JP4454685B1 - Stretchable and bendable structure - Google Patents

Abstract

An object of the present invention is to provide a structure that is excellent in strength and handleability and that can be handled in both a planar shape and a curved shape without the need for grooving.
A structure is formed by laminating a plurality of strip-shaped plate base materials with the plate surfaces facing each other, except for the plate base material at the uppermost end and the lowermost end of the plate, It is alternately bonded to the upper and lower plate bases via non-adhesive parts that are not bonded to other plate bases, and the adhesive part is at least one of the upper and lower plate bases. Two or more places are provided between the two materials, and when the structure is stretched in the laminating direction, a spindle shape in which the upper side and the lower side are composed of the two plate base materials between two adjacent plate base materials. The cell is opened.
[Selection] Figure 2

Description

  The present invention relates to a structure that can be used as a core material for furniture and building materials (such as joinery and pillars), a pallet for carrying goods, and the like.

  Some papers (cardboard) are used for parts that cannot be seen in furniture and joinery to improve strength and physical properties (such as correction of warping and bending). A typical example is a flash panel having a structure in which a paper honeycomb core is sandwiched between face materials. However, the paper core itself and the product are likely to have serious defects in strength, warpage, and surface adhesion strength. For example, in a flash panel using a paper core, since the core material is thin, the bonding area between the core material and the face material is small, and the adhesive force is insufficient. Therefore, the distortion of the face material cannot be sufficiently absorbed. Further, since the core material is thin and light and does not have sufficient strength, there is a problem that when the face material is displaced (warped or bent), the flash panel itself is warped.

In order to solve such a problem, the present inventor invented the structure according to Patent Document 1 for the purpose of providing a structure that has excellent strength and can sufficiently reinforce the face material.
According to the invention of Patent Document 1, the strength is higher than that of a paper-made honeycomb core, and when used as a core material of a flash panel, since the adhesive strength with the face material is also high, the face material is sufficiently reinforced. be able to. Furthermore, since it expands and contracts, it is convenient for storage and carrying, and when used as a core material, the effect that the size can be adjusted according to the size of the face material is obtained.

Japanese Patent No. 4286899

  However, the structure of Patent Document 1 has a problem that it takes time to process the groove, and since a flexible sheet is required, a face material (so-called decorative board) in which decorative paper or the like is pasted on both sides is used. However, when using a board without a sheet attached, it takes time to apply a flexible sheet again, and does not contribute to the effective use of waste materials other than the decorative board.

  In addition, the structure of Patent Document 1 can correspond to a free shape in the plane, but has a problem that the bending groove partially blocks the strength of the plate base material, and further has a curved shape. If you try to bend it, the flexible sheet that connects both sides of the groove for bending breaks, and the base plate is divided at the groove. There was a problem that it could not be used as a core material.

  In order to solve the above-described problems, an object of the present invention is to provide a structure that is excellent in strength and handleability, does not require labor for grooving, and can handle both a planar shape and a curved surface shape. .

  As a result of repeated studies to solve the above-mentioned problems, the present inventor is capable of expanding and contracting on a plane and bending along a curved surface while being a structure made of a highly rigid plate. The present invention was completed by successfully providing a simple structure.

In order to solve the above problems, the structure according to the present invention has the following configuration.
It is a structure formed by laminating a number of strip-shaped plate base materials with the plate surfaces facing each other,
Except for the uppermost and lowermost plate base materials, the plate base materials are alternately turned up and down with plate base materials stacked on the top and bottom via non-adhesive parts that are not bonded to other plate base materials. is bonded to, and, the adhesive portion is at least that provided at two or more locations between the upper or lower plate substrate,
Notches are formed on one edge or both edges along the longitudinal direction of the plate base material,
The notch is formed in the same position in each plate base material, and is formed in the adhesive portion;
When the structure is stretched in the stacking direction, a spindle-shaped cell having an upper side and a lower side made of the two plate bases opens between two adjacent plate bases.

The structure is very compact because it remains in a state where thin plates are laminated when it is not extended. And each board base material of the above-mentioned structure is pasted up and down alternately with the board base material laminated on the upper and lower sides via the non-adhesion part which is not pasted up with other board base materials, and Since the adhesive portion is provided at least two places between the upper and lower plate base materials, when the structure is pulled in the stacking direction, the upper side and the lower side between the two adjacent plate base materials However, a plurality of spindle-shaped cells composed of the two plate base materials appear and extend in the stacking direction (see FIGS. 1 and 2).
Here, in the plate base materials other than the uppermost layer and the lowermost layer, there are two bonding portions with one plate base material laminated on or under the plate base material, and the other base material is bonded. When the number of parts is one, one row of cell groups appears in the stacking direction, and when there are two bonding portions with both the upper and lower plate bases, two rows of cell groups appear in the stacking direction. Similarly, when there are three adhesion portions with one plate base material laminated on the top or bottom and two or three adhesion portions with the other plate base material, three rows or four rows A group of cells appears. The number of cells constituting one row is the number obtained by dividing the number of plate base materials by 2 or the number obtained by subtracting 1 from the number.
In a preferred structure, there are at least three bonding portions between the upper and lower plate bases.

