JP7300614B2 - Interior panel and method for manufacturing interior panel - Google Patents

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an interior panel that constitutes a ceiling, wall, or the like of a building, and a method for manufacturing the interior panel.

Conventionally, there have been cases in which flame retardancy (noncombustibility) is required for interior panels that constitute ceilings and walls of buildings. As such an interior panel, there is a structure in which a noncombustible layer and a decorative layer are provided on the indoor side of a heat insulating base material made of resin foam from the viewpoint of weight reduction. There was a concern that the non-combustible performance would deteriorate if exposed.
For example, in Patent Document 1 below, a foamed resin layer is folded at a folding groove provided from the back side, and a glass fiber sheet, a flame-retardant sheet and a glass fiber reinforced resin layer are attached to the end surface and the back surface of the side end portion. An interior panel provided with an inclusive layer is disclosed. In addition, in this patent document 1, instead of the aspect in which the bending groove is provided, a foamed resin is formed by an extension part in which an indoor layer including a glass fiber sheet, a flame-retardant sheet and a glass fiber reinforced resin layer is extended. An interior panel is disclosed that is constructed with a reinforcing member that is positioned adjacent to the layer.

WO2019/44985

However, if the bent grooves as described above are provided in the foamed resin layer from the back side while leaving the indoor layer, the indoor layer includes the glass fiber reinforced resin layer. For this reason, the bending grooves where the glass fiber reinforced resin layer of relatively high rigidity remains are bent, so that it is difficult to clearly form straight corners on the surface side. In addition, if the reinforcing member is provided as described above, it can be expected to improve the linearity of the corner on the front side by bending along the corner of the reinforcing member, but there is a concern that the structure will be complicated. There is

The present invention has been made in view of the above circumstances, and while it is possible to improve the flame retardancy of at least one side end in addition to the flame resistance on the indoor side, the one side end with a simple structure. An object of the present invention is to provide an interior panel capable of improving the straightness of corners in a corner and a manufacturing method of the interior panel capable of suitably manufacturing such an interior panel.

In order to achieve the above object, an interior panel according to the present invention is an interior panel that is constructed with the back side facing the interior base side, wherein a fiber reinforced resin layer and a fiber reinforced resin layer and the fiber reinforced A surface layer including a flame-retardant layer provided on the indoor side of the resin layer and a decorative layer provided on the indoor side of the flame-retardant layer is provided. The end face perpendicular to the end face and the back face perpendicular to the end face are covered by the extension part of the surface layer extending in series from the part covering the indoor side surface, At positions corresponding to the indoor side corners and the rear side corners of the end surface of the one side end portion of the extending portion, bent grooves are provided so that the groove bottoms are positioned within the fiber reinforced resin layer. It is characterized by

Further, in order to achieve the above object, a method for manufacturing an interior panel according to the present invention is a method for manufacturing an interior panel that is constructed with the back side facing the interior base side, comprising: a fiber reinforced resin layer and the fiber reinforced At least one side end of a panel body provided with a foamed resin layer on the back side of a surface layer including a flame-retardant layer provided on the indoor side of the resin layer and a decorative layer provided on the indoor side of the flame-retardant layer a step of cutting the foamed resin layer so as to leave the surface layer to form an extension portion in which the surface layer extends from the end surface of one side end portion of the foamed resin layer; Bending grooves formed at positions corresponding to the indoor side corners and the rear side corners of the end face of one side end of the foamed resin layer in the extending portion so as to be positioned in the fiber reinforced resin layer. and the step of bending the extension portion to cover the end surface and the back surface of the one side end.

Since the interior panel according to the present invention has the above-described configuration, it is possible to improve the flame retardancy of at least one side end in addition to the flame retardancy of the interior side, and furthermore, the interior panel has a simple structure. The straightness of the corners at the side ends can be improved. Moreover, the manufacturing method of the interior panel which concerns on this invention can manufacture such an interior panel suitably by having the above structures.

BRIEF DESCRIPTION OF THE DRAWINGS It is a partially broken schematic longitudinal cross-sectional view which shows typically an example of the interior panel which concerns on one Embodiment of this invention. (a) to (c) are schematic longitudinal cross-sectional views partially broken away schematically showing an example of a method for manufacturing an interior panel according to one embodiment of the present invention, and (d) corresponds to X1 part in (c). 1 is a schematic enlarged vertical cross-sectional view partially broken away. (a) is a partially broken schematic longitudinal sectional view schematically showing an example of the manufacturing method of the same interior panel, (b) is a partially broken schematic enlarged longitudinal sectional view corresponding to the X2 part in (a), (c) is a partially broken schematic plan view schematically showing an example of a method of manufacturing the interior panel. (a), (b) is a partially broken schematic longitudinal cross-sectional view which shows typically an example of the manufacturing method of the same interior panel. (a) is a partially broken schematic longitudinal sectional view schematically showing an example of a manufacturing method of the interior panel, and (b) is a partially broken schematic plan view of the interior panel.

An embodiment of the present invention will be described below with reference to the drawings.
It should be noted that some of the detailed reference numerals attached to other drawings are omitted in some of the drawings.
Further, in the following embodiments, directions such as the vertical direction will be described based on a state in which a ceiling panel, which is an example of an interior panel according to the present embodiment, is constructed.
1 to 5 are diagrams schematically showing an example of an interior panel according to this embodiment and an example of a method of manufacturing an interior panel according to this embodiment.

