Laminated panel

Abstract

To provide a laminated panel that ensures light weight while improving rigidity.SOLUTION: A laminated panel 1 comprises: a core material 11 made of a porous body; a first metal plate 12 laminated on one side 11a of the core material; and a second metal plate 13 laminated on the other side 11b of the core material, a resin layer 14 made of a plate of a non-foamed resin material being interposed between the core material and the first metal plate, and the resin layer having a plate thickness C that is greater than the sum of the plate thicknesses A, B of the first metal plate and the second metal plate.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a laminated panel comprising a core material made of a porous body, a first metal plate laminated on one side of the core material, and a second metal plate laminated on the other side of the core material. [Background technology]

[0002] 2. Description of the Related Art Laminated panels having a structure in which both sides of a non-metallic core material are covered with hard metal plates have been known.

[0003] In the laminated panel of Patent Document 1 below, aluminum plates are laminated on both sides of a foamed resin layer, which is a core material, to provide the rigidity and fire resistance of the aluminum plates and the sound absorption and light weight of the foamed resin layer. In addition, in the laminated panel of Patent Document 2 below, a non-foamed resin layer is interposed between the foamed resin layer and the aluminum plate bonded to one or both sides of the foamed resin layer, to improve adhesion between the foamed resin layer and the aluminum plate as well as strength and light weight. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2010-064307 A [Patent Document 2] JP 2011-189587 A Summary of the Invention [Problem to be solved by the invention]

[0005] By the way, the laminated panel can be used as an interior panel of a building or a vehicle, but when used as a flooring material, for example, the rigidity is insufficient, and the metal plate on the surface may be dented when walking, causing wobbling and hindering walkability. In addition, tension rods may be used between furniture and ceiling materials to prevent furniture such as shelves from falling over due to earthquakes, and between walls and between floors and ceilings to secure storage space. However, when the laminated panel is used as a flooring material, ceiling material, or wall material, the metal plate on the surface may be dented, causing the tension rod to be installed incorrectly and fall off. Therefore, further rigidity is required for the laminated panel, but in the laminated panels such as those in Patent Documents 1 and 2, if the thickness of the aluminum plate is increased to increase the rigidity, the weight increases, and there is a concern that the lightness is impaired.

[0006] The present invention has been made in consideration of the above circumstances, and has an object to provide a laminated panel which ensures light weight while improving rigidity. [Means for solving the problem]

[0007] In order to achieve the above-mentioned object, the laminated panel of the present invention is a laminated panel comprising a core material made of a porous body, a first metal plate laminated on one side of the core material, and a second metal plate laminated on the other side of the core material, wherein a resin layer made of a plate of a non-foamed resin material is interposed between the core material and the first metal plate, and the resin layer has a plate thickness greater than the sum of the plate thicknesses of the first metal plate and the second metal plate.

[0008] In the laminated panel, a third metal plate may be interposed between the core material and the resin material layer.

[0009] In the above laminated panel, the core material may be cork or foamed resin.

[0010] In the above laminated panel, the first metal plate and the second metal plate may each be formed from an aluminum material, the first metal plate having a thickness of approximately 0.5 mm to 3.0 mm, the second metal plate having a thickness of approximately 0.2 mm to 2.0 mm, and the resin layer having a thickness of approximately 1.0 mm to 5.0 mm.

[0011] In the laminated panel, a protective layer may be provided on a surface of the first metal plate. Effect of the Invention

[0012] Since the laminated panel of the present invention has the above-mentioned configuration, it is possible to improve the rigidity while ensuring light weight. [Brief description of the drawings]

[0013] [Figure 1] FIG. 2(a) is a schematic perspective view of a laminated panel according to one embodiment of the present invention, and FIG. 2(b) is a schematic vertical sectional view corresponding to part X in FIG. [Diagram 2] 1(a) is a schematic vertical cross-sectional view of a modified example, FIG. 1(b) is a schematic vertical cross-sectional view of a modified example in which a protective layer is provided on the laminated panel of FIG. 1(b), and FIG. 2(c) is a schematic vertical cross-sectional view of a modified example in which a protective layer is provided on the laminated panel of FIG. 2(a). DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0014] Hereinafter, the laminated panel according to the present embodiment will be described with reference to the drawings. Note that the upper side on the paper of Fig. 1 and Fig. 2 will be referred to as one side, and the opposite side will be referred to as the other side.

