JP6722886B2 - Decorative panel and panel manufacturing method - Google Patents

Description

The present invention relates to a decorative panel and a panel manufacturing method.

BACKGROUND ART Conventionally, as a fitting such as a hinged door or a sliding door, a decorative panel including a decorative layer on both sides of a hollow and lightweight core layer has been widely known. As such a decorative panel, for example, one using a honeycomb core for the core layer is known.

Although it is possible to reduce the weight of a conventional decorative panel using a honeycomb core, it is necessary to consider the strength of the decorative panel. Therefore, it is usually a hard plate to maintain the strength and hardness of the decorative panel surface. A makeup layer is used.

In addition, many cells are opened on the front and back surfaces of the honeycomb core, and the cross-sectional area that can be bonded is small, so that a device for bonding the hard plate-shaped decorative layer and the core layer has been devised. For example, a plate-shaped or sheet-shaped intermediate layer is provided between the decorative layer and the core layer, and an adhesive is applied to the front and back surfaces of the intermediate layer to bond the decorative layer and the core layer.

As such an intermediate layer, for example, MDF (Medium density fiberboard) is used. However, since MDF is rich in wood fibers, it has a problem that it absorbs moisture contained in the adhesive, resulting in a large dimensional change, and it is necessary to attach a moisture-proof sheet or the like.

On the other hand, for the purpose of improving the adhesive strength of the adhesive while suppressing the dimensional change, between the hard plate-shaped decorative layer and the honeycomb core, a filamentous material such as glass fiber or a soft core material made of paper, cloth, etc. There has been proposed a decorative panel in which an adhesive layer impregnated with a thermosetting resin is used for adhesion (see Patent Document 1).

JP-A-3-90340

However, even in the decorative panel described in Patent Document 1, since a hard substrate such as FRP or a metal plate is used for the decorative layer, there are restrictions from the viewpoint of weight reduction of the panel structure, and the surface of the substrate is not limited. Work processes such as attaching a decorative sheet are indispensable, and there is a difficulty in improving the design.

The present invention has been made in view of the circumstances as described above, and it is possible to achieve weight reduction and improvement in designability, high productivity, and surface hardness and strength even when the decorative layer is thin, and surface. It is an object to provide a decorative panel having good smoothness and dimensional stability and a panel manufacturing method capable of effectively manufacturing such a decorative panel.

In order to solve the above problems, the decorative panel comprises a core layer having a honeycomb core, made of veneer or a resin film constituting the front and back of a disposed on both sides decorative sheet of the core layer decorative The core layer and the decorative layer are adhered by a resin-impregnated fiber sheet layer interposed therebetween, and the resin-impregnated fiber sheet layer has a basis weight of 150 g/m. ² above 700 g / ^{m 2} or less of the fiber sheet, non-foamed or foaming magnification 5 times or less of the low foaming at 100 g / ^{m 2} or more 300 g / ^{m 2} or less of the resin, characterized in der Rukoto those impregnated ..

Further, in order to solve the above problems, in the panel manufacturing method of the present invention, the basis weight of the resin-impregnated fiber sheet layer is 150 g/m ² or more and 700 g/m ² or less on both sides of the core layer having the honeycomb core. pushing fiber sheet and, where non-foamed or foaming magnification 5 times or less of the low foaming at 100 g / m ² or more 300 g / m ² or less of the uncured resin composition is interposed respectively constituting the front and back sides of the decorative layer A decorative panel is manufactured by squeezing from both sides of the front and back in a state where a decorative sheet made of a plate or a resin film is arranged to cure the resin composition.

ADVANTAGE OF THE INVENTION According to the decorative panel of the present invention, it is possible to achieve weight reduction and improvement in designability, high productivity, and good surface hardness and strength, surface smoothness, dimensional stability, etc. even when the decorative layer is thin. Realistic makeup panel is realized. Moreover, according to the panel manufacturing method of the present invention, such a decorative panel can be effectively manufactured.

It is a partially cutaway perspective view showing one embodiment of the decorative panel of the present invention. FIG. 2 is a cross-sectional view taken along the line A-A′ of the decorative panel illustrated in FIG. 1. (A) (B) (C) (D) is a figure which illustrated the cross section in manufacture of the decorative panel of this invention. (A) shows a cross-sectional view in a step of impregnating a fiber sheet with a resin, and (B) is a cross-sectional view of a resin-impregnated fiber sheet layer and a core layer after integral molding. (C) is an enlarged view of a region surrounded by a circle of (B), and (D) is a view schematically showing a cross section of the resin-impregnated fiber sheet layer of (C). It is an exploded perspective view when a decorative panel of the present invention has a frame material in a core layer. It is the front view which showed the state before mounting one resin impregnated fiber sheet layer and the decorative layer in the manufacturing process of the fitting using the decorative panel of this invention. (A) and (B) are schematic plan views showing a fitting in which a reinforcing material is provided on a frame material and a handle is attached to the surface of the decorative layer to form an open door. (A) and (B) are the schematic top views which showed the fitting which provided the recessed part in the surface of the decorative layer and attached the metal fitting to this recessed part, and used it as the sliding door. (A) and (B) are principal part sectional drawing which illustrated one embodiment which covers the edge part of the core layer of the decorative panel of this invention with a decorative layer and a resin impregnated fiber sheet layer. (A) shows that one decorative layer and the resin-impregnated fiber sheet layer are extended, and a V-shaped groove is provided on the surface of the resin-impregnated fiber sheet layer on the core layer side. (B) shows a state in which one of the decorative layers and the resin-impregnated fiber sheet layer extended in the V-shaped groove of (A) are bent to cover the end portion of the core layer of the decorative panel. (A) and (B) are principal part sectional drawings which illustrated another embodiment which covers the edge part of the core layer of the decorative panel of this invention with a decorative layer. (A) shows that a pair of facing decorative layers are extended. (B) shows a state in which a pair of extending facing decorative layers are bent and overlapped to cover the end portion of the core layer of the decorative panel. It is a principal part sectional view which showed the state which stuck the edge part decorative material different from a decorative layer, and covered the edge part of the core layer of a decorative panel. (A) and (B) show typically an example of the makeup|decoration panel which concerns on other embodiment of this invention, (A) is the one part corresponding to the XX line arrow in FIG. 13(A). FIG. 1B is a partially cutaway schematic cross-sectional view schematically showing an example of the panel manufacturing method of the same decorative panel, corresponding to FIG. (A) (B) (C) (D) is a partially broken schematic side view which shows typically an example of the same panel manufacturing method. (A) is a schematic front view of the decorative panel, and (B) is a schematic front view schematically showing an example of a core layer included in the decorative panel.

The decorative panel and the panel manufacturing method of the present invention will be described below with reference to the drawings.
Note that in some of the drawings, some of the detailed reference numerals attached to other drawings are omitted.
FIG. 1 is a partially cutaway perspective view showing an embodiment of a decorative panel of the present invention. FIG. 2 is a cross-sectional view of the decorative panel shown in FIG.

As shown in FIGS. 1 and 2, the decorative panel 1 includes a core layer 2 having a honeycomb core 21, and a decorative layer 3 made of a decorative sheet provided on both front and back surfaces of the core layer 2. ing. In this decorative panel 1, the core layer 2 and the decorative layer 3 are adhered by the resin-impregnated fiber sheet layer 4 interposed therebetween.