The interior panel according to the present embodiment constitutes the ceiling panel 1, and as shown in FIG. 1, is constructed with the back side facing the ceiling base 3 as an interior base. The ceiling panel 1 includes a foamed resin layer 20 and a surface layer 10 provided on the indoor side of the foamed resin layer 20 . With such a configuration, it is possible to reduce the weight as compared with a wooden board or a gypsum board.
The ceiling base 3 to which the ceiling panel 1 is fixed may be a wooden ceiling base or a steel ceiling base. Also, the ceiling base 3 may be a so-called light ceiling base using a light iron material. In the example of the figure, the ceiling base 3 is a so-called suspended ceiling in which the hem 5 is suspended via a hanging member 4 such as a hanging tree or a hanging bolt. Anything is fine.

The ceiling panel 1 may be fixed to the joist 5 by fasteners such as screws or nails fixed to the joist 5 so that the side ends 2 pass through the ceiling panel 1 . In addition, the ceiling panel 1 is provided at the first end in one direction of the adjacent ceiling panel 1, and the hooking portion provided at the second end in one direction is hooked to the hooked portion fixed to the joist 5. It may be fixed by In this case, the end portion in the other direction may be fixed to the ceiling joist 5 by a magnet. In addition, the figure shows an example in which the ceiling panels 1 are constructed so that a gap like a watermark is formed between the end surfaces of the side ends 2, 2 of the adjacent ceiling panels 1, 1 facing each other in one direction. ing.

Also, this ceiling panel 1 may be constructed as the ceiling of relatively small buildings such as residences and offices, and may be constructed as the ceiling of relatively large buildings such as gymnasiums, halls, shopping malls, factories and schools. It may be constructed as a ceiling.
Also, the ceiling panel 1 may have a mass of 2.0 kg or less per unit area (1 m ² ). Further, the mass of the ceiling panel 1 may be such that the mass of the entire ceiling system including the ceiling base 3 made of the light ceiling base is 2.0 kg/m ² or less. In addition, the interior panel according to the present embodiment is not limited to that constituting the ceiling panel 1, and may constitute a wall panel. In this case, wall substrates such as studs and studs may be regarded as interior substrates.

Further, as shown in FIG. 5(b), the ceiling panel 1 has a substantially rectangular shape in plan view (viewed in the thickness direction). The ceiling panel 1 may have a substantially square shape in plan view, or may have a substantially rectangular shape. The size of the ceiling panel 1 in a plan view may be an appropriate size from the viewpoint of ease of handling and workability. For example, the length of one side may be 0.3 m or more. 2.0 m or less may be used. Further, the substantially rectangular ceiling panel 1 may have a short side length of 0.3 m or more and a long side length of 2.0 m or less. In addition, in the substantially square ceiling panel 1, the length of one side may be 0.6 m or more and 1.5 m or less, or about 0.9 m to 1.2 m. . The thickness of the ceiling panel 1 may be, for example, about 2.5 mm to 15.0 mm, preferably about 3.0 mm to 12.0 mm, more preferably about 3.0 mm to 12.0 mm, although it depends on the layer structure and the like. may be about 3.0 mm to 6.0 mm.

As shown in FIG. 1, the surface layer 10 includes a fiber-reinforced resin layer 14 provided on the indoor side of the foamed resin layer 20, a flame-retardant layer 13 provided on the indoor side of the fiber-reinforced resin layer 14, and this and a decorative layer 11 provided on the indoor side of the flame-retardant layer 13 . With such a configuration in which the flame-retardant layer 13 is provided on the surface layer 10, the flame-retardant property on the indoor side can be improved. Further, if the surface layer 10 is provided with the fiber reinforced resin layer 14, the fiber reinforced resin layer 14 functions as a reinforcing layer, and the bending rigidity and dimensional stability of the ceiling panel 1 as a whole can be improved. As a result, it is possible to effectively suppress sagging after construction while achieving weight reduction, and the ceiling panel 1 is suitable.

The decorative layer 11 is in the form of a thin sheet with a thickness of about 0.1 mm to 0.5 mm, and constitutes the decorative surface of the ceiling panel 1 . In this embodiment, the decorative layer 11 is a glass fiber sheet. With such a configuration, rigidity and flame retardancy can be improved compared to the case where the decorative layer 11 is made of printed paper or veneer. The decorative layer 11 may be glass non-woven fabric (glass paper), and may have a basis weight of about 20 g/m ² to 250 g/m ² , preferably about 30 g/m ² to 100 g/m ² . It may be
Further, the decorative layer 11 may be a glass fiber sheet whose surface is subjected to appropriate surface decorative treatment such as printing or painting. Note that the decorative layer 11 is not limited to the glass fiber sheet, and may be another sheet material subjected to appropriate surface decorative treatment such as printing or painting, or may be formed by printing, painting, or the like. In addition, the pigments, additives, and the like contained in the paint used for printing the decorative layer 11 are preferably inorganic from the viewpoint of ensuring flame retardancy.