The conventional paper honeycomb structure (hexagonal cells appear when stretched) is provided with folds, and the structure of Patent Document 1 is also provided with a groove for bending on the plate surface. In both cases, cells surrounded by straight lines appear. If folds and grooves are provided in this way, there is a problem that the strength inherent in the material is partially blocked. On the other hand, in the structure according to the present invention, since a groove or the like for bending the plate base material is not configured, a cell surrounded by a curve appears. That is, since the product of the present invention is used without damaging the strength of the plate base material itself, the strength against bending is improved as compared with the structure of Patent Document 1. Moreover, since stress is applied to the material itself in the open state, a resistance force is always applied, and the bending strength is further improved.
Further, unlike the structure of Patent Document 1, it is not necessary to provide a bending groove, a flexible sheet, or the like, and it can be manufactured only by bonding the plate base material. Therefore, the manufacturing is simple, low-cost production, and mass production. Is possible. For example, after applying adhesive to a 4 m x 2 m size face material with a certain width, laminating the face material, pressing and bonding with a press machine, and then cutting to a desired width, the length 4 m ( Alternatively, a large number of structures made of a plate substrate having a size of 2 m) × several cm can be produced. Since a structure having a long length can be manufactured in this manner, a flash panel or the like that maintains strength against bending can be manufactured.

  Further, the structure can be curved so as to form a curved surface. That is, when the plate body at the uppermost end and the lowermost end of the laminated structure is grasped and a force is applied to warp in the lamination direction, the structure is curved to form an arcuate curved surface (see FIG. 3). . By curving the plate substrate while stretching it in the laminating direction, it is possible to deal with both small and large arcs. It is also possible to make a cylindrical shape by curving until the uppermost and lowermost plate substrates come into contact with each other, and further to form a partial arc shape or bend into an S shape. Since only a part of the curved surface shape is possible, various curved surface shapes can be handled.

The length of the adhesive portion in the longitudinal direction of the plate substrate is preferably 20 mm or more. Further, the length of the upper side and the lower side of the cell (hereinafter also referred to as the length of one side of the cell) is preferably 3 times or more, more preferably 4 times or more of the length of the adhesive portion. .
When the length of one side of the cell is too shorter than the above, the upper limit of the cell opening height (maximum value of the inner diameter of the cell in the stacking direction) becomes small, so that sufficient deformation cannot be achieved.

When the structure according to the present invention is stretched in the laminating direction (that is, extended in a plane) or warped in the laminating direction (that is, extended so as to form a curved surface). However, since the cells appear almost uniformly, the strength is not biased.
And the state which deform | transformed can be maintained by putting the material which plays the role of a crosspiece in each cell in the state which the cell opened. Such a fixture is preferably a plate-like fixture having rigidity, and a U-shaped notch or U-shaped notch is provided at a desired pitch on one edge along the longitudinal direction. The structure can be fixed in a state where the cells are opened by disposing the fixing tool in a direction orthogonal to the plate substrate of the structure and fitting the plate substrate into the notch. At this time, a linear fixture may be used to hold the deformation on the plane, and a curved fixture may be used to hold the deformation on the curved surface. Since it is preferable to hold the adhesive part of the plate base material for stable fixation, the notch of the fixing tool is a size suitable for fitting the adhesive part of the plate base material (that is, the base material 2). It is preferable to use a size that allows insertion of sheets.
Correspondingly, a U-shaped or U-shaped notch is formed at one edge along the longitudinal direction of the plate base material constituting the structure, and this notch is formed on each plate base material. If they are formed at the same position, it is convenient to fix the structure with the cells open. For example, as a fixture described above, using a fixture having the same plate width as the plate base material, the total of the notch of the fixture and the notch depth of the plate base material (length in the width direction of the plate) If the notches of both are formed to match the width of the plate base material, the fixture and plate base material can be combined completely in the same space by fitting the notches of the fixture and plate base material together. Therefore, it is possible to fix without causing unevenness on a flat surface or curved surface formed by extension. If the notch of the plate base is too deep, there is a risk of breakage. Therefore, the depth of the notch on the side of the plate base is preferably less than half the width of the plate base (more preferably the plate base 1/5 to 2/5 of the width). The notches on the plate substrate side may be provided on both edges along the longitudinal direction, but in this case, the positions of the notches on each edge are preferably different.
Moreover, it is preferable to provide the notch of a board | substrate base material in an adhesion part.

  As an example of a suitable structure, it is composed of a plate substrate having a thickness of 1 to 5 mm, the length of the adhesive portion is 20 to 80 mm, the length of one side of the cell is 200 to 800 mm, and one side of the cell The structure whose length is 4 times or more of the length of the said adhesion part can be mentioned.

  The structure of the present invention is suitable for use as a core material of a building material or furniture having a flat surface and / or a curved surface (for example, a flash panel, a pillar, a back portion of a chair, etc.). At this time, if a structure made of the same material as the face material (surface material) is used, adhesion to the face material is easy.

  The structure of the present invention is suitable for use as a pallet for carrying goods. As a preferable example when used as a pallet, a plate base material having a width of 100 to 200 mm is used (as a material, a synthetic resin such as vinyl chloride is preferable), and at least half (more preferably 2/3) from one end side in the stacking direction. A structure in which holes for inserting a fork of a forklift are continuously provided on the plate surface of the plate base material as described above.

