JPH0882024A - Bed panel and manufacture thereof - Google Patents

Abstract

PURPOSE: To reduce the weight of the bed panel of a decorative panel used for a sanitation room and the like, minify variation of dimension due to humidity, and prevent generation of deformation or warp. CONSTITUTION: A reinforcing frame 14 having prescribed thickness in the peripheral direction and slits 15 in the longitudinal direction is arranged along the outer edge part of a bed panel 10, a core body 16 of honeycomb construction of the actually same height as the thickness of the reinforcing frame 14 is filled in the space part inside the reinforcing frame 14, and metallic foils 18 of the size concealing the surface and the back both faces of the reinforcing frame 14 and the core body 16 are arranged. The metallic foil 18 is joined with the reinforcing frame 14 and the core body 16 through a hot melt film 20 interposed between the metallic foil 18 and the reinforcing frame 14 and the core body 16.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a base panel such as a tile panel or a stone panel.

[0002]

2. Description of the Related Art A decorative panel formed by adhering a finishing material such as tile or stone on the surface of a base panel is widely used as a wall material for a unit bathroom or other sanitary rooms. FIG.
Shows a typical example of those conventionally used as the base panel. This base panel 100 is
An inorganic board (cement-based fiber reinforced board, thickness 3 to 5 mm) 104 is provided on one surface of the reinforcing frame 102 made of metal or the like.
The adhesive 106 alone or the screws 108 alone, or the adhesive 106 and the screws 108.
Are used together and are fixed to the reinforcing frame 102 and integrated.

[0003]

However, this base panel 100 has the following problems. That is, in this base panel 100, the inorganic board 104 has a large dimensional change (expansion and contraction) rate when dry and wet (0.1 to 0.1).
On the other hand, the metal composing the reinforcing frame 102 hardly changes in size when dry and wet, and as a result, the base panel 100 is largely warped and deformed due to the difference in dimensional change rate between the two. Alternatively, the adhesive 106 may be peeled off, or the inorganic board 104 may be cracked (especially, cracks tend to occur starting from the screw 108).

Further, in the case of the base panel 100, it takes a long curing time for the adhesive 106 in manufacturing the base panel 100,
There is also a problem in that a large number of man-hours are required for production because it is necessary to fix a large number of screws 108 and the lead time becomes long.

In addition to this, the base panel 100 has a drawback that it is heavy. Specifically, in the case of the inorganic board 104, the specific gravity and the rigidity are in a substantially proportional relationship, and for example, in the case of a specific gravity of 0.8, a thickness of about 5 mm is required,
Even if the specific gravity is 1.6, a thickness of about 3 mm is required,
It becomes heavy.

[0006]

The invention of the present application has been made to solve such a problem. Thus, the first invention of the present application relates to the base panel itself, in which a reinforcing frame having a predetermined thickness is arranged in the circumferential direction along an outer edge portion of the base panel, and the reinforcing frame is provided in a space portion inside the reinforcing frame. After filling the honeycomb structure core having substantially the same height as the thickness of, the metal foil having a size that covers both the front and back surfaces of the reinforcing frame and the core is arranged, and the metal foil is The hot melt film interposed between the reinforcing frame and the core body adheres to the reinforcing frame and the core body, and at the same time, the reinforcing frame is vertically joined to one outer end surface of at least one pair of vertical side portions. A slit for use is provided (Claim 1).

[0007] Another invention of the present application is that, in claim 1, the metal foil has a thickness of 30 to 300 µm (claim 2).

According to still another aspect of the present invention, a reinforcing frame having a predetermined thickness, which has slits for joining panels in the vertical direction on one outer end surface of at least one pair of vertical sides along the outer edge of the base panel, is circumferentially provided. Then, the inner space of the reinforcing frame is filled with a honeycomb structured core having substantially the same height as the thickness of the reinforcing frame, and hot melt films are arranged on both front and back surfaces of the reinforcing frame and the core. At the same time, a metal foil having a size concealing the reinforcing frame and the core is arranged on the outside thereof, and the metal foil is bonded to the reinforcing frame and the core by hot pressing them in an integrated state. (Claim 3).

[0009]

As described above, the invention of the present application (Claims 1 and 2) is such that metal foils are disposed as face materials on both sides of the reinforcing frame and fixed to the reinforcing frame. In the present invention, since the base panel has a symmetrical shape on the front and back sides, and the face materials on the front and back sides are made of a metal material (metal foil), the dimensional change rate is small. Therefore, the difference in the dimensional change rate between the face material and the reinforcing frame is small. It is possible to significantly reduce deformation such as warpage caused by the above, and it is also possible to prevent the occurrence of cracks due to concentrated stress acting locally on the face material due to the difference in dimensional change rate.