[0015] <Embodiment> The laminated panel 1 according to this embodiment shown in Fig. 1 includes a core material 11 made of a porous body, a first metal plate 12 laminated on one surface 11a of the core material 11, and a second metal plate 13 laminated on the other surface 11b of the core material 11. A resin layer 14 made of a plate of a non-foamed resin material is interposed between the core material 11 and the first metal plate 12. The resin layer 14 has a thickness greater than the sum of the thicknesses of the first metal plate 12 and the second metal plate 13. The details are explained below.

[0016] Fig. 1(a) shows a schematic perspective view of a laminated panel 1 according to this embodiment. The laminated panel 1 shown in Fig. 1(a) is intended to be used as an interior panel (floor material, wall material, ceiling material, etc.) for buildings and vehicles such as bullet trains, and is intended to be used with one surface 12a of the first metal plate 12 disposed on the front side. Next, each member constituting the laminated panel 1 will be described with reference to Fig. 1(b), which is a schematic vertical cross-sectional view of the laminated panel 1 corresponding to the X portion in Fig. 1(a).

[0017] As shown in FIG. 1(b), the laminated panel 1 is formed by laminating a second metal plate 13, a core material 11, a resin layer 14, and a first metal plate 12 in this order from the bottom. An aluminum material is preferably used for the first metal plate 12 and the second metal plate 13. Examples of the aluminum material include aluminum and various aluminum alloys. In this embodiment, the first metal plate 12 and the second metal plate 13 are made of an aluminum alloy plate material having a composition defined by alloy number 5052 (hereinafter referred to as "alloy number 5052") in JIS H4000:2014 "Aluminum and aluminum alloy plate and strip".

[0018] The first metal plate 12 is desirably formed with a plate thickness A of about 0.5 mm to 3.0 mm, and more desirably about 1.0 mm. The second metal plate 13 is desirably formed with a plate thickness B of about 0.2 mm to 2.0 mm, and more desirably about 0.5 mm. The plate thickness A of the first metal plate 12 is greater than the plate thickness B of the second metal plate 13. In this embodiment, the first metal plate 12 is an aluminum alloy with a plate thickness A of about 1.0 mm, and the second metal plate 13 is an aluminum alloy with a plate thickness B of about 0.5 mm.

[0019] A resin layer 14 is provided on the other surface 12b side of the first metal plate 12. The resin layer 14 is made of a plate of a non-foaming resin material. Examples of the material of the resin layer 14 include various non-foaming resin materials such as polyvinyl chloride (PVC), polyethylene terephthalate (PET), acrylic resin (PMMA), polycarbonate (PC), polyethylene (PE), and polypropylene (PP). The non-foaming resin material is a resin material that does not contain bubbles, and a molded product made of the non-foaming resin material has higher rigidity than a molded product made of a foaming resin material. The resin layer 14 is preferably formed to have a plate thickness C of about 1.0 mm to 5.0 mm, and more preferably about 3.0 mm. As shown in FIG. 1(b), the plate thickness C of the resin layer 14 may be larger than the sum of the plate thickness A of the first metal plate 12 and the plate thickness B of the second metal plate 13. The resin layer 14 of this embodiment is made of polycarbonate, which is a thermoplastic resin. The resin layer 14 has a thickness C greater than the sum of the thickness A of the first metal plate 12 and the thickness B of the second metal plate 13 .