  The structure of the present invention can be manufactured by a simple process. In addition to being able to expand and contract within a plane, it can be expanded and contracted within a curved surface, and can be adjusted to a desired size by the strength of the extending force, so it is very versatile. It is convenient for storage and carrying because it has the capacity of just stacking the plates when not extended. In addition, since the strength can be adjusted by adjusting the material, thickness, and width of the plate base material, it can be used not only as a core material for furniture or the like but also as a pallet on which tons of luggage are placed.

It is a figure which shows typically the state at the time of the non-extension of the structure concerning this invention, Comprising: A is a side view, B is a front view, C is a top view. It is a front view which shows typically the state which extended the structure of FIG. 1 planarly, and was fixed with the fixing tool. It is a front view which shows typically the state which extended the structure of FIG. 1 in the curved surface form. It is a figure explaining the adhesion part of each board | substrate base material in the structure concerning Example 1. FIG. It is a figure which shows the fixing tool (4 types) concerning this invention. It is a figure which illustrates typically the structure concerning Example 7, Comprising: A is a front view and B is a bottom view. It is a figure which shows the structure and fixing tool concerning Example 8, Comprising: A is a bottom view of a structure, B is the front view which fixed the structure in the extended state, C shows a fixing tool. 4 is a photograph showing a structure similar to that in Example 2. 6 is a photograph showing a structure similar to that in Example 4. 6 is a photograph showing a structure similar to that in Example 5. It is a photograph which shows the non-extension state of the structure similar to FIG. It is a photograph which shows the extension state of the structure similar to FIG. FIG. 10 is a diagram schematically illustrating another structure and a fixture according to Example 8, wherein A is a bottom view of the structure, B is a front view of the structure fixed in an extended state, and C is fixed. Indicates ingredients. FIG. 10 is a diagram schematically showing another structure and a fixture according to Example 8, wherein A is a bottom view of the structure fixed by the fixture, and B is a front view of the structure fixed in the extended state. And C represents a fixture. It is a figure explaining the flash door concerning Example 12. FIG.

The plate base material of the present invention bends when a force is applied, but has rigidity and flexibility enough to return to the original linear shape when the force is removed, and is made of a material that can be bonded. Any plate substrate may be used. Bonding includes not only bonding with an adhesive but also welding.
Examples of such plate base materials include 1 mm to 5.5 mm thick MDF (medium fiberboard), 3 mm to 4 mm thick particle board, 1 mm to 5 mm thick plywood, 1 mm to 5 mm thick resin board (vinyl chloride resin) , Acrylic resin, etc.) 1 mm to 4 mm thick reinforced paper, about 0.5 mm thick iron plate, 0.3 to 1 mm thick aluminum plate. If the surface of the board substrate is coated with a sheet of paper or synthetic resin (for example, a decorative board), the sheet layer may be peeled off during extension, so use a board substrate that is not coated with the surface. Is preferred.

Adhesion between plate base materials may be performed using an appropriate adhesive in consideration of the material of the plate base material. For example, when the plate substrate is made of a synthetic resin or a wood material, a vinyl acetate resin adhesive can be used.
Further, when the plate substrate is made of a metal / synthetic resin, it may be bonded by welding or welding without using an adhesive.

  Moreover, the structure of this invention can be used for various uses besides core materials, such as furniture, by adjusting the material, width | variety, thickness, etc. of a board | substrate base material. For example, if a synthetic resin plate (acrylic resin plate, vinyl chloride resin plate, etc.) is used, it is excellent in weather resistance, and thus is suitable for external use. Further, if the strength is increased, it is also suitable for use as a snowboard, gate, gutter lid, shutter, container, pallet (loading platform that moves with a forklift or the like while carrying the load).

  The thickness of the plate substrate is preferably 0.3 mm or more and 1 mm or less in the case of a metal plate (iron plate or aluminum plate), and preferably 1 mm or more and 6 mm or less (more preferably 2 to 4 mm) in the case of a synthetic resin plate or a wood material plate. . If it is too thin, the strength decreases, and if it is too thick, the weight increases.

  The board width of the board substrate may be appropriately selected according to the use (furniture core material, pallet, etc.). When used as a core material, a width of 10 to 40 mm is common, and 25 to 35 mm is a commonly used size.

  What is necessary is just to select the length of a board | substrate base material suitably according to a use. For example, when used as a core material of a flash panel, the length of the plate base material is in a general range of 650 to 2000 mm. When used as a pallet, 900 to 2000 mm is a general range.

  In the present invention, the fact that a large number of plate substrates are laminated means that at least four plate substrates are laminated. What laminated | stacked 8 or more sheets is more preferable.

About 20 mm-70 mm are preferable and, as for the length (length in the longitudinal direction of a board | substrate base material) of an adhesion part, about 30-60 mm is more preferable. If the bonded portion is too short, it is easy to peel off, which causes a problem in terms of durability. On the other hand, if the bonded portion is too long, the stretch ratio is lowered. Moreover, although it is ideal that the length of all the adhesion parts is equal, you may differ somewhat for every adhesion part. For example, in the case of an average of 50 mm, even if it is different within a range of 40 to 60 mm (± 20% with respect to the average value), it can be used without any problem.
The length of one side of the cell may be appropriately changed depending on the desired extension of the structure, but is preferably about 200 to 800 mm, and more preferably about 300 to 600 mm. Further, the length of one side of the cell is preferably 4 times or more, and more preferably 5 times or more the length of the bonded portion. Ideally, the length of one side of the cell should be uniform in all places, but it may be slightly different for each cell, and may be about ± 15% different from the average value.

