Building material panel and method for manufacturing the same

Abstract

To provide a building material panel and a method for manufacturing the same, in which an adhesive layer between a core material and a surface material is formed with a substantially uniform thickness and has enhanced strength.SOLUTION: A building material panel comprises a core material (1), a surface material (2) disposed on one surface (1a) of the core material (1), and a fiber layer (4) that is interposed between the core material and the surface material and is impregnated with an adhesive (3).SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a building panel and a manufacturing method thereof, and more particularly to a building panel in which a core material and a face material are bonded together, and a manufacturing method thereof. [Background technology]

[0002] BACKGROUND ART In architectural structures such as exterior wall materials and roofing materials, sandwich panel structures are well known in which a core material is sandwiched between a pair of face materials and bonded together with an adhesive to improve strength (such as bending rigidity).

[0003] For example, Japanese Patent Laid-Open Publication No. 2005-105731 (Patent Document 1) discloses a panel structure in which a core material made of synthetic resin foam is sandwiched between plywood boards on both sides and bonded together with an adhesive. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2005-105731 Summary of the Invention [Problem to be solved by the invention]

[0005] Generally, adhesive is applied to bond the core material and the facing material by brush, roller, or spraying, making it difficult to apply the adhesive evenly. If the application is uneven, the adhesive strength decreases, making the core material and the facing material more likely to peel off, leading to a decrease in the strength of the panel.

[0006] In addition, since there are many irregularities on the surface of the core material and the surface of the face material that come into contact with the adhesive, the interfaces between the adhesive layer and the core material, and between the adhesive layer and the face material, are firmly fixed.However, if the inside of the adhesive layer itself is brittle, destruction will occur from within the adhesive layer, leading to a decrease in the strength of the panel.

[0007] Patent Document 1 does not address the above-mentioned problem. The object of the present invention, which has been made to solve the above-mentioned problem, is to provide a building material panel in which an adhesive layer of uniform thickness is formed between the core material and the face material, and in which the strength of the adhesive layer itself is improved, and a manufacturing method thereof. [Means for solving the problem]

[0008] The building panel according to the present invention comprises a core material, a facing material disposed on one side of the core material, and a fiber layer sandwiched between the core material and the facing material and impregnated with adhesive.

[0009] Preferably, the sheet further comprises another face material disposed on the other side of the core material, and another fiber layer sandwiched between the core material and the another face material and impregnated with adhesive.

[0010] Preferably, the fibrous layer comprises a mesh cloth.

[0011] Preferably, the mesh cloth is made of glass fiber, carbon fiber or aramid fiber.

[0012] Preferably, the facing material is a wood material, the core material is a foam insulation material, and the adhesive is a vinyl acetate adhesive.

[0013] The manufacturing method for a building material panel according to the present invention comprises the steps of preparing a core material and a face material to be bonded together, transporting a fiber sheet made of a fiber material, impregnating the fiber sheet with adhesive during transport, overlapping and bonding the core material to one side of the fiber sheet, and overlapping and bonding the face material to the other side of the fiber sheet.

[0014] Preferably, the facing material comprises a first facing material and a second facing material to be adhered to one surface and the other surface of the core material. [Effects of the Invention]

[0015] According to the present invention, by placing a fiber layer impregnated with adhesive between the core material and the face material, the thickness of the adhesive can be made almost uniform. In addition, because the fiber layer is impregnated with adhesive, the strength is greater than that of a layer made of adhesive alone. [Brief explanation of the drawings]

[0016] [Figure 1] 1 is a schematic diagram showing a building material panel according to an embodiment of the present invention. [Figure 2] FIG. 1(A) is a schematic diagram showing a process of impregnating one fiber sheet with an adhesive, and FIG. 1(B) is a schematic diagram showing a process of impregnating another fiber sheet with an adhesive. [Figure 3] FIG. 2 is a diagram schematically illustrating cohesive failure of an adhesive layer. DETAILED DESCRIPTION OF THE INVENTION

[0017] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS An embodiment of the present invention will be described in detail with reference to the drawings. In the drawings, the same or corresponding parts are designated by the same reference numerals and description thereof will not be repeated.

