JPH03213333A - Composite panel - Google Patents

Abstract

PURPOSE:To improve a panel in a degree wherein warpage of the panel does not practically cause trouble by forming a holding base plate of a honeycomb sandwich plate wherein the skin material made of a metallic thin plate is laminated on the surface of a honeycomb core and utilizing the material such as a honeycomb pattern is embossed when the same is contact-bonded and laminated onto the honeycomb core as the skin material. CONSTITUTION:The core material is made of a metallic foil e.g. an aluninum foil and a stainless steel foil and has a honeycomb structure. The sufficiently thin skin material is contact-bonded and laminated to this metallic core. Thereby the skin material easily receives deformation and a core pattern is embossed. A honeycomb sandwich panel is obtained wherein the part surrounded by one core cell is free from smoothness of a specular degree slightly showing a recessed face. A composite panel is obtained by contact-bonding and laminating the facing such as a thin slate, a ceramic plate and a metallic plate to this honeycomb sandwich panel. In such a way, for example when slate is contact-bonded and laminated to the panel, the skin is surrounded by the embossed core part and slightly deformed into a recess. Since this skin follows expansion and shrinkage of slate, the title panel is improved so that warpage does not practically cause trouble.

Description

Detailed Description of the Invention [Field of Industrial Application] The present invention relates to a thin film useful as an interior or exterior material for buildings, interior panels for ships, aircraft, and vehicles, partition panels, or decorative materials for furniture. The present invention relates to a composite panel in which surface plates such as stone plates, ceramic plates, metal plates, etc. are laminated, and more particularly to a composite panel panel that has been improved so that warping of the panel does not become a practical problem under the usage environment.

[Conventional technology]

In recent years, composite panels in which surface plates such as thin stone plates, ceramic plates, metal plates, or precious wood plates are laminated have been developed and are being put into practical use. In particular, stone has high expectations as a high-quality building material due to its desirable natural properties and functions.

However, stone has drawbacks such as brittleness and weight, is difficult to process into thin-walled materials, and has poor workability.For this reason, it has been extremely difficult to use it as a building material for large areas. In recent years, the construction of commercial buildings, especially high-rise buildings, has been active, but it has been difficult to incorporate stone into them as interior materials.

However, as shown in Japanese Patent Publication No. 56-8217, etc., there is a technology to press a backing material onto both sides of a stone slab such as marble and then separate the center of the stone slab to obtain a thin layer of stone. A panel using a thin layer of stone was developed and proposed in British Patent No. 1,215,501, etc., and recently, composite panels that utilize these technologies and are used as building interior materials, which are made by laminating thin stone plates, have been attracting attention. ing.

In addition, various types of composite panels are being developed and put into practical use by laminating surface materials made of stone, ceramic, glass, mirror, metal, precious wood, plastic, etc.

[Problem to be solved by the invention]

However, composite panels made of laminated surface materials such as stone, ceramic, metal, wood, plastic, etc., have a new problem of ``warping'' under the usage environment.
It has become clear that the advantages of surface materials such as stone, such as excellent design, are greatly impaired. In particular, warping is particularly noticeable in composite panels made of laminated stones, ceramics, etc. with a large area of 45 cm square or more, which poses a serious problem in practical use.

An object of the present invention is to provide an improved composite panel that eliminates the above-mentioned drawbacks and prevents warping of the panel from becoming a practical problem under the usage environment.

[Means to solve the problem]

The gist of this invention is a composite panel formed by adhesively laminating a surface material on a retaining substrate, wherein the retaining substrate is a honeycomb sand inch board in which a skin material is laminated on the surface of a honeycomb core, and the surface material is adhesively laminated on the surface material. The composite panel is made of thin metal sheets and features a honeycomb core with a pressed honeycomb pattern that stands out during lamination.

The skin material used in the present invention has a homogeneous structure that does not cause chemical or structural changes during the heating and pressure bonding process so as to be integrated with the honeycomb core material, and has a mirror-like smoothness before being pressed. The rest is thin enough to allow easy deformation so that the core material pattern stands out on the surface. The following metal materials, iron, stainless steel, copper, aluminum, titanium, etc., various alloys, and various surface-treated metals are used. The thickness of the skin material is 0.0
5-0.4 mm is used, preferably 0.1-0.
．． The range is 35 mm. The thickness of the skin material is 0.35
If the thickness exceeds mm, the core material pattern does not stand out on the surface after pressing and integration, and the mirror-like smoothness before pressing remains and is not easily deformed. Also, the thickness of the epidermis is 0.05m.
If the material is less than m, the core material will obviously bulge out after being pressed together, and a noticeable depression will be observed in the area surrounded by the honeycomb core, but if it is significant, the strength will be greater and it will break. This is not preferable because there are cases.

The core material used in the present invention is a metal foil, such as an aluminum foil or a stainless steel foil, and has a honeycomb structure (hexagonal cells, pseudo-hexagonal cells, or square cells). The thickness of the core foil is 30μ
~100μ, and a cell size (distance between facing sides) of 3,175~45μ can be used. The thickness of the entire core used is 3 to 100III11.

