JPH09314708A - Structure of composite panel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To enable a process to make a product lightweight as thin as possible irrespective its high flexural rigidity and strength compatible with a surface material, and possible to be produced relatively inexpensively. SOLUTION: A core material 7 placed between two opposite surface material is formed to have an uneven cross section by bending a thin steel plate. The first-fourth contact surfaces 71, 73, 75, 76 which are contacted alternately with the inner surfaces of two surface materials and the first-third support surfaces 72, 74, 76 which connect these contact surfaces are provided continuously. The first contact surface 71 is contacted with the inner surface of one surface material, the first support surface 72 is bent from the first contact surface to extend toward the other surface material. The second contact surface 73 is bent from the first support surface to be contacted with the inner surface of the other surface material, and the second support surface 74 is bent from the second contact surface to extend toward one surface material.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a composite panel structure.

[0002]

2. Description of the Related Art Composite panels in which a core material is interposed between facing surface materials are widely used as building components such as doors, doors, interiors and exteriors. First of all, such a composite panel is required to be lightweight and highly rigid. Therefore, a material that is light and has a large shearing force or compressive force is selected as the core material. The most commonly used core material is a honeycomb material such as a paper honeycomb, and other porous materials such as urethane foam and styrene foam, and fiber materials such as rock wool and glass wool. All of these are filled in the gaps between the surface materials. In addition, as in the case of being used for a flush door, there are some in which a large number of particle boards, balsa, etc. are arranged as frame cores or crosspieces in the gap.

[0003]

However, the light weight and the securing of high bending rigidity and strength have a relationship that is difficult to coexist in the first place. For example, a composite panel using a porous core material is thin and lightweight, but its bending rigidity is significantly lower than other materials, and the surface material of PVC sheet steel sheet is filled with pearlite or mortar. Has high rigidity and strength, but increases in thickness and becomes heavy. Even if a particle board or the like is used as a frame core, weight reduction must be sacrificed if the rigidity is to be increased. As a result, the composite panels of this type tend to have limited uses depending on the material.

Composite panels using a honeycomb material as a core material are widely used for doors and doors because they have a certain degree of bending rigidity and strength in spite of their relatively light weight. There is no change in strength, and there is a limit to thinning. In addition, the surface material that comes into contact with the end faces of the honeycomb is likely to be inconsistent.

The object of the present invention is to have high flexural rigidity and strength, but at the same time, it is lightweight and can be made as thin as possible.
Providing a new structure for composite panels.

[0006]

The present invention is characterized in that it has the following constitution in order to achieve the above object.
That is, according to the present invention, the core material interposed between the two facing surface materials is formed in a concavo-convex cross-section by bending a thin steel plate, and the inner surfaces of the two surface materials are alternately contacted with each other. It continuously has four abutting surfaces, which are in contact with each other, and three supporting surfaces, which are first to third and which connect these abutting surfaces. The first contact surface is in contact with the inner surface of the one surface material, and the first support surface is bent from the first contact surface and extends toward the other surface material. The second contact surface is bent from the first support surface to contact the inner surface of the other surface material, and the second support surface is bent from the second contact surface to face the one surface material. Is extended. The third contact surface is bent from the second support surface in the direction opposite to the second contact surface and abuts against the inner surface of the one surface material, and the third support surface is the third contact surface. Is bent from the contact surface and extends again toward the other surface material. The fourth contact surface is bent from the third support surface and is in contact with the inner surface of the other surface material. The first contact surface and the second contact surface and the third contact surface and the fourth contact surface are in the same direction at both ends of the first support surface or both ends of the third support surface, respectively. Alternatively, the first and / or fourth abutting surfaces bent in the opposite directions and bent in the same direction are formed narrower than the second or third abutting surfaces, respectively.

This composite panel may have a structure in which a covering sheet material such as vinyl chloride or synthetic paper is attached to the entire outer surface of the composite panel body including both surface materials. The first contact surface and the second contact surface are bent in the same direction or opposite directions at both ends of the first support surface and contact the inner surfaces of different surface materials. Further, the core material is interposed in the internal gap of the composite panel along its length direction,
A plurality of composite panels may be arranged at intervals in the width direction. A medium quality fiberboard (MDF) is suitable for the surface material.

[0008]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The present invention will be described below in detail based on illustrated embodiments. 1 to 4 show an embodiment in which the present invention is applied to a folding door.

This door 1 is provided with a door 3 as shown in FIGS.
The door body 2 having the same structure is foldably connected at a joint end, and one end thereof is attached to an attached portion such as an open end of a storage shelf through an attaching member such as a hinge member (not shown).

Each door 2 will be described with reference to the sectional view of FIG. Reference numeral 3 in the drawing is a surface material made of a medium quality fiberboard, so-called MDF, which are opposed to each other with a required gap 6 (for example, about 18 mm). The surface material has a thickness of less than 3 mm, for example. Similarly, 4 is a side frame member made of MDF, and a vertical core member 5 made of particle board is additionally provided inside.

