JP6899212B2 - Composite board - Google Patents

Description

The present invention relates to a composite plate. The present invention particularly relates to a composite plate in which a synthetic resin foam is sandwiched between two resin plates.

Generally, in a toilet room of a public facility, a phenol resin plate having a diameter of 10 to 20 mm is widely used as a toilet booth for partitioning each toilet space (for example, Patent Document 1). This phenol resin plate is a panel in which a surface layer material of melamine resin and a core material of phenol resin are integrally molded at a high temperature.

However, since the phenolic resin plate has a high density and a large total weight, there is a risk that the toilet user or the like may be injured or trapped if it falls from the fixture or the like due to an earthquake or the like, and in an emergency. There is a safety problem. Further, the phenolic resin plate has a problem that the burden on the operator is heavy from the viewpoint of transportation and the like even in the construction work of the toilet booth. Further, since the phenolic resin plate is relatively expensive as compared with other general-purpose resin materials, there is also a problem that the cost increases.

Due to these problems, in general facilities such as office buildings, phenol resin plates are not used for toilet booths, and the paper honeycomb structure of the core material is made of single plate laminated material (LVL) or medium density fiberboard (MDF). A structure in which a frame is constructed of synthetic wood and a melamine plate is used as a surface material is used (for example, Patent Document 2).
When such a paper honeycomb structure is adopted, the cost is low and the weight is small as compared with the case where a single phenol resin plate is adopted.

Japanese Unexamined Patent Publication No. 10-067075 Japanese Unexamined Patent Publication No. 10-138404

However, although the paper honeycomb structure of the above-mentioned general facility is lightweight and can be made at low cost, it has a problem that the rigidity is low as compared with the phenol resin plate and it takes time to assemble the frame material.

In addition, since the toilet room of a public facility is used by an unspecified number of people, some users perform vandalism such as stabbing a partition with an umbrella or kicking a toilet booth.
However, in the above-mentioned paper honeycomb structure, since most of the core material is hollow, if the umbrella is stabbed in the thickness direction and the surface material is destroyed, the fracture resistance in the thickness direction is significantly reduced, and in some cases, the fracture resistance strength in the thickness direction is significantly reduced. , The problem that the umbrella penetrates in the thickness direction may occur. Therefore, there is a problem that the above-mentioned paper honeycomb structure cannot be substantially adopted in public facilities.

Therefore, it is an object of the present invention to provide a composite plate that is lighter than a single resin plate having the same thickness while maintaining a certain level of fracture resistance even if the overall thickness is thin.

In view of the above problems, the present inventor uses two styrene resins having a low foaming ratio in order to reduce the amount of the phenol resin used and reduce the weight while ensuring the fracture resistance. A composite plate sandwiched between a resin plate or a melamine resin plate was prototyped.

Specifically, if the thickness of the phenolic resin plate or the melamine resin plate is reduced, the weight is reduced, but the fracture resistance is reduced. Therefore, with the above-mentioned composite plate structure, the thickness of the phenolic resin plate or the melamine resin plate is gradually reduced to obtain the same degree of fracture resistance as the fracture resistance of the phenolic resin plate or the melamine resin plate alone. The thickness that can be maintained was examined. As a result, it was found that the fracture resistance sharply decreases when the thickness is less than a certain level.
In response to this result, the present inventor considers that the optimum value of the phenolic resin plate or the melamine resin plate is generally constant, and based on the optimum value, the foaming ratio of the synthetic resin foam is increased to reduce the density. By doing so, it was expected that a composite board that was lightweight and maintained a certain level of fracture resistance could be obtained.
However, as a result of examining by increasing the expansion ratio of the synthetic resin foam and decreasing the density, when the density is lower than a certain density, even if the phenol resin plate or the melamine resin plate has the above-mentioned optimum thickness, it can withstand. The breaking strength was reduced.
Therefore, as a result of reexamining the relationship between the thickness of the phenol resin plate or the melamine resin plate and the expansion ratio (density) of the foamed styrene resin, the thickness of the phenol resin plate or the melamine resin plate was equal to or larger than a certain thickness and It was discovered that the decrease in fracture resistance due to the thinning of the thickness of the composite plate can be alleviated by setting the density of the synthetic resin foam to a certain level or higher.

The invention according to claim 1, which was derived as a result of diligent studies based on the above findings, has the synthetic resin foam sandwiched between two resin plates, and the two sheets are placed on both sides of the synthetic resin foam. It is a composite plate to which a resin plate is bonded, and the thickness of the two resin plates is in the range of 1.7 mm or more and 6.0 mm or less, respectively, and the density of the synthetic resin foam is 111 kg / m ³ or more and 334 kg. The composite plate is characterized in that it is / m ³ or less and the total thickness of the composite plate is 5 mm or more and 50 mm or less.
That is, the present invention is a composite plate in which a synthetic resin foam is sandwiched between two resin plates, and the thickness of the two resin plates is in the range of 1.7 mm or more and 6.0 mm or less, respectively. the density of the synthetic resin foam is a 111 kg / m ³ or more 334kg / m ³ or less, the total thickness of the composite plate is associated with at 5mm or more 50mm or less.

The "density" here means an apparent density according to JIS K 7222.

According to the configuration of the present invention, it is lighter than a single resin plate having the same thickness while maintaining a certain level of fracture resistance or higher.

In the above invention, the thickness of the two resin plates is preferably in the range of 1.7 mm or more and 3.0 mm or less, respectively.

