JPH10299166A - Composite panel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To make a surface of a composite panel perfect thin piece, and reduce weight by covering the whole surface of a synthetic resin foaming plate material by applying a phenol resin, forming a core material by forming a frame material by a wooden square bar on the peripheral edge of this plate material, and sticking wooden plates on the obverse and the reverse of this core material by reversing the obverse and the reverse. SOLUTION: A kind of resin used for a synthetic resin foaming plate material 5 is a thermoplastic resin such as polystyrene and vinyl chloride and a thermosetting resin such as eria and phenol, but particularly, polystyrene is optimal. A phenol resin adhesive 4 is applied to the whole surface of the synthetic resin foaming plate material 5, and durability, fireproof performance and waterproof performance of a core material 2 are improved. The synthetic resin foaming plate material 5 is put in a wooden frame material 6, and the corner of the wooden frame material 6 is housed by a halving joint, a nailing joint or the like. A material by connecting plates to each other is better in beautiful appearance as an obverse material 1 and a reverse material 3 being a wooden plate stuck to the obverse and the reverse, and a perfect thin piece having no butt end crack or the like is used. Therefore, a surface of a composite panel can be made perfect thin piece, and weight can be reduced.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a terrace deck, which is a composite panel made of a lightweight, highly heat-insulating synthetic resin foam plate material, the front and back surfaces and the periphery of which are made of wood.
Used for flooring such as veranda, solarium, wet edge.

[0002]

2. Description of the Related Art Wood has long been used as a building material in various parts. Although it is easy to process and lightweight, it has relatively high strength, and the unique texture of natural wood has been especially valued in Japan. Although it is a promising material that will not be depleted in terms of resources, thick wood has disadvantages in that, when it becomes heavier, its dimensions are out of order, and it is difficult to obtain good-quality wood.

Although wood has many advantages, it has the above-mentioned drawbacks, so that the material must be selected according to the construction site and application to be used. Wood rot and insect damage can be prevented to some extent by preserving them sufficiently, but this is not sufficient. The wood shrinks when it dries, causing mess, which is partially overcome by using well dried wood. Good quality wood has a solid surface and is thick, but especially thick wood is difficult to obtain and expensive.

[0004]

SUMMARY OF THE INVENTION The present invention easily solves the above-mentioned drawbacks of wood, such as its susceptibility to decay and insect damage, while making use of the advantages of wood, and its surface is solid, beautiful and lightweight. It is intended to provide a composite panel suitable for a certain exterior product.

[0005]

According to the present invention, a phenolic resin is applied to the entire surface of a synthetic resin foam plate to cover it, and a frame made of a wooden square is formed around the periphery of the plate to form a core material. A wooden flat plate is stuck on the front and back surfaces of the core material with the wood opening upside down to obtain a composite panel.

[0006] The synthetic resin foam board may be a single piece, but the synthetic resin foam board is divided by a partition wall such as a thin plastic sheet, a thin wooden board, or paper according to the dimensions of the composite panel.

[0007]

The type of resin used for the synthetic resin foam plate used in the present invention is a thermoplastic resin such as polystyrene, polypropylene, polyethylene, vinyl chloride, or polyurethane, or a thermosetting resin such as urea, epoxy, hard polyurethane, or phenol. Among them, polystyrene is most suitable as the thermoplastic resin. In addition, a crushed waste plastic foam material can be used as a part of the synthetic resin foam plate.

[0008] The phenol resin is applied to the entire surface of the synthetic resin foam plate material because of the durability, chemical resistance, fire resistance, and the like of the core material.
This is for improving waterproofness. The phenol resin applied here is a resol-type phenol resin obtained by an addition condensation reaction between phenols and aldehydes.

The resole type phenol resin is phenol,
Cresol, xylenol, paraalkylphenol,
Paraphenylphenol, phenols such as resorcinol and modified products thereof and formaldehyde, paraformaldehyde, furfural, aldehydes such as acetaldehyde, sodium hydroxide, potassium hydroxide, calcium hydroxide, hexamethylenetetramine, trimethylamine,
It is a resol type produced by reacting with an alkaline catalyst such as triethylamine.

A phenol resin to which a curing agent or the like is added may be directly applied or immersed in the phenol resin, or the phenol resin may be used as an alcohol-soluble or water-soluble adhesive. As the alcohol-soluble phenol resin adhesive, a resol type phenol resin is used as an alcohol solution. The water-soluble phenol resin adhesive is produced by reacting sodium hydroxide as a catalyst and concentrating under reduced pressure.

