JPH10323233A - Panel and its manufacture - Google Patents

Abstract

PROBLEM TO BE SOLVED: To complete the covering work for an edge part of a panel main body at just one operation by forming a covering part by a filling mold for synthetic resin in such a state as covering the circumferential wall of the panel main body, to which a decorative sheet having an external dimension possible of forming of a stage part is stuck so as to form a stage, and the stage in an outer circumferential part of one of the surfaces of the panel main body. SOLUTION: A panel main body 1 of a panel used as a top board for an experiment table, etc., is so formed as being provided with a wooden panel frame, a honeycomb core material, a plywood front board 13, and a back board 14. A decorative sheet 2 which is, for example, made of ceramics superior in drug resistance, etc., and finished into the external diameter a size smaller than the external diameter of the panel main body 1 is mounted on the panel main body 1 so that a stage difference 1a by the thickness of the decorative sheet 2 is formed on the outer circumferential part on the surface of the front board 13 of the panel main body 1. After that, when a covering part 3 is formed on the panel main body of the decorative sheet 2, thermosetting resin is filled in a clearance between the assembled framework and the panel main body 1 and after its hardening, the panel main body P having the covering part 3 of synthetic resin formed thereto is taken out.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a panel forming a top plate such as a laboratory bench or a desk used in, for example, an educational institution or a research institution, and a method of manufacturing the same.

[0002]

2. Description of the Related Art Conventionally, in a panel of this type, for example, a particle board is used as a panel main body, and a decorative plate is attached to one surface of the panel main body to cover a peripheral side wall of the panel main body including the decorative plate. , A resin edge member is attached by extrusion molding. In recent years, there has been known a type in which a synthetic resin is formed on a peripheral side wall of a panel body using a mold instead of the edge member. In the case of forming an edge portion by covering the peripheral side wall of the panel body using such a mold, in order to improve the workability of the subsequent edge portion,
A notch is formed on the panel body and the decorative board, or on the peripheral side wall near the back plate attached to the panel body facing away from the decorative board, and cut at the time of cutting for shaping the edge part after casting. , So that the processing range can be expanded so as not to reach the panel body.

[0003]

By the way, in such a panel, the panel body often adopts a flash structure in order to secure a light weight and a sufficient strength. The panel body having the flash structure can be manufactured only by superposing the members on the structure and bonding the respective members together, so that the manufacturing process can be simplified. However, as described above, in the case where the edge portion is formed by pouring synthetic resin, in the case of forming the cutout portion on the peripheral side wall, it is necessary to form the cutout portion after manufacturing the panel body,
As the number of processes increased, the structure became complicated.

[0004] Further, in the case where a notch is provided and the decorative plate and the back plate are projected from the frame material at the peripheral portion thereof, and the synthetic resin is poured into a gap between the projected portions, the panel main body is placed inside the mold. If the panel body is not positioned correctly when placed on the panel, it may appear that the decorative board is bonded to the edge portion in a bent state. In other words, at the edge part in contact with the decorative board,
In some cases, the width of one end and that of the other end may be different, and the appearance may be impaired.

[0005] An object of the present invention is to solve such a problem.

[0006]

In order to achieve the above object, the present invention takes the following measures. That is, in the panel of the present invention, the panel main body is placed in a mold, a synthetic resin is injected into a gap formed between the mold and the panel main body, and after curing, the mold is removed and the panel main body is removed. The covering portion is formed on the peripheral side wall and the step formed on the outer peripheral portion.

With such a configuration, it is possible to complete the covering of the edge portion of the panel body by one operation. In addition, since the step portion and the peripheral side wall can be integrally covered, the adhesion to the panel body is good, and it is possible to prevent a problem that the covering portion falls off from the panel body during use.

[0008]

BEST MODE FOR CARRYING OUT THE INVENTION A panel according to a first aspect of the present invention has a panel body, a decorative board having an outer dimension capable of forming a step on an outer peripheral portion of one surface of the panel body, and a decorative board attached thereto. And a cover formed by casting a synthetic resin so as to cover the peripheral side wall of the panel body on which the step is formed by wearing.

In order to make the panel lightweight and rigid, the panel body is composed of a panel frame, a honeycomb core material fixed in the panel frame, and a panel frame in which the honeycomb core material is fixed. And a plate material to be adhered to the front and back surfaces are preferred. In addition, in order to make the surface excellent in durability, it is preferable that the decorative plate is a ceramic plate. Furthermore, in order to strengthen the joining state between the covering portion and the panel main body, it is desirable that the panel main body be provided with a groove that is recessed in the horizontal direction at a substantially central position in the height direction of the peripheral side wall. .