In the structure of the present invention, each plate substrate is bonded to the upper plate substrate (a) except for the uppermost and lowermost plate substrates, and is bonded to any plate substrate. Plates that are stacked up and down in repetition of a portion (b) that is not bonded, a portion (c) that is bonded to the lower plate substrate, and a portion (b ′) that is not bonded to any plate substrate Although it connects with a base material, it is preferable that b and b 'are equal at this time (namely, c exists in the midpoint between adjacent aa). By configuring in this way, a symmetrical spindle-shaped cell with the center swelled most appears, so that strength bias and distortion are less likely to occur. Note that c may be slightly deviated from the midpoint between aa, but if it is too deviated, it becomes difficult for the cell to open. Therefore, the deviation from the midpoint between aa is 1 of the length of one side of the cell. / 5 or less is preferable.
In the present invention, the adhesive portion may be provided at two or more places between the upper and lower plate base materials (that is, each plate base material includes the above (a) or (c) at two or more locations). Just fine). When the adhesive portion is provided at two places between one plate base material laminated on the top or bottom and at one place between the other plate base materials, as shown in FIG. A row of spindle-shaped cells is opened in a row. In the case where the adhesive portion is provided at three places between one plate base material laminated on the top or bottom and at two places between the other plate base material, as shown in FIG. Three rows of cell groups are opened. The number of cells constituting each row is the number obtained by dividing the number of plate base materials by 2 or the number obtained by subtracting 1 from the number. In the structure of FIG. 2, since 22 plate base materials are used, two rows of 11 cells and one row of 10 cells (center row) appear.

  Hereinafter, the structure according to the present invention will be described in more detail by way of examples.

The structure according to the present invention was manufactured by the following procedure. 1 to 3 show a structure similar to the structure of the present embodiment (the number of plate base materials, the number of adhesion portions, the presence or absence of notches 5 and the like are different).
A 2.5 mm thick MDF (length 2150 mm × width 150 mm) was used as the plate substrate 2. Eight plate base materials 2 are prepared. As shown in FIG. 4, an adhesive (vinyl acetate emulsion adhesive) is applied to one end of the top surface of the second, fourth, sixth, and eighth plate bases in a width of 50 mm. The adhesive was further applied at a constant interval (370 mm) (also 50 mm width) (hereinafter, in this example, the area where the adhesive was applied to each plate substrate (50 mm width)) Is a bonding part 3, and a range (370 mm width) where the adhesive is not applied is called a cell side). The adhesive was applied to the third, fifth, and seventh plate base materials at the same interval and the same width so as to be located at the center of the cell side of the even-numbered plate base material. Eight plate base materials were laminated (adhesive coating amount 190 g / m ² ) and pressed for 40 minutes with a cold press pressure of 5 kg / cm ² to bond the plate base materials.
As shown in FIG. 1 (B), in the plate substrate 2 other than the uppermost layer and the lowermost layer, the structure is bonded to the upper plate substrate / unbonded to any plate substrate / lower. It is connected to the upper and lower plate bases by repeating the four places of the part bonded to the plate base material / the part that is not bonded to any plate base material, and the bonding part 3 is moved up and down via the non-bonding part. It becomes the structure repeated alternately.

When the structure 1 is stretched in the stacking direction, as shown in FIG. 2, a spindle shape (a shape in which the vicinity of the center is thick and the both ends are gradually narrowed) surrounded by curves between the plate base materials 2 is obtained. Many cells 4 appeared. The upper side and the lower side of each cell are composed of two adjacent plate base materials, and the length of the upper side and the lower side is 370 mm.
Each cell 4 opens very evenly, and the opening size of the cell can be adjusted according to the degree of force of extension.

  About the said structure 1, it cut | disconnected so that the width | variety of the board | substrate base material 2 might be set to 25 mm. By reducing the width of the plate substrate 2, the structure 1 can be freely expanded and contracted with a smaller force.

  FIG. 3 shows a state where the structure 1 is bent into a curved shape. As shown in FIG. 3, when a force is applied so that the uppermost plate base material and the lowermost plate base material of the laminated body approach each other, that is, the structure warps in the stacking direction, A spindle-shaped cell appears between the two, and the structure 1 is curved. Although FIG. 3 shows a state of being curved in a semi-columnar shape, a more cylindrical shape is obtained when more force is applied, and a gentler curved surface is formed when the force is weakened. Furthermore, a conical shape (or a partial shape of the cone) is applied by applying a force to one end side of the plate base material, or an S-shape is formed by changing the bending direction in the middle as shown in FIG. It is also possible.

  Since the opening area of the cell 4 can be adjusted by the strength of the extending force, the structure 1 can be adjusted to a desired size by appropriately adjusting the opening degree of the cell 4 during use.