In the above invention, the total thickness of the composite plate is preferably 15 mm or more and 20 mm or less.

The invention according to claim 2 is the composite plate according to claim 1, wherein the main component of the synthetic resin foam is a polystyrene-based resin or a polyolefin-based resin.

The "main component" here means a component that accounts for 50% or more of all the components.

According to the configuration of the present invention, since the main component of the synthetic resin foam is formed of polystyrene-based resin or polyolefin-based resin, it is easy to mold the synthetic resin foam.

In the above invention, it is more preferable that 90% or more of the components of the synthetic resin foam are polystyrene-based resin or polyolefin-based resin.

The invention according to claim 3 is the composite plate according to claim 1 or 2, wherein the synthetic resin foam has a foaming ratio of 3 times or more and 9 times or less.

According to the configuration of the present invention, it is easy to set the density of the synthetic resin foam within the above-mentioned density range.

The composite plate according to claim 4, wherein at least one of the two resin plates is a thermosetting resin plate. Is.

According to the configuration of the present invention, it is easy to mold the resin plate.

In the composite board according to claim 4, before the one of the resin sheet, it is preferable that the melamine resin plate or a phenol resin plate (claim 5).
In the above composite plate, the one resin plate may include at least one selected from a melamine resin plate, a melamine resin sheet, a phenol resin plate, and a phenol resin sheet.

In the present invention, the two resin plates are both laminated plates containing a melamine resin sheet and a phenol resin sheet, and the outer surfaces of the two resin plates are both based on the synthetic resin foam. It is related to being formed of a melamine resin sheet.

According to the configuration of this, since the outer surfaces of the two resin plate is formed by a melamine resin sheet, a composite plate having excellent water resistance.

The invention according to claim 6 has a dent amount of 0.5 mm or less when a 0.7 kg steel ball is dropped from a height of 0.5 m onto one of the main surfaces according to JIS K 5600-5-3. The composite board according to any one of claims 1 to 5 , wherein the composite board is characterized by the above.

According to the configuration of the present invention, even if an umbrella or the like is stabbed in the thickness direction, a dent is unlikely to be formed.

The above invention, of the two resin plates, the at least one resin plate, pulling resistance equivalent to JIS A 5905 in the thickness direction may be I der least 900 N.

According to the configuration of this, larger than the breaking strength of common screws (about 857N), screw or the like does not remove easily be attached common screws from the one of the resin plate side.

The present invention is a composite plate in which a synthetic resin foam is sandwiched between two resin plates and the two resin plates are bonded to both sides of the synthetic resin foam, and the thickness of the two resin plates is a range of each 1.7mm or 6.0 mm, the density of the synthetic resin foam is not more than 111 kg / m ³ or more 334kg / m ^3, the following 50mm total thickness 5mm or more of the composite plate The main component of the synthetic resin foam is a polystyrene resin, and the two resin plates are both laminated plates containing a melamine resin sheet and a phenol resin sheet, based on the synthetic resin foam. as the outer surface of the two resin plates, associated with multiple plywood that are together formed by a melamine resin sheet.
Further , the present invention is a composite plate in which a synthetic resin foam is sandwiched between two resin plates, and the thickness of the two resin plates is in the range of 1.7 mm or more and 6.0 mm or less, respectively. the density of the synthetic resin foam is not more than 111 kg / m ³ or more 334kg / m ^3, the total thickness of the composite plate is at 5mm or more 50mm or less, the main component of the synthetic resin foam is a polystyrene resin Yes, the two resin plates are both laminated plates containing a melamine resin sheet and a phenol resin sheet, and the outer surfaces of the two resin plates are both melamine resins based on the synthetic resin foam. Related to being formed of sheets.

According to the configuration of this, while maintaining the fracture strength of certain level, it becomes lighter than the resin plate alone of the same thickness.

The present invention is a composite plate that is directly or indirectly attached to a structure by a fastening element, and the fastening element is attached to the structure from the side surface of the synthetic resin foam. It is related to being inserted inside the foam.
Further, the present invention is a composite plate that is directly or indirectly attached to a structure by a fastening element, and when attached to the structure, the two sheets are attached to the synthetic resin foam. It is related to the fact that the fastening element is inserted in a direction intersecting the overlapping direction of the resin plates.

The term "structure" as used herein includes not only fixed structures such as buildings but also movable property structures.
The term "indirectly attached" as used herein means that it is attached via another member.
The "fastening element" here is a superordinate concept such as a screw, a nail, and a stud.

According to the configuration of this, in a state attached to the structure, since the fastening element in the synthetic resin foam is inserted, easily mount the fastening element.

In the above invention, it is more preferable that the fastening element is inserted into the edge surface or the edge surface.

In the above invention, it is more preferable that the fastening element is inserted into the synthetic resin foam so as to pass between the two resin plates.

The present invention relates to a composite plate installed in a vertical posture so as to divide it into two spaces, and the two resin plates are exposed in the two spaces in the installed state .

According to the configuration of this, two resin plates are provided on the outermost surface respectively, the two resin plates separated two spaces were are exposed respectively, scratches are hardly attached.

The present invention is a composite plate installed by passing a conductor that electrically connects two devices, and has a second hole portion formed in the synthetic resin foam and extending between the two resin plates. It is related to the fact that at least a part of the conductor passes through the second hole portion in the state of having and installing the conductor.
Further, the present invention is a composite plate installed by passing a conductor that electrically connects two devices, and in the installed state, at least a part of the conductor passes between the two resin plates. Related to what you are doing.

