WO2021038921A1 - Panneau de finition intérieur et procédé de fabrication de panneau de finition intérieur - Google Patents

Panneau de finition intérieur et procédé de fabrication de panneau de finition intérieur Download PDF

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Publication number
WO2021038921A1
WO2021038921A1 PCT/JP2020/007481 JP2020007481W WO2021038921A1 WO 2021038921 A1 WO2021038921 A1 WO 2021038921A1 JP 2020007481 W JP2020007481 W JP 2020007481W WO 2021038921 A1 WO2021038921 A1 WO 2021038921A1
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WIPO (PCT)
Prior art keywords
layer
resin layer
back surface
foamed resin
reinforced resin
Prior art date
Application number
PCT/JP2020/007481
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English (en)
Japanese (ja)
Inventor
岡田　芳弘
恒也 田中
一哲 梅岡
悠吉 新田
昇平 多田
Original Assignee
パナソニックＩｐマネジメント株式会社
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Application filed by パナソニックＩｐマネジメント株式会社 filed Critical パナソニックＩｐマネジメント株式会社
Publication of WO2021038921A1 publication Critical patent/WO2021038921A1/fr

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions
    • B32B3/04—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by features of form at particular places, e.g. in edge regions characterised by at least one layer folded at the edge, e.g. over another layer ; characterised by at least one layer enveloping or enclosing a material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
    • B32B3/30—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar shape; Layered products comprising a layer having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer characterised by a layer formed with recesses or projections, e.g. hollows, grooves, protuberances, ribs
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/92—Protection against other undesired influences or dangers
    • E04B1/94—Protection against other undesired influences or dangers against fire
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B9/00—Ceilings; Construction of ceilings, e.g. false ceilings; Ceiling construction with regard to insulation
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure

Definitions

  • the present invention relates to an interior panel and a method for manufacturing an interior panel that constitute a ceiling or wall of a building.
  • the foamed resin layer is bent at a portion of a bent groove provided from the back surface side, and a glass fiber sheet, a flame-retardant sheet, and a glass fiber reinforced resin layer are provided on the end surface and the back surface of the side end portion.
  • An interior panel provided with a including layer is disclosed.
  • the foamed resin is provided by an extension portion in which the indoor side layer including the glass fiber sheet, the flame-retardant sheet and the glass fiber reinforced resin layer is extended.
  • An interior panel having a structure in which a reinforcing member provided adjacent to the layer is covered is disclosed.
  • the indoor side layer contains a glass fiber reinforced resin layer. Therefore, since the glass fiber reinforced resin layer having a relatively high rigidity is bent at the remaining portion of the bent groove, it is considered that it is difficult to clearly form the corner portion on the surface side in a straight line. Further, if the structure is provided with the reinforcing member as described above, it can be expected that the linearity of the corner portion on the surface side can be improved by bending along the corner portion of the reinforcing member, but there is a concern that the structure will be complicated. There is.
  • the present invention has been made in view of the above circumstances, and while it is possible to improve the flame retardancy of at least one side end portion in addition to the flame retardancy on the indoor side, the one side end portion has a simple structure. It is an object of the present invention to provide an interior panel capable of improving the linearity of a corner portion thereof and a method for manufacturing an interior panel capable of suitably manufacturing such an interior panel.
  • the interior panel according to the present invention is an interior panel constructed with the back surface side facing the interior base side, and the fiber reinforced resin layer and the fiber reinforced plastic layer are placed on the indoor side of the foamed resin layer.
  • a surface layer including a flame-retardant layer provided on the indoor side of the resin layer and a decorative layer provided on the indoor side of the flame-retardant layer is provided, and an indoor side surface of at least one side end of the foamed resin layer is provided.
  • the end face orthogonal to the end face and the back surface orthogonal to the end face are covered with the extending portion of the surface layer extending in a series from the portion covering the indoor side surface.
  • Folded grooves are provided at positions corresponding to the indoor side surface side corners and the back surface side corners of the end surface of the one side end portion in the extension portion so that the groove bottom is located in the fiber reinforced resin layer. It is characterized by being.
  • the method for manufacturing an interior panel according to the present invention is a method for manufacturing an interior panel in which the back surface side is directed toward the interior base side, and the fiber reinforced resin layer and the fiber reinforced plastic are reinforced. At least one end of a panel body provided with a foamed resin layer on the back surface side of a surface layer including a flame-retardant layer provided on the indoor side of the resin layer and a decorative layer provided on the indoor side of the flame-retardant layer.
  • the present invention is characterized by comprising a step of bending the extending portion to cover the end surface and the back surface of the one side end portion.
  • the interior panel according to the present invention has the above-described configuration, so that it is possible to improve the flame retardancy of at least one side end in addition to the flame retardancy on the indoor side, and the interior panel has a simple structure. It is possible to improve the linearity of the corner portion at the side end portion. Further, the method for manufacturing the interior panel according to the present invention has the above-described configuration, so that such an interior panel can be suitably manufactured.
  • FIG. 1 It is a partial fracture schematic vertical sectional view schematically showing an example of the interior panel which concerns on one Embodiment of this invention.