As shown in FIG. 1, the decorative panel 1 has a substantially rectangular flat plate shape that is long in one direction. The decorative panel 1 may be used as a fitting panel that opens and closes an entrance and an exit or a storage opening, a partition panel such as a partition, a furniture component, and the like.
Further, the decorative panel 1 may be used to form a part of the panel, for example, a frame portion or a mirror plate portion of the frame panel. For example, a plurality of decorative panels 1 are used as a frame material of a fitting, combined with a face material and the like to be joined and fixed to form a fitting, and in a fitting using such a frame, facing surfaces of the frame material It is also possible to provide a groove part in the groove and insert a translucent plate material such as glass into the groove part to make a fitting having translucency. Further, the decorative panel 1 may be used as a ceiling panel, a wall panel (partition wall panel), a waist wall panel, a floor panel, a skirting panel, a surrounding panel, an opening frame panel, or the like.

Further, the length dimension (vertical dimension, height dimension), width dimension, thickness dimension and the like of the decorative panel 1 may be appropriately determined depending on the application of the decorative panel 1.
For example, when the decorative panel 1 is used as a fitting panel, the vertical dimension (door height dimension) of the decorative panel 1 is about 1800 mm to 3000 mm, the door width dimension is about 600 mm to 1200 mm, and the door thickness dimension is May be about 20 mm to 40 mm

The core layer 2 constitutes a panel core material. The honeycomb core 21 that constitutes the core layer 2 is not particularly limited as long as it is a honeycomb core (honeycomb-shaped core material) that is usually used for a panel having a flash structure, but the strength and durability of the decorative panel 1, Considering dimensional stability and the like, it is preferable to use kraft paper, cardboard, corrugated board, plastic molded products and the like. Such a honeycomb core 21 may be a so-called paper core composed of an assembly of a large number of hollow cylindrical cells opened on both sides in the panel thickness direction. Further, such a honeycomb core 21 may be formed by stacking and bonding paper materials such as cardboard base paper and kraft paper with an adhesive. Further, as the honeycomb core 21, such a paper material may be further impregnated with a reinforcing resin such as an epoxy resin. In addition, a metallic material such as an aluminum material, a hard polyvinyl chloride resin, or a polypropylene resin may be used. It may be formed of a synthetic resin material such as.

In the present embodiment, the honeycomb core 21 is configured such that cells 22 each having a regular hexagonal cross-sectional shape share a wall surface corresponding to one side of the regular hexagonal with adjacent cells 22 and are connected in large numbers. In the honeycomb core 21 used in the decorative panel 1 of the present embodiment, the cross-sectional shape of the cells 22 is not limited to the regular hexagon (honeycomb shape) described above, and a vertically or horizontally long hexagon, quadrangle, trapezoid, It may have a circular shape, a corrugated shape, or other various shapes.

The average diameter (cell size (cell diameter, cell width)) of the cells 22 of the honeycomb core 21 may be an appropriate size from the viewpoints of weight reduction and strength, and may be 1 mm or more and 100 mm or less, preferably May be 5 mm or more and 15 mm or less. The average diameter of the cells 22 of the honeycomb core 21 is, for example, in the range of about 10 mm, preferably 10 mm or less, although it depends on the basis weight of the fiber sheet 41 (see FIG. 3) described later. When the average diameter of the cells 22 is within the above range, the core layer 2 having both light weight and strength, and thus the decorative panel 1 is realized.

The decorative layer 3 is composed of a thin sheet of decorative sheet. As the decorative layer 3, a veneer (decorative veneer) formed of natural wood (named wood), printed decorative paper on which various patterns (patterns) such as a wood grain pattern are printed, or a synthetic resin resin film ( It may be a resin sheet or the like, or may be a veneer or a resin film.
The resin film forming the decorative layer 3 is not particularly limited as long as it is usually used for manufacturing a decorative panel or a decorative board. Examples thereof include vinyl chloride resin film, polyethylene resin film, polyethylene terephthalate resin film, polypropylene resin film, polycarbonate resin film, acrylic resin film, urethane resin film and the like.

The thickness of the resin film is, for example, 0.02 mm to 1.0 mm, preferably 0.05 mm to 0.2 mm, and more preferably 60 μm to 120 μm (0.06 mm to 0.12 mm). Considering the strength characteristics, handleability, etc. of the decorative layer 3, the above range is preferable. As the resin film, other than this, a melamine resin plate, a phenol resin plate, or a nonflammable surface material using these may be used.

The veneer plate constituting the decorative layer 3 is not particularly limited as long as it is usually used for manufacturing a decorative panel or a decorative board. For example, a wood thin plate having a thickness of 0.2 mm to 1.0 mm is exemplified.
When the decorative layer 3 is used as a veneer, considering the surface smoothness and strength of the decorative layer 3, a non-woven fabric or the like is attached to the surface facing the resin-impregnated fiber sheet layer 4 with an adhesive. And is preferably reinforced with a lining.

As the adhesive in this case, a non-water-soluble adhesive that does not easily transfer water to the veneer is preferably exemplified. Examples of the non-water-soluble adhesive include solution-type acrylic copolymers, synthetic rubber-based adhesives, hot melt-based adhesives that are thermoplastic synthetic resins, alone or in combination of two or more. can do. Examples of hot melt adhesives include ethylene vinyl acetate (EVA) and urethane hot melt (PUR). In addition, epoxy resin-based, urethane-based, vinyl chloride-based, vinyl acetate-based adhesives and the like may be used alone or in combination of two or more.
The same material may be used as the decorative layer 3 on the front and back surfaces of the decorative panel 1, or different materials may be used on the front and back surfaces.

The resin-impregnated fiber sheet layer 4 is configured such that the fiber sheet 41 is impregnated with an uncured resin composition (resin) 42 and the resin composition 42 is cured (see FIG. 3 ). The resin-impregnated fiber sheet layer 4 can also be called a fiber-reinforced resin layer.
The thickness of the resin-impregnated fiber sheet layer 4 may be an appropriate thickness depending on the type, the basis weight and the thickness of the fiber sheet 41 selected according to the application of the decorative panel 1. The thickness of the resin-impregnated fiber sheet layer 4 may be, for example, about 0.1 mm to 1.0 mm, preferably about 0.2 mm to 0.6 mm.

Examples of the fiber sheet 41 include woven and non-woven fabrics and mats of reinforcing fibers such as glass fibers, carbon fibers and mineral fibers. As the fiber sheet 41, glass fiber woven cloth, non-woven cloth or mat is preferably adopted. Examples of the woven fabric of glass fibers include a glass cloth, which is a woven fabric such as a plain weave and a entangled weave, which is woven by using glass roving for warp and weft. In the case of glass cloth, plain weave glass cloth is preferable. As the nonwoven fabric of glass fiber, for example, glass fiber having a length of about 10 mm is dispersed in water, then scooped out by a wet papermaking method, dehydrated, made into a sheet, and coated with an adhesive such as an epoxy resin or an acrylic resin. Examples thereof include glass paper. As the glass fiber mat, a glass strand cut into a long fiber shape (for example, a length of about 30 mm, preferably about 50 mm) is evenly dispersed in a non-direction, and a mat such as a polyester binder is used. An example is a glass mat or the like that is formed into a shape.