[0020] A core material 11 made of a porous material is provided on the other side of the resin layer 14. Cork material or foamed resin is preferably used as the porous material used for the core material 11, and in this embodiment, cork material is used. The cork material used in this embodiment is a compressed cork sheet having a plate thickness of 28.0 mm, which is formed by compressing cork particles. A second metal plate 13 is provided on the other surface 11b side of this core material 11.

[0021] Furthermore, when the core material 11 is made of a foamed resin, such a foamed resin having closed cells with an expansion ratio of 5 to 50 is preferably used. Furthermore, examples of the foamed resin material used for the core material 11 include expanded polystyrene (EPS), expanded polypropylene (EPP), expanded polyethylene (EPE), modified polyphenylene ether (m-PPE), and the like.

[0022] The core material 11 has a density of 0.60 kg / m 3 The following is preferable, with a density of 0.20 kg / m 3The following is more preferable: By using the core material 11 having such a density, the lightweight property of the laminated panel 1 is improved.

[0023] The above-mentioned members are bonded together with an adhesive and laminated to form the laminated panel 1. In this embodiment, an epoxy resin is used as the adhesive.

[0024] In the laminated panel 1 of this embodiment, a resin layer 14 made of a non-foaming resin material is interposed between the core material 11 and the first metal plate 12, and the plate thickness of the resin layer 14 is greater than the total plate thickness of the first metal plate 12 and the second metal plate 13. In addition, the rigidity of the resin layer 14 is greater than the rigidity of the core material 11. Therefore, the laminated panel 1 of this embodiment has improved rigidity compared to a conventional laminated panel in which a resin layer is not interposed between the core material and the first metal plate. In addition, the core material 11 is formed of a porous material such as cork or a foamed resin material, thereby improving the lightweight, sound absorption, and heat insulation properties of the laminated panel 1.

[0025] In addition, in the laminated panel 1 of this embodiment, the first metal plate 12 and the second metal plate 13 are each formed of an aluminum material. The plate thickness A of the first metal plate 12 is about 0.5 mm to 3.0 mm, the plate thickness B of the second metal plate 13 is about 0.2 mm to 2.0 mm, and the plate thickness C of the resin layer 14 is formed within the range of about 1.0 mm to 5.0 mm. By forming each plate thickness of the first metal plate 12, the second metal plate 13, and the resin layer 14 within the above numerical values, the laminated panel 1 is obtained in which rigidity and weight are well balanced. If the first metal plate 12, the second metal plate 13, and the resin layer 14 are formed with a plate thickness smaller than the above dimensions, the panel tends to be lightweight but has low rigidity. If the first metal plate 12, the second metal plate 13, and the resin layer 14 are formed with a plate thickness larger than the above dimensions, the panel tends to be rigid but has high weight.

[0026] <Modification> Next, a laminated panel 1A according to a modified example of the above-described embodiment will be described with reference to Fig. 2(a). Note that a description of the configuration and effects of parts common to the above-described embodiment will be omitted. The laminated panel 1A in Fig. 2(a) includes a first metal plate 12, a resin layer 14, a core material 11, and a second metal plate 13, which are configured substantially the same as those in the first embodiment. Furthermore, in the laminated panel 1A, a third metal plate 15 is interposed between the resin layer 14 and the core material 11. In the laminated panel 1A in Fig. 2(a), the second metal plate 13, the core material 11, the third metal plate 15, the resin layer 14, and the first metal plate 12 are laminated in this order from the bottom.

[0027] The third metal plate 15 is preferably made of an aluminum material, like the first metal plate 12 and the second metal plate 13. The third metal plate 15 of this embodiment is made of an aluminum alloy plate of alloy number 5052, like the first metal plate 12. The third metal plate 15 of FIG. 2(a) has a plate thickness D of about 0.5 mm, which is substantially the same as the plate thickness B of the second metal plate 13. The plate thickness D of the third metal plate 15 is smaller than the plate thickness A of the first metal plate 12. Also, as shown in FIG. 2(a), the plate thickness C of the resin layer 14 is preferably larger than the sum of the plate thickness A of the first metal plate 12, the plate thickness B of the second metal plate 13, and the plate thickness D of the third metal plate 15. 2(a), the thickness A of the first metal plate 12 is about 1.0 mm, the thickness B of the second metal plate 13 is about 0.5 mm, and the thickness D of the third metal plate 15 is about 0.5 mm, the total of which is about 2.0 mm, and the thickness C of the resin layer 14 is about 3.0 mm. Therefore, the thickness C of the resin layer 14 is greater than the total of the thickness A of the first metal plate 12, the thickness B of the second metal plate 13, and the thickness D of the third metal plate 15.