According to these configurations, at least a part of the conductor can be passed between the two resin plates, so that the conductor can be easily installed.

The present invention has a first hole portion that penetrates one of the two resin plates and communicates with the second hole portion, and in the installed state, the conductor has the first hole portion. And related to passing through the second hole.
Further, the present invention is a composite plate installed by passing a conductor that electrically connects two devices, and in the installed state, the conductor is the synthetic resin from the side surface of the synthetic resin foam. It is related to passing towards the inside of the foam.

According to the configuration of this, for extending towards the inside of the synthetic resin foam from the sides of the synthetic resin foam, easily passed through a conductor.

The present invention is a composite plate installed between light ray communication devices capable of unidirectional communication or bidirectional communication by light rays, and the synthetic resin foam has a space through which the light rays can pass. associated with.

According to the configuration of this, it is possible to prevent the communication by rays between ray communication apparatus is inhibited by the presence of the synthetic resin foam.

In the above-mentioned invention, in the installed state, the conductor may pass from at least one place from the four side surfaces of the synthetic resin foam.

According to the composite plate of the present invention, even if the thickness is relatively thin, the weight is lighter than that of a single resin plate having the same thickness while maintaining a certain level of fracture resistance.

It is a top view which shows typically the state of the toilet room in 1st Embodiment of this invention. It is a perspective view of the toilet booth of FIG. It is explanatory drawing which shows the boundary part of the partition plate part and the door plate part of the toilet booth of FIG. 1, (a) is a perspective view, and (b) is a partially broken perspective view. It is a partially broken perspective view which shows the vicinity of the switch device of the toilet booth of FIG. It is sectional drawing of the vicinity of the switch device of the toilet booth of FIG. It is a perspective view of the composite plate which constitutes each plate part of FIG. It is explanatory drawing of the composite board of 2nd Embodiment of this invention, (a) is the perspective view of the composite board, and (b) is the exploded perspective view of the composite board. FIG. 5 is a partially broken perspective view showing a boundary portion between a partition plate portion and a door plate portion of a toilet booth when the composite plate of FIG. 7 is used. It is a perspective view of the composite board of the 3rd Embodiment of this invention. It is an exploded perspective view of the composite plate of FIG. FIG. 5 is a partially cutaway perspective view showing a state in which a wiring member is laid on the composite plate of FIG. It is a top view which shows typically the vicinity of the switch device of the toilet booth of another embodiment of this invention. It is a perspective view which shows the other installation situation of the composite board of 1st Embodiment of this invention schematically. It is a graph showing the relationship between the thickness of the resin plate and the dent in the experimental example of this invention, (a) is the graph of Experimental Examples 1 to 9 which has a foaming ratio of 5 times, and (b) is the graph which has a foaming ratio of 7 times. It is a graph of Experimental Examples 10 to 18 and (c) is a graph of Experimental Examples 19 to 27 having a foaming ratio of 10 times. As a comparison, the values of Experimental Example 28 of the composite plate alone are shown by virtual lines.

Hereinafter, embodiments of the present invention will be described in detail. Unless otherwise specified in the following description, the physical properties show the characteristics in the standard state (1 atm, 23 ° C.).

The composite plate 1 of the first embodiment of the present invention is a plate-like body in which the synthetic resin foam 5 is sandwiched between two resin plates 2 and 3, and is used in a toilet room as shown in FIG. is there.
Specifically, the composite plate 1 is used as a part of the toilet booths 100a, 100b, 100c that partition the space 120 of the toilet room as shown in FIGS. 1 and 2. That is, the composite plate 1 constitutes a part of the toilet booth 100, and divides a part of the space 120 of the toilet room into a plurality of divided spaces 121a, 121b, 121c, 121d. As shown in FIG. 1, the toilet room of the present embodiment includes three toilet booths 100a to 100c arranged side by side in a predetermined direction.

As can be read from FIGS. 1 and 2, the toilet booth 100 is formed so as to surround the toilet unit 101, and as main constituent members, the wall portions 102a and 102b of the building and the partition plate portions 103a and 103b. , 103c (structure), door plate portions 105a, 105b, 105c, and door receiving plate portions 106a to 106d.
The composite plate 1 of the present embodiment constitutes each plate portion 103a to 103c, 105a to 105c, 106a to 106d, and is installed in a vertical posture so as to divide the divided spaces 121a, 121b, 121c, 121d. is there.

As shown in FIG. 2, the partition plate portions 103a to 103c are plate-shaped portions arranged in a vertical posture and orthogonal to the wall portion 102a when viewed in a plan view.
The partition plate portions 103a to 103c are partitions that partition the space 120 into the divided spaces 121a, 121b, 121c, 121d adjacent to the toilet booths 100a to 100c in the parallel direction.
As can be read from FIGS. 4 and 5, each of the partition plate portions 103a to 103c is provided with a switch device 110 (equipment) interlocking with the toilet unit 101 (equipment) in the middle portion of the surface on the toilet unit 101 side. , A wiring hole 117 is formed which allows the wiring member 116 (conductor) connecting the switch device 110 and the toilet unit 101 to pass through.