The thickness of the fiber sheet 41 is, for example, in the range of 0.1 mm to 0.5 mm. When the fiber sheet 41 is a glass mat, the thickness may be about 0.3 mm to 0.5 mm, and when it is a glass cloth, the thickness is about 0.1 mm to 0.3 mm. May be The density of the glass cloth is, for example, 30 to 120 pieces/25 mm. Moreover, as the count (thickness) of the glass thread that constitutes the glass cloth, for example, a range of 67 to 135 tex (g/1000 m) is exemplified.

As a fabric weight of the fiber sheet 41, for example, a range of 150 g/m ² or more and 700 g/m ² or less is exemplified, and a range of 150 g/m ² or more and 350 g/m ² or less is preferable. If the basis weight of the fiber sheet 41 is made too small, the strength tends to decrease, whereas if it is made too large, it tends to become heavy. Further, when the basis weight of the fiber sheet 41 is within the above range, the obtained decorative panel 1 can exhibit desired surface strength and surface smoothness. When glass cloth is used as the fiber sheet 41, the basis weight may be 200 g/m ² or more. When glass paper is used as the fiber sheet 41, the basis weight may be 50 g/m ² or more. When a glass mat is used as the fiber sheet 41, the basis weight may be 100 g/m ² or more, and the basis weight may be 300 g/m ² or more. Further, as the fiber sheet 41, a glass mat or a glass cloth is preferable among such glass fiber sheets.

Further, as the fiber sheet 41, a laminate of a plurality of the above-mentioned glass fiber woven fabrics, non-woven fabrics or mats (glass fiber sheets), or a glass fiber sheet and vegetable fiber woven fabrics, non-woven fabrics, films, papers or mats And may be laminated. The plant fiber is not particularly limited as long as it is a plant fiber used in a plant fiber mat or papermaking, but considering the strength and durability of the fiber sheet 41, dimensional stability and the like, hemp-based natural fiber, palm fiber and It is preferable that one or more of the agricultural waste fibers be used.

As the resin composition (resin) 42 with which the fiber sheet 41 is impregnated, a non-foaming resin or a low foaming resin is exemplified. For example, as the resin main component of the resin composition 42, urethane (polyurethane) resin, polystyrene resin, polyethylene resin, polypropylene resin, phenol resin, etc. may be used alone or in combination of two or more kinds.
On the other hand, when a liquid unsaturated polyester resin or epoxy resin is used as in the decorative panel described in Patent Document 1, it is excellent for bonding a hard substrate, but in bonding with the honeycomb core 21, It is not always satisfactory in terms of performance, handleability, cost, etc.

When the resin composition 42 is a foamed resin, it may have a low foaming ratio of 7 times or less, more preferably 5 times or less, depending on its type. Further, as the resin composition 42, urethane resin is exemplified as a preferable one, but in this case, the expansion ratio is 1 to 5 times, more preferably 1 to 3 times, and further preferably 1 to 3 times. It may be doubled. When the resin composition 42 is made of such a urethane resin, it is excellent in the impregnation property to the fiber sheet 41 and the adhesive property with the resin film of the decorative layer 3, the veneer plate, and the honeycomb core 21 of the core layer 2, Moreover, it is well-balanced. Further, as the urethane resin, ether type or castor oil type urethane resin having water resistance is preferably exemplified. Various additives such as a curing agent and a flame retardant can be added to the resin composition 42.

In the resin-impregnated fiber sheet layer 4, as the amount of the resin composition 42 impregnated into the fiber sheet 41 increases, physical properties such as surface strength, surface smoothness, and dimensional stability of the decorative panel 1 after integral molding are improved. To do.
The amount of the resin composition 42 with which the fiber sheet 41 is impregnated depends on the thickness of the fiber sheet 41, the desired thickness of the resin-impregnated fiber sheet layer 4, the surface strength and surface smoothness of the decorative panel 1, the dimensional stability, and the cost. From the viewpoint of the above, it may be an appropriate amount. For example, the amount of the resin composition 42 with which the fiber sheet 41 is impregnated may be 100 g/m ² or more, and preferably 150 g/m ² or more. Further, from the viewpoint of manufacturing cost and the like, the amount of the resin composition 42 with which the fiber sheet 41 is impregnated may be 300 g/m ² or less, and preferably 250 g/m ² or less. That is, the amount of the resin composition 42 with which the fiber sheet 41 is impregnated is preferably in the range of 150 g/m ² or more and 250 g/m ² or less.

Further, the impregnation of the fiber sheet 41 with the resin composition 42 is exemplified by a mode in which the fiber sheet 41 is uniformly applied from above the fiber sheet 41 by spray application or roller application. In addition, after uniformly coating the resin composition 42 by spray coating or roller coating on the back surface of the decorative sheet (for example, resin film or veneer), the fiber sheet 41 is placed and impregnated with the resin composition 42. Good. Further, the fiber sheet 41 may be dipped in a container storing the resin composition 42, and then the excess may be appropriately squeezed by a roller or the like to impregnate the fiber sheet 41.

By interposing such a resin-impregnated fiber sheet layer 4 between the core layer 2 and the decorative layer 3, the resin constituting the resin-impregnated fiber sheet 4 is formed at the same time as the formation of the decorative layer 3 having good hardness and strength. Due to the self-adhesiveness of the (resin composition 42), the core layer 2 and the decorative layer 3 can be laminated at almost the same time by adhesive bonding as a unit. This makes it possible to arrange the decorative layer 3 using a thin resin film or a veneer. Further, it is possible to reduce the weight of the decorative panel 1, and it is possible to take advantage of the selectivity, variety, and natural feeling of the design. Further, even if the decorative layer 3 is thin, the decorative panel 1 having high surface hardness and strength, excellent surface smoothness and dimensional stability can be realized with high productivity by integral lamination molding.
Since the decorative panel 1 of the present embodiment has such characteristics, it is particularly suitable for use as a fitting panel.

Next, an example of a panel manufacturing method for manufacturing the decorative panel 1 according to the present embodiment will be described.
In this panel manufacturing method, the fiber sheets 41, 41 and the uncured resin composition 42 constituting the resin-impregnated fiber sheet layers 4, 4 are provided on both front and back sides (both sides in the panel thickness direction) of the core layer 2 having the honeycomb core 21. , 42 are respectively interposed to arrange the decorative sheets forming the decorative layers 3, 3 on both sides of the front and back, and the resin compositions 42, 42 are cured by pressing from both sides to manufacture the decorative panel 1. It is configured. As described above, as a molding die (mold) used for clamping from both front and back sides, when heating is required for curing, a heater or a heat medium is distributed, though it depends on the type of the resin composition 42. A hot press provided with a medium flow passage may be used.

First, a decorative sheet constituting the decorative layer 3 cut into a predetermined size is placed on the surface (upper surface) of the lower mold of the upper and lower molds with the back surface (anti-decorative surface) facing upward. To do. Then, the fiber sheet 41 is placed on the back surface of this decorative sheet, and the uncured resin composition 42 is supplied so as to impregnate the fiber sheet 41 in this state, so that the resin-impregnated fiber sheet layer 4 is formed. You may As a supply mode of the resin composition 42, the resin composition 42 is applied by using a sprayer, a roller, or the like so that the amount of the resin composition 42 impregnated in the fiber sheet 41 becomes the uniform amount (application amount) as described above. You may do it.