[0018] <About adhesive layer breakdown> Before describing the embodiments of the present invention, we will briefly explain adhesive layer failure. Figure 3 shows a foam insulation core 1 and a plywood facing 2 bonded together with a vinyl acetate adhesive 3 (the adhesive 3 is shown in gray). The core 1 and facing 2 each have fine irregularities on their surfaces that allow the adhesive 3 to penetrate. The adhesive 3 hardens while penetrating the irregularities, forming an adhesive bond (anchoring). In this case, while the anchoring provides a strong bond between the adhesive 3 and the core 1 and facing 2, the inside of the adhesive 3 (the central portion in the thickness direction of the adhesive layer) becomes the weakest point, causing internal failure 9 (cohesive failure) in the adhesive layer. One of the objectives of the present invention is to prevent this cohesive failure.

[0019] <Embodiment> (About the structure of building material panels) FIG. 1 is a diagram schematically illustrating a building panel 100 according to the present embodiment. A portion of the building panel 100 is shown enlarged at the top of the page. The building panel 100 includes a core material 1, a facing material 2, and a fiber layer 4. The building panel 100 is used in locations requiring thermal insulation, such as underlayment for roofing, exterior wall materials, and floors. Its dimensions are, for example, a standard width of 910 mm and a height of 1820 mm.

[0020] The core material 1 is made of a foam-based insulating material such as polystyrene foam. The polystyrene foam may be formed by either the bead method or the extrusion method. The core material 1 may also be a urethane board.

[0021] The face material 2 includes a first face material 21 arranged on one surface 1a of the core material 1 and a second (another) face material 22 arranged on the other surface 1b of the core material 1. Examples of face materials 21 and 22 include wood materials (plywood). The plywood face material may be used as an exterior wall base material, and a finishing material may be attached to the exterior side of the face material. Furthermore, at least one of the double-sided materials may be a calcium silicate board, a thin iron plate, or ceramic siding.

[0022] A fiber layer 4 is sandwiched between the core material 1 and the face material 2. In this embodiment, the fiber layer 4 includes a first fiber layer 41 and a second (another) fiber layer 42. The first fiber layer 41 is positioned between the core material 1 and the first face material 21. The second fiber layer 42 is positioned between the core material 1 and the second face material 22.

[0023] The first and second fiber layers 41, 42 are impregnated with adhesive 3. The fiber layer 4 is a flat sheet made of a large number of fibers, such as a cloth or nonwoven fabric. In this embodiment, the fiber layers 41, 42 each include a mesh-like cloth (an example of a fiber material) 43, 44, which is impregnated with adhesive 3. That is, the mesh-like cloths 43, 44 and the adhesive 3 constitute each fiber layer 41, 42. In FIGS. 1 and 2, the adhesive 3 is shown in gray.

[0024] The mesh-like cloths 43, 44 are made of, for example, glass fiber, carbon fiber, or aramid fiber. The adhesive 3 penetrates into the gaps between the fiber threads and acts as an anchor, improving the strength of the fiber layer.

[0025] Examples of adhesive 3 include vinyl acetate adhesives, silicone adhesives, and urethane adhesives. There are no particular restrictions on the type, and the adhesive is selected appropriately depending on the materials of the objects to be adhered (core material, surface material, and fiber material).

[0026] (About the manufacturing method of building material panels) A method for manufacturing the building panel 100 will be described with reference to Figure 2. Figure 2(A) shows an example in which a core material 1 and a first face material 21 to be bonded together are prepared, and a first fiber layer 41 is formed between them.

[0027] A fiber sheet 45 made of a fiber material is fed from a feed roller 51. The fiber sheet 45 is formed, for example, by mesh-like cloth 43 of the first fiber layer 41 of each building material panel 100, which is continuously formed in the conveying direction. The fiber sheet 45 is conveyed by a pair of guide rollers 52, 52.

[0028] Guided by the guide rollers 52, the fiber sheet 45 is transported through the liquid adhesive 3 stored in the tank 6. As a result, the fiber sheet 45 is impregnated with the adhesive 3 while being transported by the guide rollers 52.

[0029] Thereafter, the fiber sheet 45 is lifted up from the adhesive 3 in the tank 6 and directed toward a pair of downstream nip rollers 53, 53. The nip rollers 53 squeeze out excess adhesive 3, adjusting the amount of adhesive 3 applied so that it is uniform.

[0030] Thereafter, the fiber sheet 45 is conveyed downstream and is placed by a placement roller 54 so that the core material 1 overlaps one surface 45a of the fiber sheet 45.