[0028] The laminated panel 1A in FIG. 2(a) has improved rigidity compared to the laminated panel 1 in FIG. 1 due to the third metal plate 15 being interposed between the resin layer 14 and the core material 11. The thickness of the core material 11 in the laminated panel 1A in FIG. 2(a) is approximately the same as that of the core material 11 in the laminated panel 1 in FIG. 1, but the thickness of the core material 11 may be reduced by the thickness D of the third metal plate 15. The thickness D of the third metal plate 15 is not limited to the above, and may be approximately the same as the thickness A of the first metal plate 12, or may be formed with a thickness different from that of the first metal plate 12 and the second metal plate 13.

[0029] <Protective layer> In addition, the laminated panel 1, 1A described above may be provided with a protective layer 16 on one surface 12a of the first metal plate 12, which is the surface of the laminated panel 1, 1A. Fig. 2(b) shows a schematic vertical cross-sectional view of a laminated panel 1' which is a modified example in which a protective layer 16 is provided on one surface 12a of the first metal plate 12 of the laminated panel 1 shown in Fig. 1. Fig. 2(c) shows a schematic vertical cross-sectional view of a laminated panel 1A' which is a modified example in which a protective layer 16 is provided on one surface 12a of the first metal plate 12 of the laminated panel 1A shown in Fig. 2(a).

[0030] 2(b) and (c), polyvinyl chloride is used as the protective layer 16, and it is adhered to one surface 12a of the first metal plate 12 with an epoxy adhesive. A non-foaming resin material is preferably used as the protective layer 16, and examples of the material include polyurethane in addition to polyvinyl chloride. The protective layer 16 may be a decorative material that covers one surface 12a of the first metal plate 12, and examples of such decorative materials include woolen fabrics such as carpet materials. If the laminated panel 1', 1A' is used as a wall material for a building or a vehicle, wallpaper may be used as the protective layer 16.

[0031] In the laminated panels 1', 1A', one side 12a of the first metal plate 12 is covered with a protective layer 16 provided on one side 12a of the first metal plate 12. By being covered with the protective layer 16, the one side 12a of the first metal plate 12 is protected and is less likely to be scratched or dented. Furthermore, if a decorative material is used as the protective layer 16, the appearance of the laminated panels 1', 1A' is improved.

[0032] The laminated panels 1, 1', 1A, 1A' are not limited to the above-mentioned configuration. The core material 11 may be made of anything other than cork or foamed resin as long as it is porous. The first metal plate 12, the second metal plate 13, and the third metal plate 15 may be made of aluminum materials of different compositions, or may be made of metal materials other than aluminum materials. In each of the above-mentioned embodiments, an epoxy resin adhesive is used to bond each member, but this is not limited thereto, and each member may be fixed together by other adhesives, thermocompression bonding, fasteners, etc. Also, one side 12a of the first metal plate 12 may be painted with a paint material or coated with a coating agent. The plate thickness of each member is not limited to the above-mentioned. For example, the plate thickness C of the resin layer 14 of the laminated panels 1A, 1A' may be greater than the sum of the plate thicknesses of the first metal plate 12 and the second metal plate 13, and may be equal to or less than the sum of the plate thicknesses of the first metal plate 12, the second metal plate 13, and the third metal plate 15. Furthermore, the end faces of the laminated panels 1, 1', 1A, and 1A' may be provided with a fitting structure having a concave-convex shape for fitting with other laminated panels, etc. This makes it easier to connect the laminated panels 1, 1', 1A, and 1A' to other laminated panels, etc.