Next, the honeycomb core 21 (core layer 2) having a predetermined size is placed on the fiber sheet 41 on the lower mold, and the fiber sheet 41 is placed on the core layer 2. Further, in substantially the same manner as above, the uncured resin composition 42 is supplied so as to impregnate the fiber sheet 41, and the decorative sheet constituting the decorative layer 3 is placed thereon. Then, the upper mold of the molding die is placed on the surface (upper surface) of the decorative sheet, the upper and lower molding dies are clamped, and the resin composition is clamped (pressurized) under a predetermined condition such as an appropriate press pressure. 42, 42 may be cured. In addition, at this time, the resin compositions 42, 42 may be heated as necessary to cure the resin compositions 42. Alternatively, the mold may be cooled and depressurized after being heated and pressed. As a result, the decorative sheet and the honeycomb core 21 (core layer 2) are bonded together via the resin composition 42 impregnated in the fiber sheet 41, and the decorative panel 1 is integrally formed.

According to the panel manufacturing method as described above, manufacturing efficiency can be improved. That is, the resin compositions 42, 42 constituting the resin-impregnated fiber sheets 4, 4 can function as an adhesive component that joins and integrates the decorative layers 3, 3 and the core layer 2, and a separate adhesive is applied. The manufacturing efficiency can be improved as compared with the case where the layers are stacked.
When a resin foam is used as the resin composition 42, 42 with which the fiber sheets 41, 41 are impregnated, foam is generated by heating and pressurizing with a molding die, and the foamed material is impregnated in the fiber sheets 41, 41. It is formed.

Further, each step of the above-described panel manufacturing method, the order thereof, and the like are merely examples, and various modifications can be made. For example, after the uncured resin composition 42 is uniformly supplied (applied) to the back surface (anti-decoration surface) of the decorative sheet (decorative layer 3), the fiber sheet 41 is impregnated with the resin composition 42. It may be configured to be laminated. In other words, by laminating the fiber sheet 41 on the uncured resin composition 42, the fiber sheet 41 may be impregnated with the resin composition 42 as a result. With such a configuration, the surface smoothness of the decorative layer 3 can be improved. In this case, for example, a decorative sheet in which the resin compositions 42, 42 are applied to the back surfaces of the honeycomb cores 21 (core layers 2) on both sides in the panel thickness direction with the fiber sheets 41, 41 fixed in advance is used. A mode in which they are laminated may be adopted. Alternatively, the prepreg-shaped fiber sheet 41 containing the resin composition 42 may be interposed between the honeycomb core 21 (core layer 2) and the decorative sheet (decorative layer 3). Further, the manufacturing method is not limited to batch molding, and continuous molding may be used, and other various modifications are possible.

For example, with respect to the decorative panel 1 of the present embodiment which can be manufactured by the method as described above, specific features of the panel structure can be illustrated by FIG.
As shown in FIG. 3(A), the honeycomb core 21 is used as the core layer 2, and the urethane resin (resin composition) 42 is spray-coated and impregnated on the glass fiber sheet (fiber sheet) 41 arranged on both front and back surfaces thereof. In the heat-press molded decorative panel 1, as shown in FIG. 3B, a strong resin-impregnated fiber sheet layer 4 is formed. FIG. 3C is an enlarged view of the area surrounded by the circle in FIG. 3B, and it can be seen that the resin-impregnated fiber sheet layer 4 is cured and adhered integrally with the honeycomb core 21. Moreover, it can be seen that the glass fiber sheet 41 secures the hardness, strength, etc. of the surface of the decorative panel 1 and is integrated with the urethane resin 42 to have good surface smoothness.

Further, as the decorative panel 1, as illustrated in FIG. 4, the core layer 2 may include a frame member 23 that houses the honeycomb core 21 inside.
The frame member 23 extends in the longitudinal direction of the core layer 2, and extends in the lateral direction of the core layer 2 along with the first crosspieces (left and right vertical frames) 5 and 5 arranged at the opposite end edges 2a, 2a. The second crosspieces (upper and lower horizontal frames) 6 and 6 arranged on the opposite edges 2b and 2b. The second crosspieces 6, 6 are joined to the first crosspieces 5, 5 at both ends of the first crosspieces 5, 5 in the length direction. The frame member 23 does not necessarily have to include both the first crosspiece members 5 and 5 and the second crosspiece members 6 and 6, and the first crosspieces are provided on the pair of opposed edges 2a and 2a of the core layer 2. A frame material provided with only the members 5 and 5 or a frame member provided with only the second crosspieces 6 and 6 at the other pair of opposed edges 2b and 2b may be used. When the core layer 2 is provided with the frame member 23, it is easy to finish the grain surface. In particular, in the frame member 23 including the first crosspiece members 5 and 5 extending in the longitudinal direction of the core layer 2, when the decorative panel 1 is used as a fitting, the door stop becomes good. Also, the addition of a function as a reinforcing material for mounting the metal fittings is considered.

The types of the first crosspiece 5 and the second crosspiece 6 are not particularly limited as long as they are materials having relatively little warpage. For example, a wood material, a metal material, a resin material, a composite material thereof, or the like is exemplified.
Examples of the wood material include solid wood, wood boards such as LVL (Laminated Veneer Lumber) and PB (Particle board), MDF (medium density fiberboard) and hard board. A wood fiber board or the like may be used. Further, the wood material may be a wood powder/plastic composite material (WPC) in which a wood powder, an inorganic filler, a compatibilizing agent, a coloring agent and the like are contained in a synthetic resin material at a predetermined content ratio.
When wood materials are used as the first crosspiece 5 and the second crosspiece 6, it is preferable to use solid wood lumber or LVL having relatively high bending strength. When a wooden material is used as the first crosspiece 5 and the second crosspiece 6, they can be easily joined, the weight of the frame member 23 can be reduced, and the weight of the decorative panel 1 can be reduced.

Examples of the metal material include iron plates and steel plates. Among these, a stainless steel plate in which generation of rust and the like is suppressed is preferably exemplified.
Generally, an adhesive, a staple, a fastener such as a nail, a screw, a bolt, a nut, or the like is preferably used for joining the first crosspiece 5 and the second crosspiece 6. The staples can be inserted by a tucker or the like from the same side of the wood material of the first crosspiece 5 and the second crosspiece 6. Therefore, the fixing strength for both is necessary and sufficient. Further, the honeycomb core 21 may be fixed to the frame member 23 by using a fixing tool similar to the above.

FIG. 5 shows an example in which the decorative panel 1 is also used as a fitting such as a hinged door or a sliding door. In this example, the core layer 2 is divided into a storage space for the honeycomb core 21 in a region surrounded by a frame member 23 composed of a pair of first crosspieces 5 and 5 and second crosspieces 6 and 6 facing each other. In consideration of the formation and the improvement of the strength of the frame member 23, the intermediate crosspiece member 7 is provided. The intermediate crosspiece 7, for example, is arranged in parallel with the second crosspiece 6, as shown in FIG. The material may be the same kind as the first crosspiece 5 and the second crosspiece 6 or may be another kind. The decorative panel 1 (core layer 2) shown in FIG. 5 has a configuration in which four intermediate crosspieces 7 are provided at substantially equal intervals in the longitudinal direction of the frame member 23. Further, the four intermediate crosspieces 7 are structured such that both longitudinal end surfaces thereof are joined to the first crosspieces 5, 5. The joining of the first crosspiece 5 and the intermediate crosspiece 7 can be performed by using a fixing tool such as an adhesive, staple, nail, screw, bolt and nut. Therefore, the fixing strength of the intermediate crosspiece 7 to the frame member 23 is ensured as necessary and sufficient.