The flame-retardant layer 13 may have an appropriate structure so that the ceiling panel 1 satisfies the technical standards regarding the performance required for noncombustible materials and the like stipulated in the Building Standards Act. For example, the ceiling panel 1 may be configured to meet the standard of "flame-retardant material" in the technical standards, preferably, it may be configured to meet the standard of "quasi-noncombustible material", More preferably, it may be configured to meet the criteria for "noncombustible materials." The flame-retardant layer 13 may be, for example, a foil-shaped aluminum sheet formed into a thin sheet. The thickness of the aluminum sheet forming the flame-retardant layer 13 may be about 5 μm to 50 μm, preferably about 7 μm to 40 μm, more preferably about 10 μm to 30 μm.
It should be noted that the flame-retardant layer 13 is not limited to the structure described above, and various other structures may be employed. For example, a resin-impregnated glass fiber non-woven fabric plate containing an endothermic metal hydroxide may be used.
The decorative layer 11 and the flame-retardant layer 13 are laminated and integrated with an appropriate adhesive layer 12 interposed therebetween. The adhesive layer 12 may be formed from a polyethylene-based adhesive.

The fiber reinforced resin layer 14 is a glass fiber reinforced resin layer containing glass fibers in this embodiment. The fiber-reinforced resin layer 14 has the same main resin component as that of the foamed resin layer 20 . With such a configuration, the conformability in each layer is improved, and boundary separation and the like can be made difficult to occur.
The glass fiber sheet 15 forming the fiber reinforced resin layer 14 is a glass cloth having a basis weight of 50 g/m ² to 300 g/m ² . With such a configuration, it is possible to ensure appropriate bending rigidity while achieving weight reduction. The basis weight of the glass fiber sheet 15 is preferably 50 g/m ² to 150 g/m ² , more preferably 50 g/m ² to 100 g/m ² . As such a glass fiber sheet 15, a thin sheet having a thickness of about 0.1 mm to 0.5 mm may be used. The glass fiber sheet 15 is preferably a glass fiber woven fabric. For example, glass cloth, which is a plain weave or a leno weave woven using glass rovings for the warp and weft, may be used. By using glass cloth, thermal deformation can be made difficult to occur. The glass fiber sheet 15 is not limited to such glass cloth, and may be glass paper or glass mat.

In the present embodiment, the fiber-reinforced resin layer 14 is formed by impregnating the glass fiber sheet 15 with the resin composition forming the foamed resin layer 20 . In other words, the fiber reinforced resin layer 14 is integrally formed on a portion of the foamed resin layer 20 . With such a configuration, boundary separation or the like can be made more difficult to occur as compared with a case in which a separately prepared sheet constituting a fiber-reinforced resin layer is laminated on the foamed resin layer 20 . Moreover, manufacturing efficiency can be improved. The fiber-reinforced resin layer 14 may be configured to contain air bubbles by foaming the resin composition.

In addition, a composite sheet in which the glass fiber sheet 15 is laminated and integrated with an appropriate adhesive on the ceiling substrate 3 side of the decorative layer 11 and the flame-retardant layer 13 laminated and integrated as described above constitutes the foamed resin layer 20. It may be laminated and integrated with the foamed resin layer 20 by using a resin composition. In this case, the flame-retardant layer 13 may be at least partially adhered to the resin composition that has passed through the glass fiber sheet 15 constituting the fiber-reinforced resin layer 14 . That is, even if the resin composition forming the foamed resin layer 20 seeps out from the glass fiber sheet 15 having a reduced basis weight and increased interstitial space as described above, it is partially adhered to the flame-retardant layer 13. good. The adhesive for laminating and integrating the flame-retardant layer 13 and the glass fiber sheet 15 is used to allow the resin composition forming the fiber-reinforced resin layer 14 to seep out from the glass fiber sheet 15. may be applied to the With such a configuration, peeling can be suppressed and wrinkles are less likely to be formed than when the flame-retardant layer 13 is laminated via an adhesive or the like, and manufacturing efficiency can be improved. can.

In addition, in this embodiment, the ceiling panel 1 includes the back side fiber reinforced resin layer 18 provided on the ceiling base 3 side which is the back side of the foamed resin layer 20, and the ceiling base 3 of the back side fiber reinforced resin layer 18. and a back side flame retardant layer 17 provided on the side. That is, the foamed resin layer 20 is sandwiched between the fiber reinforced resin layers 14 and 18 forming the reinforcing layers on both sides in the thickness direction. With such a configuration, bending rigidity and dimensional stability can be improved more effectively. As a result, it is possible to more effectively suppress sagging after construction while achieving weight reduction, and the ceiling panel 1 is more suitable.
The back-side fiber-reinforced resin layer 18 has the same main resin component as that of the foamed resin layer 20, in substantially the same manner as the fiber-reinforced resin layer 14 constituting the surface layer 10 described above. Further, in the same manner as described above, the back-side fiber-reinforced resin layer 18 is formed by impregnating the glass fiber sheet 19 with the resin composition forming the foamed resin layer 20 . The back-side fiber-reinforced resin layer 18 may be configured to contain air bubbles by foaming the resin composition as described above.

