JPH0835287A - Panel and manufacturing thereof - Google Patents

Abstract

PURPOSE:To make it possible to ensure the strength of a panel without increasing the thickness and to make it contribute to its lightweight and cost reduction by integrating a setting bed material forming the panel, a metal substrate and a metal frame into a unit to manufacture. CONSTITUTION:A metal substrate 3 is mounted on a heat panel 10, and a hot melt adhesive sheet 2 is heated until it reaches a softening point through the metal substrate 3. After that a frame 1 is placed on the softened adhesive sheet 2, and a laminate of the metal substrate 3 and frame 1 is pressed by a press holder 20. Then, a setting bed material monolithically formed of the metal substrate 3 and frame 1 is obtained by shifting it to cold press to leave it along. A face such as a tile, etc., is mounted to the surface of the metal substrate 3 to the setting bed material to manufacture a panel. According to the constitution, the setting bed material can be prevented from an inconvenience such as pansion caused by environmental change.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a panel in which a surface material such as a tile is attached to a base material and a method for manufacturing the panel, and more particularly to a panel made of a metal substrate.

[0002]

2. Description of the Related Art A panel formed by sticking a surface material typified by a tile panel to a base surface usually has a surface material such as a tile, a base material, and a reinforcing frame as constituent elements. In addition to tiles, glass and stone are also used as surface materials. As the base material, an inorganic board such as a calcium silicate plate or a slate plate is generally used. As the frame, a frame made of lightweight steel made of iron or aluminum is usually used.

[0003]

SUMMARY OF THE INVENTION The conventional panel described above is
The base material is an inorganic board, and the frame is a lightweight steel made of metal. Since the inorganic board has a large dimensional change rate based on the difference in dryness and humidity, it easily expands and contracts due to moisture absorption and drying, whereas the lightweight steel frame hardly causes expansion and contraction due to the difference in dryness and humidity. For this reason, there is a problem in that the amount of expansion and contraction of the base material and that of the frame differ.

In order to counter the difference in expansion and contraction between the base material and the frame, it is conceivable to increase the thickness of the base material to increase the strength, but in this case, it causes adverse effects such as an increase in panel weight and an increase in cost. .

It has also been proposed to improve the strength by using a fiber-reinforced inorganic board containing vinylon or the like as a base material. However, organic fibers such as vinylon are not practical because there is a problem in that substantial improvement in strength cannot be obtained because they are not well compatible with the cement-based inorganic material that is the main component of the base material.

[0006]

SUMMARY OF THE INVENTION In view of the above-mentioned problems of the prior art, it is an object of the present invention to provide a panel having no or very little difference in dimensional change between the base material and the frame. The feature of the panel that the present invention has achieved in order to achieve such an object is that a base material for attaching a surface material such as a tile is attached to the frame, which is manufactured by using a lightweight steel frame or the like as a frame. It is composed of a metal substrate.

The feature of the means adopted by the present invention for manufacturing the above-mentioned panel is that the metal substrate and the frame manufactured by framing light-weight steel or the like are integrated by using an adhesive or welding, It's about preparing the material.

Specifically, one of the preferred embodiments of the panel manufacturing method according to the present invention will be described. A hot-melt adhesive is arranged in a predetermined region of a metal substrate, and the metal substrate is heated to a temperature above the softening point of the hot-melt adhesive. After heating, the frame is made of lightweight steel, etc., and the frame is placed on the softened hot-melt adhesive and pressed, and then it is cooled to integrate the metal substrate and the frame to form a base material. Is to prepare.

Further, in another preferred aspect of the panel manufacturing method according to the present invention, a surface material such as a tile is arranged on the front surface side of the metal substrate via a hot melt adhesive, and the hot melt is formed on the back surface side of the metal substrate. After arranging a frame made by framed lightweight steel or the like through an adhesive, heating these above the softening point of the hot melt adhesive, simultaneously pressing if necessary, and then cooling the surface material. , Integrating the metal substrate and frame.

[0010]

The panel according to the present invention comprises a metal substrate and a frame as a base material to which a surface material such as a tile is attached. The metal substrate and the frame are not affected by temperature difference and humidity difference. There is no or little difference in the dimensional change rate based on it. Therefore, since there is no possibility that the amount of expansion and contraction of the metal substrate and the frame will be different, it is not necessary to increase the thickness of the base material to secure the strength.

In the panel according to the present invention, the metal substrate forming the base material and the frame are made of the same metal,
Since good thermal conductivity is obtained, both can be integrated by using a hot melt adhesive. Furthermore, the surface material can be integrated at the same time. Since the hot melt adhesive develops strength in a very short time, the manufacturing work can be performed easily and quickly, and is suitable for mass production of panels.