Reference numeral 7 denotes a plurality of reinforcing core members interposed between the left and right side frame members in the gap 6 with a required space. The reinforcing core material 7 is formed by bending a thin steel material so that the cross section has an uneven shape, and has four contact surfaces 71, 71 to 71, which contact the inner surfaces of two surface materials alternately. 73,75,7
7 and three first to third support surfaces 72, 74, 76 connecting these contact surfaces are continuously provided.

As shown in FIGS. 3 and 4, the first abutting surface 71 and the fourth abutting surface 77 located at both left and right ends of the reinforcing core member 7 are formed to be extremely narrow. A first contact surface 71 that is in contact with the inner surface of one surface material (lower surface material in FIG. 3)
The first support surface 72 is bent and connected at a substantially right angle, and extends toward the other surface material (upper surface material in FIG. 3). A second contact surface 73, which contacts the inner surface of the other surface material, is connected to the upper end of the first support surface 72 in the figure. The second contact surface 73 is formed from the upper end of the first support surface 72 to the first contact surface 7
1 extends in the same direction as 1 extends from the first support surface 72.

A second support surface 74 is similarly bent and connected to the side end of the second contact surface 73 at a substantially right angle, and the lower surface material 3 is formed.
Extending towards. A third contact surface 75, which contacts the inner surface of the lower surface material, is connected to the lower end of the second support surface 74. The third contact surface 75 further includes a third support surface 76.
Extends again toward the other surface material 3. The fourth contact surface 7 is provided on the upper end of the third support surface 76.
7 extends in the same direction as the third abutment surface 75 extends from the lower end of the third support surface.

Therefore, the reinforcing core member 7 includes the first and second contact surfaces 71 and 73 and the third and fourth contact surfaces 75 and 7.
While facing each other, the first and third contact surfaces 71, 73 contact the inner surface of one surface material, and the second and fourth contact surfaces 75, 77 contact the inner surface of the other surface material. Are abutted and three support surfaces 72, 74, 76 between these abutment surfaces
Supports the gap 6 between both surface materials. Then, in the depth width direction within the gap, the cross-section portions (first support surface 7) of alternating alternating U-shapes sharing the second support surface 74 in the middle are common.
2 from the second contact surface 73 to the third support surface 74 and from the second support surface 74 to the third contact surface 75 to the third support surface 76). To position. In the lateral width direction within the gap, a substantially U-shaped lateral cross-section portion (the cross-section portion from the first contact surface 71 through the first support surface 72 to the second contact surface 73 and the third cross-section portion) is formed on both sides. A cross-section portion from the contact surface 75 through the third support surface 76 to the fourth contact surface 77) and a Z-shaped cross-section portion are located in the middle. Therefore, it has a relatively small surface area and widely supports the inside of the gap, and has a very high bending rigidity and strength while having a small unit weight. The thickness of the composite panel is adjusted by the height of the support surface.

Further, since this composite panel has such a rigid structure, it does not cause any distortion or deflection even after the panel 8 is assembled with the decorative sheet 8 such as PVC or synthetic paper on the entire surface of the panel including the surface material. It can be easily coated.

FIG. 5 shows a main part of a composite panel according to another embodiment of the present invention. The reinforcing core material 170 interposed in the gap 6 between the surface materials 3, 3 is very similar to the above embodiment, but the extending direction of the first contact surface 171 and the fourth contact surface 177 is the above. Contrary to that of the embodiment, it is outward. In the figure, reference numeral 172 is a first support surface, 173 is a second contact surface, 174 is a second support surface, 175 is a third contact surface,
176 is a third support surface.

The composite panel of this embodiment has a reinforcing core material 17
Since 0 has the above-mentioned structure, it is slightly inferior in bending rigidity and strength as compared with the above-mentioned embodiment, but can be manufactured more economically. That is, as the reinforcing core material 170, a thin steel material 100 having a large number of concavities and convexities continuously formed as shown in FIG. 6 is manufactured once and then cut at a position indicated by a dashed line in the drawing, whereby mass production is easy.

Further, according to the present invention, the first contact surface and the second contact surface of the reinforcing core member are extended in opposite directions so that one of them closes the U-shape (FIGS. 1 to 4). (The same direction as the embodiment of FIG. 5) and the other opening direction (see the embodiments of FIGS. 5 and 6). Furthermore, the various forms of the reinforcing core material as described above may be combined and interposed in the gap between the surface materials in a well-balanced manner.

[0019]

As described above, according to the present invention, the first and third abutting surfaces of the core material made of a thin steel material are provided on the inner surface of one of the surface materials, and the second and fourth abutting surfaces thereof. Is abutted against the inner surface of the other surface material, and the three supporting surfaces between these contact surfaces support the gap between the two surface materials. However, due to the action of the combination of the plurality of contact surfaces and the support surface described above, the composite panel can have high bending rigidity and strength.