Like the flame-retardant layer 13 described above, the back-side flame-retardant layer 17 may be an aluminum sheet. The back-side flame-retardant layer 17 also functions as a seepage suppression layer that suppresses the seepage of the resin composition forming the back-side fiber-reinforced resin layer 18 . With such a configuration in which the back-side flame-retardant layer 17 is provided, it is possible to improve the flame-retardancy of the back-side, and it is also expected to improve heat shielding properties and electromagnetic wave shielding properties.
The back side flame-retardant layer 17 may be a sheet thinner than the flame-retardant layer 13 described above. For example, the thickness of the back side flame-retardant layer 17 may be about 2/5 to 3/5 of the thickness of the flame-retardant layer 13 .
In addition, a composite sheet in which the glass fiber sheet 19 constituting the back side fiber reinforced resin layer 18 is laminated and integrated with the back side flame-retardant layer 17 with an appropriate adhesive is formed by the resin composition constituting the foamed resin layer 20. It may be laminated and integrated with the foamed resin layer 20 . In this case, the back-side flame-retardant layer 17 may be at least partially adhered to the resin composition that has passed through the glass fiber sheet 19 forming the back-side fiber-reinforced resin layer 18 . That is, the resin composition forming the foamed resin layer 20 is partially adhered to the back side flame-retardant layer 17 in such a manner that the resin composition forming the foamed resin layer 20 oozes out from the glass fiber sheet 19 having a reduced basis weight and increased interstitial space as described above. Anything is fine. In addition, the adhesive for laminating and integrating the back side flame-retardant layer 17 and the glass fiber sheet 19 is used so as to allow the resin composition constituting the back side fiber reinforced resin layer 18 to seep out from the glass fiber sheet 19. It may be applied to the glass fiber sheet 19 .

With the above configuration, peeling can be suppressed and wrinkles are less likely to be formed than when the back side flame-retardant layer 17 is laminated via an adhesive or the like, improving manufacturing efficiency. can be made In addition, if the basis weight of the glass fiber sheet 19 is reduced as described above, the gap between the pores increases, and the resin composition that constitutes the back side fiber reinforced resin layer 18 oozes out during molding, and the glass fiber sheet 19 is made of resin. It is conceivable that they are embedded in the composition layer. With the configuration in which the glass fiber sheet 19 is integrated with the back side flame-retardant layer 17 as described above, it is possible to suppress the glass fiber sheet 19 from being buried during molding.

The foamed resin layer 20 occupies most of the ceiling panel 1 . The thickness of the foamed resin layer 20 is preferably 80% to 99% of the thickness of the ceiling panel 1, more preferably 85% to 95%. The thickness of the foamed resin layer 10 may be, for example, about 2.3 mm to 14.8 mm, preferably about 2.5 mm to 11.5 mm, more preferably 2.5 mm to 5.5 mm. It may be a degree. The resin composition forming the foamed resin layer 20 is a foamed polyurethane resin having an expansion ratio of 10 to 30 in this embodiment. With such a configuration, weight reduction can be achieved. In addition, one or both of the surface layer 10 and the back layer 16 on both sides in the thickness direction of the foamed resin layer 20 are laminated and integrated with the foamed resin layer 20 with the resin composition constituting the foamed resin layer 20 as described above. can be used, and manufacturing efficiency can be improved. The expansion ratio of the resin composition forming the foamed resin layer 20 is preferably about 15 to 25 times.

Moreover, in this embodiment, the resin composition which comprises the foamed resin layer 20 is made into the flame-retardant polyurethane resin composition. With such a configuration, the flame retardancy (noncombustibility) can be further improved in combination with the expansion ratio as described above. That is, since the amount of organic material contained in the foamed resin layer 20 is relatively small, the total amount of heat generated can be reduced. Such a flame-retardant polyurethane resin composition may contain a polyisocyanate compound, a polyol compound, a catalyst, a foaming agent, a foam stabilizer and additives. Moreover, such a flame-retardant polyurethane resin composition may further contain a flame retardant, a filler, or an inorganic filler. Examples of the resin forming the foamed resin layer 20 include polyurethane resin, polystyrene resin, polyethylene resin, polypropylene resin, phenol resin, epoxy resin, and the like.

An end surface 24 orthogonal to the indoor side surface 21 and a back surface 22 orthogonal to the end surface 24 of at least one side end portion 23 of the foamed resin layer 20 are continuous from a portion covering the indoor side surface 21 . is covered with an extension portion 10b of the surface layer 10 extending to the outside. With such a configuration, it is possible to improve the flame retardancy of the end surface and the back surface of at least one side end portion 2 of the ceiling panel 1 . As a result, even if a fire occurs inside the room while the one side ends 2, 2 of the adjacent ceiling panels 1, 1 are constructed with the end faces facing each other, the foamed resin layer is exposed at the end faces. Combustion from the end face can be retarded compared to the one with the In addition, moisture absorption from the end surface 24 can be suppressed as compared with the case where the end surface 24 of the foamed resin layer 20 is exposed. In addition, since the fiber reinforced resin layer 14 is also provided in series on the end surface and the back surface of the one side end portion 2, the bending rigidity of the one side end portion 2 can be improved. In addition, since the surface layer 10 is continuously provided on the end surface and the back surface of the one side end 2 from the indoor side surface, for example, compared to covering the end surface by sticking an edge sheet, The appearance of the inner corners (edges) can be improved. Moreover, peeling of the surface layer 10 can be suppressed. Further, for example, if a fastener such as a screw is fixed to a portion provided with the extension portion 10b (end rear surface layer 10d) on the back surface of the one side end portion 2, the fastener holding force can be reduced. can also be improved.

Further, as shown in FIGS. 3 and 4, groove bottoms 27a and 29a are provided at positions corresponding to the indoor side corner portion 24a and the rear side corner portion 24b of the end surface 24 of the one side end portion 23 in the extension portion 10b. are positioned within the fiber-reinforced resin layer 14. With such a configuration, the fiber-reinforced resin layer 14 is thinner at the portions where the bending grooves 27 and 29 are provided than at the other portions, and can be easily bent at those portions. As a result, the linearity of the corners of the one-side end portion 2 can be improved with a simple structure without embedding a reinforcing member or the like. In addition, since the corners of the interior side surface and the end surface are substantially perpendicular to each other, the corners are required to have more straightness compared to the case where the corners on the interior side are chamfered in a C chamfer shape. With the above configuration, it is possible to improve the linearity of the room-side corner of the one-side end 2 .