In addition, the decorative panel 1 illustrated in FIG. 6A has a configuration in which a metal fitting mounting reinforcing material (mounting base) 8 is provided in order to embed the base of the handle and the like inside the frame material 23. The metal fitting attaching reinforcing member 8 is, for example, at a height position of about 90 to 120 cm (900 mm to 1200 mm) from the lower end of the decorative panel 1 in the longitudinal direction, and is in contact with one of the first crosspiece members 5 forming the frame member 23. It is arranged so that it touches. The metal fitting attachment reinforcing member 8 may have the same thickness as the first rail member 5 and the second rail member 6, or may have a different thickness. The material may be the same kind as the first crosspiece 5 and the second crosspiece 6 or may be another kind. In the example of FIG. 6, the metal fitting attachment reinforcing member 8 is composed of a plurality of members and is arranged in a rectangular shape with one side cut off.

As shown in FIG. 6(B), the decorative panel 1 having the core layer 2 provided with the metal fitting mounting reinforcing material 8 is, for example, a space between the metal fitting mounting reinforcing material 8 and the latch case. (Not shown) is inserted, the shaft portion of the handle 10 is attached to the handle insertion hole of the latch case, and the handle pedestal is attached to the surface of the decorative layer 3 using a fixture 9 such as a screw. A hinged door, which is a fitting, is formed from 1. In this case, a rotary connecting member such as a hinge may be provided at an appropriate position on the decorative panel 1.
Further, as shown in FIGS. 7A and 7B, the pulling tabs 12 are attached to both sides of the through holes 11 provided on the surface of the facing decorative layer 3 of the facing decorative panel 1 by using a fixture 9 such as a screw or an adhesive. It is also possible to use the decorative panel 1 as a sliding door by fixing it by fixing. In this case, a running member such as a runner or a door roller, a guide groove, or the like may be provided in an appropriate place on the decorative panel 1. The pull tab 12 may be fixed by being fitted into the through hole 11 from both sides.

Further, the decorative panel 1 may be configured such that at least one of the decorative layers 3 extends and is bent at the end of the core layer 2 and covers the end of the core layer 2. Further, the pair of facing decorative layers 3 are both extended, and at the end portions of the core layer 2, the facing decorative layers 3 are bent toward the core layer 2 side and overlapped with each other. The two ends may be covered. Further, a pair of facing decorative layers 3 are all extended, and at the end portions of the core layer 2, the facing decorative layers 3 are mutually bent toward the core layer 2 side, and the end portions of the facing decorative layer 3 are opposed to each other. The end portions of the core layer 2 may be covered in a state where they are butted.

FIG. 8A and FIG. 8B are cross-sectional views of a main part showing a modified example in which the end portion of the core layer 2 of the decorative panel 1 is covered with the decorative layer 3 and the resin-impregnated fiber sheet layer 4. Bent grooves (V-shaped grooves) 13 are provided on the surface (rear surface) of the extending one decorative layer 3a and the resin-impregnated fiber sheet layer 4a on the core layer 2 side. In this bent groove 13, as shown in FIG. 8(B), the extending portions of one of the decorative layer 3a and the resin-impregnated fiber sheet layer 4a are bent toward the end 14 side of the core layer 2 and an adhesive agent is interposed therebetween. The end portion 14 of the core layer 2 is covered by being joined to the end portion 14 of the core layer 2.

The bent groove 13 is provided on the back surface side of the resin-impregnated fiber sheet layer 4a so as to leave at least the decorative layer 3a at a position corresponding to the corner of the end 14 of the core layer 2. In the decorative layer 3a and the resin-impregnated fibrous sheet layer 4a, at least the part of the decorative layer 3a remaining in the part of the bent groove 13 functions like a hinge part (bent part), and the part can be bent at these parts. There is.
Further, in the illustrated example, an example is shown in which the tip end surface in the extending direction of the resin-impregnated fiber sheet layer 4a is covered with the end of the decorative layer 3a. Further, in the illustrated example, with the decorative layer 3a and the resin-impregnated fiber sheet layer 4a folded in the bending groove 13, the decorative layer 3a that covers the tip end surface in the extending direction of the resin-impregnated fiber sheet layer 4a is the other decorative layer. An example is shown in which the layer 3 and the layer 3 have substantially the same plane. In the illustrated example, the bent groove 13 is provided so that the corner portion formed by bending the bent groove 13 has a substantially right angle. However, the corner portion has an R chamfered shape or a C shape. The bent groove 13 may be provided so as to have a chamfered shape.

When the decorative layer 3a and the resin-impregnated fibrous sheet layer 4a are extended from the core layer 2 as described above, the extension portion is formed when the decorative panel 1 is formed by pressing with the above-described upper and lower molding dies. May be formed. At this time, the upper and lower molds may be deformed, or spacers may be interposed to form the decorative layer 3a and the resin-impregnated fiber sheet layer 4a by pressing. Further, in this case, the bent groove 13 may be formed by a molding die or a spacer-shaped die member instead of cutting or the like.
Further, the coating of the end portion 14 of the core layer 2 is not limited to the example of FIG. 8, and a mode in which the extended portions of the other decorative layer 3 and the resin-impregnated fiber sheet layer 4 are overlapped or abutted to cover When the frame member 23 is arranged on the end portion 14 of the core layer 2, the end surface of the frame member 23 may be covered.

9(A) and 9(B) are cross-sectional views of essential parts showing another modified example in which the end portion of the core layer 2 of the decorative panel 1 is covered with the decorative layer 3. For example, as shown in FIG. 9(A), the decorative panel 1 includes a frame member 23 in the core layer 2, and a pair of facing decorative layers 3a and 3b are extended. As shown in FIG. 9(B), the pair of facing decorative layers 3 a and 3 b are bent toward the end 14 side of the core layer 2 and are joined together with an adhesive in an overlapped state. It is configured to cover the end portion 14. That is, in this example, the end portion 14 of the core layer 2 is covered with the extending portions of the decorative layers 3a and 3b on which the resin-impregnated fiber sheet layers 4 and 4 are not provided on the back surface. In this case, when the resin composition 42 is applied so that the resin-impregnated fiber sheet layers 4 and 4 are not formed on the back surfaces of the extending portions of the decorative layers 3a and 3b, the resin composition 42 is applied to the portions. In order to prevent this, it may be applied with appropriate masking (curing).

In the illustrated example, the resin-impregnated fiber sheet layers 4 and 4 are not provided on the back surface side of the portions of the decorative layers 3a and 3b that cover both sides of the frame member 23 in the panel thickness direction. The impregnated fiber sheet layers 4 and 4 may be provided. Moreover, the coating of the end portion 14 of the core layer 2 is not limited to the example of FIG. 9. For example, the end portion 14 of the core layer 2 is covered with the extended portion of the one decorative layer 3a where the resin-impregnated fiber sheet layer 4 is not provided on the back surface, or the resin-impregnated fiber sheet layers 4 and 4 are provided on the back surface. The decorative layers 3a and 3b which are not provided may be abutted and covered. Further, when the frame member 23 is not arranged at the end of the decorative panel 1, the end 14 of the honeycomb core 21 of the core layer 2 may be simply covered.