[0031] The first face material 21 is placed on the other surface 45b of the fiber sheet 45 placed on the core material 1. In this way, the core material 1 and the first face material 21 are bonded together with the core material 1 and the first face material 21 placed on both surfaces of the fiber sheet 45. The fiber sheet 45 is cut as needed by a cutter (not shown) to match the length of the core material 1 in the longitudinal direction, resulting in the first fiber layer 41 shown in FIG. 1.

[0032] 2(B) shows the process of overlapping the fiber sheet 46 on the second face material 22. The process of the fiber sheet 46 reaching the placement roller 54B is similar to the transport of the fiber sheet 45 in FIG. 2(A), so it will be explained briefly.

[0033] The fiber sheet 46 is fed by a feed roller 51B, transported by a pair of guide rollers 52B, 52B, and passes through the adhesive 3 stored in a tank 6B, thereby being impregnated with the adhesive 3. The fiber sheet 46 is then lifted up from the adhesive 3 in the tank 6B, and excess adhesive 3 is squeezed out by a pair of nip rollers 53B, 53B downstream, adjusting the amount of adhesive 3 applied to be uniform.

[0034] Thereafter, the fiber sheet 46 is conveyed downstream and is placed by the placement roller 54B so that the second face material 22 overlaps the other face 46b of the fiber sheet 46.

[0035] Then, the core material 1 is placed on one surface 46a of the fiber sheet 46, and the core material 1 and the second face material 22 are bonded together with the core material 1 and the second face material 22 placed on both surfaces of the fiber sheet 46. The fiber sheet 46 is cut as needed by a cutter (not shown) to match the longitudinal length of the core material 1, to form the second fiber layer 42 shown in FIG.

[0036] In the method of this embodiment, fiber sheets 45 and 46 are laid on both sides of core material 1, so adhesive layers can be uniformly provided on both sides without turning core material 1 over.

[0037] It should be noted that when overlapping the core material 1 with the first and second face materials 21, 22, either of the double-sided materials may be placed first.

[0038] According to the present invention, the adhesive layer between the core material and the facing material is a fiber layer impregnated with adhesive, which makes it easy to uniformize the amount of coating (eliminate uneven coating) and adjust the amount of coating. This eliminates coating variations during manufacturing and ensures uniform strength. In addition, the anchoring effect of the adhesive impregnated into the fiber increases the strength of the adhesive layer itself, improving the strength (rigidity) of the building material panel.

[0039] The embodiments disclosed herein should be considered to be illustrative in all respects and not restrictive. The scope of the present invention is defined by the claims, not by the above description, and is intended to include all modifications within the meaning and scope of the claims.

[0040] In this embodiment, facing materials are adhered to both sides of the core material 1, but if the building panel is a flooring material, for example, a facing material may be provided on only one of the surfaces.

[0041] Although the embodiments of the present invention have been described above with reference to the drawings, the present invention is not limited to the illustrated embodiments. Various modifications and variations can be made to the illustrated embodiments within the same scope as the present invention or within an equivalent scope. [Explanation of symbols]

[0042] 1 core material, 2 facing material, 21 first facing material, 22 second facing material, 3 adhesive, 4 fiber layer, 41 first fiber layer, 42 second fiber layer, 43, 44 cloth, 45, 46 fiber sheet

Claims

1. A core material and A face material disposed on one side of the core material; A building material panel comprising a fiber layer sandwiched between the core material and the face material and impregnated with adhesive.

2. Another surface material disposed on the other surface side of the core material; The building material panel according to claim 1 , further comprising another fibrous layer sandwiched between the core material and another facing material and impregnated with adhesive.

3. The building panel according to claim 1 or 2, wherein the fiber layer includes a mesh cloth.

4. 4. The building panel according to claim 3, wherein the cloth is made of glass fiber, carbon fiber, or aramid fiber.

5. The surface material is a wood material, the core material is a foam insulation material, 2. The building panel according to claim 1, wherein the adhesive is a vinyl acetate adhesive.

6. providing a core material and a face material to be bonded together; A step of conveying a fiber sheet made of a fiber material; impregnating the fiber sheet with adhesive during the transport of the fiber sheet; a step of overlapping and adhering the core material to one side of the fiber sheet; and a step of overlapping and adhering the face material to the other side of the fiber sheet.

7. The manufacturing method according to claim 6 , wherein the face material comprises a first face material and a second face material to be adhered to one surface and the other surface of the core material.

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