Composite panel and method for manufacturing the same

Abstract

To provide a composite panel and a method for manufacturing the same that can achieve both sufficient strength and lightweight design, and can be produced in large sizes. [Solution] The composite panel 1 comprises terrazzo 10 and a base plate 20 that supports the terrazzo 10. The base plate 20 has a first base material 21 and a second base material 22 which has properties that provide better adhesion to the terrazzo 10 than the first base material 21.

Description

Technical Field

[0001] The present invention relates to a composite panel and a method for manufacturing the same.

Background Art

[0002] A concrete structure with a terrazzo finish (artificial stone polished finish) is known (see Patent Document 1). The terrazzo finish described in Patent Document 1 is a finishing method in which a mortar obtained by kneading crushed stone (aggregate) such as marble, cement, and pigment is applied to concrete, and after curing, the surface is polished with a grindstone to make it flat.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] As described above, the conventional terrazzo finish is generally made by applying terrazzo (mortar) to the base of concrete. Therefore, the terrazzo finish has been targeted at objects that are not assumed to be moved, such as the lobby, hall, floor of a building, and the slide of a park. However, due to its beautiful color tone, there has been a need to target portable objects as well. For small-sized objects such as tiles, they can be made only with terrazzo materials. However, when trying to make a relatively large panel (for example, a single board such as a tabletop), a thickness that does not cause bending deformation or shear fracture due to its own weight is required, and the panel becomes heavy. Therefore, it has been unsuitable to make a practical panel only with terrazzo materials.

[0005] The present invention aims to provide a composite panel and a method for manufacturing the same that can achieve both sufficient strength and lightweight properties, and can be produced in large sizes. [Means for solving the problem]

[0006] A composite panel according to one aspect of the present invention comprises terrazzo and a base plate supporting the terrazzo, wherein the base plate has a first base material and a second base material located between the first base material and the terrazzo in the thickness direction of the base plate and having properties that provide higher adhesion to the terrazzo than the first base material.

[0007] In this embodiment, instead of a panel made solely of terrazzo, terrazzo is combined with a baseboard to form a composite panel. This makes it possible to ensure sufficient strength as a composite panel with the baseboard without increasing the thickness of the terrazzo itself. By using a material lighter than terrazzo as the first base material of the baseboard, the overall weight of the terrazzo-finished composite panel can be reduced, making it possible to create larger panels. Furthermore, since the baseboard has a second base material that has higher adhesion to terrazzo than the first base material, adhesion between the terrazzo and the baseboard can be ensured in the composite panel.

[0008] A composite panel according to another aspect of the present invention comprises terrazzo and a base plate supporting the terrazzo, wherein the base plate has either a first base material or a second base material having properties that provide better adhesion to the terrazzo than the first base material.

[0009] In this embodiment, instead of a panel made solely of terrazzo, terrazzo is combined with a baseboard to form a composite panel. This makes it possible to improve the strength of the composite panel by using a baseboard without increasing the thickness of the terrazzo itself. By using a baseboard that is lighter than terrazzo, the overall weight of the terrazzo-finished composite panel can be reduced, making it possible to create larger sizes. [Brief explanation of the drawing]

[0010] [Figure 1] An example of a table comprising a composite panel according to the embodiment, where (a) is a plan view and (b) is a front view. [Figure 2] (a) is a longitudinal section view of section A in Figure 1, and (b) is a longitudinal section view of section B in Figure 1. [Figure 3] This figure shows an example of a method for manufacturing a composite panel according to the embodiment, where (a) is the state before terrazzo is placed on the base plate, (b) is the state after terrazzo is placed on the base plate, (c) is the state after the formwork has been removed, and (d) is the state after the surface of the composite panel has been polished. [Modes for carrying out the invention]

[0011] Hereinafter, with reference to the attached drawings, a preferred embodiment of the present invention will be described, specifically an example in which a composite panel is applied to the tabletop. In each drawing, the same or similar elements are denoted by the same reference numerals, and redundant explanations are omitted. The dimensional ratios in the drawings do not represent actual ratios, and actual ratios are not limited to those shown.