Further, as shown in FIG. 10, an end cosmetic material 15 which is a separate body from the decorative layer 3 is attached to the end portion 14 of the core layer 2 via an adhesive, and an edge is attached to cover the end portion 14. You can go.
The material of the end portion decorative material 15 may be the same as that of the decorative layer 3, or may be another type. Moreover, as the adhesive used for sticking the edge decorative material 15, the same kind of resin as the resin impregnated in the resin-impregnated fiber sheet 4 may be used, or another kind may be used. In FIG. 10, the end decorative material 15 has a decorative layer 3 in which a resin film or a veneer is attached to the surface of a resin plate 16 to form a plate body having a two-layer structure.

In the decorative panel 1 in which the end portion 14 of the core layer 2 is covered as in each of the above-described examples, it is possible to prevent the entire decorative panel 1 from warping due to moisture absorption from the end portion 14 of the core layer 2. In addition, since the end portion 14 of the core layer 2 is covered, there is an advantage that the decorative surface of the decorative panel 1 has a high design and the finish is easy.
Although only one end side of the core layer 2 of the decorative panel 1 is shown in FIGS. 8 to 10, the other end side may be similarly covered by various modes. Further, both end portions in the panel width direction of the core layer 2 of the decorative panel 1 may be covered by various aspects as described above, and both end portions in the panel longitudinal direction of the core layer 2 of the decorative panel 1 may be the above. It may be coated by various modes such as.

Next, an example of manufacturing the decorative panel according to the first embodiment of the present invention will be shown as an example, but the decorative panel according to the present embodiment is not limited thereto.
(Example 1)
A polyethylene terephthalate resin film having a thickness of 60 μm was used as a decorative layer, and 200 g/m ² of a non-foaming urethane resin having a foaming ratio of 1 was applied to the back surface of the resin film. A glass paper having a basis weight of 50 g/m ² was placed on the urethane resin and impregnated with the urethane resin to form a resin-impregnated fiber sheet layer. Next, on the resin-impregnated fiber sheet layer, a corrugated cardboard honeycomb core having a cell diameter of 10.5 mm fitted inside a frame material made of LVL was placed as a core layer. Further, a fiber sheet was placed on the surface of the core layer, the urethane resin was applied and impregnated on the fiber sheet, and then the resin film was placed thereon to form a laminate. This laminate was heated and pressed for 2 minutes under the conditions of 80° C. and 1.25 kgf/cm ² (about 0.12 MPa) using a hot plate to integrally form a decorative panel test body.

(Example 2)
A decorative panel test body was obtained in the same manner as in Example 1 except that the fiber sheet was changed to a glass mat having a basis weight of 100 g/m ² .
(Example 3)
A decorative panel test piece was obtained in the same manner as in Example 1 except that the fiber sheet was changed to a glass mat having a basis weight of 200 g/m ² .
(Example 4)
A decorative panel test piece was obtained in the same manner as in Example 1 except that the fiber sheet was changed to a glass mat having a basis weight of 200 g/m ^{2 and} the resin applied to the fiber sheet was changed to a urethane resin having a foaming ratio of 2 times. It was
(Example 5)
A decorative panel test body was obtained in the same manner as in Example 1 except that the fiber sheet was changed to a glass mat having a basis weight of 200 g/m ^{2 and} the resin applied to the fiber sheet was changed to a urethane resin having a foaming ratio of 3 times. It was
(Example 6)
A decorative panel test piece was obtained in the same manner as in Example 1 except that the fiber sheet was changed to a glass mat having a basis weight of 200 g/m ^{2 and} the resin applied to the fiber sheet was changed to a urethane resin having a foaming ratio of 5 times. It was
(Example 7)
A decorative panel test piece was obtained in the same manner as in Example 1 except that the fiber sheet was changed to a glass mat having a basis weight of 200 g/m ^{2 and} the resin applied to the fiber sheet was changed to a urethane resin having a foaming ratio of 6 times. It was
(Example 8)
A decorative panel test piece was obtained in the same manner as in Example 1 except that the fiber sheet was changed to a glass cloth having a basis weight of 200 g/m ^{2 and} the resin applied to the fiber sheet was changed to a urethane resin having a foaming ratio of 6 times. It was

(Comparative example)
Except that a resin containing 20 parts by mass of wollastonite as a filler was applied to a predetermined amount between the decorative layer and the core layer with respect to 100 parts by mass of a non-foamed urethane resin having a foaming ratio of 1 times, without using a fiber sheet. A decorative panel test body was obtained in the same manner as in Example 1.

The test pieces of the decorative panels obtained in Examples and Comparative Examples were subjected to a weight drop resistance test and a scratch hardness test, and the following physical properties were evaluated.
<Impact strength>
The test pieces of the decorative panels obtained in Examples and Comparative Examples were subjected to a weight drop resistance test in accordance with the falling ball type of JIS K5600 5-3, and the surface strength was measured. That is, a dent on the surface of the test piece after dropping a 300 g steel ball from the height of 50 cm (500 mm) onto the test piece was visually evaluated. The evaluation criteria are as follows.
◎: No dent at all ○: Almost no dent △: Slight dent (not applicable)
×: Clearly dented

<Pencil hardness>
The test pieces of the decorative panels obtained in Examples and Comparative Examples were subjected to a scratch hardness test according to the pencil method of JIS K5600 5-4 to measure the pencil hardness. That is, the dent produced when the surface of the test piece was scratched with a pencil hardness of 3B was visually evaluated. The evaluation criteria are as follows.
◎: No dent at all ○: Almost no dent △: Slight dent (not applicable)
×: Clearly dented (not applicable)
The evaluation results are shown in Table 1.

表１に示したように、ハニカムコアを有する芯層と、芯層の表裏の両面に配設された樹脂フィルムからなる化粧層とを備え、芯層と化粧層との間に樹脂含浸繊維シート層が介設された実施例１〜８については、表面強度および鉛筆硬度がいずれも良好であることが確認された。
しかしながら、樹脂含浸繊維シート層を備えていない比較例では、鉛筆硬度は良好であるが、表面強度が実施例１〜８に比べて著しく劣ることが確認された。
これらの結果から、軽量化や意匠性の向上を図ることができ、生産性が高く、かつ化粧層が薄くても表面の硬度や強度、寸法安定性等が良好な化粧パネルが実現されることが確認された。

As shown in Table 1, a core layer having a honeycomb core and a decorative layer made of a resin film disposed on both front and back surfaces of the core layer are provided, and the resin-impregnated fiber sheet is provided between the core layer and the decorative layer. It was confirmed that in Examples 1 to 8 in which the layers were provided, the surface strength and the pencil hardness were both good.
However, it was confirmed that the comparative example not having the resin-impregnated fiber sheet layer had a good pencil hardness, but the surface strength was remarkably inferior to those of Examples 1 to 8.
From these results, it is possible to reduce the weight and improve the design, and to realize a decorative panel with high productivity and good surface hardness, strength, dimensional stability, etc. even if the decorative layer is thin. Was confirmed.

Next, an example of a decorative panel and a panel manufacturing method according to another embodiment of the present invention will be described with reference to FIGS. 11 to 13.
It should be noted that differences from the above-described examples will be mainly described, and similar components will be denoted by the same reference symbols, and description thereof will be omitted or briefly described.