  • FIG. 1 A) to (c) are schematic vertical cross-sectional views of partial fractures schematically showing an example of a method for manufacturing an interior panel according to an embodiment of the present invention, and (d) corresponds to part X1 in (c). It is a schematic enlarged vertical cross-sectional view of the partially broken part.
  • (A) is a partially broken schematic vertical sectional view schematically showing an example of a method for manufacturing the interior panel
  • (b) is a partially broken schematic enlarged vertical sectional view corresponding to the X2 portion in (a).
  • (C) is a partially broken schematic plan view schematically showing an example of a method for manufacturing the interior panel.
  • FIG. 1 A and (b) are partial fracture schematic vertical sectional views schematically showing an example of a method for manufacturing the interior panel.
  • FIG. 1 A) is a schematic vertical sectional view of a partially broken interior panel schematically showing an example of a method for manufacturing the interior panel, and
  • (b) is a schematic plan view of a partially broken interior panel.
  • FIGS. 1 to 5 are diagrams schematically showing an example of an interior panel according to the present embodiment and an example of a manufacturing method of the interior panel according to the present embodiment.
  • the interior panel according to the present embodiment constitutes the ceiling panel 1, and as shown in FIG. 1, is constructed with the back surface side facing the ceiling base 3 side as the interior base.
  • the ceiling panel 1 includes a foamed resin layer 20 and a surface layer 10 provided on the indoor side of the foamed resin layer 20. With such a configuration, it is possible to reduce the weight as compared with a wood-based board or a gypsum board.
  • the ceiling base 3 to which the ceiling panel 1 is fixed may be a wooden ceiling base or a steel ceiling base. Further, the ceiling base 3 may be a so-called light ceiling base using a light iron material. In the illustrated example, the ceiling base 3 is shown as a so-called suspended ceiling in which the field edge 5 is suspended via a hanging member 4 such as a hanging tree or a hanging bolt, but various configurations are shown. It may be a thing.
  • the ceiling panel 1 may be fixed to the field edge 5 by a fixing tool such as a screw or a nail fixed to the field edge 5 so as to penetrate the side end portion 2. Further, the ceiling panel 1 is provided at the first end portion in one direction of the adjacent ceiling panel 1, and the hook portion provided at the second end portion in one direction is hooked on the hooked portion fixed to the field edge 5. It may be fixed. In this case, the end portion in the other direction may be fixed to the field edge 5 by a magnet. Further, in the illustrated example, an example is shown in which the ceiling panel 1 is constructed so that a watermark-like gap is formed between the end faces of the side end portions 2 and 2 facing each other in one direction of the adjacent ceiling panels 1 and 1. ing.
  • the ceiling panel 1 may be constructed as a ceiling of a relatively small building such as a residence or an office, and may be used in various relatively large buildings such as a gymnasium, a hall, a shopping mall, a factory, or a school. It may be constructed as a ceiling. Further, the ceiling panel 1 may have a mass of 2.0 kg or less per unit area (1 m 2). Further, the mass of the ceiling panel 1 may be such that the mass of the entire ceiling system including the ceiling base 3 made of the light ceiling base as described above is 2.0 kg / m 2 or less.
  • the interior panel according to the present embodiment is not limited to the one that constitutes the ceiling panel 1, and may be the one that constitutes the wall panel. In this case, the wall base such as studs and studs may be grasped as the interior base.
  • the ceiling panel 1 has a substantially rectangular shape in a plan view (viewed in the thickness direction).
  • the ceiling panel 1 may have a substantially square shape in a plan view, or may have a substantially rectangular shape.
  • the size of the ceiling panel 1 in a plan view may be an appropriate size from the viewpoint of handleability, workability, etc.
  • the length of one side may be 0.3 m or more. It may be 2.0 m or less.
  • the length of the short side may be 0.3 m or more and the length of the long side may be 2.0 m or less.
  • the length of one side may be 0.6 m or more and 1.5 m or less, or 0.9 m to 1.2 m or so. ..
  • the thickness of the ceiling panel 1 may be, for example, about 2.5 mm to 15.0 mm, preferably about 3.0 mm to 12.0 mm, and more preferably about 3.0 mm to 12.0 mm, although it depends on the layer structure and the like. May be about 3.0 mm to 6.0 mm.
  • the surface layer 10 includes a fiber-reinforced resin layer 14 provided on the indoor side of the foamed resin layer 20, a flame-retardant layer 13 provided on the indoor side of the fiber-reinforced resin layer 14, and the flame-retardant layer 13.
  • a decorative layer 11 provided on the indoor side of the flame-retardant layer 13 is provided. If the surface layer 10 is provided with the flame retardant layer 13 in this way, the flame retardancy on the indoor side can be improved. Further, if the surface layer 10 is provided with the fiber reinforced resin layer 14, the fiber reinforced resin layer 14 functions as a reinforcing layer, and the bending rigidity and dimensional stability of the entire ceiling panel 1 can be improved. As a result, it is possible to effectively suppress sagging after construction while reducing the weight, which makes the ceiling panel 1 suitable.
  • the decorative layer 11 is in the form of a thin sheet having a thickness of about 0.1 mm to 0.5 mm, and constitutes the decorative surface of the ceiling panel 1.
  • the decorative layer 11 is a glass fiber sheet.