According to a fourth aspect of the present invention, there is provided a panel manufacturing method, wherein a frame body is formed in an inner method in which a panel body can be mounted with a gap around the panel body, and an outer peripheral portion of one surface of the panel body is provided. A decorative plate capable of forming a step is attached to one surface of the panel body, and the panel body on which the decorative plate is attached is separated from the form body by a gap between the decorative body and the mold. The synthetic resin is injected into the gaps and the steps, and after the synthetic resin covers and cures the peripheral side wall and the steps of the panel body, the mold is removed.

In order to position the decorative plate substantially at the center of the panel surface, the panel body is placed in the mold based on the distance from the peripheral side wall of the decorative plate to the inner surface of the mold to perform casting. Is preferred. Further, in order to firmly join the casted coating portion to the panel main body, it is desirable that the panel main body be provided with a groove that is recessed in the horizontal direction at a substantially central position in the height direction of the peripheral side wall.

[0012]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS One embodiment of the present invention will be described below with reference to FIGS. The panel P is used, for example, as a top plate of a laboratory bench, and includes a panel body 1 and a decorative plate 2 having an outer dimension capable of forming a step 1a on an outer peripheral portion of the surface of the panel body 1.
And a peripheral side wall 1b of the panel main body 1 having a stepped portion 1a formed on one surface of the panel main body 1 and a decorative plate 2 stuck thereto, and a stepped portion 1
and a covering portion 3 formed by casting a synthetic resin R so as to cover the substrate a. Normally, the panel P has a rectangular shape in plan view, and has various sizes depending on the application.

The panel body 1 has a wooden panel frame 11 for determining the outer shape of the panel P, a honeycomb core material 12 made of paper, for example, fixed inside the panel frame 11, and a honeycomb core material 12 fixed. A front plate 13 and a back plate 14 of a plywood plate material attached to the front and back of the panel frame 11 are provided. The honeycomb core material 12 is formed by joining a large number of hexagonal pillars formed of paper having the same height as the thickness of the panel frame 11 by closely contacting their respective sides, and having an outer dimension matching the inner method of the panel frame 11. It was formed in a flat plate shape. By using such a honeycomb core material 12, even a relatively large panel P can be reduced in weight,
Moreover, sufficient strength can be obtained. Panel body 1
Is to glue the panel frame 11 on the back plate 14 cut to the same outer dimensions as the panel frame 11 with an adhesive, and to bond the honeycomb core material 12 in the panel frame 11 in the same manner.
A front plate 13 having the same size as that of the panel frame 11 is bonded to the panel frame 11 and manufactured.
At the time of bonding, a large number of panels P of the same dimensions being manufactured are stacked, and the weight is used to improve the bonding state. At this time, it is important that the panel frame 11 and the front plate 13 and the back plate 14 are completely overlapped without being positioned.

In contrast to the panel body 1, the decorative plate 2 is made of, for example, ceramic and has excellent chemical resistance, heat resistance, abrasion resistance, impact resistance, and the like. Has been improved. The decorative plate 2 in this embodiment is finished to an outer dimension slightly smaller than the outer dimension of the panel body 1. That is, the decorative board 2 is formed in a similar shape to the panel main body 1, and when placed on the center of the panel main body 1 with each side parallel, the periphery of the decorative board 2, that is, the front surface of the panel main body 1. A step 1 a corresponding to the thickness of the decorative plate 2 is formed on the outer peripheral portion of the surface of the plate 13. In other words, around the decorative plate 2 of the panel main body 1, a room where the decorative plate 2 does not exist is formed. This decorative board 2 also
As in the case of the panel body 1, the front plate 1 of the panel body
3 is attached with an adhesive.