As shown in FIG. 11, the decorative panel 1A according to the present embodiment has a configuration in which a surface side resin layer 44 is interposed between the decorative layer 3 and the resin-impregnated fiber sheet layer 4. That is, in this embodiment, the core layer 2A and the decorative layer 3 are bonded and integrated via the resin-impregnated fiber sheet layer 4 and the surface-side resin layer 44.
Further, the resin composition 43 (see FIG. 12(A)) that constitutes the surface-side resin layer 44 has the same resin main component as the resin composition 42 (see FIG. 12(C)) that constitutes the resin-impregnated fiber sheet layer 4. It is assumed to be the same. In other words, the fibrous sheet 41 (see FIG. 12D) included in the resin layers 4 and 44 on the back surface side of the decorative layer 3 is the back surface side (core layer 2A side) that is the anti-decorative layer side in the thickness direction. It is arranged so that it is located at (distributed).
Further, the resin-impregnated fiber sheet layers 4 and 4, the surface side resin layers 44 and 44, and the decorative layers 3 and 3 are provided on the outer sides of the core layer 2A in the panel thickness direction on both sides (both front and back sides) of the core layer 2A. The surface layers 24, 24 having this order are provided.

As shown in FIG. 13B, in the core layer 2A, the honeycomb core 21A is housed in a space surrounded by a frame member 23A including four peripheral frames 5A, 5A, 6 and 6 as in the example of FIG. It is configured.
In addition, in the present embodiment, as shown in FIGS. 11B and 13B, the insertion pieces of the surface layers 24, 24 are provided on the outer surfaces of the first crosspieces 5A, 5A facing outward in the panel width direction. The insertion grooves 5Aa, 5Aa into which the portions 24a, 24a are inserted are provided over the entire length. The insertion grooves 5Aa and 5Aa on both sides in the panel width direction are provided so as to open outward in the panel width direction. Further, the insertion grooves 5Aa, 5Aa are provided so as to be located substantially at the centers of the first crosspieces 5A, 5A in the panel thickness direction. The groove depth dimension of the insertion grooves 5Aa, 5Aa along the panel width direction and the groove width dimension along the panel thickness direction are appropriate dimensions from the viewpoint of the insertability and the retainability of the insert pieces 24a, 24a. May be
Further, in the illustrated example, the cells 22A of the honeycomb core 21A are shown to have a wavy shape.

The surface side resin layer 44 is provided over substantially the entire back surface side of the decorative layer 3. The surface side resin layer 44 may have an appropriate thickness from the viewpoint of improving the surface appearance, dimensional stability, productivity and the like. For example, the thickness of the resin layer 44 on the surface layer is in the range of 0.01 mm to 1.5 mm, preferably 0.03 mm to 1.0 mm, and more preferably 0.05 mm to 0.5 mm. If the thickness of the surface layer resin layer 44 is too small, the surface appearance tends to deteriorate, and if the thickness of the surface layer side resin layer 44 is too large, the influence of thermal expansion due to the surface layer side resin layer 44 is caused. It tends to become large and productivity decreases.

Further, the surface side resin layer 44 has a configuration that does not substantially include the fibers contained in the resin-impregnated fiber sheet layer 4 (a configuration that does not substantially include the fibers). Note that the configuration that substantially does not include fibers includes a case where fibers are slightly mixed in the surface-side resin layer 44 during the manufacturing process or the like.
The resin composition 43 (see FIG. 12A) that constitutes the surface side resin layer 44 is the resin composition 42 (see FIG. 12C) in which the resin main component constitutes the resin-impregnated fiber sheet layer 4. It is the same as the resin main component of. As the resin compositions 42 and 43, resins similar to the above can be adopted.

Further, in the present embodiment, the expansion ratio of the resin composition 43 forming the surface-side resin layer 44 is set to be equal to or lower than the expansion ratio of the resin composition 42 forming the resin-impregnated fiber sheet layer 4. That is, the expansion ratio of the resin composition 43 forming the surface side resin layer 44 is the same as or smaller than the expansion ratio of the resin composition 42 forming the resin-impregnated fiber sheet layer 4. With such a structure, the strength of the surface layer resin layer 44 can be relatively improved. Further, by appropriately adjusting the expansion ratio of the resin composition 42 constituting the resin-impregnated fiber sheet layer 4, it is possible to efficiently increase the thickness of the surface layer 24 or reduce the weight thereof. Become.
When these resin compositions 42 and 43 are foamed resins, they may have a low foaming ratio of 7 times or less, and more preferably 5 times or less, as described above, although depending on the kind. Note that various additives such as a curing agent and a flame retardant can be added to the resin composition 43 that constitutes the surface-side resin layer 44, as in the above.

Further, the amount of the resin composition 43 forming the surface layer resin layer 44 may be an appropriate amount so that the surface layer resin layer 44 has the thickness as described above. The surface-side resin layer 44 may be a resin composition 43 applied by a spray, a roller or the like on the back surface (anti-decorative surface) of the decorative layer 3 and cured. Further, the resin composition 42 and the fiber sheet 41 forming the resin-impregnated fiber sheet layer 4 may be arranged in a semi-cured (uncured) state of the resin composition 43 forming the surface-side resin layer 44. ..
Moreover, the resin-impregnated fiber sheet layer 4 has substantially the same configuration as that of the first embodiment. In the present embodiment, the thickness of the resin-impregnated fiber sheet layer 4 is set to be larger than the thickness of the surface side resin layer 44. For example, the thickness of the resin-impregnated fiber sheet layer 4 may be about 2 to 10 times the thickness of the surface-side resin layer 44.

Further, in the present embodiment, both the surface layers 24, 24 including the pair of facing decorative layers 3, 3 are extended at both widthwise end portions of the core layer 2A, and these extended portions are bent and abutted against each other. In this state, the end of the core layer 2A is covered. Further, the extension portions of the surface layers 24, 24 are provided with insertion piece portions 24a, 24a to be inserted into the insertion grooves 5Aa, 5Aa provided in the frame member 23A. In addition, bending grooves 13A, 13A, 17 and 17 are provided on the back surface side of these surface layers 24 and 24 such that the groove bottoms are located on the surface side resin layers 44 and 44 (FIG. 11(B). )reference). That is, these bent grooves 13A, 13A, 17, 17 remain on the surface side resin layers 44, 44 so that the groove bottoms do not reach the decorative layers 3, 3, and the thickness of the resin-impregnated fiber sheet layers 4, 4 is increased. It is provided over the entire length direction. With such a configuration, unevenness due to the fibers contained in the resin-impregnated fiber sheet layers 4 and 4 is less likely to occur in the bent corner portion, and the appearance of the corner surface can be improved.
Further, on the back surface side of these surface layers 24, 24, end portions corresponding to both opening edges of the corner bending grooves 13A, 13A, 13A, 13A corresponding to the corner portions of the core layer 2A and the insertion grooves 5Aa, 5Aa. The bent grooves 17, 17, 17, 17 are provided.

The thickness of the surface side resin layer 44 at the portion where the corner bending groove 13A and the end bending groove 17 are provided, that is, the remaining thickness on the groove bottom side, functions as a hinge portion as described above. In addition, the thickness may be an appropriate value depending on the thickness of the decorative layer 3 and the thickness of the surface-side resin layer 44. In the illustrated example, the remaining thickness of the surface layer side resin layer 44 on the groove bottom side is about 1/2 of the total thickness of the surface layer side resin layer 44, but it is not limited to such a thickness. Absent.
The corner bending groove 13A and the end bending groove 17 may be formed by cutting or the like as described above, or may be formed by a molding die or a spacer-shaped die member.