  • the decorative layer 11 may be a glass non-woven fabric (glass paper), may have a basis weight of about 20 g / m 2 to 250 g / m 2 , and preferably has a basis weight of about 30 g / m 2 to 100 g / m 2. It may be the one that is said to be.
  • the decorative layer 11 may be a glass fiber sheet on which an appropriate surface decorative treatment such as printing or painting is applied.
  • the decorative layer 11 is not limited to the glass fiber sheet, and may be another sheet material that has been subjected to an appropriate surface decorative treatment such as printing or painting, or may be formed by printing, painting or the like.
  • the pigments, additives and the like contained in the paint used for printing the decorative layer 11 are preferably inorganic from the viewpoint of ensuring flame retardancy.
  • the flame-retardant layer 13 may have an appropriate configuration so that the ceiling panel 1 satisfies the technical standards for performance required for non-combustible materials and the like specified in the Building Standards Act.
  • the ceiling panel 1 may be configured to satisfy the standard of "flame-retardant material" in the technical standard, and preferably may be configured to satisfy the standard of "quasi-non-combustible material". More preferably, it may be configured to meet the criteria for "non-combustible material”.
  • the flame-retardant layer 13 may be, for example, a foil-shaped aluminum sheet in the form of a thin sheet.
  • the thickness of the aluminum sheet constituting the flame-retardant layer 13 may be about 5 ⁇ m to 50 ⁇ m, preferably about 7 ⁇ m to 40 ⁇ m, and more preferably about 10 ⁇ m to 30 ⁇ m.
  • the flame retardant layer 13 is not limited to the one having the above-mentioned configuration, and other various configurations can be adopted. For example, a resin-impregnated glass fiber non-woven fabric plate containing a heat-absorbing metal hydroxide may be used.
  • the decorative layer 11 and the flame-retardant layer 13 are laminated and integrated via an appropriate adhesive layer 12.
  • the adhesive layer 12 may be formed of a polyethylene-based adhesive.
  • the fiber reinforced resin layer 14 is a glass fiber reinforced resin layer containing glass fibers. Further, the fiber-reinforced resin layer 14 has the same resin main component as the resin main component of the foamed resin layer 20. With such a configuration, the compatibility in each layer is improved, and boundary peeling and the like can be prevented from occurring.
  • the glass fiber sheet 15 constituting the fiber reinforced resin layer 14 is a glass cloth having a basis weight of 50 g / m 2 to 300 g / m 2. With such a configuration, it is possible to secure an appropriate flexural rigidity while reducing the weight.
  • the basis weight of the glass fiber sheet 15 may be preferably 50 g / m 2 to 150 g / m 2 , and more preferably 50 g / m 2 to 100 g / m 2 .
  • a glass fiber sheet 15 may be in the form of a thin sheet having a thickness of about 0.1 mm to 0.5 mm.
  • the glass fiber sheet 15 is preferably a glass fiber woven fabric, and may be, for example, a glass cloth which is a woven fabric such as a plain weave or a entwined weave woven by using glass roving for the warp and weft. By using a glass cloth, it is possible to prevent thermal deformation from occurring.
  • the glass fiber sheet 15 is not limited to such a glass cloth, and may be a glass paper or a glass mat.
  • the fiber reinforced resin layer 14 is formed by impregnating the glass fiber sheet 15 with the resin composition constituting the foamed resin layer 20. That is, the fiber reinforced resin layer 14 is integrally provided on a part of the foamed resin layer 20. With such a configuration, boundary peeling and the like can be made less likely to occur as compared with a separately prepared sheet constituting the fiber reinforced resin layer laminated on the foamed resin layer 20. Moreover, the manufacturing efficiency can be improved.
  • the fiber-reinforced resin layer 14 may be configured to contain air bubbles by foaming the resin composition.
  • a composite sheet in which a glass fiber sheet 15 is laminated and integrated with an appropriate adhesive on the ceiling base 3 side of the decorative layer 11 and the flame retardant layer 13 which are laminated and integrated as described above constitutes the foamed resin layer 20. It may be laminated and integrated with the foamed resin layer 20 by the resin composition to be used. In this case, the flame-retardant layer 13 may be at least partially adhered to the resin composition that has passed through the glass fiber sheet 15 constituting the fiber-reinforced resin layer 14. That is, even if the resin composition constituting the foamed resin layer 20 is exuded from the glass fiber sheet 15 having a small basis weight and a large number of gaps as described above, the resin composition is partially adhered to the flame retardant layer 13. Good.
  • the adhesive for laminating and integrating the flame-retardant layer 13 and the glass fiber sheet 15 allows the resin composition constituting the fiber-reinforced resin layer 14 to seep out from the glass fiber sheet 15. It may be applied to. With such a configuration, peeling can be suppressed, wrinkles and the like are less likely to be formed, and manufacturing efficiency can be improved, as compared with a flame-retardant layer 13 laminated with an adhesive or the like. it can.
  • the ceiling panel 1 has a back surface side fiber reinforced resin layer 18 provided on the ceiling base 3 side which is the back surface side of the foamed resin layer 20, and a ceiling base 3 of the back surface side fiber reinforced resin layer 18.
