Honeycomb panel structure

Abstract

To provide a honeycomb panel that can be manufactured in a relatively short period, is hard to be damaged, and can exert excellent fire resistance.SOLUTION: A honeycomb panel structure comprises a plate-like core material 10, a pair of surface plates 20, a foamed resin heat insulation material 30, a decorative sheet 40, and a fireproof layer 50. The plate-like core material 10 has a honeycomb structure, and the pair of surface plates 20 is arranged on both surfaces of the core material 10. The foamed resin heat insulation material 30 has thermal conductivity of 0.015 to 0.022 W / (m K), includes a plurality of air bubbles inside, and is bonded to one of the pair of surface plates 20. The decorative sheet 40 is arranged on a surface of the foamed resin heat insulation material 30. The fireproof layer 50 includes an adhesive coating layer 51 which adheres the foamed resin heat insulation material 30 and the decorative sheet 40. The adhesive coating layer 51 is formed by applying a heat-resistant adhesive agent containing an inorganic material onto the foamed resin heat insulation material 30.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a honeycomb panel structure manufactured using a honeycomb panel as a base material, and more particularly to a honeycomb panel structure that facilitates improved design. [Background technology]

[0002] Patent Document 1 describes a lightweight, high-rigidity honeycomb panel that includes a thick honeycomb core and a pair of surface plates. The honeycomb core has a structure in which regular hexagonal cylinders made of aluminum foil are arranged without gaps. The pair of surface plates are bonded to both sides of the honeycomb core with an adhesive, sandwiching the honeycomb core between them.

[0003] According to the honeycomb panel described in Patent Document 1, the honeycomb core is lightweight yet highly rigid, so that it is possible to obtain bending rigidity and compressive strength, by weight, that are several times that of general metal panels. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2010-196307 A Summary of the Invention [Problem to be solved by the invention]

[0005] When the honeycomb panel described in Patent Document 1 is used as a ceiling or sidewall material for a building, heat insulation, sound insulation, and fire resistance may become problems. For example, when the honeycomb panel is used as a ceiling, a decorative board is attached to the indoor surface of the honeycomb panel. When a flammable board material is used as the decorative board, conventionally, fire resistance has been improved by, for example, applying a fire-resistant paint to the decorative board and forming a fire-resistant coating film on the surface of the decorative board.

[0006] However, because fireproof coating is formed by repeatedly applying and drying fireproof paint, and applying multiple coats of fireproof paint, it usually takes one or two months to form a fireproof coating film several millimeters thick. In addition, when applying multiple coats by spraying, the finish of the painted surface may become uneven and matte, the fireproof coating film has low hardness and is easily scratched, the fireproof coating film has poor water resistance and is easily damaged by condensation, and the fireproof coating film has poor fire resistance because it is only several millimeters thick.

[0007] The present invention has been made in consideration of the above problems, and an object of the present invention is to provide a honeycomb panel structure which can be manufactured in a relatively short period of time, is resistant to damage, and exhibits good fire resistance. [Means for solving the problem]

[0008] The honeycomb panel structure disclosed in the present application comprises a plate-shaped core material (10), a pair of surface plates (20), a foamed resin insulation material (30), a decorative plate (40), and a fireproof layer (50). The plate-shaped core material (10) has a honeycomb structure. The pair of surface plates (20) are disposed on both sides of the core material (10). The foamed resin insulation material (30) is joined to one of the pair of surface plates (20), has a thermal conductivity of 0.015 to 0.022 W / (m·K), and contains a plurality of bubbles therein. The decorative plate (40) is disposed on the surface of the foamed resin insulation material (30). The fireproof layer (50) includes an adhesive coating layer (51) that bonds the foamed resin insulation material (30) and the decorative plate (40). The adhesive coating layer (51) is formed by applying a heat-resistant adhesive containing an inorganic material to the foamed resin insulation material (30).