Next, an example of a panel manufacturing method for manufacturing the decorative panel 1A according to the present embodiment will be described.
In the present embodiment, after supplying the uncured resin composition 43 forming the surface-side resin layer 44 to the back surface of the decorative sheet forming the decorative layer 3, the resin is placed so as to be positioned on the back surface side of the surface-side resin layer 44. The impregnated fiber sheet layer 4 is formed.
First, as shown in FIG. 12(A), a decorative sheet is placed on the upper surface of the lower mold of the upper and lower molds so that the decorative surfaces face each other, and the back surface (anti-makeup) is substantially the same as above. The surface) is coated with the resin composition 43 that constitutes the surface-side resin layer 44. The resin composition 43 may be applied to the decorative sheet by using a spray or a roller in a uniform application amount in the same manner as above so that the surface-side resin layer 44 has the desired thickness as described above. You may The resin composition 43 forming the surface layer resin layer 44 is supplied in a state where the lower mold is heated to an appropriate temperature (for example, a relatively low temperature of about 40° C. to 80° C.) and cured or semi-cured. May be. At this time, in addition to the heating by the lower mold, heating may be performed from the upper side by an appropriate radiant heater such as a far infrared heater. The curing (semi-curing) time at this time may be about 1 minute to 30 minutes, preferably 15 minutes or less, depending on the type and amount of the resin composition 43.

Then, after the resin composition 43 constituting the surface side resin layer 44 is cured or semi-cured, the uncured resin composition 42 constituting the resin-impregnated fiber sheet layer 4 is supplied, and the resin-impregnated fiber sheet layer 4 is supplied. The resin composition 42 constituting the above is impregnated into the fiber sheet 41.
That is, as shown in FIGS. 12B and 12C, when the resin composition 43 forming the surface side resin layer 44 is cured or semi-cured, the uncured resin composition forming the resin-impregnated fiber sheet layer 4 is formed. Apply so that 42 is applied repeatedly. Then, as shown in FIG. 12D, the fiber sheet 41 is laminated so as to be impregnated with the resin composition 42. At this time, after the resin composition 43 forming the surface-side resin layer 44 is semi-cured or completely cured so that the fiber sheet 41 does not substantially move into the surface-side resin layer 44, the resin-impregnated fiber sheet layer 4 is not formed. The cured resin composition 42 and the fiber sheet 41 may be arranged.

Then, as shown in FIG. 12(D) and FIG. 11(B), the core layer 2A is placed in substantially the same manner as described above, and the surface layers arranged on both sides of the core layer 2A by the upper and lower molds. Alternatively, the resin compositions 42, 42 constituting the resin-impregnated fiber sheet layers 4, 4 may be hardened to be integrated with each other. At this time, the extension portions are formed after the spacer layers are integrated with each other so that the extension portions of the surface layers 24, 24 are formed on both sides in the width direction of the core layer 2A. Both ends 14 of the core layer 2A may be folded and covered with an appropriate adhesive.
Note that, in place of the above-described embodiment, the resin sheet 42 impregnated with the resin composition 42 is laminated on the surface-side resin layer 44, or the fiber sheet 41 is laminated on the surface-side resin layer 44. The composition 42 may be applied to the fiber sheet 41. Further, the order of the steps of the panel manufacturing method according to the present embodiment described above is merely an example, and the steps may be performed in a different order, and various modifications are possible.

According to the decorative panel 1A according to the present embodiment configured as described above, since the surface side resin layer 44 is provided on the back surface side of the decorative layer 3, even when the decorative layer 3 is thin, Irregularities due to the fibers contained in the resin-impregnated fiber sheet layer 4 hardly occur on the surface. Therefore, the surface smoothness can be further improved, and the appearance of the surface can be improved.
Further, since the resin composition 42 constituting the resin-impregnated fiber sheet layer 4 is the surface layer resin layer 44 having the same resin main component, the familiarity in each layer can be improved and boundary peeling or the like is less likely to occur. You can

In addition, in the present embodiment, an example is shown in which the insertion piece portions 24a and 24a of the surface layers 24 and 24 are inserted and housed in the insertion grooves 5Aa and 5Aa provided in the frame member 23A. The extended portions of 24 may be butted against each other. Further, as a mode of covering the end portion 14 of the core layer 2A, various modes such as those described with reference to FIGS. 8 to 10 can be adopted, and each embodiment and each modified example can be adopted. Different configurations may be combined with each other or rearranged to be applied.

1,1A Decorative panel 2,2A Core layer 21,21A Honeycomb core 22,22A Cell 23,23A Frame material 3,3a,3b Decorative layer 4,4a,4b Resin impregnated fiber sheet layer 41 Fiber sheet 42 Resin composition (resin Resin composition constituting the impregnated fiber sheet layer, resin)
43 Resin composition (resin composition constituting the surface side resin layer)
44 Surface layer resin layer 5, 5A First crosspiece 6 Second crosspiece 7 Intermediate crosspiece 8 Reinforcing metal fittings 9 Fixing device 10 Handle 11 Through hole 12 Pull tab 13, 13A Bending groove 14 End 15 End makeup Material 16 Resin plate

Claims (8)

A core layer having a honeycomb core, provided with a decorative layer made of veneer or a resin film constituting the arranged on both sides of the front and back of the core layer decorative sheet,
The core layer and the decorative layer are adhered by a resin-impregnated fiber sheet layer interposed therebetween ,
The resin-impregnated fibrous sheet layer is a resin sheet having a basis weight of 150 g/m ² or more and 700 g/m ² or less and a resin having a non-foaming property or a low foaming ratio of 5 times or less and 100 g/m ² or more and 300 g/m ² or less. There decorative panel, characterized in der Rukoto those impregnated. The decorative panel according to claim 1 , wherein the fiber sheet is a woven fabric, a non-woven fabric, or a mat of glass fibers. The said core layer is equipped with the frame material which accommodates the said honeycomb core inside, The decorative panel of Claim 1 or 2 characterized by the above-mentioned. Wherein at least one of the decorative layer, at the end of the core layer, one of claims 1 of 3, wherein the covering the end portion of the core layer in a state of being bent so as to extend The decorative panel according to item 1. The surface side resin layer is interposed between the decorative layer and the resin-impregnated fiber sheet layer, and the decorative panel according to any one of claims 1 to 4 . The resin composition forming the surface-side resin layer has the same resin main component as the resin composition forming the resin-impregnated fiber sheet layer, and the expansion ratio is a resin composition forming the resin-impregnated fiber sheet layer. 6. The decorative panel according to claim 5 , wherein the foaming ratio is less than or equal to. A fiber sheet having a basis weight of 150 g/m ² or more and 700 g/m ² or less forming a resin-impregnated fiber sheet layer on both front and back sides of a core layer having a honeycomb core, and 100 g with no foaming or low foaming ratio of 5 times or less. /M ² or more and 300 g/m ² or less of uncured resin composition is interposed between them, and veneer plates constituting the decorative layers on both front and back sides or a decorative sheet made of a resin film are arranged, and pressed from both front and back sides. And then curing the resin composition to produce a decorative panel. After supplying the uncured resin composition constituting the surface side resin layer to the back surface of the decorative layer on both the front and back sides, the resin-impregnated fiber sheet layer is formed so as to be located on the back surface side of the surface layer resin layer. The panel manufacturing method according to claim 7 , wherein the decorative panel is manufactured.

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