Further, in the present embodiment, the extending portion 10b is provided so as to cover the ceiling base 3 side of the back surface layer 16 of the one side end portion 2 extending to the back surface side corner portion 24b. With such a configuration, as shown in FIG. The bending rigidity in the side end portion 2 can be improved more effectively. In addition, the back layer 16 may be provided so as to cover the entire back surface 22 of the foamed resin layer 20 .
The extending portion 10b extends continuously from the indoor side layer 10a forming the indoor side surface of the ceiling panel 1 and covering the indoor side surface 21 of the foamed resin layer 20 . The extension portion 10b includes an end face layer 10c covering the end face 24 of the one side end 23 of the foamed resin layer 20, an end back layer 10d covering the ceiling foundation 3 side of the back layer 16 of the one side end 2, including.

Moreover, the extending portions 10b including the end face layer 10c and the end back face layer 10d as described above may preferably be provided at both side end portions 2, 2 of the ceiling panel 1 in one direction. With such a configuration, it is possible to improve the flame retardancy of the end faces of both side end portions 2, 2 of the ceiling panel 1 in one direction. In this embodiment, as shown in FIG. 5(b), extension portions 10b including an end surface layer 10c and an end back surface layer 10d are provided at the four side end portions 2, 2, 2, 2 of the ceiling panel 1. It is configured. With such a configuration, it is possible to improve the flame retardancy of the end surfaces of the four side end portions 2, 2, 2, 2 of the ceiling panel 1. FIG. Since each of the side ends 2, 2, 2, 2 has the same structure, the details of one side end 2 will be described below as an example.

The end surface of the side end portion 2 is orthogonal to the interior side surface and the back surface of the ceiling panel 1 . Here, the term "perpendicular" is not limited to 90-degree angles formed by the end surface and the interior side surface and back surface, and includes, for example, angles of about 85-95 degrees. Also, when the end faces of the adjacent ceiling panels 1, 1 are placed in contact with each other, the angle formed by the end faces and the interior side surface may be less than 90 degrees (eg, 85 to 89 degrees). With such a configuration, it is possible to suppress the occurrence of a gap on the indoor side when the end surfaces of the adjacent ceiling panels 1, 1 are brought into contact with each other for construction.
The end surface 24 of the side end portion 23 of the foamed resin layer 20 is orthogonal to the indoor side surface 21 and the rear surface 22 of the foamed resin layer 20 in the same manner as described above. In this embodiment, as shown in FIG. 3(b), a notch 25 opening at the end face 24 is provided at a corner portion 24a of the end face 24 on the indoor side. The notch 25 opens in the extending direction of the extending portion 10b when the extending portion 10b is not bent (deployed state), and extends along the side end portion 23. It is provided in a groove shape. The groove depth dimension along the extension direction of the cut 25 and the groove width dimension along the panel thickness direction may be, for example, about 0.1 mm to 1.0 mm. Although the drawing shows an example in which the groove depth dimension of the cut 25 is larger than the groove width dimension, it is not limited to such an aspect. In addition, although an example in which the groove bottom side of the cut 25 is substantially V-shaped when viewed in the groove longitudinal direction is shown, the present invention is not limited to such an aspect.

The bent grooves 27 and 29 of the extension portion 10b are formed at positions corresponding to the first bent groove 27 and the rear side corner portion 24b of the end face 24, respectively. and a second bent groove 29 provided in the . The first bending groove 27 is provided so as to be positioned at an internal corner between the end surface 24 and the extension portion 10b in the unfolded state (deployed state). The second bent groove 29 is provided so as to be positioned at the boundary between the end surface layer 10c of the extension portion 10b and the end back surface layer 10d. That is, the dimension along the extension direction (groove width direction) of the extension portion 10b from the first bent groove 27 to the second bent groove 29 is determined according to the thickness of the foamed resin layer 20. .
These first bent grooves 27 and second bent grooves 29 are opened toward one side in the panel thickness direction (the side of the ceiling base 3) when the extension portion 10b is in an unfolded state. grooves extending parallel to each other along the entire length. The groove depth dimension and the groove width dimension of the first bent groove 27 and the second bent groove 29 may be set appropriately from the viewpoint of the thickness of the extension portion 10b, bendability, strength, and the like. For example, it may be about 0.1 mm to 1.0 mm. Although the illustrated example shows an example in which the groove width dimension of the first bent groove 27 and the second bent groove 29 is larger than the groove depth dimension, it is not limited to such an aspect. Further, although an example in which the first bent groove 27 and the second bent groove 29 are substantially V-shaped when viewed in the longitudinal direction of the groove is shown, it is not limited to such an aspect.

Further, the first bent groove 27 and the second bent groove 29 are provided so as to leave a part of the glass fiber sheet 15 constituting the fiber reinforced resin layer 14 on the side of the groove bottoms 27a and 29a. . These first bent grooves 27 and second bent grooves 29 are provided so that only a part of one of the warp and weft threads remains when the glass fiber sheet 15 is made of glass cloth as described above. may have been In the present embodiment, the thickness T2 of the fiber reinforced resin layer 14 on the side of the groove bottoms 27a and 29a of the portion where the first bent groove 27 and the second bent groove 29 are provided in the extension portion 10b is defined as the thickness T2 of the extension portion 10b. The thickness T1 of the fiber reinforced resin layer 14 at the other portion of 10b is set to 1/2 or less. With such a configuration, it becomes easier to bend the portion where the first bending groove 27 and the second bending groove 29 are provided, and the straightness of the corner portion of the one side end portion 2 is effectively improved. be able to. The thickness T2 of the fiber reinforced resin layer 14 on the side of the groove bottoms 27a and 29a may be ⅓ or less of the thickness T1 of the fiber reinforced resin layer 14 on the other portion of the extension portion 10b. It may be about 4 to 1/10.