[0009] In the honeycomb panel structure disclosed in the present application, the fireproof layer (50) further includes a heat-resistant tape (52) attached to the foamed resin insulation material (30).

[0010] The honeycomb panel structure disclosed in the present application is provided on its end surface with a retaining portion (90). The retaining portion (90) retains the thermally expandable fireproof material (80). Effect of the Invention

[0011] The honeycomb panel structure according to the present invention can be manufactured in a relatively short period of time, is resistant to damage, and exhibits good fire resistance. [Brief description of the drawings]

[0012] [Figure 1] 1 is a cross-sectional view showing a honeycomb panel structure according to an embodiment of the present invention. [Diagram 2] 1 is an exploded perspective view showing a honeycomb panel structure according to an embodiment of the present invention. [Diagram 3] 1 is a plan view showing a honeycomb panel structure according to an embodiment of the present invention. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0013] Hereinafter, a honeycomb panel structure according to an embodiment of the present invention will be described in detail with reference to the drawings. Note that the embodiment described below is a preferred specific example for carrying out the present invention, and therefore various technical limitations are imposed thereon. However, the present invention is not limited to this embodiment unless otherwise specified in the following description to limit the invention.

[0014] <Embodiment> Hereinafter, a honeycomb panel structure according to an embodiment of the present invention will be described with reference to Figs.

[0015] Fig. 1 is a cross-sectional view showing a honeycomb panel structure according to an embodiment of the present invention. Fig. 2 is an exploded perspective view showing a honeycomb panel structure according to an embodiment of the present invention. Fig. 3 is a plan view showing a honeycomb panel structure according to an embodiment of the present invention.

[0016] As shown in Fig. 1, the honeycomb panel structure of the embodiment is used as a ceiling plate material for a building, and includes a plate-shaped core material 10, a pair of surface plates 20, a foamed resin insulation material 30, a decorative plate 40, a fireproof layer 50, and an insulation frame material 60, and is suspended from a steel ceiling beam (not shown) via connectors 1 and angle irons 2. When used as a ceiling plate material, the honeycomb panel structure of the present invention may be suspended from the ceiling beam as in the embodiment, or may be placed on top of the ceiling beam.

[0017] The core material 10 is made of an aluminum alloy in this embodiment, and as shown in FIG. 2, has a honeycomb structure in which regular hexagonal cylinders formed from aluminum foil are arranged without gaps.

[0018] In this embodiment, the pair of surface plates 20 are also made of an aluminum alloy, are disposed on both sides of the core material 10, and are joined to the core material 10 by an adhesive.

[0019] Additionally, a main frame material 11, which is a shaped material with a rectangular cross section, is disposed on the outer periphery of the core material 10. The vertical length of the cross section of the main frame material 11 is equal to the thickness of the core material 10, and a pair of surface plates 20 are also bonded to both the upper and lower surfaces of the main frame material 11 with an adhesive. In the following description, the pair of surface plates 20 bonded to both sides of the core material 10 and the main frame material 11 disposed on the outer periphery of the core material 10 will be referred to as the "honeycomb panel main body."

[0020] The foamed resin insulation material 30 is bonded to one of the pair of face plates 20 by, for example, a heat-resistant adhesive, has a thermal conductivity of 0.015 to 0.022 W / (m·K), and contains a plurality of bubbles therein. When the honeycomb panel structure is used as a ceiling plate material, the foamed resin insulation material 30 is bonded to the face plate 20 facing the room. The thickness of the foamed resin insulation material 30 is preferably 20 to 30 mm.

[0021] The foamed resin insulation material 30 of the embodiment is made by foaming phenolic resin, and has countless fine bubbles in which gas with higher thermal insulation properties than air is sealed. Phenol resin has high gas barrier properties, so that the gas in the bubbles is unlikely to escape to the outside, and even if it is exposed to flames in the event of a fire, it is simply carbonized from the surface, and is unlikely to spread.

