Panel body and method for manufacturing the panel body

Abstract

To make it possible to simply form a groove-shaped storage part 6 for storing an external device 5 by hollowing out a back surface material 10 and fillers when a panel body 3 is formed by adhering front and back materials 9, 10 and the fillers 8 interposed between them via an adhesive by pressing processing.SOLUTION: By forming a panel body 3 by press processing a sheet material 13 in a state where it is interposed between storage part fillers 8a and a surface material 9 at a storage part 6 forming part of the surface material 9, the panel body 3 is in a state where the storage part fillers 8a are not adhered to the surface material 9. Thereby, it is possible to easily process the storage unit 6 even on site.SELECTED DRAWING: Figure 6

Description

[Technical field]

[0001] The present invention relates to the technical field of a panel body provided to divide an indoor space to form a toilet booth or the like, and a method for manufacturing the panel body. [Background technology]

[0002] Generally, a panel body constructed by inserting a filler such as a paper core between the front and back surface materials (indoor and outdoor side surface materials) is used as a member for partitioning booths (small rooms) such as toilet booths, but there are cases where such a panel body is required to be configured with an external device such as a terminal device for a remote control system or a sound imitation device, and if an external device is attached to the indoor side surface material of the panel body to meet this requirement, the external device will be disposed in a protruding state from the panel body, which not only mars the appearance but also makes it easy for people or luggage to bump into the protruding external device and make it easy for it to be vandalized. Therefore, it is proposed to form a groove-shaped storage section by hollowing out the indoor side surface material of the panel body and the filling material, and to incorporate the external device in this storage section. However, when attempting to hollow out and remove the interior side material and the filler material to form the storage section, there is a problem in that the filler material and the exterior side material are bonded together and integrated, making the work of forming the storage section tedious, complicated, and difficult to work with. Incidentally, when manufacturing such a panel body, if it is desired to have a space for forming a window, it has been proposed to form the panel body with the space removed in advance (see, for example, Patent Document 1). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] JP 2001-241270 A Summary of the Invention [Problem to be solved by the invention]

[0004] It is proposed to adopt this conventional technology and manufacture a panel body in a state where the interior side material and filler from the area where the storage section is to be formed are removed in advance, while leaving the storage section area of ​​the exterior side material. Such panel bodies are generally manufactured by pressing (known press processes include hot pressing and cold pressing, depending on the type of adhesive) a filler material (including crosspiece material) between front and back materials to which adhesive has been applied. However, when manufacturing using this type of press processing, the areas of the exterior side material where there is no filler (where the filler has been removed) are not pressed and bonded to the filler, and therefore do not have the same tension as areas where there is filler and which are bonded together, resulting in a distinct appearance that impairs the appearance; these are the problems that the present invention aims to solve. [Means for solving the problem]

[0005] The present invention has been created in view of the above-mentioned circumstances and with the objective of solving these problems. The invention of claim 1 comprises a front and back surface material, a filler interposed between the front and back surface materials, The material is pressed into a press and then bonded with an adhesive. In a panel body, the panel body The press-formed storage section is formed in a rectangular shape by upper and lower horizontal bars and left and right vertical bars. Panel body , Storage area One of the front and back surfaces For storage area By removing the filler In order to form a groove-shaped storage section in which the inner surface of the other face material of the storage section becomes the bottom surface and the removed face plate portion becomes an opening, the panel body before being pressed is The other surface material The auxiliary surface material is placed on the inner surface of the storage section, and the storage section filler is assembled in a state where it covers the auxiliary surface material. The panel body is characterized by the above. The invention of claim 2 is as follows: The opening of the storage section is set to a size smaller than the storage section, and the auxiliary surface material is between the opening of the storage section and the storage section. 2. The panel body according to claim 1, characterized in that the dimensions are set to be equal to or larger than the dimensions of the panel body. The invention of claim 3 is the panel body according to claim 1 or 2, characterized in that the auxiliary surface material is also provided between one of the surface materials and the filling material. In the invention of claim 4, the auxiliary surface material is a metal plate, or gypsum, calcium silicate, or melamine. Consists of materials selected from 2. The panel body according to claim 1, characterized in that: The invention of claim 5 is a surface / back surface material and a filler interposed between the surface / back surface materials. The material is pressed into a press and then bonded with an adhesive. In a panel body, the panel body The press-formed storage section is formed in a rectangular shape by upper and lower horizontal bars and left and right vertical bars.Panel body , Storage area One of the front and back surfaces For storage area By removing the filler a method for manufacturing a structure in which a groove-shaped storage section is formed with the inner surface of the other face material of the storage section becoming a bottom surface portion and the removed face plate portion becoming an opening, the method including the steps of: placing horizontal and vertical bars for forming the storage section on one of the front and back surface materials, and placing an auxiliary face material on a portion that will become the bottom surface portion of the storage section; incorporating a storage section filler in a state in which the auxiliary face material is covered; After pressing, the following process is carried out: a step of removing a portion of the other face plate that will become an opening for the storage portion; and a step of removing the storage portion filler that is not bonded to the auxiliary face plate. This is a method for manufacturing a panel body, characterized in that the following steps are carried out. Effect of the Invention