Further, since the back surface of the surface material is surface-supported by the abutting surface of the core material, the surface material does not become inconsistent.

Furthermore, since the core material is formed by bending a thin steel plate and is formed in a form having a relatively large surface area, the manufacturing cost can be reduced.

[Brief description of drawings]

FIG. 1 is a front view of a door to which a composite panel according to an embodiment of the present invention is applied.

FIG. 2 is a plan view of the door of FIG.

3 is a cross-sectional view taken along the line AA of FIG.

FIG. 4 is a partially enlarged perspective view of a reinforcing core material used in the composite panel of FIG.

FIG. 5 is a sectional view of a main part of a composite panel according to another embodiment of the present invention.

6 is an explanatory view showing an example of manufacturing a reinforcing core material used in the composite panel of FIG.

[Explanation of symbols]

 1 ... Door 2 ... Door body 3 ... Surface material 6 ... Gap 7,107 Reinforcement core material 71,171 -First contact surface 72,172-First support surface 73,173-Second contact surface 74,174-Second support surface 75,175-Third contact surface 76 , 176 ... 3rd support surface 77, 177 ... 4th contact surface

Claims (6)

[Claims] 1. A composite panel in which a core material is interposed between two surface materials facing each other with a required gap, and the core material is bent on a thin steel plate to form an inner surface of the two surface materials. The first to fourth four contact surfaces that are alternately contacted with each other and the first to third support surfaces that connect the contact surfaces are continuously formed in a concavo-convex cross section, The first contact surface is in contact with the inner surface of one surface material, the first support surface is bent from the first contact surface and extends toward the other surface material, The abutment surface is bent from the first support surface and abuts against the inner surface of the other surface material, and the second support surface is bent from the second abutment surface toward the one surface material. The third abutment surface is bent from the second support surface in a direction opposite to the second abutment surface, and the one surface member The third contact surface is bent from the third contact surface and extends again toward the other surface member, and the fourth contact surface is bent from the third support surface. Is abutted against the inner surface of the other surface material, the first abutting surface and the second abutting surface are bent in the same direction at both ends of the first supporting surface, and The contact surface and the fourth contact surface are bent in the same direction at both ends of the third support surface, and the first contact surface and the fourth contact surface form the second contact surface. The structure of the composite panel is characterized in that it is formed narrower than the third contact surface. 2. A composite panel in which a core material is interposed between two surface materials facing each other with a required gap, and the core material is bent to a thin steel plate to form an inner surface of the two surface materials. The first to fourth four contact surfaces that are alternately contacted with each other and the first to third support surfaces that connect the contact surfaces are continuously formed in a concavo-convex cross section, The first contact surface is in contact with the inner surface of one surface material, the first support surface is bent from the first contact surface and extends toward the other surface material, The abutment surface is bent from the first support surface and abuts against the inner surface of the other surface material, and the second support surface is bent from the second abutment surface toward the one surface material. The third abutment surface is bent from the second support surface in a direction opposite to the second abutment surface, and the one surface member The third contact surface is bent from the third contact surface and extends again toward the other surface member, and the fourth contact surface is bent from the third support surface. Is abutted against the inner surface of the other surface material, the first contact surface and the second contact surface are bent in opposite directions at both ends of the first support surface, and The structure of the composite panel, wherein the contact surface and the fourth contact surface are bent in opposite directions at both ends of the third support surface. 3. A composite panel in which a core material is interposed between two surface materials facing each other with a required gap, wherein the core material is bent on a thin steel plate to form an inner surface of the two surface materials. The first to fourth four contact surfaces that are alternately contacted with each other and the first to third support surfaces that connect the contact surfaces are continuously formed in a concavo-convex cross section, The first contact surface is in contact with the inner surface of one surface material, the first support surface is bent from the first contact surface and extends toward the other surface material, The abutment surface is bent from the first support surface and abuts against the inner surface of the other surface material, and the second support surface is bent from the second abutment surface toward the one surface material. The third abutment surface is bent from the second support surface in a direction opposite to the second abutment surface, and the one surface member The third contact surface is bent from the third contact surface and extends again toward the other surface member, and the fourth contact surface is bent from the third support surface. Is abutted against the inner surface of the other surface material, the first abutting surface and the second abutting surface are bent in the same direction at both ends of the first supporting surface, and The contact surface and the fourth contact surface are bent in opposite directions at both ends of the third support surface, and the first contact surface is formed narrower than the second contact surface. , The structure of the composite panel characterized by the following. 4. The structure of a composite panel according to claim 1, wherein a covering sheet material such as vinyl chloride or synthetic paper is post-applied to the entire outer surface of the composite panel body including both surface materials. The structure of the composite panel is characterized by the following. 5. The composite panel according to claim 1 or 2, wherein a plurality of the core materials are arranged in an inner space of the composite panel at intervals in a width direction of the composite panel. Construction. 6. The structure of the composite panel according to claim 1 or 2, wherein the surface material is a medium-quality fiberboard (MDF).