Note that the extending portion 10b may consist of only the surface layer 10 including the fiber reinforced resin layer 14, or may have a part of the foamed resin layer 20 provided on the back side, or the fiber reinforced resin layer. 14 may be partly excised. In addition, the dimension (width dimension) of the extension portion 10b along the extension direction of the end back layer 10d is appropriately determined from the viewpoint of the strength of the side end portion 2, the viewpoint of suppressing peeling, the viewpoint of weight reduction, and the like. may be the size of For example, the width dimension of the end back layer 10d may be about 1 to 15 times the thickness dimension of the ceiling panel 1, preferably about 2 to 10 times. Further, a recessed stepped portion for receiving the end back layer 10d may be provided on the back surface side of the side edge portion 2 . Such a recessed stepped portion may be formed by cutting or the like, or may be formed by compression.

Further, in this embodiment, each of the four side end portions 2, 2, 2, 2 is provided with the extending portion 10b that can be bent as described above. Therefore, as shown in FIG. 3(c), the corner portion is provided with a notch-shaped recess 9 for reducing overlapping of the bent extension portions 10b.
The notch-shaped recess 9 is provided so as to open diagonally outward in the unfolded state. In addition, the notch-shaped recess 9 is formed in a widening shape from a portion where the end surfaces 24, 24 of the foamed resin layer 20 intersect so as to reduce overlap between the end surface layers 10c, 10c of the adjacent side end portions 2, 2. The proximal side portions of both side edges are partitioned by the first edge portions 9a, 9a provided on the side. These first edge portions 9a, 9a are portions where the first bending grooves 27, 27 are provided, and if the end surface layers 10c, 10c of the respective side end portions 2, 2 are bent with respect to the interior side layer 10a, These first edge portions 9a, 9a are in contact with each other or closely face each other, and constitute a corner portion where the end faces intersect each other.

In addition, the opening side portions of both side edges of the notch-shaped recess 9 are connected to the first edges 9a, 9a so as to reduce overlap between the end back layers 10d, 10d of the adjacent side edges 2, 2. It is delimited by second edges 9b, 9b provided in such a manner. These second edge portions 9b, 9b are portions where the second bending grooves 29, 29 are provided, and the end back layers 10d, 10d of the respective side end portions 2, 2 are bent with respect to the end surface layers 10c, 10c. If so, the second edges 9b, 9b abut or face each other. By this. As shown in FIG. 5(b), the corner portions where the end back layers 10d and 10d intersect are formed. That is, the second edge portions 9b, 9b of the end back layers 10d, 10d of the adjacent side end portions 2, 2 are butted together in a miter shape.
In addition, the configuration for reducing the overlap of the bent portions at the corner portion is not limited to the configuration described above, and various other modifications are possible.

Next, an example of a method for manufacturing an interior panel according to this embodiment will be described with reference to the drawings. In this embodiment, a method of manufacturing the above ceiling panel 1 as an interior panel will be described, but it is also possible to manufacture other interior panels such as wall panels.
In the manufacturing method, as shown in FIGS. 2 and 3, a step of forming an extension portion 10b on at least one side end portion 2A of a panel body 1A having a foamed resin layer 20A provided on the back side of a surface layer 10A. (Extension portion forming step). In this extending portion forming step, the foamed resin layer 20A is cut so as to leave the surface layer 10A, and the extended portion 10b is formed by extending the surface layer 10A from the end surface 24 of the one side end portion 23 of the foamed resin layer 20A. to form Further, in the same manufacturing method, the bent grooves 27 and 29 formed at positions corresponding to the indoor side corner portion 24a and the rear side corner portion 24b of the end surface 24 of the one side end portion 23 of the foamed resin layer 20A extend. A step of folding the portion 10b to cover the end surface 24 and the back surface 22 of the one side end portion 23 is provided.

With the configuration as described above, the ceiling panel 1 as described above can be suitably manufactured. In addition, for example, it can be manufactured more easily than, for example, molding the foamed resin layer 20A so as to form the extending portion 10b with respect to the surface layer 10A. Further, since the grooves 27, 29 are formed so that the groove bottoms 27a, 29a are positioned in the fiber-reinforced resin layer 14, the bending becomes easier, and the corners of the one-side end 2 are straightened. can improve sexuality. In this embodiment, the extending portions 10b formed on the four side ends 2A of the panel body 1A are bent to cover the end surfaces 24 and the back surface 22 of the four side ends 23 of the foamed resin layer 20. However, one side end 2A (23) will be described below as an example.