As shown in FIG. 5, the wiring holes 117 are the first hole 118 having a depth in the thickness direction of the partition plate 103a to 103c, and the spreading directions (width direction and length direction) of the resin plates 2 and 3. ) Is provided with a second hole portion 119.
The first hole portion 118 is a hole that penetrates the resin plate 3 and further reaches the intermediate portion of the synthetic resin foam 5.
The second hole portion 119 is a hole that communicates with the depth direction end portion of the first hole portion 118 and extends between the resin plates 2 and 3. That is, the second hole portion 119 is a hole formed only in the synthetic resin foam 5, and the end portion thereof communicates with the outside at the end portion of the partition plate portions 103a to 103c.

As shown in FIG. 2, the door receiving plate portions 106a to 106d are arranged in a vertical posture and are plate-shaped portions orthogonal to the partition plate portions 103a to 103c when viewed in a plan view. The door receiving plate portions 106a to 106d are receiving plate portions whose intermediate portions are connected to the tip portions of the partition plate portions 103a, 103b, 103c and receive the door plate portions 105a, 105b, 105c when closed.
A receiving metal fitting 112 for receiving the door plate portions 105a, 105b, 105c is provided at one end of the door receiving plate portions 106a to 106d, and a mounting hole into which the fastening element 125 can be inserted is provided at the other end portion. 113 is formed.
The receiving metal fitting 112 is an overhanging piece protruding from a part of the end portions of the door receiving plate portions 106a to 106d.
The mounting hole 113 is a fastening hole for mounting the fastening element 125, and extends from the side surface (the surface other than the main surface) of the synthetic resin foam 5 of the partition plate portions 103a to 103c toward the inside of the synthetic resin foam 5. It is a bottomed hole or a through hole. That is, the mounting hole 113 is a hole extending in a direction intersecting the thickness direction (overlapping direction of the resin plates 2 and 3) between the resin plates 2 and 3, and is formed only in the synthetic resin foam 5. There is.

As shown in FIG. 2, the door plate portions 105a, 105b, 105c are doors that open and close the space in the toilet booths 100a, 100b, 100c, and hinges 111 are provided on the end faces, and partition plates are provided via the hinges 111. It is connected to the units 103a, 103b, and 103c so as to be openable and closable. In other words, the door plate portions 105a, 105b, 105c are rotatably attached to the partition plate portions 103a, 103b, 103c.

The toilet units 101, 101, 101 are composed of a toilet main body 115, a switch device 110, and a wiring member 116 as main constituent members, and the toilet main body 115 is interlocked by operating the switch device 110. is there.

The wiring member 116 is a connecting member that electrically connects the toilet body 115 and the switch device 110. The wiring member 116 is a conductor and is a linear body extending linearly.

Subsequently, the positional relationship of each member of the toilet booth 100 will be described.

As shown in FIG. 2, the partition plate portions 103a, 103b, 103c and the wall portion 102b face each other so as to sandwich the toilet unit 101. A switch device 110 is attached to one of the main surfaces (the surface on the toilet unit 101 side) of the partition plate portions 103a, 103b, and 103c.
A wiring member 116 crawls in the wiring hole 117 formed in the synthetic resin foam 5 of the partition plate portions 103a, 103b, 103c so as to connect the switch device 110 and the toilet body 115, and the wiring member 116 is a partition plate. It extends from the end faces of the portions 103a, 103b, 103c across the wall portion 102a.
From another point of view, one end of the wiring member 116 passes through the second hole 119 from the end faces of the partition plates 103a, 103b, 103c, passes through the first hole 118, and with the switch device 110. It is connected.

As shown in FIG. 3, one end of the hinge 111 is attached to the end faces of the door plate portions 105a, 105b, 105c by the fastening element 126, and the fastening element is attached to the end faces of the door receiving plate portions 106a to 106d. The other end of the hinge 111 is attached by 125. That is, the side surfaces of the synthetic resin foam 5 of the plate portions 105a, 106a (105b, 106b, 105c, 106c) are exposed to the outside, and the fastening elements 125, 126 are the plate portions 105a, 106a (105b, 106b, It is inserted into the synthetic resin foam 5 from the side surface of the synthetic resin foam 5 of 105c, 106c).

Subsequently, each component of the composite plate 1 will be described in detail.

As described above, the composite plate 1 has the synthetic resin foam 5 sandwiched between the two resin plates 2 and 3, and has the resin plates 2 and 3 on both sides of the synthetic resin foam 5.
The composite plate 1 of the present embodiment has a three-layer cross-sectional shape, and the resin plates 2 and 3 and the synthetic resin foam 5 have different colors.
The composite plate 1 is a plate-like body having a planar shape, and an outer shell is formed by two main surfaces and a side surface connecting the two main surfaces.

(Resin plates 2 and 3)
The resin plates 2 and 3 are mainly composed of a thermoplastic resin or a thermosetting resin, and are laminated plates obtained by impregnating a plurality of sheets with a resin and laminating them.
As shown in FIG. 6, the resin plates 2 and 3 of the present embodiment are thermosetting resin plates, a phenol resin sheet 10 impregnated with a phenol resin which is a thermosetting resin, and melamine which is a thermosetting resin. It has a laminated structure in which a melamine resin sheet 11 impregnated with a resin is laminated. The resin plates 2 and 3 of the present embodiment have the melamine resin sheet 11 arranged on the outermost side of the synthetic resin foam 5 as a reference. That is, the outer surfaces of the resin plates 2 and 3 of the present embodiment are both formed of the melamine resin sheet 11.
The resin plates 2 and 3 may be a single plate containing a single resin as a main component.
The resin plates 2 and 3 of the present embodiment are black and have a color different from that of the synthetic resin foam 5.