Further, since the front and back face materials are made of metal foil and the core body has a honeycomb structure, the weight of the entire base panel is light and it is not necessary to use an inorganic board. Therefore, there is also an advantage that it is not necessary to use asbestos for reinforcing it. Incidentally, the panel joining means becomes a problem as metal foils are fixed as face materials on both front and back surfaces of the reinforcing frame. Here, in the present invention, the panel joining slit is provided on at least one outer end surface of the vertical side portion of the reinforcing frame, and the panels can be joined by using the slit.

A third aspect of the present invention relates to a method for manufacturing a base panel, and the present invention basically arranges a hot-melt film on the outside of a reinforcing frame and a metal foil on the outside, and superimposes them. It is a hot press in the state of being made. By doing so, the reinforcing frame, the core, and the metal foil as the face material can be bonded and integrated in a short time based on the melting of the hot melt film, and the base panel can be manufactured very easily. can do.

Here, in the case of adhesion by a hot melt film, it does not require a long time for curing unlike an ordinary adhesive, and the adhesion can be completed simultaneously with cooling after melting by hot pressing. The method of the present invention is an effective method in the case of mechanically mass-producing a base panel.

[0013]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Next, embodiments of the present invention will be described in detail with reference to the drawings. In FIGS. 1 and 2, reference numeral 10 denotes a base panel to which tiles 12, stones and other decorative materials (finishing materials) are attached on the surface, which has a planar rectangular shape and is arranged in the circumferential direction along the outer edge portion. A reinforcing frame 14 made of a metal such as steel and aluminum and a core body 16 having a honeycomb structure filled in the inner space surrounded by the reinforcing frame 14.
A metal foil 18 made of stainless steel, aluminum or the like as a face material is fixed to both front and back surfaces of the reinforcing frame 14 and the core body 16.

Here, the reinforcing frame 14 has an internal hollow structure, and vertical slits 15 for joining the panels are continuously formed on the outer end surfaces of the left and right sides (vertical sides) over the entire height of the left and right sides. Has been done. The slit 15 is formed by bending a reinforcing frame material in this example.

FIG. 1A is an exploded view of constituent members of the base panel 10 before assembly. As shown in the figure, the reinforcing frame 14 is configured by joining frame constituent members by welding or the like. Honeycomb structure core 16
Is made of non-combustible paper material in this example, and its height is substantially the same as the thickness of the reinforcing frame 14 (20 mm in this example).

Reference numeral 20 is a hot melt film for adhering the reinforcing frame 14 and the core body 16 to the metal foil 18, and a polyamide resin film is used here. In this example, the hot melt film 20 has a thickness of 30 μm, the melting point is 120 ° C., and the metal foil 18 has a thickness of 50 μm.

In the base panel 10 of this example, as shown in FIG. 1A, the core space 16 having a honeycomb structure is filled in the inner space of the reinforcing frame 14, and the hot melt film 20 and the metal are formed on both sides of the core body 16. It can be easily manufactured by arranging the foils 18 and hot-pressing them in a stacked state.

When hot-pressed, the heat from the hot platen is satisfactorily transferred to the hot-melt film 20 through the thin metal foil 18 having a large area and a large thermal conductivity over the entire surface of the base panel 10, and thereby the hot-melt film is melted. Film 2
0 melts and the metal foil 18, the reinforcing frame 14, and the core 1
6 and 6 are welded well. Then, when it is cooled, the metal foil 18, the reinforcing frame 14, and the core body 16 are bonded to each other by the hot melt film 20, and these members are integrated to form the base panel 10.

By the way, in the case of the base panel 10 of this example, the melting point of the hot melt film 20 is 120 ° C. and the thickness is 30 μm.
m, the metal foil 18 (stainless steel) has a thickness of 50 μm,
When the temperature of the hot plate of the hot press machine is set to 150 ° C,
The base panel 10 can be manufactured by heating / pressurizing for about 100 seconds and cooling / pressurizing for 60 seconds at room temperature. That is, the base panel 10 can be manufactured in an extremely short time of about 160 seconds as a whole.

The base panel 10 of this example also has the feature of being lightweight. For example, the conventional base panel 1 shown in FIG.
In the case of No. 00, if the thickness of the inorganic board 104 is 3 mm and the specific gravity is 1.6, the weight of the base panel of a normal size is 4.8 kg. On the other hand, in the case of the base panel 10 of the present example, the weight of the two metal foils 18 is 0.8 kg and the weight of the core body 16 of the honeycomb structure is 0.6 kg (the thickness is 20 mm) in the base panel of the same size. And)
The total weight is 1.4 kg, which is significantly lighter than the conventional base panel.