The reason why the synthetic resin foam plate is partitioned by a plastic thin plate, a wooden thin plate, paper or the like is to increase the surface pressure strength of the synthetic resin foam plate. When the dimensions of the composite panel are small, it is not necessary to put a partition wall in the synthetic resin foam plate, but when the composite panel becomes large, dents or distortions etc. occur in the synthetic resin foam plate due to the load applied to the wooden flat plate attached to the surface. There are cases. The simplest method of reinforcing the surface pressure applied to the synthetic resin foam plate is to provide a partition wall in the synthetic resin foam plate. The effect can be maximized by subdividing the pressure receiving area.

The partition wall to be installed on the synthetic resin foam plate is sufficient to be a thin plastic plate, a thin wooden plate, paper, or the like, and its thickness is in the range of 0.3 to 1.5 mm. When the thickness is 0.3 mm or less, the reinforcing effect is not sufficiently exhibited, and when the thickness is 1.5 mm or more, there is no difference in the effect of strength development.

The wooden frame material to be installed around the synthetic resin foam plate material has a width of 20 to 100 mm and a thickness of 20 to 100 mm, and the synthetic resin foam plate material is put in the wooden frame material. The material of the wooden frame is not particularly limited.

[0014] The corners of the wooden frame material are set to accommodate a hook-and-groove joint, a buckle-shaped grooving joint, a buckle-shaped wrap-around splice, a single-body add-on splice, and a wrap-around lap joint.

The wooden flat plate to be adhered to the front and back surfaces may be a single plate made of plywood or the like, but it is preferable that the flat wooden plates are seamed for aesthetic reasons. The type of flat plate is not particularly limited, but the flat plate on the surface should be solid and have no roots (addresses), without skin, round, raw knots, dead knots, missing knots, knotted knots, cracks at the mouth, etc. use. The flat plate used on the back surface may have some of the above-mentioned disadvantages. The thickness of the flat plate is 5 to 20 mm and the width is 3 times or more the thickness.

The flat plate to be adhered to the front and back with the front and back sides turned upside down has the same front and back sides, and the boards are joined by a method such as a butt seam, a split seam, a feather seam, a hiring splicing, and a main splicing. . The flat plate is attached to the wooden frame material with an adhesive or nailing. The reverse of the front and back edges is to prevent distortion and distortion of the composite panel.

The front and back materials are made slightly larger than the size of the wooden frame material in which the synthetic resin foam plate material is placed, so that the edge of the composite panel is concave. This is because it can be hired when joining composite panels. The concave dent is 10 to 30 mm.

[0018]

Embodiments of the present invention will be described below in detail.

EXAMPLE A polystyrene foam plate having an expansion ratio of 80 was immersed in a water-soluble phenol resin adhesive, and six surfaces of the polystyrene foam plate were coated with a phenol resin. The dimensions of the polystyrene foam plate were 50 mm in thickness, 430 mm in width, and 860 mm in length, and two of them were produced.

As the wooden frame surrounding the periphery of the polystyrene foam plate, a wooden square having a width of 50 mm and a height of 50 mm was used. The inside dimensions of the wooden frame are 860 mm both vertically and horizontally, and the outside dimensions are 9
60 mm.

Two polystyrene foam plates are placed inside the wooden frame, and the thickness of the polystyrene foam plate is 0.8 m.
m of a thin wooden plate was inserted into the core material of the composite panel.

The thickness of the core material is 8 mm, the width is 100 mm,
A cypress board with a length of 1000 mm and a solid surface, and a cedar board with the same dimensions on the back were nailed on the back with nails. The flat plate of the front and back materials was made to be a butt joint, and the front edge of the front and back materials was aligned at 90 degrees. The end of the composite panel was concave with a 20 mm dent inside.

[0023]

As described above, according to the present invention, the synthetic resin foam plate is coated with a phenol resin to improve the durability, chemical resistance, fire resistance and waterproofness of the synthetic resin foam plate as the core material.
By surrounding the periphery with a wooden frame material and using a solid wooden flat plate as a surface material, a composite panel with a beautiful surface and a light weight could be obtained.

[Brief description of the drawings]

FIG. 1 is a cross-sectional view of a composite panel.

FIG. 2 is an exploded view of a composite panel.

[Explanation of symbols]

 1. 1. Surface material Core material 3. Back material 4. 4. Phenolic resin adhesive 5. Polystyrene foam board Wooden frame material 7. Nail 8. Wooden sheet 9. Phenolic resin-coated polystyrene foam board

Claims (2)

[Claims] 1. A frame made of a wooden square material is formed around the periphery of a synthetic resin foam plate material coated and coated with a phenol resin on the entire surface to form a core material. A composite panel characterized by: 2. The composite panel according to claim 1, wherein the synthetic resin foam plate has a structure divided by a partition wall such as a plastic thin plate, a wooden thin plate, and paper.