  Since the length of one side of the cell 4 and the length of the bonding portion 3 are determined at the time of manufacturing the structure, they may be appropriately adjusted according to the intended use. If the length of one side of the cell is increased, the upper limit of the cell area at the time of opening is increased, so that a structure with a higher extension rate can be obtained. On the other hand, if the length of one side of the cell is shortened, the plate A substrate having a high density and excellent strength can be obtained. The length of the adhesive portion may be a length having sufficient adhesive strength in consideration of the length of one side of the cell or the force applied to the structure. Since this varies depending on the rigidity, material, desired adhesive strength, etc. of the plate base material, it may be adjusted as appropriate.

Using a 2.5 mm thick MDF, a structure composed of 16 plate base materials having a length of 2150 mm and a width of 25 mm was prepared. The configuration is the same as that of Example 1 except for the number of plate base materials. After that, put the structure in the frame for flash door (frame inner diameter size: height 2030mm, width 780mm, frame thickness 25m) so that the plate base material is parallel to the height direction of the door, The structure was stretched until the uppermost end and the lowermost plate base material of the structure reached the vertical core of the frame, and the uppermost and lowermost plate base materials and the vertical core of the frame were bonded (see FIG. 8; The number of plate base materials and the bonding location are different from the structure of this embodiment). Adhesion with the vertical core was performed so as to be the same as the adhesion pattern between the plate substrates. Note that the length of the plate base material is 2150 mm compared to the frame height of 2030 mm, but when stretched in the stacking direction, the plate base material deforms so as to wave, so the structure can be put into the frame without any problem. I was able to pay.
Nine rows of cell groups appeared in the stacking direction, and the number of cells in each row was 8 or 7. Each cell was almost uniform, and the opening height of each cell (the maximum value of the cell inner diameter in the stacking direction) was about 93 mm. However, since the force to return to the original laminated state is large, the vertical core of the frame body is slightly bent inward, and it becomes difficult to cut the vertical core in the subsequent process (equal 3 mm cut-off).
In order to make the opening of each cell small and weaken the force to return to the original laminated state, a structure in which the number of plate bases was increased to 28 was created. When fixed in the frame as above, the opening height of each cell was about 50 mm. As a result, the rigidity of the vertical core exceeded the contraction force of the structure. This time, the vertical core did not bend, and the vertical core cut in the subsequent process could be performed.

In order to reduce the weight, a structure having the same structure composed of 28 plate base materials was manufactured in the same manner as in the above example except that 1 mm thick MDF was used instead of 2.5 mm thick MDF.
Since the 1 mm thick MDF is weaker than the 2.5 mm thick MDF, the non-adhesive length between two plate bases (the length of one side of the cell) is 370 mm. As the core material, the hardness was insufficient. (When the uppermost and lowermost plate bases are fixed to the vertical core of the door frame, if the door frame is made upright, the center part will be bent. It occurred and I couldn't stand up and fell down).
For this reason, when the length of one side of the cell was set to 200 mm, the cell opened very neatly and had no problem in terms of hardness. The opening height of each cell was about 55 mm.
However, when the cell opening height was 55 mm for 1 mm MDF, the rigidity was somewhat weak against pressure, so the number of plate substrates was 36, and the cell opening height was about 40 mm. It was made to become. As a result, sufficient rigidity against pressure was obtained.

  In this way, structures with different strength and rigidity can be created by changing the thickness, number of sheets, the length of one side of the cell, etc. As appropriate, various structures can be obtained.

As a result of repeating the trial production, in the configuration in which only the uppermost and lowermost plate base materials are bonded to the frame (see FIG. 8), the shape of each cell may be non-uniform. Attempts were made to develop a fixture that can be adjusted to a certain level and can hold the structure in an extended state.
A fixture for fixing the 2.5 mm-thick plate base material (MDF) · 28 structure manufactured in Example 2 was prepared. The fixture is a plate made of 2.5 mm thick MDF, using a plate with a length of about 780 mm and a width of 25 mm, with a groove width (length in the plate length direction) at one edge along its longitudinal direction. 15 U-shaped grooves (notches) of about 5 mm and groove depth (length in the width direction of the plate) of about 15 mm were provided at a pitch of about 55 mm. Only the both ends of the fixture were cut out in an L shape, and when both ends of the fixture were bonded to the vertical core of the frame, a U-shaped groove was formed between the wall of the frame.
On the other hand, at one edge along the longitudinal direction of the plate base material of the structure body, a U-shaped groove with a groove width of about 2.5mm and a groove depth of about 10mm A groove (notch) in the mold was made. Notches were provided in the longitudinal direction instead of all the bonded portions. By arranging this fixture perpendicular to the plate base material and fitting the notches of both, the structure could be maintained in the extended state (FIG. 9). In addition, since the fixture is housed in the same space as the structure and no unevenness is generated on the extended surface, the fixture does not get in the way when the structure is bonded to the face material.
By using the fixture, the shape of the cell can be kept uniform, so that the structure is less likely to be uneven in strength. In addition, work efficiency can be improved because it can be self-supported in the extended state. Furthermore, since the extended state can be maintained without applying a load to the vertical core, there is no problem that the vertical core is bent, and there is no hindrance to the vertical core cutting in the subsequent process.

