizing means can be used repeatedly, and it is not necessary to process the lower surface of the upper mold 20b into a special convex shape. Further, the pressing device 20 is provided with a heating means (not shown) which is, for example, a sheet-shaped heater, and sets the curing time of the thermosetting resin used when attaching the second surface material. It can be greatly reduced (especially when the thickness of the sandwich panel is 30 mm or more, the required curing time can be reduced to about 1/10).

FIG. 8 is a perspective view of a curved sandwich panel according to a second embodiment of the present invention. The curved sandwich panel 30 includes two sets of wooden rods 32 (only one set is shown), a flexible connecting member 34 for interconnecting the rods 32 of each set, and a rod 32. Mainly consisting of a corrugated paper core 36 disposed in the middle of the surface material and a surface material 38 attached to both surfaces thereof (a front half of one of the surface materials is cut away to specifically show the internal structure), The difference from the first embodiment is that the number of sets of rod-like bodies is two less and that the curved shape is S-shaped.

When manufacturing the curved sandwich panel 30, first, similarly to the first embodiment, a plurality of rods 32 are arranged in parallel, or an edge material corresponding to the first core of FIG. After disposing, a nonwoven fabric (connecting member) 34 is adhered to both surfaces thereof to maintain a space between the adjacent rod-shaped bodies 32. Next, the first core, which is the rod-shaped body 32 connected by the non-woven fabric 34, is flattened with an appropriate adhesive.
Affix to the left and right sides. Then, a second core (paper core) 36, which is a corrugated cardboard paper, is inserted into a central portion sandwiched between two sets of right and left rods 32. At this time, it is more advantageous in terms of strength to dispose the ridge line of the corrugated second core so as to extend in the thickness direction of the sandwich panel 30.

When the adhesive used for one-sided application is cured,
Another surface material 38 is adhered to one side of the side on which the surface material is not adhered using an adhesive made of a thermosetting resin to form a double-sided sandwich panel. At this point, the sandwich panel is flat and the thermosetting resin remains uncured.
Then, the double-sided sandwich panel is moved from this state in FIG.
As shown in the figure, the pressing device 40 is placed on the S-shaped recess of the lower die 40a. Next, the upper mold 40b of the pressing device 40 is lowered, and as shown in FIG.
Press the double-sided sandwich panel in between. When pressed, the curved sandwich panel curves along the S-shaped inner surface of the mold and is entirely deformed into the S-shape shown in FIG. In this embodiment, as in the previous embodiment, a heating means (not shown) is additionally provided to the pressing device 40, so that the curing time of the thermosetting resin can be greatly reduced. Further, it goes without saying that the use of the auxiliary pressurizing means used in the first embodiment makes it easier to process one mold.

FIG. 11 is a perspective view of a curved sandwich panel according to a third embodiment of the present invention (a part of a surface material is cut away to specifically show an internal structure), and FIG. The difference is that the thickness of the front and rear side portions in the figure is different. The curved sandwich panel 50 of the present embodiment is useful, for example, when used on a back plate of a chair. Conventionally, such panels having different thicknesses have been manufactured using a single plate, but the cutting process has been difficult. In the present invention, if the so-called "rebate" is applied to the method of the first embodiment, it can be easily manufactured.

In manufacturing, first, a plurality of rod-like members 52
a to 52e are arranged in parallel as shown in FIG.
Non-woven fabric 54 is stuck on both sides of the
The interval between a to 52e is maintained. In this embodiment, the rods 52a to 52a are moved from one side to the opposite side.
Although the thickness of e is made thinner, it may be the same as the rod-shaped body of the first embodiment. Next, the rod is cut along the line AA. At this time, the width W of the bar-like body 52e in front is
The cutting line is set so that 1 is narrower than the width W2 of the rod 52a at the back. Then, from the state shown in FIG. 12, when a set of cut rods is turned 90 degrees in a direction opposite to the clockwise rotation direction and placed sideways, as shown in FIG. The height H1 (which is also the thickness of the curved sandwich panel) is lower than the height H2 on the opposite side. Heights H1 and H2 correspond to widths W1 and W2, respectively. In order to use this curved sandwich panel as a back plate of a chair, it is preferable to attach the rod-shaped body 52a to the seat plate. This allows
The radius of curvature of the back plate becomes smaller toward the upper end side, and the back plate has a curved surface that is just right for the shape of the human back. In the case of this embodiment, a fixed shape type, such as a round core, which cannot be extended, is suitable for the paper core as the second core.

[0021]

As described above, according to the present invention, a place where a certain degree of strength is required, a place where dowels and screws need to be applied, a place where cutting is required, and a place where water resistance is required Etc., a plurality of wooden rods are provided to meet the demands, and paper paper cores are placed where they are not necessary, so that weight and manufacturing costs can be reduced while maintaining the required strength. Can be reduced. In addition, the present invention has various effects, such as easy processing into a primary curved surface by appropriately setting the interval between adjacent rods.