[0022] The decorative board 40 may be made of various materials and of various sizes, whether incombustible or combustible, and is disposed on the surface of the foamed resin insulation material 30. In the embodiment, a plurality of decorative boards 40 are joined together and disposed on the surface of the foamed resin insulation material 30.

[0023] The fireproof layer 50 includes an adhesive coating layer 51 and a heat-resistant tape 52, and functions to protect the foamed resin insulation material 30 so that its insulating function is not lost in the event of a fire, and to prevent the honeycomb panel body from being heated to such a high temperature (e.g., a high temperature of 600°C or higher) that metals such as aluminum will melt.

[0024] The adhesive coating layer 51 of the fireproof layer 50 bonds the foamed resin insulation material 30 and the decorative board 40, and is formed by applying a heat-resistant adhesive containing an inorganic material to the foamed resin insulation material 30. The heat-resistant adhesive forming the adhesive coating layer 51 contains an inorganic material such as calcium silicate, and has a heat resistance of, for example, 900°C or higher.

[0025] The heat-resistant tape 52 is, for example, a ceramic tape, and has a heat resistance of 800°C or more. In this embodiment, the heat-resistant tape 52 is arranged at the joints of multiple decorative panels 40, attached to the surface of the foamed resin insulation material 30, and fastened to the main frame material 11 and the face plate 20 with screws 53. Fastening the heat-resistant tape 52 to the main frame material 11 and the face plate 20 with screws 53 can prevent the adhesive coating layer 51 from falling off from the surface of the foamed resin insulation material 30 even if the decorative panels 40 melt and burn in the event of a fire. The heat-resistant tape 52 also functions as a guide for the thickness when applying a heat-resistant adhesive to the surface of the foamed resin insulation material 30 to form the adhesive coating layer 51.

[0026] The heat-insulating frame material 60, together with reinforcing hanger materials 61, is installed on the surface of one of the surface panels 20 along the outer peripheral edge of the honeycomb panel structure, and is fastened to the main frame material 11 and one of the surface panels 20 with short screws 62. When the honeycomb panel structure is used as a ceiling panel material, the heat-insulating frame material 60 is installed on the surface of the surface panel 20 on the indoor side (lower side).

[0027] The reinforcing hanger 61 is a steel section with a P-shaped cross section that is pre-adhered to the decorative panel 40 and is fastened to the insulating frame material 60 and the foamed resin insulation material 30 with long screws 63. The insulating frame material 60 is fastened to the main frame material 11 and one of the face panels 20 with screws 62, and the reinforcing hanger 61 is fastened to the insulating frame material 60 and the foamed resin insulation material 30, which more reliably prevents the foamed resin insulation material 30 and the decorative panel 40 from falling off from the honeycomb panel body.

[0028] The honeycomb panel structure of the embodiment also has a retaining portion 80 at the end face for retaining the thermally expandable fireproof material 70. In the embodiment, the space defined by the insulating frame material 60, the reinforcing hanging member 61, and one of the surface panels 20 functions as the retaining portion 80. The thermally expandable fireproof material 70 is a member mainly made of an inorganic filler and a thermal expansion agent, the apparent volume of which expands several tens of times when heated to a high temperature. Various types of fireproof materials such as tape, sheet, putty, and sponge can be used as the thermally expandable fireproof material 70.

[0029] As described above with reference to Figures 1 to 3, according to the honeycomb panel structure of the embodiment, the plate-shaped core material 10 has a honeycomb structure, a pair of surface panels 20 are arranged on both sides of the core material 10, a foamed resin insulation material 30 is joined to one of the pair of surface panels 20, a decorative panel 40 is arranged on the surface of the foamed resin insulation material 30, and a fireproof layer 50 including an adhesive coating layer 51 bonds the decorative panel 40 and the foamed resin insulation material 30 together.