The structure of the present invention not only extends in a plane, but can also correspond to a curved shape by curving in the stacking direction. In order to make it stand in a curved shape, it was possible to produce a self-supporting curved panel by making a fixture that fits the desired shape with 3mm thick MDF.
FIG. 5 shows an example of a fixture, and FIG. 10 shows a structure that is fixed in an S shape by the fixture and has a decorative sheet attached to one side.
The structure of the present invention can be formed into a curved surface while adjusting the degree of expansion and contraction by adjusting the force.
Therefore, when using a ring-shaped fixture with a diameter of 200 mm, 150 mm, or 130 mm, and a semicircular fixture with a radius of 100 mm, 75 mm, or 65 mm as the fixture, a cylindrical body or a semi-cylindrical body with the same structure but different radii Could be manufactured. Moreover, it was possible to make it into a conical shape, and it was possible to freely correspond to the shape of a partly flat surface and partly curved surface.

The fixture 6 is preferably made of a member having an elongated shape and provided with a number of U-shaped (or U-shaped) notches 7 on the periphery in the longitudinal direction. The shape may be adjusted to the desired deformed shape of the structure. For example, as shown in FIG. 5, in the case of a partial plane / partial curved surface, a fixture (A When using B) as a cylinder, use a ring-shaped fixture (C). When using B-shape, use an S-shaped fixture (D). Moreover, in order to extend and fix in a plane, a linear fixing tool is used as shown in FIG.
As in the above example, if the width of the fixture and the plate base material is the same, and the total depth of both notches is the same as the width of the plate base material (may be slightly larger), The fixture and the structure are completely contained in the same space, and there is no unevenness on the surface formed by extension. Therefore, even when a cover material is pasted on the extended surface of the structure, a uniform adhesion between the plate base material / fixture and the cover material is maintained, and a flat surface is formed (see FIG. 10). ).

A structure having the same structure consisting of 28 plate base materials was manufactured in the same manner as in Example 2 except that a 2.5 mm thick plywood was used instead of the 2.5 mm thick MDF.
As in Example 2, this structure was stretched, and the uppermost and lowermost plate substrates were bonded to the vertical core of the frame (state shown in FIG. 8). Since the plywood has higher rigidity than the MDF, the vertical core of the frame is bent inward as in the case of 16 MDF.
For this reason, the extension state of the structure was held using the same fixing tool as in Example 4 and placed in the frame (the state shown in FIG. 9), and the bending of the vertical core could be suppressed.

  An attempt was made to create a structure that can flow the air inside the door to the outside. Regarding the door, there is a specification that allows the air inside the door to flow to the outside, but the existing paper honeycomb cannot flow the air. About the structure similar to Example 2, 12 mm diameter through-holes 8 (air holes) are formed on the plate surface of each plate substrate, one on each plate surface where the upper and lower plate substrates are not bonded. When provided (FIG. 6B), the flow of air inside the door could be confirmed. FIG. 6A is a diagram schematically showing a front view of the structure according to Example 7. In order to explain the configuration, a gap is provided between each plate base material, and an adhesion portion is indicated by []. It is a figure. 6B is a bottom view of A. FIG.

For the purpose of use as a pallet, the structure 1 according to the present invention was manufactured using 36 plate base materials 2 (material: MDF) having a thickness of 4 mm, a width of 170 mm, and a length of 1190 mm. The length of the bonded portion was 50 mm, and the length of the non-bonded portion between the two plate base materials was 330 mm. FIG. 7 shows a structure according to this example. As shown in a bottom view (A) of FIG. 7, two 80 mm × 170 mm rectangular through holes 9 (fork insertion holes) were provided on the plate surface of each plate substrate 2. Further, a U-shaped notch 5 having a depth of 60 mm was provided at three locations (a location 25 mm from each end and the central portion of the plate substrate) on one edge along the longitudinal direction of each plate substrate.
Further, as shown in FIG. 7C, a plate (material: MDF) having a thickness of 4 mm, a width of 170 mm, and a length of 900 mm is prepared as the fixture 6, and a width of 8 mm and a depth are formed on one edge along the longitudinal direction. 18 U-shaped notches 7 having a thickness of 110 mm were formed at a constant pitch.
The notch 7 of the fixture 6 was inserted into the notch 5 of the structure 1 to fix the structure 1 in the extended state, and the fork 10 of the forklift was inserted into the rectangular hole 9 to be used as a pallet. FIG. 7B is a front view of the extended state, and shows a state in which the fork 10 of the forklift is inserted. When a load of about 1.5 tons was placed on the structure and moved up and down, the structure was not damaged and could be used as a pallet without any inconvenience.
When the structure was pressed to examine the strength of the structure, it was not damaged even when a pressing pressure of 30 tons was applied. From this, it was proved that it can sufficiently withstand use as a pallet for carrying goods.
FIG. 11 shows a non-stretching photograph of the same structure (the number of plate base materials, the number of bonding portions, etc.) as in this example, and FIG. 12 shows a photograph fixed in the stretched state. As shown in FIG. 11, since the structure returns to the original laminated state when the fixture is removed, the dimension in the laminating direction is about the thickness of the plate base × the number of plate bases. Therefore, it can be stored very compactly when not in use, and is very convenient to carry. A conventional pallet does not have such a function, and according to the present invention, it is possible to provide a pallet that has sufficient strength and can be stored and transported compactly when not in use.