  • a back surface layer 16 including a back surface side flame retardant layer 17 provided on the side is provided. That is, the foamed resin layer 20 is sandwiched between the fiber reinforced resin layers 14 and 18 forming the reinforcing layers on both sides in the thickness direction.
  • the back surface side fiber reinforced resin layer 18 has the same resin main component and resin main component as the foamed resin layer 20 in substantially the same manner as the fiber reinforced resin layer 14 constituting the front surface layer 10 described above. Further, similarly to the above, the back surface side fiber reinforced resin layer 18 is formed by impregnating the glass fiber sheet 19 with the resin composition constituting the foamed resin layer 20.
  • the fiber-reinforced resin layer 18 on the back surface side may be configured to contain air bubbles by foaming the resin composition as described above.
  • the flame retardant layer 17 on the back surface side may be an aluminum sheet as in the flame retardant layer 13 described above.
  • the back surface side flame retardant layer 17 also functions as an exudation suppressing layer that suppresses exudation of the resin composition constituting the back surface side fiber reinforced resin layer 18. With such a configuration in which the flame retardant layer 17 on the back surface side is provided, the flame retardancy on the back surface side can be improved, and improvement in heat shielding property and electromagnetic wave shielding property can be expected.
  • the back surface side flame retardant layer 17 may be a sheet thinner than the flame retardant layer 13 described above. For example, the thickness of the flame-retardant layer 17 on the back surface side may be about 2/5 to 3/5 of the thickness of the flame-retardant layer 13.
  • a composite sheet in which the glass fiber sheet 19 constituting the back surface fiber reinforced resin layer 18 is laminated and integrated with the back surface side flame retardant layer 17 with an appropriate adhesive is formed by the resin composition constituting the foamed resin layer 20. It may be laminated and integrated with the foamed resin layer 20.
  • the flame retardant layer 17 on the back surface side may be at least partially adhered to the resin composition that has passed through the glass fiber sheet 19 constituting the fiber reinforced resin layer 18 on the back surface side. That is, as described above, the resin composition constituting the foamed resin layer 20 was partially adhered to the flame retardant layer 17 on the back surface side so as to exude from the glass fiber sheet 19 having a small basis weight and a large number of gaps. It may be a thing.
  • the adhesive for laminating and integrating the flame retardant layer 17 on the back surface side and the glass fiber sheet 19 allows the resin composition constituting the fiber reinforced resin layer 18 on the back surface side to seep out from the glass fiber sheet 19. It may be applied to the glass fiber sheet 19.
  • the foamed resin layer 20 occupies most of the ceiling panel 1.
  • the thickness of the foamed resin layer 20 is preferably 80% to 99%, more preferably 85% to 95% of the thickness of the ceiling panel 1.
  • the thickness of the foamed resin layer 10 may be, for example, about 2.3 mm to 14.8 mm, preferably about 2.5 mm to 11.5 mm, and more preferably about 2.5 mm to 5.5 mm. It may be a degree.
  • the resin composition constituting the foamed resin layer 20 is a foamed polyurethane resin having a foaming ratio of 10 to 30 times. With such a configuration, weight reduction can be achieved.
  • one or both of the front surface layer 10 and the back surface layer 16 on both sides of the foamed resin layer 20 in the thickness direction are laminated and integrated with the foamed resin layer 20 by the resin composition constituting the foamed resin layer 20 as described above. It is possible to improve the manufacturing efficiency.
  • the foaming ratio of the resin composition constituting the foamed resin layer 20 is preferably about 15 to 25 times.
  • the resin composition constituting the foamed resin layer 20 is a flame-retardant polyurethane resin composition.
  • the flame retardancy non-flammability
  • the total calorific value can be reduced.
  • a flame-retardant polyurethane resin composition may be configured to include a polyisocyanate compound, a polyol compound, a catalyst, a foaming agent, a defoaming agent, and an additive.
  • such a flame-retardant polyurethane resin composition may further contain a flame retardant, a filler, and an inorganic filler.
  • a flame retardant examples include polyurethane resin, polystyrene resin, polyethylene resin, polypropylene resin, phenol resin, epoxy resin and the like.
  • the end surface 24 orthogonal to the indoor side surface 21 of at least one side end portion 23 of the foamed resin layer 20 and the back surface 22 orthogonal to the end surface 24 form a series from the portion covering the indoor side surface 21. It is covered with the extension portion 10b of the surface layer 10 extending to the surface layer 10.
  • the absorption of moisture from the end face 24 can be suppressed as compared with the case where the end face 24 of the foamed resin layer 20 is exposed.
  • the fiber reinforced resin layer 14 is provided in a series on the end surface and the back surface of the one side end portion 2, the bending rigidity at the one side end portion 2 can be improved.
  • the surface layer 10 is provided in a series from the indoor side surface on the end surface and the back surface of the one side end portion 2, the chamber is compared with, for example, an edge sheet is attached to cover the end surface. The appearance of the inner corner (edge) can be improved. In addition, peeling of the surface layer 10 can be suppressed.
  • the stopper holding force is increased. It can also be improved.
  • the groove bottoms 27a and 29a are located at the positions corresponding to the indoor side corners 24a and the back side corners 24b of the end face 24 of the one side end 23 in the extension portion 10b.