The density of the resin plate 2 is greater than the density of the synthetic resin foam 5, it is preferably not more than 1311g / m ³ or more 2334kg / m ^3, is 1483kg / m ³ or more 1720kg / m ³ or less More preferred.
The thickness of the resin plates 2 and 3 is in the range of 1.7 mm or more and 6.0 mm or less, and preferably 1.8 mm or more and 3.0 mm or less.
Within this range, the weight can be reduced while ensuring sufficient fracture resistance.

Examples of the thermosetting resin constituting the resin plates 2 and 3 include epoxy resin, phenol resin, urea resin, unsaturated polyester resin, melamine resin, alkyd resin, polyimide resin, silicone resin, hydroxyl group functional acrylic resin, and carboxyl functionality. Acrylic resin, amide functional copolymer, urethane resin and the like can be adopted.
As the thermoplastic resin constituting the resin plates 2 and 3, acrylonitrile-butadiene-styrene copolymer (ABS resin), polypropylene (PP) and the like can be adopted.

(Synthetic resin foam 5)
The synthetic resin foam 5 is a foamed resin body formed by foaming a foamed resin composition.
The density of the synthetic resin foam 5, from the viewpoint of obtaining good load-bearing and resistance to breaking strength, it is 111 kg / m ³ or more 334kg / m ³ or less, preferably not more than 143kg / m ³ or more 200 kg / m ³ ..
The foaming ratio of the synthetic resin foam 5 is preferably 3 times or more and 9 times or less, and more preferably 5 times or more and 7 times or less, from the viewpoint of obtaining good load capacity and fracture resistance.
This "foaming ratio" is a value calculated by dividing the density of the foamed resin composition before foaming by the density of the foamed resin composition (synthetic resin foam 5) after foaming.

The compressive elastic modulus of the synthetic resin foam 5 according to JIS A 9511 is preferably 58 MPa or more, more preferably 58 MPa or more and 148 MPa or less, and 88 MPa from the viewpoint of obtaining good load capacity and fracture resistance. It is particularly preferably 118 MPa or less.

Since the surface condition taken out from the mold at the time of molding has feeder marks and filling holes, at least one surface of the synthetic resin foam 5, preferably both surfaces, is taken out from the mold, including removing them. It is preferable that the surface is roughened by grinding with a belt sander or the like so that the surface becomes coarser than in the state of being rough, and the thickness deviation amount is made uniform so as to be ± 0.3 to 0.5 mm.
The center line average roughness (Ra) of the synthetic resin foam 5 according to JIS B 0601: 2013 is preferably 45 μm or more and 60 μm or less.
Within this range, high bonding strength can be ensured between the resin plates 2 and 3 and the synthetic resin foam 5.

The synthetic resin foam 5 is obtained by foaming a foamed resin composition and contains the foamed resin composition as a main component. In the synthetic resin foam 5 of the present embodiment, the foamed resin composition accounts for 90% or more of all the components.

The foaming method of the foamed resin composition, which is the material of the synthetic resin foam 5, is not particularly limited.
As the foaming method of the foamed resin composition, it is preferable to use the bead method from the viewpoint of obtaining a homogeneous synthetic resin foam 5.
In the bead method, foamed resin particles, which are foamed resin compositions impregnated with a foaming agent, are used as raw materials, and the foamed resin particles are filled in the cavity of a mold. Then, the synthetic resin foam 5 is obtained by integrating the pre-foamed particles with each other by heat fusion while secondary foaming the filled foamed resin particles with steam.

The foamed resin composition is preferably a thermoplastic resin.
Examples of this thermoplastic resin include polyolefin resins such as polyethylene, propylene, polystyrene, ethylene-vinyl acetate copolymer resin (EVA), and ethylene- (meth) acrylic acid-based resin, and acrylonitrile-butadiene-styrene copolymer (ABS). Resin), acrylonitrile-styrene copolymer, polyvinyl chloride resin, polyvinyl acetate resin, polyvinyl resin such as polyvinyl alcohol resin, polyester resin such as polyethylene terephthalate resin (PET resin), nylon, polyacetal resin, acrylic resin, polycarbonate resin , A single thermoplastic resin such as a polyurethane resin and a copolymer, or a mixed resin thereof and the like can be adopted. Among these, a polyolefin-based resin or a polystyrene-based resin is preferable, and a polystyrene-based resin is more preferable, in consideration of the strength of the resin itself.
The synthetic resin foam 5 of the present embodiment is obtained by foaming a polystyrene-based resin as a foamed resin composition, and the polystyrene-based resin accounts for 90% or more of all the components.

The styrene-based resin constituting the foamed resin composition of the synthetic resin foam 5 is preferably foamable styrene-based resin beads obtained by polymerizing a styrene-based monomer as a main component.
Examples of this styrene-based monomer include styrene-based derivatives such as styrene, α-methylstyrene, paramethylstyrene, t-butylstyrene, and chlorostyrene.
Further, the styrene resin constituting the foamed resin composition is a component capable of copolymerizing with the styrene monomer, for example, acrylic acid such as methyl acrylate, butyl acrylate, methyl methacrylate, ethyl methacrylate, cetyl methacrylate and methacrylic acid. Or the ester of the above, or various monomers such as acrylotril, dimethyl fumarate, and ethyl fumarate may be added in one or more kinds and copolymerized. Further, a bifunctional monomer such as divinylbenzene or alkylene glycol dimethacrylate can also be used in combination.