[0012] As shown in Figure 1, the table 100 has a tabletop made of a composite panel 1 supported by table legs 3. The composite panel 1 has a predetermined thickness in the vertical direction, and a portion of its underside is supported by the support surface 3a of the table legs 3. The composite panel 1 is circular when viewed from above, but is not limited to this and may have other shapes such as a rectangle. The surface of the composite panel 1 is terrazzo-finished.

[0013] As shown in Figure 2(a), the composite panel 1 comprises terrazzo 10 and a base plate 20 that supports the terrazzo 10. The base plate 20 has a first base material 21 and a second base material 22. The terrazzo 10, the first base material 21, and the second base material 22 are all basically configured in a plate-like or layered manner in the composite panel 1. As shown in Figure 2(b), a part of 10 may cover the periphery of the base plate 20 (details will be described later). Also, as will be described later, the base plate 20 does not have to have two base materials; the base plate 20 only needs to have at least one of the first base material 21 and the second base material 22.

[0014] Terrazzo 10 is made by hardening a mixture of cement-containing liquid and / or resin with aggregate, and then grinding it. Terrazzo is also called artificial marble. Cement is a substance that hardens when mixed with a liquid, and cement-containing liquids include, for example, concrete and mortar. Resin is a substance that hardens, and for example, thermoplastic resins and / or thermosetting resins. Aggregates are, for example, glass and / or stone. Stones include, for example, at least one of granite, marble, sandstone, limestone, andesite and tuff. Hereinafter, with respect to terrazzo 10, the mixture of cement-containing liquid and / or resin with aggregate before hardening will be referred to as "terrazzo 10 before hardening," and the hardened terrazzo 10 before grinding will be referred to as "terrazzo 10 before grinding."

[0015] The base plate 20 serves as a base for installing or supporting the plate-shaped or layered terrazzo 10, and strengthens the structure of the composite panel 1. The base plate 20 ensures sufficient strength for the composite panel 1. The base plate 20 is not a single plate but has a laminated structure, and in this case comprises a first base material 21 and a second base material 22. In other embodiments, the base plate 20 may comprise three or more base materials, or the base plate 20 may be a single plate having the first base material 21 or the second base material 22.

[0016] The first base material 21 constitutes the base and foundation of the composite panel 1. The first base material 21 is made of a board material that can reduce the overall weight of the panel compared to the case where the thickness of the terrazzo 10 is increased. As a material having such characteristics, at least one of board materials made of wood, metal, resin, and other materials can be used. Examples of wood-based board materials include lumber core, MDF (Medium Density Fiberboard), veneer, plywood, laminated wood, solid wood, particleboard, and OSB (Oriented Strand Board). Examples of metal board materials include stainless steel sheets, galvanized iron sheets, and aluminum sheets. Examples of resin board materials include melamine decorative sheets, polyethylene sheets, acrylic sheets, polycarbonate sheets, epoxy sheets, ABS (Acrylonitrile Butadiene Styrene) resin sheets, rigid polyvinyl chloride sheets, low-foaming polyvinyl chloride sheets, and phenolic resin sheets. Examples of other material board materials include ceramic, glass, and cork.

[0017] The second base material 22 is positioned between the first base material 21 and the terrazzo 10 in the thickness direction of the base board 20. The second base material 22 has properties that provide higher adhesion to the terrazzo 10 than the first base material 21. "High adhesion to terrazzo 10" means that it easily adheres to the terrazzo 10 before it hardens, and as the terrazzo 10 hardens in this state, it is easy for the terrazzo 10 to be fixed in place. As a second base material 22 having such relatively high adhesion properties, for example, lath cut (registered trademark), lath, or fiber net (net made of glass fiber) can be used.