  • the bent grooves 27 and 29 are provided so that the sill is located in the fiber reinforced resin layer 14.
  • the fiber reinforced resin layer 14 becomes thinner at the portion where the bent grooves 27 and 29 are provided than at other portions, and is easily bent at the portion.
  • the linearity of the corner portion at the one side end portion 2 can be improved with a simple structure without providing a reinforcing member or the like in an embedded shape.
  • the corners of the indoor side surface and the end surface are substantially orthogonal to each other, more linearity of the corners is required as compared with the case where the C-chamfered chamfered portion is provided at the corner on the indoor side. With the above configuration, the linearity of the corner portion on the indoor side at the one side end portion 2 can be improved.
  • the extension portion 10b is provided so as to cover the ceiling base 3 side of the back surface layer 16 of the one side end portion 2 provided up to the back surface side corner portion 24b.
  • the fiber-reinforced resin layers 14 and 18 and the flame-retardant layers 13 and 17 are provided in a plurality of layers on the back surface side of the one-side end portion 2.
  • the flexural rigidity at the side end portion 2 can be improved more effectively.
  • the back surface layer 16 may be provided so as to cover the back surface 22 of the foamed resin layer 20 over the entire surface.
  • the extending portion 10b extends in a series from the indoor side surface layer 10a constituting the indoor side surface of the ceiling panel 1 and forming a portion covering the indoor side surface 21 of the foamed resin layer 20.
  • the extension portion 10b includes an end face layer 10c that covers the end surface 24 of the one side end portion 23 of the foamed resin layer 20, and an end back surface layer 10d that covers the ceiling base 3 side of the back surface layer 16 of the one side end portion 2. including.
  • extension portion 10b including the end face layer 10c and the end back surface layer 10d as described above may be preferably provided at both side ends 2 and 2 in one direction of the ceiling panel 1. With such a configuration, it is possible to improve the flame retardancy of the end faces of the side end portions 2 and 2 in one direction of the ceiling panel 1.
  • extension portions 10b including an end face layer 10c and an end back surface layer 10d are provided on the side end portions 2, 2, 2, 2 of the four circumferences of the ceiling panel 1. It has a structure. With such a configuration, it is possible to improve the flame retardancy at the end faces of the side end portions 2, 2, 2, 2 of the four circumferences of the ceiling panel 1. Since each of the side end portions 2, 2, 2, and 2 has the same configuration, the details thereof will be described below by taking one side end portion 2 as an example.
  • the end surface of the side end portion 2 is orthogonal to the indoor side surface and the back surface of the ceiling panel 1.
  • the orthogonal shape is not limited to the one in which the angle formed by the end surface and the indoor side surface and the back surface is 90 degrees, and also includes, for example, the one having an angle of about 85 degrees to 95 degrees.
  • the angle formed by the end faces and the indoor side surface may be less than 90 degrees (for example, 85 degrees to 89 degrees). With such a configuration, it is possible to prevent a gap from being generated on the indoor side when the end faces of the adjacent ceiling panels 1 and 1 are brought into contact with each other for construction.
  • the end surface 24 of the side end portion 23 of the foamed resin layer 20 has the same orthogonal shape as the above with respect to the indoor side surface 21 and the back surface 22 of the foamed resin layer 20.
  • the indoor side surface side corner portion 24a of the end surface 24 is provided with a notch 25 that opens in the end surface 24.
  • the notch 25 is opened in the extending direction of the extending portion 10b in a state where the extending portion 10b is not bent (expanded state), and extends along the side end portion 23 over the entire portion. It is provided in a groove shape.
  • the groove depth dimension along the extension direction and the groove width dimension along the panel thickness direction of the notch 25 may be, for example, about 0.1 mm to 1.0 mm.
  • the groove depth dimension of the notch 25 is made larger than the groove width dimension, but the present invention is not limited to such an embodiment.
  • an example is shown in which the groove bottom side of the notch 25 is substantially V-shaped when viewed in the groove longitudinal direction, but the present invention is not limited to this aspect.
  • the bent grooves 27, 29 of the extending portion 10b are positioned according to the first bent groove 27 provided at the position corresponding to the indoor side surface side corner portion 24a of the end surface 24 and the back surface side corner portion 24b of the end surface 24. It is composed of a second bent groove 29 provided in the above.
  • the first bent groove 27 is provided so as to be located at the inside corner of the extension portion 10b and the end surface 24 in the unbent state (expanded state).
  • the second bent groove 29 is provided so as to be located at the boundary between the end face layer 10c and the end back surface layer 10d of the extension portion 10b.
  • the dimension along the extending direction (groove width direction) of the extending portion 10b from the first bent groove 27 to the second bent groove 29 is set according to the thickness of the foamed resin layer 20. ..
  • the first bent groove 27 and the second bent groove 29 are opened toward one side (ceiling base 3 side) in the panel thickness direction with the extension portion 10b in the expanded state, and the side end portion 2 (2A). It is provided in a groove shape over the entire surface so as to extend parallel to each other along the ceiling.
  • the groove depth dimension and groove width dimension of the first bent groove 27 and the second bent groove 29 may be set as appropriate from the viewpoint of the thickness of the extending portion 10b, the bendability, the strength, and the like.