Moreover, as a structure used as a pallet, a structure schematically shown in FIGS. 13 and 14 was produced.
In the structure shown in FIG. 13, as shown in the bottom view (A), a plate substrate having a plate width of 90 mm was used, and a part of the plate surface was cut out to provide a fork hole 9 of 60 mm × 200 mm. . At the time of use, as schematically shown in the front view (B), the structural body 1 is fixed in the extended state using the fixture 6 of (C), and the fork 10 is put into the hole 9 for use.
In the structure shown in FIG. 14, a fixture 6 having a plate width of 90 mm is inserted into a structure made of a plate base material having a plate width of 40 mm. FIG. 14A is a bottom view in a state where the fixture 6 is used, FIG. 14B is a diagram schematically showing a front view thereof, and FIG. 14C is a diagram showing the fixture.

  Thus, when using as a pallet, various embodiments are possible, and an appropriate structure can be manufactured according to the weight of the load and the purpose of use.

The length of the adhesion part in the longitudinal direction, the length of one side of the cell, etc. were examined.
The length of the bonded portion only needs to achieve a strength at which the plate base materials do not peel off due to the force applied at the time of extension, and therefore varies depending on the desired opening height of the cell. Generally, a length of 20 mm or more is preferable for maintaining strength. It was good. As an example, with an MDF having a thickness of 2 to 3 mm (length 2150 mm, width 150 mm), if the length of the bonded portion was about 10 mm, the bonded portion was easily detached at the time of extension, and could not be sufficiently extended. However, when a plate base material having a lower rigidity was used and the opening height was set to be small (for example, about 10 mm), the adhesive part could be extended without peeling even if the length was about 10 mm.
When used as a core material for furniture or joinery, generally it is preferably 20 mm or more, more preferably about 40 to 60 mm.
Also, in order to study the rigidity of different types of plates, both ends of the plate do not lift up, and the pitch that lifts by 50 mm when pressed with wood and pulled with a force of 0.5 kg (the length of one side of the cell) Was 380 mm for 2.5 mm thick MDF, 490 mm for 3 mm thick MDF, 650 mm for 4 mm thick MDF, and 350 mm for 2 mm thick resin board (vinyl chloride resin) (all board widths were 30 mm) ).
From this result, it can be seen that if the same extension rate is desired when the same force is applied, if the plate base material is strong, the length of one side of the cell can be increased. If the length is too long, the strength is lowered. Therefore, in general, a plate base material having a rigidity with a pitch of 50 mm lifting about 300 to 800 mm when pulled with a force of 0.5 kg in the above-described situation is preferable. In particular, when used as a core material for furniture or building materials, a plate substrate having a rigidity of about 300 to 500 mm is preferable, and when used as a pallet, a plate having a rigidity of about 400 to 800 mm when the pitch is used. A substrate is preferred.

Furthermore, in order to examine a structure suitable for use as a core material for furniture and building materials, the width of the plate base is 15 to 35 mm and the thickness of the plate base is 1 to 4 mm for the structure made of MDF. The length of the bonded part was changed to 20-60 mm, and various structures were made as prototypes, and the length of one side of the appropriate cell (non-bonded length between two plate base materials) was examined. The results are summarized in Table 1.

In addition, in order to examine a structure suitable for use as a pallet, etc., for a structure made of vinyl chloride resin, the width of the plate substrate is 100 to 200 mm, the thickness of the plate substrate is 2 to 4 mm, and the bonded portion Various structures were made by changing the length of the cell from 30 to 70 mm, and the length of one side of the appropriate cell was examined. The results are summarized in Table 2.

Although the rigidity of the plate base material varies depending on the plate width and plate thickness, in general, a structure with an adhesive portion length of 30 mm or more (more preferably 40 mm or more) was easy to handle.
Even if it is a plate substrate made of MDF, if a decorative board (double-sided decorative sheet attached) is used, the sheet layer peels off as it is repeatedly opened and closed, so there is no sheet layer on the surface. Was preferred.

A structure was produced using a plate substrate made of melamine resin. A melamine plate having a thickness of 1.2 mm, a width of 25 mm, and a length of 2150 mm was used as a plate base material, and a structure having an adhesive portion length of 50 mm and a cell side length of 370 mm was prepared in the same manner as in Example 2. In addition, a notch (groove width: about 1.2 mm, groove depth: about 10 mm) having the same configuration as that of Example 4 is formed on the plate base material, and is composed of a melamine plate having a thickness of 1.2 mm. A fixture having the same configuration as the fixture of Example 4 having a notch of 2.4 mm and a groove depth of about 15 mm was produced.
When the material was melamine resin, it was possible to produce a structure that could be extended into a planar shape and a curved shape, as in the case of using a woody material.
In addition, the melamine structure is lighter than the 3 mm MDF structure, and the plate base at the uppermost end and the lowermost end is fixed to the vertical core of the door frame (without using a fixture) to maintain the extended state. The risk of bending under its own weight has decreased.