[Brief description of the drawings]

FIG. 1 is a perspective view of a curved sandwich panel according to a first embodiment of the present invention. However, one surface material has been removed to specifically show the internal structure.

FIG. 2 is a partial perspective view illustrating a method for manufacturing a first core.

FIG. 3 is a view similar to FIG. 2, with the edges of the rods chamfered.

FIG. 4 is a perspective view illustrating one manufacturing process of the curved sandwich panel of FIG. 1;

FIG. 5 is a view for explaining one manufacturing process of the curved sandwich panel of FIG. 1;

FIG. 6 is a view for explaining one manufacturing process of the curved sandwich panel of FIG. 1;

FIG. 7 is a view for explaining one manufacturing process of the curved sandwich panel of FIG. 1;

FIG. 8 is a perspective view of a curved sandwich panel according to a second embodiment of the present invention. However, a part of the surface material is cut out to specifically show the internal structure.

FIG. 9 is a view for explaining one manufacturing process of the curved sandwich panel of FIG. 8;

FIG. 10 is a view for explaining one manufacturing process of the curved sandwich panel of FIG. 8;

FIG. 11 is a partial perspective view of a curved sandwich panel according to a third embodiment of the present invention. However, a part of the surface material is cut out to specifically show the internal structure.

FIG. 12 is a perspective view of a first core used for manufacturing the curved sandwich panel of FIG. 11;

[Explanation of symbols]

 12 rod-shaped body 14 connecting member 16 paper core 18 surface material 20 pressing device 20a lower die 20b upper die 22 auxiliary pressing means 32 rod-shaped body 34 connecting member 36 paper core 38 surface material 40 pressing device 40a lower die 40b upper die 52a rod-shaped body 52b rod-shaped body 52c rod-shaped body 52d rod-shaped body 53e rod-shaped body 54 connecting member

──────────────────────────────────────────────────続 き Continuation of the front page (56) References JP-A-57-191001 (JP, A) JP-A-4-37532 (JP, A) JP-A-63-210342 (JP, A) 79640 (JP, U) Fully open sho 57-201260 (JP, U) Fully open sho 58-36108 (JP, U) (58) Fields investigated (Int. Cl. ⁷ , DB name) B32B 1/00-35 / 00

Claims (12)

(57) [Claims] 1. A curved sandwich panel, comprising: a first core having a plurality of wooden rods arranged in a predetermined curved surface and a flexible connecting member interconnecting the rods; A curved paper second core disposed adjacent to the first core, formed into a curved surface corresponding to the respective curved surfaces of the first core and the second core, the first core and the second core A curved sandwich panel comprising a surface material attached to one or both sides. 2. The curved sandwich panel according to claim 1, wherein the rod-shaped body has a rectangular cross section and an edge is chamfered. 3. The curved sandwich panel according to claim 1, wherein the plurality of rods are provided at a predetermined distance. 4. The curved sandwich panel according to claim 1, wherein the plurality of rods are arranged in an arc shape, the inner surface of which is in contact with the outer surface, and the outer surface of which is separated. 5. The curved sandwich panel according to claim 1, wherein said flexible connecting member is a non-woven fabric. 6. The curved sandwich panel according to claim 1, wherein the second core is a round core. 7. The curved sandwich panel according to claim 1, wherein the second core is a wing core. 8. A method of manufacturing a curved sandwich panel, comprising: a) arranging a plurality of wooden rods in parallel; and b) connecting the rods with a flexible connecting member to form a first core. C) arranging the first core at an appropriate place on the first surface material and sticking it; and d) adhering a second core made of paper adjacent to the first core. Disposing the single-sided sandwich panel by arranging the first-sided material in an empty place; and e) pressing the single-sided sandwich panel between upper and lower molds of a pressing device having a predetermined curved surface. Forming a curved sandwich panel. 9. A double-sided sandwich panel obtained by attaching a second surface material to a surface opposite to a side to which the first surface material is attached, and then pressing the double-sided sandwich panel having a predetermined curved surface. 9. The method for manufacturing a curved sandwich panel according to claim 8, wherein a predetermined curved surface is formed by pressing between upper and lower molds of the apparatus. 10. The second surface material is adhered using a thermosetting resin, and a heating means is attached to the pressing device, so that the thermosetting resin is heated by the heat generated by the heating means. The method for producing a curved sandwich panel according to claim 9, which is cured. 11. The method for manufacturing a curved sandwich panel according to claim 8, wherein a flexible auxiliary pressing means is inserted between the upper and lower molds to press the double-sided sandwich panel. . 12. The method for manufacturing a curved sandwich panel according to claim 8, wherein the first core is used by being returned.