[0018] Structurally, the second base material 22 has an uneven surface and / or a mesh-like shape configured to anchor the terrazzo 10. For example, the surface of the second base material 22 has an anchoring structure S that includes an uneven surface and / or a mesh-like shape. The anchoring structure S extends in the horizontal direction. The anchoring structure S intertwines with the terrazzo 10 before it hardens, thereby increasing adhesion with the terrazzo 10. The terrazzo 10 is also anchored to the anchoring structure S and fixed to the surface of the second base material 22.

[0019] The base plate 20 is fixed between the first base material 21 and the second base material 22, for example, with adhesive or an adhesive sheet. The base plate 20 and the terrazzo 10 are fixed together so as to be laminated by the hardening of the terrazzo 10 before it hardens. The composite panel 1 thus formed is supported on the support surface 3a of the table leg 3 via the first base material 21. In this case, the composite panel 1 may be fixed to the table leg 3 by fastening the support surface 3a and the first base material 21 with screws B, for example. In other embodiments, the support surface 3a and the first base material 21 may be fixed with adhesive instead of screws B.

[0020] As shown in Figure 2(b), the terrazzo 10 has a main covering portion 11 that covers the surface of the baseboard 20 and a side covering portion 12 that covers at least a part of the side surface of the baseboard 20. The main covering portion 11 is the part that contacts and is fixed to the surface (upper surface) of the first base material 21. The side covering portion 12 is the part that extends downward from the periphery of the main covering portion 11 and contacts and is fixed to the side surface (in this case, the entire circumferential surface) of the baseboard 20. In other embodiments, the terrazzo 10 may not include the side covering portion 12, or a part of the side covering portion 12 may be in contact with the back surface of the first base material 21.

[0021] In the composite panel 1, the terrazzo 10 is thinner than the first base material 21 and / or the second base material 22. The main body covering portion 11 is thinner than the first base material 21 and the second base material 22. Also, the main body covering portion 11 is thinner than the side covering portion 12. For example, in the table 100 to which the composite panel 1 having a diameter of 1100 mm and a thickness of 27.5 mm is applied, the thickness of the terrazzo 10 can be 5 mm, the thickness of the second base material 22 can be 7.5 mm, and the thickness of the first base material 21 can be 15 mm.

[0022] Next, a method for manufacturing the composite panel 1 will be described using FIG. 3. Here, a method for manufacturing the composite panel 1 by previously forming the base plate 20 and laminating the terrazzo 10 on the base plate 20 will be described.

[0023] As shown in FIG. 3(a), a mold F is provided, and the base plate 20 is installed inside it. For example, as the mold F, an annular mold F1 and a mold F2 serving as a base are used, and the base plate 20 and the mold F1 are placed on the upper surface of the mold F2 so as to surround the base plate 20. The upper surface of the mold F1 is provided at a position higher than the upper surface of the base plate 20.

[0024] Next, as shown in FIG. 3(b), uncured terrazzo 10 is provided on the base plate 20. The uncured terrazzo 10 poured into the region defined by the mold F has the back surface of the main body covering portion 11 in close contact with the fixing structure S, and the side covering portion 12 contacts the side surfaces of the first and second base materials 21 and 22. By maintaining this state for a predetermined time and curing the uncured terrazzo 10, the terrazzo 10 before grinding is fixed to the second base material 22.

[0025] Next, the formwork F is removed as shown in Figure 3(c). Since the surface of the terrazzo 10 before grinding is rough, the surface of the terrazzo 10 is finished as shown in Figure 3(d). The finishing treatment includes, for example, grinding and polishing. In the grinding treatment, for example, grinding is done with a grinding wheel, polishing machine, or grinder. The thickness of the terrazzo 10 removed by the grinding treatment (thickness removed) is, for example, 2 mm. The polishing treatment is performed after the grinding treatment. The polishing treatment is an abrasive treatment that makes the surface of the target smoother, and for example, a sander is used. As an example of the finishing treatment, grinding is performed with a grinder and then polishing is performed with a sander. This makes the surface of the terrazzo 10 flat and gives it a gloss. In this way, a composite panel 1 with a terrazzo finish is manufactured.