  • the groove width dimension of the first bent groove 27 and the second bent groove 29 is set to be larger than the groove depth dimension, but the present invention is not limited to such an embodiment. Further, an example is shown in which the first bent groove 27 and the second bent groove 29 are substantially V-shaped when viewed in the longitudinal direction of the groove, but the present invention is not limited to this aspect.
  • first bent groove 27 and the second bent groove 29 are provided on the groove bottoms 27a and 29a so as to leave a part of the glass fiber sheet 15 constituting the fiber reinforced resin layer 14. .
  • the first bent groove 27 and the second bent groove 29 are provided so that only a part of one of the warp and weft remains. It may have been.
  • the thickness T2 of the fiber reinforced resin layer 14 on the groove bottoms 27a and 29a side of the portion where the first bent groove 27 and the second bent groove 29 are provided in the extending portion 10b is set as the extending portion.
  • the thickness of the fiber reinforced resin layer 14 at other parts of 10b is set to 1/2 or less of T1.
  • the thickness T2 of the fiber reinforced resin layer 14 on the groove bottoms 27a and 29a side may be 1/3 or less of the thickness T1 of the fiber reinforced resin layer 14 at other sites of the extension portion 10b. It may be about 4 to 1/10.
  • the extension portion 10b may be composed of only the surface layer 10 including the fiber reinforced resin layer 14, but may be one in which a part of the foamed resin layer 20 is provided on the back surface side, or the fiber reinforced resin layer. A part of 14 may be excised.
  • the dimension (width dimension) along the extending direction of the end back surface layer 10d of the extending portion 10b is appropriately determined from the viewpoint of the strength of the side end portion 2, the viewpoint of suppressing peeling, the viewpoint of weight reduction, and the like. It may be the dimension of.
  • the width dimension of the end back surface layer 10d may be about 1 to 15 times, preferably about 2 to 10 times, the thickness dimension of the ceiling panel 1.
  • a concave step portion for receiving the end back surface layer 10d may be provided on the back surface side of the side end portion 2. Such a concave step portion may be formed by cutting by cutting or the like, or may be formed by compression.
  • the side end portions 2, 2, 2, 2 of the four circumferences are each provided with the above-mentioned bendable extension portion 10b. Therefore, as shown in FIG. 3C, the corner portion is provided with a notch-shaped recess 9 for reducing the overlap of the bent extension portions 10b.
  • the notch-shaped recess 9 is provided so as to open diagonally outward in the expanded state. Further, the notch-shaped recess 9 is expanded from a portion where the end faces 24, 24 of the foamed resin layer 20 intersect with each other so as to reduce the overlap between the end face layers 10c, 10c of the adjacent side end portions 2, 2.
  • the base end side portions of both side edges are partitioned by the first edge portions 9a and 9a provided in the above.
  • first edge portions 9a and 9a are the portions where the first bending grooves 27 and 27 are provided, and if the end surface layers 10c and 10c of the side end portions 2 and 2 are bent with respect to the indoor side surface layer 10a, These first edge portions 9a, 9a are in contact with each other or face each other in close proximity to form a corner portion where the end faces intersect with each other.
  • the opening side portions of both side edges of the notch-shaped recess 9 are connected to the first edge portions 9a and 9a so as to reduce the overlap between the end back surface layers 10d and 10d of the adjacent side end portions 2 and 2. It is partitioned by the second edge portions 9b, 9b provided as described above. These second edge portions 9b and 9b are portions where the second bending grooves 29 and 29 are provided, and the end back surface layers 10d and 10d of the side end portions 2 and 2 are bent with respect to the end face layers 10c and 10c. If so, the second edge portions 9b and 9b are brought into contact with each other or face each other in close proximity to each other. By this. As shown in FIG.
  • a corner portion where the end back surface layers 10d and 10d intersect each other is formed. That is, the second edge portions 9b and 9b of the end back surface layers 10d and 10d of the adjacent side end portions 2 and 2 are butted against each other in a joint shape.
  • the configuration for reducing the overlap of the bent portions at the corners is not limited to the above configuration, and various other modifications are possible.
  • the manufacturing method is a step of forming an extension portion 10b at at least one side end portion 2A of a panel body 1A provided with a foamed resin layer 20A on the back surface side of the front surface layer 10A. (Extension site forming step) is provided.
  • the foamed resin layer 20A is cut off so as to leave the surface layer 10A, and the surface layer 10A is extended from the end surface 24 of the one side end portion 23 of the foamed resin layer 20A.
  • the same manufacturing method extends in the bent grooves 27 and 29 formed at positions corresponding to the indoor side corner portion 24a and the back surface side corner portion 24b of the end surface 24 of the one side end portion 23 of the foamed resin layer 20A.
  • a step of bending the portion 10b to cover the end surface 24 and the back surface 22 of the one side end portion 23 is provided.
  • the ceiling panel 1 as described above can be suitably manufactured. Further, for example, it can be easily manufactured as compared with the case where the foamed resin layer 20A is formed so that the extension portion 10b is formed with respect to the surface layer 10A. Further, since the groove bottoms 27a and 29a are bent in the bent grooves 27 and 29 formed so as to be located in the fiber reinforced resin layer 14, it is easy to bend and the straight corners at the one side end portion 2 are straight. The sex can be improved.