For pressure bonding between the thin and easily deformable skin material and the core material, a cold-curing or thermosetting adhesive, particularly a thermosetting resin structural adhesive, can be used as the adhesive. For example, epoxy adhesives, unsaturated polyester adhesives, and polyurethane adhesives can be used. Flame retardants and inorganic fillers may also be mixed.

A normal press is used for compression, and a heat press can be used. By evenly applying the adhesive to the end face of the honeycomb core, it is also possible to promote the appearance of the honeycomb pattern on the surface of the skin material.

As mentioned above, by laminating a sufficiently thin skin material onto a metal core, the skin material is easily deformed, the core pattern is embossed, and the area surrounded by one core cell has a slightly concave surface. It is possible to obtain a honeycomb sandwich panel that does not have mirror-like smoothness as shown in FIG.

Surface materials used in this invention include natural stone plates, artificial stone plates, ceramic plates, glass plates, mirror plates, metal decorative plates, natural precious wood plates, plastic decorative plates, and the like. Its thickness is 0.5-10
m, and marble, granite, various ceramics, artificial stone, etc. having a thickness of I n+m to 8 mm are more preferably used.

In order to pressure-bond and laminate surface materials such as thin stone plates, ceramic plates, and metal plates onto a honeycomb core sandwich panel with an embossed pattern and a non-smooth mirror surface using a thin, easily deformable skin made of metal, organic , inorganic adhesives can be used, and can be selected from room temperature curing, thermosetting, thermoplastic types, etc. Flame retardants, inorganic fillers, etc. can also be mixed.

A vacuum back method, an air bag method, a flat plate press method, or the like is used for crimping.

Generally, a composite panel in which a substrate and a surface material that expand and contract at different degrees under the usage environment are adhesively laminated will warp. However, honeycomb cores that are made of a specific metal, such as those obtained by the present invention, are made of a thin skin material that is easily deformable, have a protruding core pattern, and have a slightly concave surface surrounded by the core, and do not have mirror smoothness. When a sandwich panel is laminated with, for example, stone plates, the skin, which is surrounded by a protruding core and slightly deformed into a concave part, follows the expansion and contraction of the stone plates, and when the stone plates expand, the concave surface disappears. If the stone slab expands in the direction and shrinks, the concave surface will change in the direction of becoming deeper, so it will be improved so that warping will not become a problem.

On the other hand, in the case of a combination in which the honeycomb core sandwich panel side with a raised core pattern expands and contracts more than the expansion and contraction of the stone plate, the slight concave surface surrounded by the raised core part changes in the direction of disappearing. Warpage can be practically improved by making the concave surface deeper or even deeper.

The pattern pattern of the honeycomb core itself can be easily deformed by expanding and contracting as the composite panel expands and contracts while being fixed by the surface material such as a stone plate and the metal skin material, which is thought to contribute to improving warpage.

Examples 1 to 9 Honeycomb sandwich board (length 200c) serving as a holding substrate
m, width 100 cm, thickness 1.8 cm> were those shown in Table 1. This honeycomb sandwich board is made by bonding thin metal skin materials to both sides of a metal honeycomb core using epoxy adhesive, applying pressure 1 to 1 (1 kg/cd, temperature 1
Pressure bonding was carried out under the conditions of 00° C. to 180° C. for 0.5 to 2 hours.

The surface of the honeycomb sandwich board with the honeycomb core pattern embossed on the skin material obtained in this way was
, Marble thin plates with the same length and width as the substrate were bonded together using epoxy adhesive. The crimping method is to place the pasted items in a vacuum bag, then evacuate the inside of the bag with a vacuum pump, and
Pressure bonding was carried out by maintaining an appropriate pressure in the range of ~700 mmHg for 1 to 5 hours.

In the thus obtained composite panel, warpage was improved to such an extent that there was no substantial problem under the usage environment.

Example 10 A stone plate was prepared using the same material as in Example 1, except that a 7 mm thick granite thin plate and a thin stone plate were used as the skin material, and an unsaturated polyester resin was used as the bonding adhesive to the honeycomb core sandwich panel. I made a composite panel.

The obtained slate composite panel had improved warpage to the extent that there was virtually no problem under the usage environment.

Comparative Example 1 A honeycomb sandwich board was made in the same manner as in Example except that aluminum having a thickness of IX[lI[l] was used as the skin material. The surface of the skin material of the obtained board was as smooth as a mirror without any embossed honeycomb core pattern. A thin marble plate was adhesively laminated on this plate surface in the same manner as in Example 1 to produce a composite panel.

This panel clearly showed large warpage under the usage environment, and it was difficult to correct the warpage when this composite panel was used for interior walls. When I tried to force the correction, cracks appeared in the stone slab. The interior finish was also warped and the design was poor.

〔Effect of the invention〕

Claims (1)

[Claims] (1) In a composite panel formed by adhesively laminating a surface material on a retaining substrate, the retaining substrate is a honeycomb sandwich board in which a skin material is laminated on the surface of a honeycomb core, and the surface skin material on which the surface material is adhesively laminated is metal. A composite panel made of thin sheets and characterized by a honeycomb pattern that is pressed into the honeycomb core during crimping and lamination.