[0033] <Evaluation test> Next, an evaluation test of the examples of this embodiment will be described. In the evaluation test, a load of 100 kg was applied to the surface (surface of the first metal plate) of a laminated panel having a length and width of 100 mm x 100 mm at a speed of 6.0 mm / min through a cylindrical jig made of aluminum alloy No. 5052 with a diameter of 10 mm attached to the evaluation test machine, and the displacement of the laminated panel was measured. In addition, after the test, the surface (one side) of the first metal plate of each laminated panel was observed to see if any dents caused by the metal jig remained. The dents were evaluated according to the following criteria. ◯: No change in the surface of the first metal plate. △: A slight dent remains on the surface of the first metal plate. ×: A clear dent remains on the surface of the first metal plate.

[0034] The configurations and test results of Examples 1 to 4 and Comparative Examples 1 to 3 are shown in Table 1. Example 1 is configured by laminating the second metal plate, core material, resin layer, and first metal plate in this order from the bottom. Examples 2 to 4 include a third metal plate, and are configured by laminating the second metal plate, core material, third metal plate, resin layer, and first metal plate in this order from the bottom. Comparative Examples 1 to 3 are conventional laminated panels that do not include a resin layer, and are configured by laminating the second metal plate, core material, and first metal plate in this order from the bottom. In addition, the alloy numbers in Table 1 indicate the alloy numbers specified in JIS H4000:2014 "Aluminum and aluminum alloy plates and strips".

[0035] [Table 1]

[0036] As shown in Table 1, the composition and thickness of the first metal plate in Examples 1 to 4 are the same, and an aluminum alloy having alloy number 5052 and a thickness of 1.0 mm is used. The first metal plate in Comparative Example 1 is an aluminum alloy having a thickness of 1.0 mm and specified by alloy number 5754 (hereinafter referred to as "alloy number 5754") in JIS H4000:2014. Alloy number 5754 is an aluminum alloy with higher strength than alloy number 5052. The first metal plate in Comparative Example 2 is an aluminum alloy having alloy number 5052 and a thickness of 1.0 mm, which is the same as in Examples 1 to 4. The first metal plate in Comparative Example 3 is the same as in Examples 1 to 4 in that it is an aluminum alloy having alloy number 5052, but has a thickness of 2.0 mm. The core material and the second metal plate have the same configurations in Examples 1 to 4 and Comparative Examples 1 to 3.

[0037] As shown in Table 1, in Comparative Example 1, since the first metal plate is made of aluminum alloy No. 5754, which has higher strength than alloy No. 5052, no change in the dents on the surface of the first metal plate was observed. However, since Comparative Example 1 does not have a resin layer, the core material was displaced significantly, and the amount of displacement in the evaluation test was larger than those of Examples 1 to 4.

[0038] In Comparative Example 2, the first metal plate had the same structure as in Examples 1 to 4, but did not include a resin layer. Therefore, as shown in Table 1, the amount of displacement in the evaluation test of Comparative Example 2 was larger than the amounts of displacement in Examples 1 to 4. Furthermore, when the surface of the first metal plate of Comparative Example 2 was observed after the evaluation test, clear dents remained on the surface of the first metal plate.

[0039] In Comparative Example 3, an aluminum alloy having alloy number 5052 and a thickness of 2.0 mm, which is thicker than those in Examples 1 to 4, is used as the first metal plate. Therefore, as shown in Table 1, the displacement in the evaluation test of Comparative Example 3 was 0.79 mm, which was substantially the same as the displacement of Example 1, 0.80 mm. However, when the surface of the first metal plate of Comparative Example 3 was observed after the evaluation test, slight dents remained on the surface of the first metal plate. On the other hand, no change was observed on the surface of the first metal plate of Example 1 after the evaluation test.