Further, in the case of the base panel 10 of this example, since the front and back surfaces are symmetrical and the face material is a metal foil whose dimensional change is extremely small when dry and wet, warping deformation and cracking of the face material occur. It has the advantage of not causing problems.

The base panel 10 of this example is a reinforcing frame 1.
Panels can be easily joined to each other by utilizing the slits 15 formed in the vertical direction in FIG. FIG. 3 shows a specific example thereof. In the figure, reference numeral 22 denotes a joint tool, which includes a shaft portion 24 having a circular cross section, a plate-shaped retaining portion 26, a rectangular block-shaped main body portion 28 facing in a direction perpendicular to the shaft portion 24, the retaining portion 26 and the main body portion 28. Connecting part 3 with circular cross section
0 and the compression coil spring 32 fitted to the shaft portion 24
And have.

Here, the retaining portion 26 and the main body portion 28 have substantially the same width as the slit 15, and the length in the direction perpendicular to this is larger than this. On the other hand, the connecting portion 30 has substantially the same diameter as the width of the slit 15.

In this example, the panels may be joined together as follows. That is, as shown in FIG. 3 (A), in the state in which the retaining portion 26 of the joint tool 22 is in the same vertical direction as the direction of the slit 15, the joint tool 2 is provided.
The second shaft portion 24 is inserted into the holding hole 34 provided in the reinforcing frame 14 in advance while compressing and elastically deforming the spring 32, and the retaining portion 26 has just passed the tip of the bent portion 36 of the reinforcing frame 14. By the way, joint tool 22
The whole is rotated by 90 ° so that the retaining portion 26 is engaged with the tip of the bent portion 36. As a result, the joint tool 22 is prevented from being pulled out from the slit 15 of the one reinforcing frame 14, and at the same time, the block-shaped main body portion 28 is oriented in the vertical direction.

Then, the block-shaped main body 28 is pushed into the slit 15 so that the outer end surface of the other panel 10 is aligned with the outer end surface of the one panel 10.
The main body 28 is projected again and fits into the slit 15 of the other panel 10. This causes the panels 10 and 10 to be joined together. In addition, this joint tool 2
2 shows only an example, and it is of course possible to use other joint tools.

Although the embodiment of the present invention has been described in detail above, this is merely an example. For example, it is possible to use a core made of aluminum or another material as the core of the honeycomb structure, and it is also possible to use other materials and thicknesses as the reinforcing frame and the metal foil. Others The present invention can be configured and embodied in various modified forms and modes without departing from the spirit of the invention.

[Brief description of drawings]

FIG. 1 is a diagram showing a configuration of a base panel which is an embodiment of the present invention.

FIG. 2 is an overall perspective view of a base panel of FIG.

FIG. 3 is a diagram showing an example of a method for joining the panels shown in FIGS. 1 and 2.

FIG. 4 is an explanatory diagram of a configuration of a conventional base panel and its defects.

[Explanation of symbols]

 10 Base Panel 14 Reinforcement Frame 15 Slit 16 Core 18 Metal Foil 20 Hot Melt Film

Claims (3)

[Claims] 1. A reinforcing frame having a predetermined thickness is arranged in a circumferential direction along an outer edge portion of a base panel, and a honeycomb structure core having substantially the same height as the thickness of the reinforcing frame is provided in a space portion inside the reinforcing frame. After filling the body, a metal foil having a size that covers both the front and back surfaces of the reinforcing frame and the core is arranged, and the metal foil is interposed between the metal foil and the reinforcing frame and the core. A base panel characterized by being adhered to the reinforcing frame and the core body with a melt film, and the reinforcing frame is provided with a panel joining slit in a vertical direction on at least one outer end surface of a pair of vertical side portions. . 2. The metal foil according to claim 1, wherein
A base panel having a thickness of 300 μm. 3. A reinforcing frame having a predetermined thickness, which has a panel joining slit in the vertical direction, is arranged in the circumferential direction along at least one pair of vertical side portions along the outer edge of the base panel. After filling the inner space of the core body having a honeycomb structure having substantially the same height as the thickness of the reinforcing frame, a hot melt film is arranged on both front and back surfaces of the reinforcing frame and the core body, and outside of them. A metal foil having a size to cover the reinforcing frame and the core is arranged, and the metal foil is bonded to the reinforcing frame and the core by the hot pressing in a state where they are stacked. A method of manufacturing a base panel.