  • the extension portion 10b formed on the side end portions 2A on the four circumferences of the panel body 1A is bent to cover the end surface 24 and the back surface 22 of the side end portions 23 on the four circumferences of the foamed resin layer 20.
  • one side end portion 2A (23) will be described as an example.
  • the resin composition constituting the foamed resin layer 20A is supplied between the front surface layer 10A and the back surface layer 16A, and the panel body 1A is molded. May be good.
  • the surface layer 10A is a composite sheet in which the decorative layer 11, the adhesive layer 12, the flame retardant layer 13 and the glass fiber sheet 15 (see FIG. 1) are laminated and integrated, and the supplied resin composition is glass fiber.
  • the sheet 15 may be impregnated to form the fiber reinforced resin layer 14.
  • the back surface layer 16A is a composite sheet in which the back surface side flame retardant layer 17 and the glass fiber sheet 19 (see FIG. 1) are laminated and integrated, and the supplied resin composition impregnates the glass fiber sheet 19 to the back surface side.
  • the fiber reinforced resin layer 18 may be formed.
  • the resin composition constituting the foamed resin layer 20A is supplied (coated) to the back surface side of one of the front surface layer 10A and the back surface layer 16A, and the other is covered with the supplied resin composition. May be arranged and foamed while controlling the thickness.
  • continuous molding may be performed by a double belt press device, a press device provided with an endless track zone in which a plurality of foot plates are connected, or the like.
  • the four circumferences are cut so that the panel body 1A has an appropriate size.
  • the dimensions of each side of the panel body 1A whose four circumferences are cut in this way are extended to the dimensions of each side of the ceiling panel 1 to be manufactured as described above.
  • the dimensions of the portion 10b may be taken into consideration to obtain appropriate dimensions.
  • the foamed resin layer 20A is divided from the back surface side into one side end portion 2A of the panel body 1A, and the cutting edge 6a is fiber-reinforced. It is configured to form bent grooves 27 and 29 by cutting so as to be located in the resin layer 14.
  • the foamed resin layer 20A is cut off to form the extension portion 10b.
  • the foamed resin layer 20A of the one side end portion 2A is cut off and then the bent grooves 27 and 29 are formed so that the extension portion 10b is formed, the relatively thin extension portion 10b is formed. It is necessary to provide the bent grooves 27 and 29 in a state where wrinkles are not formed by expanding the bent grooves 27 and 29. According to the above configuration, since the bent grooves 27 and 29 can be formed by cutting together with the foamed resin layer 20A, it is difficult for wrinkles to be formed and the bent grooves 27 and 29 can be formed easily and accurately. it can.
  • the cutting blade 6 that divides the foamed resin layer 20A from the back surface side of the one side end portion 2A has slit-shaped grooves (first groove 26 and second groove 28) 26, 28 formed in the one side end portion 2A.
  • the structure is appropriately configured so that the above-mentioned bent grooves 27 and 29 are formed at the bottom of the groove.
  • the cutting blade 6 may have a blade thickness of, for example, about 0.2 mm to 1.0 mm, or may have a blade thickness corresponding to the groove widths of the bent grooves 27 and 29.
  • the first groove 26 and the second groove 28 are formed so that the thickness direction of the panel body 1A is the groove depth direction and the panel body 1A opens on the back surface side.
  • the first groove 26 and the second groove 28 are provided so as to extend over the entire one side end portion 2A of the panel body 1A.
  • the first groove 26 is provided so that the first bent groove 27 formed in the groove bottom is at the above-mentioned position, and the groove inner wall on one side in the groove width direction constitutes the end surface 24 of the foamed resin layer 20.
  • the second groove 28 is provided so that the second bent groove 29 formed at the bottom of the groove is at the position described above.
  • the foamed resin layer 20A on the back surface side of the one side end portion 2A is cut off to form the extension portion 10b.
  • the cutting blade 6 is aligned with the back surface side of the extension portion 10b so that the above-mentioned cut 25 that opens at the end surface 24 of the one side end portion 23 of the foamed resin layer 20 is formed.
  • the foamed resin layer 20A is cut off. With such a configuration, it is possible to prevent the foamed resin layer 20A from remaining at the entrance corner between the end surface 24 of the one side end portion 23 of the foamed resin layer 20 and the extending portion 10b.
  • the linearity of the corner portion when bent in the first bent groove 27 on the end surface 24 side of the one side end portion 23 of the foamed resin layer 20 can be more effectively improved.
  • the foamed resin layer 20A on the back surface side of the one side end portion 2A is cut off, the first bent groove 27 and the second bent groove 29 which are the groove bottom sides of the first groove 26 and the second groove 28 are formed.
  • the extension site 10b on which the is formed is formed. After cutting the foamed resin layer 20A on the back surface side of the one side end portion 2A, the foamed resin layer 20A remaining on the back surface side of the extension portion 10b may be appropriately removed by polishing or the like, if necessary. ..
  • a notch-shaped recess 9 is formed at the corner portion.
  • the notch-shaped recess 9 may be performed after the extension portion 10b is formed, or may be performed before the extension portion 10b is formed or before the first groove 26 and the second groove 28 are formed. ..