[0040] In Example 2, a third metal plate made of an aluminum alloy having alloy number 5052 and having a thickness of 0.5 mm was disposed under the resin layer, and the configuration of each of the other members was the same as in Example 1. As shown in Table 1, the displacement amount in the evaluation test in Example 2 was 0.50 mm, which was smaller than the displacement amount of 0.80 mm in Example 1. Furthermore, when the surface of the first metal plate in Example 2 was observed after the evaluation test, there was no change in the surface of the first metal plate, as in Example 1.

[0041] Examples 2 to 4 include a third metal plate having the same configuration, but the material of the resin layer is different. The material of each resin layer is polyvinyl chloride (PVC) in Example 2, polyethylene terephthalate (PET) in Example 3, and polycarbonate (PC) in Example 4. As shown in Table 1, the displacement amount in the evaluation test was 0.50 mm in Example 2, 0.54 mm in Example 3, and 0.49 mm in Example 4, and there was no significant change in the displacement amount due to the difference in the material of the resin layer. Furthermore, in Examples 2 to 4, no change was observed in the surface of the first metal plate after the evaluation test, and no dents were left on the surface of the first metal plate due to the difference in the material of the resin layer.

[0042] From the above test results, Examples 1 to 4, which include a resin layer, tend to have smaller displacements due to load than Comparative Examples 1 to 3, which do not include a resin layer, and have improved rigidity. Also, Examples 1 to 4, which include a resin layer, are less likely to leave dents due to load. Also, Examples 2 to 4, which include the third metal plate, have smaller displacements due to load than Example 1, which does not include the third metal plate, and have improved rigidity.

[0043] As described above, the laminated panel 1 shown in FIG. 1 and the laminated panel 1A shown in FIG. 2(a), which are configured in a manner substantially similar to Examples 1 to 4 in Table 1, are suitably used as interior panels for buildings and vehicles, since the amount of displacement due to load is small and dents due to load are unlikely to remain on the surface. Since the amount of displacement is small even when a load is applied locally and dents are unlikely to remain on the surface, if the laminated panel 1, 1A is adopted for flooring materials for buildings, vehicles, etc., dents become small and less likely to wobble, improving walkability. In particular, in vehicles, it is suitable for flooring materials for railway cars with many pedestrians. In addition, even if a person wearing heels, which are footwear that apply a load locally to the floor, walks, heel marks are unlikely to remain on the flooring material. In addition, the laminated panels 1', 1A' in which the protective layer 16 is provided on the laminated panels 1, 1A are also suitably used for interior panels for buildings and vehicles, particularly flooring materials for buildings and vehicles. Note that the laminated panels 1, 1', 1A, 1A' are not limited to being used for interior panels for buildings, vehicles, etc. [Explanation of symbols]

[0044] 1,1',1A,1A' laminated panel 11 Core material 11a One side 11b Other side 12 1st metal plate 12a One side (front side) 13 Second metal plate 14 Resin layer 15 Third metal plate 16 Protective layer

Claims

1. A laminated panel comprising a core material made of a porous body, a first metal plate laminated on one side of the core material, and a second metal plate laminated on the other side of the core material, a resin layer made of a plate of a non-foamed resin material is interposed between the core material and the first metal plate, The resin layer has a thickness greater than the sum of the thicknesses of the first metal plate and the second metal plate.

2. In claim 1, A laminated panel, comprising: a third metal plate interposed between the core material and the resin material layer.

3. In claim 1 or 2, A laminated panel, wherein the core material is cork or foamed resin.

4. In claim 1 or 2, The first metal plate and the second metal plate are each made of an aluminum material, The first metal plate has a plate thickness of about 0.5 mm to 3.0 mm, The second metal plate has a thickness of about 0.2 mm to 2.0 mm, The resin layer has a plate thickness of about 1.0 mm to 5.0 mm.

5. In claim 1 or 2, A laminated panel comprising: a protective layer provided on a surface of the first metal plate.

Images