In this manufacturing method, as shown in FIG. 2(a), a resin composition forming a foamed resin layer 20A is supplied between the surface layer 10A and the back layer 16A to form the panel body 1A. good too. At this time, the surface layer 10A is a composite sheet in which the decorative layer 11, the adhesive layer 12, the flame-retardant layer 13 and the glass fiber sheet 15 (see FIG. 1) are laminated and integrated, and the supplied resin composition is made of glass fiber. The fiber-reinforced resin layer 14 may be formed by impregnating the sheet 15 . In addition, the back layer 16A is a composite sheet in which the back side flame-retardant layer 17 and the glass fiber sheet 19 (see FIG. 1) are laminated and integrated, and the supplied resin composition is impregnated into the glass fiber sheet 19 to impregnate the back side. A fiber reinforced resin layer 18 may be formed. At this time, the resin composition forming the foamed resin layer 20A is supplied (applied) to the back side of one of the surface layer 10A and the back layer 16A, and the other is coated so as to cover the supplied resin composition. may be placed and foamed while regulating the thickness. In this case, for example, continuous molding may be performed using a double belt press device or a press device equipped with an endless track band connecting a plurality of track shoes.

Then, as shown in FIG. 2(b), the four circumferences are cut so that the panel body 1A has an appropriate size. The dimensions of each side (dimensions along one direction and the other direction) of the panel body 1A whose four circumferences are cut in this way are the dimensions of each side of the ceiling panel 1 to be manufactured. An appropriate size may be set in consideration of the size of the portion 10b.
Further, in the present embodiment, as shown in FIGS. 2(c) and 2(d), the cutting edge 6a is fiber reinforced so as to divide the foamed resin layer 20A from the back side of the one side end 2A of the panel body 1A. The bent grooves 27 and 29 are formed by cutting so as to be positioned within the resin layer 14 . After forming the bending grooves 27 and 29 in this manner, the foamed resin layer 20A is excised to form the extending portion 10b. For example, when forming the bending grooves 27 and 29 after removing the foamed resin layer 20A of the one side end 2A so as to form the extending portion 10b, the relatively thin extending portion 10b is formed. The bent grooves 27 and 29 must be provided in such a state that wrinkles are not formed by stretching them. According to the above configuration, since the bent grooves 27 and 29 can be formed by cutting together with the foamed resin layer 20A, wrinkles are less likely to be formed, and the bent grooves 27 and 29 can be formed easily and accurately. can.

The cutting blade 6 for dividing the foamed resin layer 20A from the back side of the one side end 2A has slit-shaped grooves (first groove 26 and second groove 28) 26, 28 formed in the one side end 2A. The bent grooves 27 and 29 as described above are formed at the bottom of the groove. The cutting blade 6 may have a blade thickness of, for example, about 0.2 mm to 1.0 mm, or may have a blade thickness corresponding to the groove widths of the bent grooves 27 and 29 . The first groove 26 and the second groove 28 are formed so that the thickness direction of the panel body 1A is the groove depth direction, and the rear surface side is open. These first groove 26 and second groove 28 are provided so as to extend over the entire one side end portion 2A of the panel body 1A. The first groove 26 is provided so that the first bent groove 27 formed in the groove bottom is located at the position described above, and the groove inner wall on one side in the groove width direction constitutes the end surface 24 of the foamed resin layer 20. be provided. The second groove 28 is provided so that the second bent groove 29 formed in the groove bottom is located at the position described above. In addition, when forming the first groove 26 and the second groove 28, the back side flame-retardant layer 17 of the panel body 1A may be peeled off.

Then, as shown in FIGS. 3(a) and 3(b), the foamed resin layer 20A on the back side of the one-side end portion 2A is excised to form the extending portion 10b. In this embodiment, the cutting blade 6 is arranged along the back side of the extension portion 10b so as to form the above-described cut 25 that opens at the end surface 24 of the one side end portion 23 of the foamed resin layer 20. It is set as the structure which excises 20 A of foamed resin layers. With such a configuration, it is possible to prevent the foamed resin layer 20A from remaining at the inner corner between the end surface 24 of the one side end 23 of the foamed resin layer 20 and the extension portion 10b. As a result, the linearity of the corner when the one side end 23 of the foamed resin layer 20 is bent at the first bending groove 27 on the side of the end face 24 can be more effectively improved.
If the foamed resin layer 20A on the back side of the one-side end portion 2A is removed in this way, the first bent groove 27 and the second bent groove 29 that become the groove bottom sides of the first groove 26 and the second groove 28 are formed. is formed. After removing the foamed resin layer 20A on the back side of the one-side end portion 2A, the foamed resin layer 20A remaining on the back side of the extension portion 10b may be removed by polishing or the like as needed. .

Further, as shown in FIG. 3(c), a notch-shaped recess 9 is formed in the corner portion. The notch-shaped recess 9 may be formed after forming the extension portion 10b, or may be formed before forming the extension portion 10b or before forming the first groove 26 and the second groove 28. .
Then, as shown in FIG. 4(a), an adhesive 7 is applied to one side end portion 2A of the panel body 1A to bond the extension portion 10b by bending it. In this embodiment, the adhesive 7 is applied to the back surface (back surface layer 16) of the one side end portion 2A of the panel body 1A. Also, the adhesive 7 is applied so as to partially drip onto the end surface 24 . With such a configuration, the step of applying the adhesive to the end surface 24 can be omitted, and when the extension portion 10b is folded, excess adhesive 7 will protrude at the corner where the end surface layers 10c, 10c intersect each other. can be suppressed. In addition, instead of such a mode, a mode may be adopted in which the adhesive 7 is applied to the rear surface of the extension portion 10b.