Among these styrene-based resins, polystyrene resin is preferable as the foamed resin composition of the synthetic resin foam 5 from the viewpoint of versatility, cost, and physical characteristics.

The particle size of the foamed resin particles, which is the foamed resin composition, is preferably 0.2 to 4.0 mm, more preferably 0.5 to 2.0 mm.

As the foaming agent to impregnate the foamed resin particles, it is preferable to use aliphatic hydrocarbons such as propane, isobutane, normal butane, isopentane, normal pentane, and neopentane, which are hydrocarbons of C3 or more and C5 or less. Further, in addition to hydrocarbons of C3 or more and C5 or less, volatile foaming agents such as fluorinated hydrocarbons having an ozone depletion potential of 0 such as difluoroethane and trafluoroethane can also be used.

Subsequently, the physical characteristics of the composite plate 1 will be described. The following values are the results of the examples described later and the results of examination based on the empirical rule.

The overall thickness of the composite plate 1 is 5 mm or more and 50 mm or less, preferably 10 mm or more and 30 mm or less, and more preferably 17.6 mm or more and 20 mm or less.
Within this range, versatility can be ensured as a substitute member for the resin plate alone or for other uses.
The composite plate 1 has a dent amount of 0.5 mm or less when a 0.7 kg steel ball is dropped from a height of 0.5 m onto one of the main surfaces in accordance with JIS K 5600-5-3. It is preferably 0.4 mm or less, and more preferably 0.4 mm or less.
Within this range, sufficient fracture resistance can be ensured even when used in public facilities.

In the composite plate 1, it is preferable that the resin plates 2 and 3 both have the same thickness and are thinner than the thickness of the synthetic resin foam 5.
The resin plates 2 and 3 preferably have a pull-out strength of 900 N or more, more preferably 1200 N or more, according to JIS A 5905 in the thickness direction. That is, the pull-out strength of the composite plate 1 in the thickness direction is preferably 900 N or more, and more preferably 1200 N or more.
Within this range, the pull-out strength of the resin plates 2 and 3 is larger than the breaking strength (about 857N) of a general screw, so that even if a general screw or the like is attached, the screw or the like is difficult to come off.
Further, the composite plate 1 preferably has a pull-out strength of 900 N or more according to JIS A 5905 in the stacking direction of the resin plates 2 and 3 and the synthetic resin foam 5 (the overlapping direction of the resin plates 2 and 3). The above is more preferable. That is, the pull-out strength of the composite plate 1 in the thickness direction is preferably 900 N or more, and more preferably 1200 N or more.
Within this range, the pull-out strength of the composite plate 1 is larger than the breaking strength (about 857N) of a general screw, so that even if a general screw or the like is attached, the screw or the like is difficult to come off.

The density of the apparent composite plate 1 is preferably not more than 1511kg / m ³ or more 1734kg / m ^3, more preferably not more than 1543kg / m ³ or more 1600 kg / m ^3.
The "apparent density of the composite plate 1" as used herein means the total weight of the composite plate 1 with respect to the total volume.
Within this range, since the weight per volume is small, it is possible to ensure transportation to the work site and safety in an emergency as compared with the case of using a single resin plate of the same size.

According to the composite plate 1 of the present embodiment, the thickness of the resin plates 2 and 3 and the density of the synthetic resin foam 5 are within a predetermined range, so that even if the total thickness is relatively thin, 5 mm or more and 50 mm or less. , Both high fracture resistance and weight reduction can be achieved. That is, it is lighter than a plate formed of a single resin plate and can have higher fracture resistance than a panel having a paper honeycomb as a core material, so that it is a highly versatile composite plate.

According to the composite plate 1 of the present embodiment, since the colors of the resin plates 2 and 3 and the color of the synthetic resin foam 5 are different, it is easy to grasp the portion of the synthetic resin foam 5 and the synthetic resin foam is formed. It is easy to attach the fastening elements 125, 126, etc. only to the body 5.
Further, according to the composite plate 1 of the present embodiment, since the end faces have a plurality of colors, the design is higher than that of the case where the composite plate 1 is formed only of a resin plate having a single color.

According to the composite plate 1 of the present embodiment, when the materials of the resin plates 2 and 3 are more expensive than the material of the synthetic resin foam 5, the resin plates alone are the plate portions 103a to 103c, 105a to 105c, 106a to Since the amount of the resin plates 2 and 3 used can be reduced as compared with the case of forming 106d, the cost can be reduced.

Subsequently, the composite plate 150 of the second embodiment of the present invention will be described. The same configurations as those of the composite board of the first embodiment are assigned the same numbering, and the description thereof will be omitted.

As shown in FIG. 7, the composite plate 150 of the second embodiment of the present invention includes resin plates 2 and 3, a synthetic resin foam 5, and end face protection members 151a to 151d.
The end face protection members 151a to 151d are plate-shaped or sheet-shaped members that protect each end face of the synthetic resin foam 5.
The end face protection members 151a to 151d cover and fix at least the exposed portions of the synthetic resin foam 5 from the resin plates 2 and 3, and in the present embodiment, also cover the end faces of the resin plates 2 and 3. That is, the end face protection members 151a to 151d constitute the end face of the composite plate 150.
The end face protection members 151a to 151d are members having higher rigidity than the synthetic resin foam 5, and are composed of a thermosetting resin plate such as a phenol resin plate or a melamine resin plate.