When an adhesive is used to bond the metal substrate and the frame, the adhesive layer formed between the two functions as an insulating layer. Can be prevented.

Further, since the adhesive layer fills the gap between the metal substrate and the frame, it also has a function of preventing crevice corrosion that frequently occurs in stainless steel.

[0014]

Embodiments of the present invention will be described below. FIG. 1 shows a procedure for manufacturing a base material for a panel according to the present invention using a hot melt adhesive. In order to manufacture the base material, first, a heating plate 10 having a heating means built-in or attached thereto is provided.
The metal substrate 3 is placed on top of this, and the hot melt adhesive sheet 2 is placed thereon. The adhesive sheet 2 is formed into a plane shape that is substantially the same as the frame 1 that is manufactured by using a frame of lightweight steel or the like. Next, the heating plate 10 is heated,
The hot melt adhesive sheet 2 is heated through the metal substrate 3 until its softening point (about 150 ° C.) is reached.

When the adhesive sheet 2 is softened, the frame 1 is laminated on it. Since the adhesive sheet 2 is formed in the same shape as the frame 1, it is possible to match the two. While continuing to heat the hot platen 10,
A pressing die 20 arranged above the frame 1 presses the laminate of the metal substrate 3 and the frame 1. By maintaining this heating and pressurizing state for a predetermined time, the hot-melt adhesive sheet 2 is melted and evenly spreads between the metal substrate 3 and the frame 1 to form an adhesive layer that fills the two without a gap. To do.

Since both the metal substrate 3 and the frame 1 have good thermal conductivity, the heating and pressurizing time described above can be shortened, so that the manufacturing time can be shortened.

Thereafter, the laminate is transferred to a cold press and left standing, or if the temperature is lowered to room temperature by using an appropriate cooling means, the metal substrate 3 and the frame 1 are bonded together by a hot melt adhesive. An integrated base material can be obtained. Then, by appropriately attaching a surface material such as a tile to the surface of the base material, a panel P as shown in FIG. 2 is obtained.
Can be manufactured.

In the panel P according to the present invention thus obtained, since the base material 4 is made of the metal substrate 3 and the metal frame 1, the dimensional change between them due to temperature change or humidity change. There is almost no difference in the rate, and therefore there is no problem of causing a difference in the amount of expansion and contraction.

Further, a uniform hot melt adhesive layer 2a is formed between the metal substrate 3 and the frame 1, whereby the metal substrate 3 and the frame 1 are electrically insulated. When the metal substrate 3 and the frame 1 are made of different metals, a potential difference occurs when the two are in contact with each other to cause electrolytic corrosion.
Since they are insulated from each other, there is an advantage that electrolytic corrosion does not occur even if different metals are used.

Further, since the hot melt adhesive layer 2a fills the space between the metal substrate 3 and the frame 1 without any gap, it also has a function of preventing crevice corrosion which is likely to occur in stainless steel.

The embodiment of the present invention can be applied and modified in various ways other than the above. Looking first at the constituent members, as the material of the metal substrate 3 forming the base material 4, a steel plate, an aluminum plate or the like is used in addition to the stainless steel plate. The frame 1 is generally made of lightweight steel of about 16 mm square, which is made of iron or aluminum, but is not limited thereto. As the type of the surface material 5, a glass material or a stone material can be used in addition to the illustrated tile. As described above, the material, shape, size, and the like of each member forming the panel P can be appropriately changed according to the implementation conditions.

Various application examples can be considered for the specific structure of the base material 4. This is shown in FIGS. FIG.
Is obtained by bending the edge 3a of the metal substrate 3 at a right angle, and such a configuration can improve the rigidity.

Further, as shown in FIG. 4, it is conceivable that rigidity is imparted by attaching the splint 6 to an appropriate position on the back surface side of the metal substrate 3.

Further, as shown in FIG. 5, a porous plate 7 may be attached to the back side of the metal substrate 3 to form a heat insulating structure. The material of the porous plate 7 is not particularly limited, but it is considered that foamed ceramics such as foamed glass and foamed concrete are used, and foamed plastics such as styrene foam and urethane foam are used. In the case of the former foam ceramic, rigidity can be imparted together with heat insulation. However, the weight tends to be slightly increased as compared with the case of using the latter foamed plastic.

When foamed plastic is used as the porous plate 7, as shown in FIG. 6, the backing material 8 can be further attached to the back side in order to improve the rigidity. The backing material 8 may be a metal plate such as a steel plate, a stainless steel plate, or an aluminum plate as with the surface material, but since the surface material such as tiles is not attached, synthetic resin, paper, ceramic or the like is used. A plate made of a non-metallic material may be used. Alternatively, the backing material 8 may be the same as the metal substrate 3 on the front surface side, and the surface material may be attached to the backing material 8 to manufacture a panel having both surfaces.