Then, as shown in FIGS. 4(b) and 5(a), the extending portion 10b is bent at each of the bending grooves 27 and 29 by an appropriate guide roller 8, and the end portion back layer 10d is folded into the back layer 16. and the adhesive 7 is cured. In the figure, a guide roller 8 axially aligned in the thickness direction of the panel body 1A that presses the end layer 10c and a guide roller axially aligned in the width direction of the end back layer 10d that presses the end back layer 10d are shown. 8 is shown, but the present invention is not limited to such an aspect. A plurality of guide rollers 8 may be provided to guide the bending of the extending portion 10b along the end surface 24 from the side of the indoor side layer 10a and further to the back side.
Through such steps, the ceiling panel 1 is manufactured as shown in FIGS. 1 and 5(b). Appropriate joining members, hooking members, etc. to be joined to the adjacent ceiling panel 1 are provided at the side end portions 2 of the ceiling panel 1, and fixing portions, magnets, adhesive materials, etc., to be fixed to the ceiling base 3 are provided. You can Moreover, the manufacturing process described above is merely an example, and can be modified as appropriate.

In the present embodiment, the fiber-reinforced resin layers 14 and 18 on both sides in the thickness direction of the foamed resin layer 20 are formed by impregnating the glass fiber sheets 15 and 19 with the resin composition constituting the foamed resin layer 20. Although a non-limiting example is shown, it is not limited to such an aspect. Both or one of the fiber reinforced resin layers 14 and 18 on both sides in the thickness direction of the foamed resin layer 20 are formed separately from the foamed resin layer 20 and laminated and integrated with an appropriate adhesive. good too. Similarly, the flame-retardant layer 13 and the back-side flame-retardant layer 17 may be laminated and integrated with the fiber-reinforced resin layers 14 and 18 with an appropriate adhesive.
Further, in this embodiment, an example is shown in which the back layer 16 including the back side fiber reinforced resin layer 18 and the back side flame-retardant layer 17 is provided on the ceiling substrate 3 side of the foamed resin layer 20. Both or one of the reinforced resin layer 18 and the back-side flame-retardant layer 17 may be omitted. The above configuration of each part of the ceiling panel 1 according to the present embodiment is merely an example, and various other modifications are possible.

1 Ceiling panel (interior panel)
1A panel body 2A side end 10, 10A surface layer 10a indoor side layer (surface layer)
10b extension part (surface layer)
10c end face layer (surface layer, extension part)
10d end back layer (surface layer, extension part)
11 decorative layer 13 flame-retardant layer 14 fiber-reinforced resin layer 16 back layer 17 back-side flame-retardant layer 18 back-side fiber-reinforced resin layer 20, 20A foamed resin layer 21 indoor side 22 back 23 side end 24 end face 24a indoor side corner Part 24b Back side corner 25 Notch 27 First bending groove (bending groove)
27a groove bottom 29 second bent groove (bent groove)
29a groove bottom 3 ceiling base (interior base)
6 Cutting blade 6a Cutting edge T1 Thickness of the fiber reinforced resin layer at the extending portion T2 Thickness of the fiber reinforced resin layer at the groove bottom side

Claims (6)

An interior panel that is constructed with the back side facing the interior base side,
A surface layer including a fiber reinforced resin layer, a flame retardant layer provided on the indoor side of the fiber reinforced resin layer, and a decorative layer provided on the indoor side of the flame retardant layer is provided on the indoor side of the foamed resin layer. and
An end surface perpendicular to the indoor side surface and a back surface perpendicular to the end surface of at least one side end portion of the foamed resin layer extend in series from a portion covering the indoor side surface. The groove bottom is covered with the extending portion of the surface layer, and the fiber-reinforced resin An interior panel, characterized in that a fold groove is provided so as to be positioned within the layer. In claim 1,
On the back side of the foamed resin layer, a back layer including a back side fiber reinforced resin layer and a back side flame-retardant layer provided on the interior substrate side of the back side fiber reinforced resin layer is an end face of the one side end. It is provided up to the corner on the back side of the
The interior panel, wherein the extending portion of the surface layer is provided so as to cover an interior substrate side of the back layer of the one side end portion. In claim 1 or 2,
The thickness of the fiber reinforced resin layer on the groove bottom side of the portion of the extending portion where the bent groove is provided is 1/2 of the thickness of the fiber reinforced resin layer on the other portion of the extending portion. An interior panel characterized by: A method for manufacturing an interior panel that is constructed with the back side facing the interior base side,
A foamed resin layer is provided on the back side of a surface layer including a fiber-reinforced resin layer, a flame-retardant layer provided on the indoor side of the fiber-reinforced resin layer, and a decorative layer provided on the indoor side of the flame-retardant layer. At least one side end of the panel body is provided with an extension part in which the surface layer is extended from the end surface of one side end of the foamed resin layer by cutting the foamed resin layer so as to leave the surface layer. forming;
It is formed at a position corresponding to the indoor side corner and the back side corner of the end surface of one side end of the foamed resin layer in the extending portion so that the groove bottom is located in the fiber reinforced resin layer. a step of bending the extending portion in the bending groove to cover the end surface and the back surface of the one side end;
A method for manufacturing an interior panel, comprising: In claim 4,
After cutting the one side end of the panel body so as to divide the foamed resin layer from the back side and to position the cutting edge in the fiber reinforced resin layer to form the bent groove, the foamed A method of manufacturing an interior panel, wherein the extending portion is formed by cutting the resin layer. In claim 5,
The foamed resin layer is cut by cutting the foamed resin layer along the back side of the extended portion so as to form a cut open at one end of the foamed resin layer, and cut the extended portion. A method of manufacturing an interior panel, characterized by forming a

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