At the end faces of the composite plates 150 constituting the door plate portions 105a, 105b, 105c, as shown in FIG. 8, the fastening element 125 (126) passes through the end face protection member 151b (151d), and the synthetic resin foam 5 It is inserted into the synthetic resin foam 5 from the side surface.

According to the composite plate 150 of the second embodiment, since the end face protection members 151a to 151d are provided on the exposed portions of the synthetic resin foam 5 from the resin plates 2 and 3, scratches such as dents are made on the end face. Hard to stick.

According to the composite plate 150 of the second embodiment, since the fastening element 125 (126) is inserted through the end face protection member 151d (151b) bonded to the end face of the synthetic resin foam 5, the fastening element 125 (126) Is hard to come off.

Subsequently, the composite plate 200 of the third embodiment of the present invention will be described. The same configurations as those of the composite plates of the first and second embodiments will be assigned the same numbering, and the description thereof will be omitted.

The composite plate 200 of the third embodiment of the present invention is mainly different in that it includes the composite plate 150 of the second embodiment and a plurality of synthetic resin foams 5.
That is, as shown in FIGS. 9 and 10, the composite plate 200 of the third embodiment includes resin plates 2 and 3, a plurality of synthetic resin foams 5a to 5d, and end face protection members 151a to 151h. There is.

The synthetic resin foams 5 (5a to 5d) are arranged vertically and horizontally in a grid pattern, and are sandwiched by two resin plates 2 and 3 in the thickness direction.
As shown in FIG. 11, there is a gap between the adjacent synthetic resin foams 5 and 5, and the surrounding space 201 surrounded by the resin plates 2 and 3 and the adjacent synthetic resin foams 5 and 5 is provided. Is formed. The wiring member 116 can pass through the surrounding space 201.

According to the composite plate 200 of the third embodiment, since the surrounding space 201 through which the wiring member 116 can pass is provided, the wiring member 116 can be installed without providing the wiring hole 117 in the synthetic resin foam 5. Is possible.

In the third embodiment described above, the case where the composite plate 200 includes the four synthetic resin foams 5 has been described, but the present invention is not limited thereto.
The composite board may include two or three synthetic resin foams 5, or may include five or more synthetic resin foams 5.

In the above-described embodiment, the toilet unit 101 and the switch device 110 are interlocked with each other by the wiring member 116, but the present invention is not limited to this.
The toilet unit 101 and the switch device 110 may be interlocked with each other by a light ray such as infrared rays or visible light.
In this case, for example, an infrared transmitter and / or an infrared receiver as a ray communication device is provided in each of the toilet unit 101 and the switch device 110, and as shown in FIG. 12, the infrared transmitter 210 and the infrared receiver are mounted on the composite plate. A communication space 212 is provided so as to connect the 211s.
By doing so, unidirectional or bidirectional infrared communication becomes possible between the toilet unit 101 and the switch device 110.
The communication space 212 is a space provided between the resin plates 2 and 3, and is formed by linear communication holes formed in the synthetic resin foam 5.

In the above-described embodiment, the case where the synthetic resin foam 5 is directly sandwiched between the two resin plates 2 and 3 has been described, but the present invention is not limited thereto. Another layer may be interposed between the resin plate and the synthetic resin foam.

In the above-described embodiment, the resin plates 2 and 3 have a multilayer structure of the phenol resin sheet 10 and the melamine resin sheet 11, but the present invention is not limited thereto.
The resin plates 2 and 3 may have a structure in which only the phenol resin sheet 10 is laminated in multiple layers, or may have a structure in which the melamine resin sheets 11 are laminated in multiple layers. Further, another resin sheet may be inserted.
The resin plates 2 and 3 may be a phenol resin plate or a melamine resin plate in which the plate material is impregnated with a phenol resin or a melamine resin.

In the above-described embodiment, the synthetic resin foam 5 of the partition plate portions 103a to 103c is formed with a wiring hole 117 through which the wiring member 116 passes, but the present invention is not limited to this. A part or all of the wiring hole 117 may be a notch. Moreover, it is not necessary to provide it.

In the above embodiment, the door plate portions 105a, 105b, 105c are indirectly attached to the partition plate portions 103a to 103c by the fastening elements 125, 126 via the hinge 111, but the present invention relates to this. It is not limited. Another plate may be directly attached to the plate by a fastening element.

In the above-described embodiment, the composite plate 1 is used in a vertical posture, but the present invention is not limited thereto. The composite plate 1 may be used in a posture other than the vertical posture, for example, a horizontal posture.

In the above-described embodiment, the resin plates 2 and 3 have the same thickness, but the present invention is not limited thereto. The resin plates 2 and 3 may have different thicknesses as long as they both fall within a predetermined range.

In the above-described embodiment, the case where the composite plate is used for the wall surface of the toilet booth in the toilet room has been described, but the present invention is not limited to this. The composite board may be used for other purposes. For example, as shown in FIG. 13, it may be used for a partition that partitions rooms such as offices.

Hereinafter, the present invention will be specifically described with reference to Examples. The present invention is not limited to the following examples, and can be appropriately modified and implemented without changing the gist thereof.