Next, an application example relating to the panel manufacturing method will be described. In manufacturing the base material 4, instead of interposing the hot melt adhesive sheet 2 between the frame 1 and the metal substrate 3, the hot melt adhesive is applied to the frame 1 or the metal substrate 3 A method of printing a hot melt adhesive on the back surface in accordance with the planar shape of the frame 1 can be adopted.

In the above embodiment, the base material 4 was prepared in advance and the surface material 5 was attached to the base material 4 to manufacture the panel, but instead of this, the panel is manufactured by the following method. You can also That is, although not shown,
A hot melt adhesive is interposed on each of the front and back surfaces of the metal substrate 3 to arrange a surface material 5 such as a tile and the frame 1 to produce a laminate, and the laminate is made to have a softening point of the hot melt adhesive or higher. In this method, the surface material, the metal substrate, and the frame are integrated by heating, pressurizing at the same time if necessary, and then cooling, to manufacture a target panel.

In addition to the above-mentioned hot melt adhesive, a thermosetting adhesive, a solvent volatilizing adhesive, or the like may be used as a unit for integrating the frame 1 and the metal substrate 3 forming the base material 4. You can also When using a thermosetting or solvent volatilizing adhesive, it usually takes longer to cure and develop strength than a hot-melt adhesive. Must be set. Further, a double-sided adhesive tape may be used together as a means for maintaining the bonded state of the frame 1 and the metal substrate 3 until the adhesive has sufficiently developed strength.

Further, it is possible to integrate the frame and the metal substrate by welding means such as spot welding.

Besides, the present invention does not prevent various modifications depending on the implementation conditions.

[0031]

According to the present invention, since the base material forming the panel is manufactured by integrating the metal substrate and the metal frame, there is no possibility that the base material expands and contracts due to environmental changes. Therefore, it is not necessary to increase the thickness of the base material and the surface material to secure the strength, which leads to the weight reduction of the panel and the cost reduction.

When a panel is manufactured based on the method of the present invention using a hot melt adhesive, the manufacturing process can be simplified and shortened. As a result, the manufacturing efficiency is improved, and eventually the panel can be mass-produced.

[Brief description of drawings]

FIG. 1 is an exploded perspective view illustrating a manufacturing procedure of a base material for a panel according to the present invention.

FIG. 2 is a side sectional view showing a part of a panel according to the present invention.

FIG. 3 is a side sectional view showing a modified example of a base material for a panel according to the present invention.

FIG. 4 is a side sectional view showing a modified example relating to a base material for a panel according to the present invention.

FIG. 5 is a side sectional view showing a modified example of a base material for a panel according to the present invention.

FIG. 6 is a side sectional view showing a modified example relating to a base material for a panel according to the present invention.

[Explanation of symbols]

 1 Frame 2 Hot Melt Adhesive Sheet 2a Hot Melt Adhesive Layer 3 Metal Substrate 4 Base Material 5 Surface Material P Panel 10 Hot Plate 20 Pressing Type

 ─────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Kubota Gozo, 5-1-1, Koiehoncho, Tokoname City, Aichi Prefecture Inax Co., Ltd.

Claims (4)

[Claims] 1. A panel formed by attaching a surface material such as tile to a base material, wherein the base material is composed of a frame made of lightweight steel or the like as a frame and a metal substrate attached to the frame. Panel that is characterized by being. 2. A method for manufacturing a panel in which a surface material such as a tile is attached to a base material, wherein a metal substrate and a frame manufactured by framing lightweight steel or the like are integrated using an adhesive or welding. A method for manufacturing a panel, characterized in that the base material is prepared by forming the base material. 3. A method of manufacturing a panel comprising a surface material such as a tile attached to a base material, wherein a hot melt adhesive is placed in a predetermined region of a metal substrate, and the metal substrate is softened by the hot melt adhesive. After heating above a point and placing a frame made of lightweight steel frame on softened hot melt adhesive and pressurizing it, cool it to integrate the metal substrate and frame A method of manufacturing a panel, comprising preparing the base material according to 4. A surface material such as a tile is arranged on the front surface side of a metal substrate through a hot melt adhesive, and a lightweight steel or the like is framed on the back surface side of the metal substrate through a hot melt adhesive. After arranging the frames, the surface material, the metal substrate and the frame are integrated by heating them to a temperature above the softening point of the hot-melt adhesive, pressing at the same time if necessary, and then cooling. Panel manufacturing method.