  • an adhesive 7 for bending and adhering the extension portion 10b is applied to one side end portion 2A of the panel body 1A.
  • the adhesive 7 is applied to the back surface (back surface layer 16) of the one side end portion 2A of the panel body 1A. Further, the adhesive 7 is applied so that a part of the adhesive 7 hangs down on the end face 24.
  • the coating step on the end face 24 can be omitted, and when the extension portion 10b is bent, the excess adhesive 7 squeezes out at the corner where the end face layers 10c and 10c intersect with each other. Can be suppressed.
  • the adhesive 7 may be applied to the back surface of the extension portion 10b.
  • the extension portion 10b is bent at each of the bent grooves 27 and 29 by an appropriate guide roller 8, and the end back surface layer 10d is changed to the back surface layer 16. Fold it back so that it overlaps with the adhesive 7 and cure the adhesive 7.
  • the guide roller 8 is along the axial direction in the thickness direction of the panel body 1A that holds the end face layer 10c, and the guide roller is along the axial direction in the width direction of the end back layer 10d that holds the end back layer 10d.
  • a plurality of guide rollers 8 for guiding the bending may be provided so that the extension portion 10b is aligned from the indoor side surface layer 10a side to the end surface 24 and further involved in the back surface side.
  • the ceiling panel 1 is manufactured as shown in FIGS. 1 and 5 (b).
  • the side end 2 of the ceiling panel 1 is provided with an appropriate joining member, a hooking member, or the like to be joined to the adjacent ceiling panel 1, or a fixing portion, a magnet, an adhesive material, or the like fixed to the ceiling base 3. You may do it.
  • the above manufacturing process is only an example, and can be appropriately modified.
  • the fiber-reinforced resin layers 14 and 18 on both sides of the foamed resin layer 20 in the thickness direction are formed by impregnating the glass fiber sheets 15 and 19 with the resin composition constituting the foamed resin layer 20.
  • the present invention is not limited to such an embodiment. Assuming that both or one of the fiber-reinforced resin layers 14 and 18 on both sides of the foamed resin layer 20 in the thickness direction is formed separately from the foamed resin layer 20 and laminated and integrated with an appropriate adhesive. May be good. Similarly, both or one of the flame-retardant layer 13 and the back-side flame-retardant layer 17 may be laminated and integrated with the fiber-reinforced resin layers 14 and 18 with an appropriate adhesive.
  • the back surface layer 16 including the back surface side fiber reinforced resin layer 18 and the back surface side flame retardant layer 17 is provided on the ceiling base 3 side of the foamed resin layer 20 .
  • the reinforced resin layer 18 and the back surface side flame retardant layer 17 may not be provided or one of them.
  • the configuration of each of the above-mentioned parts of the ceiling panel 1 according to the present embodiment is merely an example, and various other modifications are possible.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Laminated Bodies (AREA)
  • Building Environments (AREA)
  • Finishing Walls (AREA)

Abstract

Panneau de finition intérieur 1 construit pour avoir la face arrière faisant face au côté de la surface sous-jacente 3. Une couche de face avant 10 est disposée sur le côté interne d'une couche de résine de mousse 20, la couche de face avant 10 comprenant une couche de résine renforcée par des fibres 14, une couche ignifuge 13 disposée sur le côté interne de la couche de résine renforcée par des fibres, et une couche décorative 11 disposée sur le côté interne de la couche ignifuge. Au moins une partie d'extrémité latérale 23 de la couche de résine de mousse est configurée de telle sorte qu'une face d'extrémité 24 orthogonale à une face interne 21 de celle-ci et une face arrière 22 orthogonale à ladite face d'extrémité sont recouvertes par une partie étendue 10b de la couche de face avant s'étendant dans le prolongement de la partie recouvrant la face interne. Des rainures courbées 27, 29 sont disposées sur des positions de la partie étendue correspondant à un coin de face interne 24a et un coin de face arrière 24b sur la partie d'extrémité latérale de sorte que les fonds de rainure 27a, 29a sont positionnés dans la couche de résine renforcée par des fibres.
PCT/JP2020/007481 2019-08-30 2020-02-25 Panneau de finition intérieur et procédé de fabrication de panneau de finition intérieur WO2021038921A1 (fr)

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JP2019-158653 2019-08-30

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Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH0737120B2 (ja) * 1989-01-10 1995-04-26 旭ファイバーグラス株式会社 吸音断熱板
JP2013099864A (ja) * 2011-11-07 2013-05-23 Sekisui Chem Co Ltd 不燃積層材
JP2018164982A (ja) * 2017-03-28 2018-10-25 パナソニックＩｐマネジメント株式会社 表面化粧パネル及びこれを備えた化粧パネル

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JPH0737120B2 (ja) * 1989-01-10 1995-04-26 旭ファイバーグラス株式会社 吸音断熱板
JP2013099864A (ja) * 2011-11-07 2013-05-23 Sekisui Chem Co Ltd 不燃積層材
JP2018164982A (ja) * 2017-03-28 2018-10-25 パナソニックＩｐマネジメント株式会社 表面化粧パネル及びこれを備えた化粧パネル

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