In order to form the covering portion 3 serving as an edge portion on the panel body 1 provided with the decorative board 2 prepared as described above, the formwork 4 is assembled. The formwork 4 is obtained by applying a coating to the inner surface of the angle material and finishing the inner surface with less unevenness. The coating is preferably one that can form a coating film having high elasticity and releasability. For example, Teflon (trade name) processing is preferable in terms of releasability, and by increasing the coating film thickness, elasticity as well as releasability can be imparted. By using a coating film having such elasticity, it is possible to improve the adhesion between the decorative board 2 and the formwork 4, and to ensure that the synthetic resin R leaks to the decorative board 2 side when poured. Can be prevented. The formwork 4 includes four linear members 41 and four corner members 42 connecting the linear members 41. The straight member 41 and the corner member 42 have a height dimension substantially equal to the finished dimension of the panel P, and
It has a width dimension larger than the width of the step portion 1a of the attached panel body 1. The insides of the corners of the straight member 41 and the corner member 42 are curved so that the corners of the cover 3 are chamfered.

Each linear member 41 is connected to the panel body 1.
Prepare various lengths according to the size. When each straight member 41 is connected to the corner member 42 and assembled into the form 4, the substantial thickness of the vertical portion 3 a of the covering portion 3 is located between the peripheral side wall 1 b of the panel body 1 and the inner surface of the form 4. So that a gap G corresponding to
Length dimensions are set. Further, a connecting metal fitting, for example, a turn, is provided on a vertical outer surface near the both ends of the straight member 41 and the corner member 42 so that no gap is generated between the connecting portions between the both ends of each straight member 41 and the corner member 42. We can attach something like a buckle.

The step of forming the covering portion 3 on the panel body 1 with the decorative plate 2 will be described below. First, for example, on a horizontal worktable 5 such as a surface plate having no unevenness on the surface as much as possible,
The linear member 41 of the mold 4 is temporarily arranged so as to be outside the size of the panel body 1 (FIG. 5). Next, the linear member 4
The panel main body 1 with the decorative board 2 is placed in the area inside 1. In this state, the positional relationship between the linear member 41 and the panel main body 1 does not correspond to casting, and the linear member 41 is adjusted using the jig 6 so that the positional relationship between the two becomes appropriate.
And the position of the panel body 1 are adjusted. The jig 6 is longer than the linear member 41 and has a width dimension equal to the width dimension of the stepped portion 1a and a coating portion 3 formed around the peripheral side wall 1b of the panel body 1.
Is the total thickness of the vertical portions 3a. With one edge of the jig 6 in contact with the peripheral side wall 2a of the decorative member 2, the linear member 41 is moved so that the inner surface of the vertical portion 41a of the linear member 41 is in close contact with the other edge. This positioning operation is performed on the four peripheral side walls 2a of the decorative board 2 (FIG. 7A).

After the relative positions of the panel main body 1 and the linear members 41 are set in this way, they are temporarily fixed so as not to move on the work table 5, and each corner member is attached to both ends of each linear member 41. 42 are connected. By connecting the straight members 41 with the corner members 42, the formwork 4 is formed, and the panel main body 1 is placed at a predetermined position inside the formwork 4. After assembling the form 4, an external force is applied in the vertical direction of the panel main body 1, and movement of the form 4 and the panel main body 1 is prohibited on the worktable 5 so as not to change the relative positional relationship. More specifically, the panel main body 1 is pressed onto the work table 5 with a heavy object such as a vice or a thick iron plate or a weight. As a result, the decorative board 2 and the formwork 4 come into close contact with each other, and the flow of the synthetic resin R between the decorative board 2 and the formwork 4 can be prevented.

After the panel body 1 and the frame 4 are set in the movement-prohibited state, a synthetic resin R, specifically, an epoxy resin, A thermosetting resin such as a saturated polyester resin, an alkyd resin, a urethane resin, a urea resin, a melamine resin, and a phenol resin is injected. As the synthetic resin R, from the viewpoint of curing time,
An unsaturated polyester resin is preferred, and an epoxy resin is
In general, the mold can be released in about 3 hours, compared to the time required for curing and releasing the mold approximately one day and night, so that the production efficiency is improved. Moreover, since the curing shrinkage is large, the bonding strength between the step portion 1a and the peripheral side wall 1b can be increased. The synthetic resin R injected into the gap G is
a, and is filled in the gap G and the space of the step portion 1a. The injection amount is set to such a degree as to slightly protrude from the upper edge of the formwork 4 in consideration of the amount of absorption into the woody portion such as the panel frame 11 and the shrinkage during hardening (FIG. 7B).