[0026] As described above, the composite panel 1 of this embodiment comprises terrazzo 10 and a base plate 20 that supports the terrazzo 10. The base plate 20 has a first base material 21 and a second base material 22 that is located between the first base material 21 and the terrazzo 10 in the thickness direction of the base plate 20 and has properties that provide better adhesion to the terrazzo 10 than the first base material 21.

[0027] In this embodiment, the panel is not made solely of terrazzo 10, but rather the terrazzo 10 is combined with a baseboard 20 to form a composite panel 1. This makes it possible to ensure sufficient strength as a composite panel 1 with the baseboard 20 without increasing the thickness of the terrazzo 10 itself. By using a material lighter than the terrazzo 10 as the first base material 21 of the baseboard 20, the overall weight of the terrazzo-finished composite panel 1 can be reduced, making it possible to make it larger in size. Furthermore, since the baseboard 20 has a second base material 22 that has higher adhesion to the terrazzo 10 than the first base material 21, it is also possible to ensure good adhesion between the terrazzo 10 and the baseboard 20 in the composite panel 1.

[0028] Therefore, while it has been difficult to manufacture terrazzo panels (single panels) conventionally, this embodiment makes it possible to manufacture large-sized terrazzo-finished panels that achieve both sufficient strength and lightweight properties. The terrazzo-finished composite panel 1 of this embodiment can be used to manufacture relatively large, portable items, such as furniture with beautiful color tones.

[0029] In particular, in one embodiment of this design, the side covering portion 12 of the terrazzo 10 covers the side surface of the base plate 20. This allows the beautiful color tone to be visible not only on the top surface of the composite panel 1, but also on the side surface of the composite panel 1.

[0030] The embodiments described above are provided to facilitate understanding of the present invention and are not intended to limit its interpretation. The elements, arrangement, materials, conditions, shapes, and sizes of the embodiments are not limited to those exemplified and can be modified as appropriate. Furthermore, it is possible to partially substitute or combine the configurations shown in different embodiments.

[0031] For example, composite panel 1 can be used not only for tables but for anything that uses a board. For example, composite panel 1 may be used for furniture such as chairs, cabinets or chests of drawers, or for interior finishes such as walls, floors, ceilings or doors. [Explanation of Symbols]

[0032] 1...Composite panel, 10...Terrazzo, 11...Main body covering, 12...Side covering, 20...Base plate, 21...First base material, 22...Second base material, 100...Table, 3...Table legs, 3a...Support surface, B...Screw, F, F1, F2...Formwork, S...Fixing structure

Claims

1. Terrazzo and, The terrazzo is supported by a base plate, The aforementioned baseboard is The first base material, A composite panel comprising: a second base material located between the first base material and the terrazzo in the thickness direction of the base board, and having properties that provide higher adhesion to the terrazzo than the first base material.

2. The composite panel according to claim 1, wherein the second base material has an uneven surface and / or a mesh-like shape configured to fix the terrazzo.

3. The composite panel according to claim 1, wherein the terrazzo is thinner than the first base material and / or the second base material.

4. The aforementioned terrazzo is The main covering portion covers the surface of the aforementioned base plate, A composite panel according to any one of claims 1 to 3, comprising a side covering portion that covers at least a portion of the side surface of the base plate.

5. A baseboard having first and second base materials in order in the thickness direction is provided with unhardened terrazzo, and the unhardened terrazzo is fixed to the second base material. The process then includes finishing the surface of the terrazzo fixed to the second base material, A method for manufacturing a composite panel, wherein the second base material has properties that provide better adhesion to the terrazzo than the first base material.

6. Terrazzo and, A base plate supporting the terrazzo, and a provision, The aforementioned baseboard is a composite panel having either a first base material or a second base material having properties that provide better adhesion to the terrazzo than the first base material.

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