[0006] Claim 1 or 5 By using this invention, when the panel body is constructed so that a space is formed by removing a portion of one of the panel materials and the filling material in that portion of the panel material, an auxiliary panel material is provided on the other panel material in the portion where the groove-like space is formed, thereby reinforcing the other panel material and protecting it from deformation due to moisture absorption, etc. Furthermore, the panel body can be manufactured so that a space is formed by removing a portion of one of the face materials and the filler from that portion of the face material, and the panel body can be manufactured with the filler still present in the area where the space is to be formed.As a result, the front and back surfaces are pressed uniformly as a whole, and the appearance is not marred.Furthermore, when the filler is removed to form the space, the adhesive applied to the other face material adheres to the auxiliary face material and not to the filler, making the process of removing the filler easier and improving workability. Claim 2 According to the invention, when removing the filler, the auxiliary surface material is larger than the filler to be removed, so that the filler can be removed more easily and workability is improved. Claim 3 By adopting this invention, the auxiliary surface material is also provided on the side of the surface material to be removed, so that when forming a space, one of the surface materials can be removed while being separated from the filling material, improving workability. According to the invention of claim 4, the auxiliary surface material is made of a metal plate, gypsum, calcium silicate, or melamine. Made from selected materials Therefore, the other surface material of the space portion can be reinforced in a waterproof state. [Brief description of the drawings]

[0007] [Figure 1] FIG. [Diagram 2] 1A, 1B, and 1C are a rear view, a side view, and a longitudinal sectional view of the panel body. [Diagram 3] 1A and 1B are a rear view and a vertical cross-sectional view of a panel body before an external device is installed. [Figure 4]1A, 1B, and 1C are a rear view and a longitudinal sectional view of the surface material with the filler incorporated therein, and a longitudinal sectional view of the surface material before the storage section filler is incorporated therein. [Diagram 5] FIG. 2 is an exploded side view of an end surface of a panel body to be pressed. [Figure 6] 1A, 1B, and 1C are enlarged cross-sectional views of the storage section of the panel body after it has been pressed, after the backing material and filler have been removed, and after the storage section has been formed. [Figure 7] 13A and 13B are a rear view and a vertical sectional view of a storage portion showing a sheet material arrangement state of a second embodiment, and FIG. 13C and 13D are a vertical sectional view and a rear sectional view of a storage portion showing a sheet material arrangement state of a third embodiment. [Figure 8] 13A, 13B, and 13C are enlarged cross-sectional views of the storage section of the panel body according to the fourth embodiment, showing the panel body in a pressed state, the panel body with the backing material and the filler removed, and the panel body with the storage section formed. [Figure 9] 13A, 13B, and 13C are enlarged cross-sectional views of the storage section of the panel body according to the fifth embodiment, showing the panel body in a pressed state, the panel body with the backing material and the filler removed, and the panel body with the storage section formed. [Figure 10] 13A, 13B, and 13C are enlarged cross-sectional views of a storage section of a panel body according to a sixth, seventh, and eighth embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0008] Hereinafter, an embodiment of the present invention will be described with reference to the drawings. In the drawings, reference numeral 1 denotes a toilet booth (a private room for a toilet), which is composed of various members and devices such as left and right front (front) panel bodies 2 forming an entrance E, a depth panel body 3 provided between a wall part W and the front panel body 2, and a door body 4 for opening and closing the entrance E, all of which are conventional. In this embodiment, a groove-shaped storage section 6 is formed in the depth panel body 3 for mounting the external device 5 of the present invention therein, and hereinafter, except where necessary, the "depth panel body" in which the storage section 6 is formed will be referred to simply as the "panel body" 3, except where there is a need to refer to it as the "depth panel body." In this embodiment, the depth panel body 3 is constructed by connecting two panel bodies, a panel body 3 on the wall W side and a panel body 3 on the front panel body 2 side, in a continuous manner, and the external device 5 is provided on the panel body 3 on the wall W side.