After the synthetic resin R is cured (FIG. 7 (c)), that is, the synthetic resin R is contracted by being cured and is exposed between the mold 4 and the panel body 1a. After the concave surface is formed in the portion, the mold 4 is disassembled to take out the panel P on which the covering portion 3 of the synthetic resin R is formed. Since the injection of the synthetic resin R was performed in a state where the mold 4 and the decorative board 2 were in close contact with each other, the step P 1
There is no level difference between the horizontal portion 3b of the covering portion 3 formed on the portion a and the decorative plate 2, and they are flush with each other. Therefore, the boundary between the horizontal portion 3b and the decorative board 2 does not need to be processed after casting, and the number of processing steps can be reduced. Also, when casting, the position of the formwork 4 with respect to the panel body 1 is set with reference to the peripheral side wall 2a of the decorative board 2, so that when the decorative board 2 is attached to the panel body 1, Even if the position 2 is slightly displaced on the panel main body 1, the relative positional relationship between the covering portion 3 and the decorative plate 2 can be set to be constant. That is, even when the peripheral side wall 1b of the panel main body 1 is not slightly parallel to the peripheral side wall 2a of the decorative panel 2, the distortion of the peripheral side wall 1b of the panel main body 1 with respect to the decorative panel 2 is caused by the vertical portion 3a of the covering portion 3. It is absorbed in the thickness, such distortion cannot be discriminated from the appearance, and a good appearance can be maintained. In addition, since the covering portion 3 is continuously formed on the step portion 1a and the peripheral side wall 1b of the panel main body 1, even if an impact is applied to the covering portion 3 during use, the covering portion 3 is easily removed from the panel main body 1. A structure excellent in strength that does not fall off can be obtained. Further, as described above, the concave curved surface formed at the time of curing is covered with the covering portion 3 at the time of completion.
The groove 3c is formed at the lower end of the groove 3c and is curved upward. The groove 3c functions as a groove for draining when used.

The present invention is not limited to the embodiment described above. For example, the decorative board 102 is shown in FIG.
As shown in FIG. 5, the outer dimensions of the panel main body 1 are substantially the same or slightly smaller, and an inclined surface 102a is formed so that the periphery thereof is inclined obliquely upward, and a portion corresponding to the step portion 1a in the above embodiment is formed. It may be formed. In this case, in order to align the panel body 1 on which the decorative plate 102 is stuck and the formwork 4, one edge portion has an inclined surface 102.
If a jig having a shape closely adhering to a is used, the panel body 1 can be accurately positioned with respect to the mold frame 4 in the same manner as in the above embodiment.

Further, in order to increase the bonding strength of the covering portion 103 formed by casting to the panel main body 101, a width at which the synthetic resin R easily penetrates substantially at the center of the peripheral side wall 101b of the panel main body 101 in the height direction. May be formed. By forming such a groove 8 and allowing the synthetic resin R to penetrate and cure the inside, the vertical portion 103 of the covering portion 103 is formed.
a, the rib 103c is formed on the back surface side of the cover portion 1a, and as long as the rib 103c does not fall out of the groove 8, the covering portion 1
03 does not fall off from the panel main body 101.

Similarly, in order to increase the bonding strength of the covering portion, a step may be provided also on the outer peripheral portion of the back surface of the panel body. Specifically, as shown in FIG. 10, the back plate 214 of the panel main body 201 is sized so that the edge thereof is located at, for example, a position about 1/2 in the width direction of the panel frame 211. Alternatively, after the panel body 201 is created, the back plate 214 is processed with a router or the like, and the stepped portion 201d is formed.
To form The step portion 201d may be formed continuously over the entire circumference of the panel main body 201, or may be formed discontinuously at several locations to form a cutout. In addition, since the lower corner portion of the covering portion 203 is exposed while the synthetic resin R is in a hardened state, it is preferable to perform a chamfering process or the like so that a smooth shape is obtained so that an unexpected accident does not occur. .

By forming such a step 201d, the injection efficiency of the synthetic resin R can be improved.
That is, when the synthetic resin R is injected, the step 201d
Then, the synthetic resin R is flown into the gap between the mold and the panel body 201, and the panel body 20 is
If it flows down along the peripheral wall part 201b of No. 1,
The synthetic resin R does not block the upper opening portion of the gap, the air layer inside and the synthetic resin R are efficiently replaced, and the synthetic resin R can be injected into the step formed by the gap and the decorative plate. Further, after the synthetic resin R is cured, the covering portion 203 is formed so as to sandwich the panel body 201 from the front and back by curing shrinkage, so that the bonding strength between the panel body 201 and the covering portion 203 increases. However, the possibility of falling off of the covering portion 203 is low and the reliability can be increased. In particular, when an unsaturated polyester resin is used as the synthetic resin R, the curing shrinkage is large, so that the clamping force on the panel body 201 can be increased as compared with other resins. Needless to say, such a structure may be combined with the structure shown in FIG. 9 to further increase the bonding strength.