The thickness is 14 mm, and the foaming ratio is 5 times (density: 200 kg / m ³ equivalent), 7 times (density: 143 kg / m ³ equivalent), and foaming ratio 10 times (density: 100 kg / m ³ equivalent). ^{A melamine resin plate (density: 1480 kg / m 3} ) or a phenol plate (density: 1400 kg / m ³ ) having a thickness shown in Table 1 containing a synthetic resin foam 5 containing three types of beaded polystyrene resin (EPS) as a main component. The composite plates of Experimental Examples 1 to 27 were formed by sandwiching and adhering them with each other. That is, in Experimental Examples 1 to 7, 10 to 16, 19 to 25, melamine resin plates were used as the resin plates 2 and 3, and in Experimental Examples 8, 9, 17, 18, 26 and 27, the resin plates 2 and 3 were used. A phenol plate was used.

(Test condition)
In each Experimental Example 1-27, a 0.7 kg steel ball was dropped twice from a drop height of 0.5 m on a 70 × 70 mm test piece by a DuPont impact tester according to JIS K 5600-5-3. It was lowered and the amount of dent (depth of dent) of the composite plate was calculated. As a criterion for evaluating each Experimental Example 1 to 27, a phenol plate (density: 1400 kg / m ³ ) having a thickness of 16 mm was used as Experimental Example 28. The results are summarized in Table 1 and FIG.

In the test pieces in which the foaming ratios of the synthetic resin foam 5 shown in FIGS. 14 (a) and 14 (b) are 5 times and 7 times, the foaming ratio of the synthetic resin foam 5 shown in FIG. 14 (c) is high. The tendency was different from that of the 10-fold test piece.
That is, in Experimental Examples 1 to 9 having a foaming ratio of 5 times shown in FIG. 14 (a), the amount of dents sharply increased from 1.6 mm (Experimental Example 5) to 1.8 mm (Experimental Example 6) in the thickness of the resin plate. Was alleviated, and the amount of dent was about the same as the amount of dent of the phenol plate alone in Experimental Example 28.
Similarly, in Experimental Examples 10 to 18 having a foaming ratio of 7 times shown in FIG. 14 (b), the thickness of the resin plate is sharply dented from 1.6 mm (Experimental Example 14) to 1.8 mm (Experimental Example 15). The amount was relaxed, and the amount of dent was about the same as the amount of dent of the phenol plate alone in Experimental Example 28.
On the other hand, in Experimental Examples 10 to 18 having a foaming ratio of 10 times shown in FIG. 14 (c), the amount of dent was relaxed from 1.6 mm (Experimental Example 23) to 1.8 mm (Experimental Example 24) in the thickness of the resin plate. Was not observed, and a rapid relaxation of the amount of dent was observed from 2.0 mm (Experimental Example 25) to 2.5 mm (Experimental Example 26) in the thickness of the resin plate. That is, it was found that when the foaming ratio was 10 times or more, even if the thickness of the resin plate was 1.8 mm, the sudden relief of the amount of dents did not occur.

From the above results, by setting the foaming ratio to less than 10 times and the thickness of the resin plate to exceed 1.6 mm, the phenol plate can be used even when the total thickness is 17.6 mm or more and 20 mm or less. It was found that the same level of fracture resistance as that of a single substance can be secured.
This is because if the thickness of the resin plate is thick, the rigidity of the resin plate itself can be secured, so that the dent can be eliminated by its own repulsive force. However, if the thickness of the resin plate is 2.0 mm or less, the rigidity of the resin plate itself becomes high. The size becomes smaller, and the impact is easily transmitted to the underlying synthetic resin foam 5. Therefore, the impact on the resin plate is received by the synthetic resin foam 5, but if the hardness of the synthetic resin foam 5 is less than a certain level, the impact cannot be mitigated and remains dented. Therefore, when the amount of dents becomes large and the hardness of the synthetic resin foam 5 is equal to or higher than a certain level, the dents on the resin plate become smaller because the synthetic resin foam 5 repels while being moderately relaxed by the elasticity of the synthetic resin foam 5 itself. It is considered to be.

1 Composite board 2, 3 Resin board 5 Synthetic resin foam 10 Phenol resin sheet 11 Melamine resin sheet 100, 100a-100c Toilet booth 101 Toilet unit (equipment)
102a, 102b Wall part 103a-103c Partition plate part (structure)
105a to 105c Door plate part 106a to 106d Door receiving plate part 110 Switch device (equipment)
111 Hinge 113 Mounting hole 115 Toilet body 116 Wiring member (conductor)
117 Wiring holes 121a to 121d Divided space 125 Fastening element 126 Fastening element

Claims (6)

A composite plate in which a synthetic resin foam is sandwiched between two resin plates and the two resin plates are adhered to both sides of the synthetic resin foam.
The thickness of the two resin plates is in the range of 1.7 mm or more and 6.0 mm or less, respectively.
The density of the synthetic resin foam is a 111 kg / m ³ or more 334kg / m ³ or less,
A composite plate characterized in that the total thickness of the composite plate is 5 mm or more and 50 mm or less. The composite plate according to claim 1, wherein the main component of the synthetic resin foam is a polystyrene-based resin or a polyolefin-based resin. The composite plate according to claim 1 or 2, wherein the synthetic resin foam has a foaming ratio of 3 times or more and 9 times or less. The composite plate according to any one of claims 1 to 3, wherein at least one of the two resin plates is a thermosetting resin plate. The one of the resin plate is a composite plate according to claim 4, characterized in that the melamine resin plate or a phenol resin plate. A claim characterized in that the amount of dent when a 0.7 kg steel ball is dropped from a height of 0.5 m onto one main surface according to JIS K 5600-5-3 is 0.5 mm or less. The composite plate according to any one of 1 to 5.

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