[0030] Since the core material 10 has a honeycomb structure, the honeycomb panel body is lightweight and has high rigidity. In addition, since the fireproof layer 50 including the adhesive coating layer 51 bonds the decorative board 40 and the foamed resin insulation material 30, even if the decorative board 40 melts or burns during a fire, the foamed resin insulation material 30 is protected by the adhesive coating layer 51 as the fireproof layer 50. Therefore, even if the foamed resin insulation material 30 is carbonized by the heat during a fire, the adhesive coating layer 51 prevents it from being directly exposed to the flames, and the insulation properties can be better maintained. The honeycomb panel body can be prevented from being heated to a high temperature of, for example, 600°C or more and melting, and the flames can be prevented from spreading to the roof of the building.

[0031] Furthermore, according to the honeycomb panel structure of the embodiment, the foamed resin insulation material 30 is disposed between the decorative panel 40 and the honeycomb panel body, thereby suppressing the transfer of heat between the outdoors and the indoors, and preventing condensation, which is a common problem with aluminum alloy plate materials.

[0032] Furthermore, the honeycomb panel structure of the embodiment can be manufactured in a relatively short period of time, taking about one day per panel, since it can be manufactured by a simple process of simply attaching each component, such as the foamed resin insulation 30, to the honeycomb panel body and fastening them with screws. Also, the adhesive coating layer 51 as the fireproof layer 50 bonds the decorative board 40 and the foamed resin insulation 30, and since it is covered by the decorative board 40, it is less susceptible to damage than conventional fireproof coatings and can maintain a good appearance for a long period of time.

[0033] 1 to 3, in the honeycomb panel structure of the embodiment, the fireproof layer 50 further includes a heat-resistant tape 52, such as a ceramic tape, attached to the foamed resin insulation material 30. By including the heat-resistant tape 52 in the fireproof layer 50, when the decorative board 40 melts or burns in the event of a fire, the adhesive coating layer 51 is less likely to fall off from the foamed resin insulation material 30, protecting the foamed resin insulation material 30 from flames, and even if the foamed resin insulation material 30 is carbonized, the insulating properties can be maintained, and the honeycomb panel body can be more effectively prevented from being heated to a high temperature of, for example, 600°C or more and melting, and the flames can be more effectively prevented from spreading to the roof of the building.

[0034] Furthermore, by including heat-resistant tape 52 in fireproof layer 50, it becomes easier to adjust the thickness when forming adhesive coating layer 51, and by arranging heat-resistant tape 52 at the joints of decorative boards 40, it is possible to prevent the heat-resistant adhesive from spilling out of the joints of decorative boards 40, making it easier to attach decorative boards 40. Furthermore, by arranging heat-resistant tape 52 at the joints of a plurality of decorative boards 40, it is possible to make it function as a ventilation section that helps the heat-resistant adhesive to dry after the heat-resistant adhesive is applied to form adhesive coating layer 51 and the decorative boards 40 are bonded together.

[0035] Furthermore, by placing heat-resistant tape 52 at the joints of the decorative board 40, it becomes easy to join decorative boards 40 of standard dimensions, which are readily available on the market, and attach them to the surface of a large-sized honeycomb panel body, allowing greater freedom in the selection of materials for the decorative board 40.

[0036] Furthermore, according to the honeycomb panel structure of the embodiment, by providing the end faces with the holding parts 80 for holding the thermally expandable fireproof material 70, the joints between the honeycomb panel structures used as ceiling panels can be opened under normal circumstances, preventing moisture caused by condensation or the like from accumulating inside the honeycomb panel body. In the event of a fire, the joints between the honeycomb panel structures can be closed, preventing flames from penetrating above the honeycomb panel structure.

[0037] <Example> The procedure for producing examples of the honeycomb panel structure of the present invention will be described below.