[0009] The panel body 3 comprises a frame material 7 around all four sides, a filler material 8 made of a paper core material or the like which is interposed in the space surrounded by the frame material 7, and front and back surface materials 9, 10, and the panel body 3 is formed by integrally bonding the front and back surface materials 9, 10 to the frame material 7 and the filler material 8 via an adhesive (not shown).

[0010] The panel body 3 thus constructed has a groove-shaped storage section (corresponding to the "space section" of the present invention) 6 formed in a region lower than the vertical center and in the horizontal center (middle region) from which the backing material 10 and filling material 8 have been removed so as to open to the inside of the booth room. Upper and lower cross bars 11 are provided at both the upper and lower ends of the storage section 6, reaching the left and right frame members 7, and left and right vertical bars 12 are provided at both the left and right ends of the storage section 6, reaching the upper and lower horizontal bars 11, so that the storage section 6 is formed into a rectangular compartment. The filling material 8 is not only filled in the filling section excluding the storage section 6, specifically, the upper filling section S1 formed above the upper horizontal bar 11 and the lower filling section S2 formed below the lower horizontal bar 11, but also in the side filling sections S4 located on the left and right of the storage section 6, as side filling material 8b. In this case, one of the side filling materials 8b is provided with a wiring tube 8c in consideration of wiring to the external device 5.

[0011] In the storage section (corresponding to the "space section" of the present invention) 6 of the panel body 2 constructed in this manner, a sheet material 13 made of a moisture-proof material is adhered to the inner surface (the side facing the booth room) of the surface material 9 which forms the bottom panel of the storage section 6 as an intermediate surface material (corresponding to the "auxiliary surface material" of the present invention). In this embodiment, the storage section 6 is surrounded on all four sides by cross members 11 and 12, and the opening 6a formed in the back material 10 of the storage section 6 is narrower than the size (area) of the storage section 6, as shown in Figure 6, and the back material 10 extends from the cross members 11 and 12 in a flange-like shape. As described later, the panel body 3 is formed by pressing in a state in which the storage section 6 is also filled with filler (storage section filler) 8a, and after the formation, the opening-equivalent portion 10a of the back plate 10 corresponding to the storage section opening 6a and the corresponding portion of the storage section filler 8a are removed by cutting or the like, and further the storage section filler 8a remaining on the crosspiece members 11 and 12 side is removed by peeling or the like, thereby forming the storage section 6 with an internal space larger than the opening 6a. In this case, the sheet material 13 is set to a size larger than the storage section filler 8a removed together with the opening-equivalent portion 10a, in other words, larger than the opposing surface of the storage section filler 8a removed first with respect to the front plate 9 (it protrudes from the opposing surface). Incidentally, in this embodiment, the size of the storage section 6 is larger than the size of the storage section filler 8a that is removed first, but this is not limited to this, and the present invention can be implemented even if they are the same size.

[0012] Next, a manufacturing process for the panel body 3 thus configured will be described. In this case, an adhesive (not shown) is applied to the inner surfaces of the front and back surface materials 9, 10, and the filler 8 is interposed between the front and back surface plates 9, 10 to which the adhesive has been applied, and then the front and back surface materials 9, 10 and the filler 8 are pressed and bonded to each other by pressing (there are press processes such as hot pressing and cold pressing depending on the type of adhesive), thereby forming the panel body 3 in which the front and back surface plates 9, 10 and the filler 8 are bonded together, and since this process employs a conventionally known method, a detailed description thereof will be omitted. Incidentally, in this embodiment, the adhesive has been described as being applied to the front and back surface materials 9 and 10, but it goes without saying that the adhesive may also be applied to the filler 8, or even to both the front and back surface materials 9, 10 and the filler 8, and such can be implemented as appropriate as necessary.

[0013] First, the frame 7, the vertical and horizontal bars 11 and 12, and the fillers 8, 8a, and 8b cut into the shapes of the corresponding fillers S1 to S4 are assembled into the front surface material 9 (or back surface material 10) to which adhesive has been applied, but before the storage section filler 8a is assembled into the storage section filler S3, the sheet material 13 is placed on the back surface of the front surface material 9, and then the storage section filler 8a is assembled in a state of covering the sheet material 13 from above, and thus the sheet material 13 is interposed between the front surface material 9 and the storage section filler 8a. In this case, the sheet material 13 can be supported on the front surface material 9 via a supporting means such as double-sided adhesive tape so as not to be misaligned. After the backing material 10 is placed over the front surface material 9 filled with the fillers 8, 8a, and 8b in this manner and assembled, the panel body 3 is formed by pressing.