A structure similar to that of Example 4 was prepared except that the plate width was 6.75 mm, and a flash door was formed using two of the structures. A structure maintained in a stretched state with a fixture is attached to both sides of a plywood board with a thickness of 11.5 mm, a width of 850 mm, and a height of 2000 mm to form a single plate (ie, a plywood sandwiched between two structures). Have). In addition, a 2.5mm thick decorative board was attached to both sides of the plate to create a flash door. FIG. 15 schematically shows a cross-sectional view of the flash door. As shown in FIG. 15, the cross section of the flash door according to the present embodiment has a configuration of “decorative board 12 / structure 1 / plywood 11 / structure 1 / decorative board 12”, and the door thickness is 30 mm (2.5 mm + 6 .75mm + 11.5mm + 6.75mm + 2.5mm). Reference numeral 13 denotes a lip tape attached to the lip face. The conventional flash door manufacturing process required a core assembly process (making the door), but the flash door manufactured by the method of this embodiment has a plywood sandwiched in the center, Since there is a wood part (plywood part) that can stop the screw even if it is cut, a conventional core assembly process is not required.
In addition, by using a thick tape of about 2mm as the tape to be applied to the door mouth, we were able to cover the side of the door without any unevenness. It was also possible to insert a hardware and fix the screw.

The structure manufactured in Example 6 (made of 2.5 mm thick plywood) is fixed in the door frame while maintaining the extended state with a fixture (see FIG. 9), and a face material having a thickness of about 2.5 mm is formed on both sides thereof. A flash door was prepared by pasting. The door frame was made of square material with a width of about 35mm and a thickness of about 25mm. The finished dimensions of the door are a door width of about 850mm, a door height of about 2000mm, and a door thickness of about 30mm. A warpage environment test was performed on the flash door (hereinafter referred to as door A) and the flash door manufactured in Example 12 (hereinafter referred to as door B). As the face material, a face material having an olefin sheet on the front side and a moisture-proof sheet on the back side was used. The face material and the frame material / structure were bonded with a vinyl acetate emulsion adhesive. The amount of adhesive applied was 190 g / m ² . In addition, a flush door of the same size using a paper honeycomb core, which is a conventional product, was prepared and used as a comparative example.

Each door was installed on the boundary between two rooms (room A and room B) where the temperature and humidity could be controlled, and the test was conducted. The temperature and humidity in room A was maintained at 40 ° C./90% RH for 16 hours, and then maintained at 20 ° C./55% RH for 8 hours, and this was repeated for another cycle. During this time, the temperature and humidity in the room B were maintained at 20 ° C./55% RH. The displacement amount and warpage deformation amount of the face material were measured at nine locations of the flash door, and the maximum deflection and history during the test and the residual deflection after the test were observed.
Both door A and door B were less warped and deformed than the comparative flash door using a paper honeycomb, and were excellent in strength.

  The structure of the present invention is very suitable for use as a core material for curved furniture and pillars as well as flat joinery, and can improve these performances (preventing warping and bending). It can also be used as a pallet for forklifts that are loaded with tons. Moreover, since it can manufacture using the end material of the wooden board which generate | occur | produces in manufacturing processes, such as joinery, it leads also to the effective utilization of a wooden material and contributes to recycling. And since it can manufacture from a board | plate of wood or a metal, a high intensity | strength structure can be produced compared with the honeycomb core and pallet made from a corrugated cardboard which exist conventionally. In particular, when used as a pallet, it not only withstands the weight of the load, but is also very practical because it is not easily damaged by the forklift claws. Furthermore, since it is a very compact size when not in use (when not extended), it is convenient for storage and transportation.

DESCRIPTION OF SYMBOLS 1 Structure 2 Board | substrate base material 3 Adhesion part 4 Cell 5 Notch 6 of board base material Fixture 7 Notch 8 of fixing tool Through-hole (air hole)
9 holes (fork insertion hole)
10 forks

Claims (8)

It is a structure formed by laminating a number of strip-shaped plate base materials with the plate surfaces facing each other,
Except for the uppermost and lowermost plate base materials, the plate base materials are alternately turned up and down with plate base materials stacked on the top and bottom via non-adhesive parts that are not bonded to other plate base materials. is bonded to, and, the adhesive portion is at least that provided at two or more locations between the upper or lower plate substrate,
Notches are formed on one edge or both edges along the longitudinal direction of the plate base material,
The notch is formed in the same position in each plate base material, and is formed in the adhesive portion;
When the structure is stretched in the stacking direction, a spindle-shaped cell having an upper side and a lower side made of the two plate bases opens between two adjacent plate bases. The length of the adhesion part in the longitudinal direction of the plate substrate is 20 mm or more, and the length of the upper side and the lower side of the cell is three times or more of the length of the adhesion part. 1. The structure according to 1. The plate base is a plate having a thickness of 1 to 5 mm, and the length of the adhesive portion is 20 to 80 mm;
3. The structure according to claim 1, wherein the length of the upper side and the lower side of the cell is 200 to 800 mm and is four times or more of the length of the adhesion portion. The structure according to any one of claims 1 to 3, wherein the bonding portion is provided at least at three positions between at least one of the upper and lower plate base materials. The structure according to any one of claims 1 to 4, wherein the structure is a building material or a core material for furniture having a flat surface and / or a curved surface. The structure according to any one of claims 1 to 4, wherein the structure is a cargo carrying pallet. The plate base material is a plate having a width of 100 to 200 mm, and a hole for inserting a fork of a forklift is continuously provided on the plate surface of at least half of the plate base material from one end side in the stacking direction. The structure according to claim 6, wherein the structure is characterized. The furniture or building material which uses the structure of any one of Claims 1-5 as a core material.