Further, a film having a minimum thickness sufficient to inhibit the movement of the decorative plate 2 is attached to the inner surface of the mold frame 4 at a position where the peripheral side wall 2a of the decorative plate 2 contacts, and a jig is used. Alternatively, the panel body 1 with the decorative plate 2 may be positioned. If such a film is adhered to the width of the step portion 1a, it is possible to minimize the occurrence of a step in the covering portion 3.

Further, if a convex portion swelling toward the inner surface is provided in a vertical portion of the mold 4, the vertical portion 3 a
A concave portion can be formed on the substrate, and a product excellent in design can be manufactured. In addition, the configuration of each unit is not limited to the illustrated example, and various modifications can be made without departing from the spirit of the present invention.

[0027]

As described above, according to the present invention, it is possible to obtain a panel which does not require post-processing of the covering portion in its manufacturing process and has excellent appearance. In addition, since the covering portion is formed integrally with the outer peripheral portion of the surface of the panel main body and the outer peripheral portion of the peripheral side wall, it has good adhesion to the panel main body, and falls off from the panel main body even when a shocking external force is applied during use. Can be prevented. In addition, since the cover portion is formed by providing the step portion on the panel body, even if the thickness of the peripheral side wall portion is reduced, it is possible to give the cover portion a heavy weight by increasing the width of the step portion. In addition, the bonding strength can be increased and the appearance can be improved. In addition, the amount of synthetic resin used can be kept low, and manufacturing costs can be reduced.

[Brief description of the drawings]

FIG. 1 is a perspective view showing an embodiment of the present invention.

FIG. 2 is a sectional perspective view showing a sectional shape of the embodiment.

FIG. 3 is an exploded perspective view of the panel body of the embodiment.

FIG. 4 is a perspective view showing a panel main body with a decorative plate and a formwork of the embodiment.

FIG. 5 is an exemplary perspective view showing a step of positioning the panel body of the embodiment.

FIG. 6 is a sectional perspective view showing a step before casting in the embodiment.

FIG. 7 is a process chart showing a manufacturing process of the example.

FIG. 8 is a sectional perspective view of another embodiment of the present invention.

FIG. 9 is a sectional perspective view of still another embodiment of the present invention.

FIG. 10 is a sectional perspective view of another embodiment of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 ... Panel main body 1a ... Step part 1b ... Peripheral side wall 2 ... Decorative board 3 ... Covering part 4 ... Mold frame 8 ... Groove 11 ... Panel frame 12 ... Honeycomb core material 13 ... Front plate 14 ... Back plate G ... Gap P ... Panel R: Synthetic resin

Claims (6)

[Claims] 1. A panel body, a decorative plate having an outer dimension capable of forming a step on an outer peripheral portion of one surface of the panel body, and a peripheral wall of the panel body having a step formed by attaching the decorative plate. And a cover formed by casting a synthetic resin so as to cover the step and the step. 2. A panel body comprising a panel frame, a honeycomb core material fixed inside the panel frame, and plate materials adhered to the front and back of the panel frame fixed with the honeycomb core material. The panel according to claim 1, wherein: 3. The panel according to claim 1, wherein the decorative plate is a ceramic plate. 4. A decorative plate capable of forming a frame on an inner side thereof in which a panel body can be placed with a gap around the panel body and forming a step on an outer peripheral portion of one surface of the panel body. The panel body with the decorative plate attached to one surface is placed in the mold with the decorative plate facing downward with a gap between the panel body and the mold, and synthetic resin is applied to the gap and the step. A method of manufacturing a panel, comprising: injecting a synthetic resin to cover and cure a peripheral side wall and a step portion of a panel main body, and then removing a mold. 5. The method for manufacturing a panel according to claim 4, wherein the panel main body is placed in the mold based on a distance from a peripheral side wall of the decorative plate to an inner surface of the mold. 6. The panel body according to claim 1, wherein said panel body is provided with a groove which is recessed in a horizontal direction at a substantially central position in a height direction of a peripheral side wall thereof. A method for manufacturing the panel described in the above.