[0038] (1) An aluminum alloy honeycomb panel body was prepared, in which the core material 10 was 75 mm thick and a pair of surface panels 20 were 2 mm thick. An insulating frame material 60 was attached to one of the surface panels 20, a heat-resistant adhesive was applied to one of the surface panels 20 to a thickness of 0.2 mm, and a foamed resin insulating material 30 was cut so that the gap between the insulating frame material 60 and the foamed resin insulating material 30 was 5 mm, and the foamed resin insulating material 30 was attached to one of the surface panels 20. The foamed resin insulating material 30 was fixed to the honeycomb panel body with four screws per square meter. A foamed resin insulating material made of phenolic resin, 25 mm thick, and with a thermal conductivity of 0.019 W / (m·K) (nominal value) was used as the foamed resin insulating material 30.

[0039] (2) The gap between the insulation frame material 60 and the foamed resin insulation material 30 is filled with a heat-resistant adhesive.

[0040] (3) The heat-resistant tapes 52 were attached to the foamed resin insulation material 30 so as to align with the joints of the decorative board 40 so that the intervals between the heat-resistant tapes 52 were 610 mm or less. The heat-resistant tapes 52 were also fixed to the honeycomb panel body with screws so as to penetrate the foamed resin insulation material 30 in the thickness direction.

[0041] (4) A heat-resistant adhesive was applied to the foamed resin insulation material 30 so as to have the same thickness as the heat-resistant tape 52 (2 mm) to form an adhesive coating layer 51. The adhesive coating layer 51 was applied carefully so as not to leave any gaps between the heat-resistant tape 52 and the adhesive coating layer 51.

[0042] (5) The decorative board 40 was joined to the foamed resin insulation material 30 by the heat-resistant adhesive forming the adhesive coating layer 51, and a load was applied to the entire surface and fixed with a jig. The heat-resistant adhesive was expected to harden within 8 hours, and was left to cure for 2 to 3 days.

[0043] The material of the decorative board 40 is not particularly limited, and various board materials such as aluminum alloy board, aluminum resin composite board, color steel board, polycarbonate board, ABS board (acrylonitrile butadiene styrene resin board), melamine board, gypsum board, and MDF (Medium Density Fiberboard) can be used as the decorative board 40.

[0044] The adhesive coating layer 51 of the fireproof layer 50 is made of a sodium silicate inorganic binder as the main ingredient, to which a heat-resistant inorganic filler is added and kneaded to form a paste.

[0045] An aluminum alloy plate was used as the material for the heat insulating frame material 60. A heat resistant adhesive was filled into the space surrounded by the heat insulating frame material 60, the heat resistant tape 52, and the foamed resin insulation material 30. The material for the reinforcing hanger material 61 was the same as that for the heat insulating frame material 60.

[0046] The embodiments of the present invention have been described above with reference to the drawings (FIGS. 1 to 3). However, the present invention is not limited to the above-described embodiments, and can be embodied in various forms without departing from the spirit and scope of the present invention. [Explanation of symbols]

[0047] 10…Core material 20…Surface plate 30...Foam resin insulation material 40…Decorative board 50…Fire protection layer 51...adhesive coating layer 52...Heat-resistant tape 70…Thermally expandable fireproof material 80...Holding part

Claims

1. A plate-shaped core material (10) having a honeycomb structure; A pair of surface plates (20) arranged on both sides of the core material (10); a foamed resin insulation material (30) joined to one of the pair of surface plates (20), the foamed resin insulation material (30) having a thermal conductivity of 0.015 to 0.022 W / (m·K) and containing a plurality of bubbles therein; A decorative board (40) arranged on a surface of the foamed resin insulation material (30); A fireproof layer (50) including an adhesive coating layer (51) formed by applying a heat-resistant adhesive containing an inorganic material to the foamed resin insulation material (30) and bonding the foamed resin insulation material (30) and the decorative board (40). A honeycomb panel structure comprising:

2. 2. The honeycomb panel structure according to claim 1, wherein the fireproof layer (50) further comprises a heat-resistant tape (52) attached to the foamed resin insulation material (30).

3. 3. The honeycomb panel structure according to claim 1, further comprising a holding portion (90) for holding the thermally expandable fireproof material (80) on the end surface.

Images