[0014] When the panel body 3 thus formed is used as the depth panel body 3 of the toilet booth 1, a storage section 6 will be formed in the panel body 3, and for this purpose, the opening-equivalent portion 10a of the back panel 10 and the portion of the storage section filler 8a corresponding to said corresponding portion 10a will be removed, such as by cutting. In this case, for the portion of the storage section filler 8a to be removed, the sheet material 13 interposed between the front material 9 and the portion is adhered to the back surface of the front material 9 by an adhesive applied to the front material 9, and the storage section filler 8a is not adhered to the front material 9. As a result, by removing the unadhered storage section filler 8a together with the opening-equivalent portion 10a of the back material 10 adhered to the storage section filler 8a, the sheet material 13 can be easily removed while remaining adhered to the front material 9.

[0015] In the present embodiment configured as described above, the panel body 3 has the storage section 6 for storing the external device 5 formed in a groove shape with the surface material 9 remaining, and the panel body 3 has the sheet material 13 adhered to the portion of the surface plate 9 corresponding to the storage section 6 via an adhesive applied to the surface material 9. As a result, even if the panel body 3 is manufactured by pressing the storage section filling section S3 in which the storage section 6 is formed with the storage section filler 8a present, the storage section filler 8a is not adhered to the surface material 9 and can be easily removed, improving workability, while the surface material 9 is pressed in a state where the fillers 8, 8a, and 8b are filled throughout, making it uniform and not damaging the appearance.

[0016] Furthermore, in this case, the sheet material 13 has dimensions larger than the storage section filler 8a which is removed together with the opening-corresponding portion 10a of the back surface material 10, making the removal of the storage section filler 8a even easier and improving workability. In this manner, when the sheet material 13 is made to have the larger dimensions, the size of the storage section filler 8a to be finally removed is made the same size as the storage section filler S3 (in this case, a space surrounded on all four sides by horizontal bars 11 and vertical bars 12) as in the second embodiment shown in Figures 7(A) and (B), which has the advantage that the work of removing the storage section filler 8a becomes easier. Furthermore, in this case, as in the third embodiment shown in Figures 7(C) and (D), the size of the storage section 6 and the size of the opening 6a can be made the same size (the size of the storage section filling section S3 surrounded by horizontal bars 11 and vertical bars 12 on all four sides). In this way, when the size of the storage section 6 and the size of the opening 6a are made the same, for example, as shown in Figure 6 (B), the storage section 6 can be sized so that the storage section filler 8a remains around it.

[0017] Furthermore, in this product, the intermediate surface material (auxiliary surface material) adhered to the surface material 9 is a flexible sheet material 13, which makes it simple and easy to handle, does not cause any problems in press processing, and provides good workability. Moreover, since the sheet material 13 has a moisture-proof function, it is possible to suppress the influence of changes in humidity on the surface material 9 of the storage section 6 after the storage section filler 8a is removed. Such intermediate surface materials (auxiliary surface materials) are not limited to the sheet material 13, but may be metal plates such as iron plates, stainless steel plates, copper plates, aluminum plates, brass plates, etc., or hard plates made of moisture-proof hard materials such as gypsum, calcium silicate, calcium carbonate, melamine, etc. (the hard plates may be decorative plates that are covered with a surface material such as a sheet material, or that have been given a decorative treatment on the surface.) Furthermore, as described above, when the intermediate surface material is a sheet material, various flexible moisture-proof materials such as melamine, polyester, polyvinyl chloride, polyethylene, polypropylene, polystyrene, etc. can be used as the material, and these can be selected appropriately as needed.

[0018] In the above-described embodiment, the sheet material 13 serving as an intermediate surface material is interposed between the front surface material 9 and the storage section filler material 8a, but it is also possible to further interpose a sheet material 14 between both the front and back surface materials 9, 10 and the storage section filler material 8a, as in the fourth embodiment shown in Figure 8. In this case, not only is it possible to form the storage section 6 from either the front or back side of the panel body 3, improving convenience, but when forming the storage section 6, it is possible to remove the opening equivalent portion 10a together with the sheet material 14, and then remove the storage section filler material 8a, thereby enabling the work to be individualized. Furthermore, according to the present invention, as in the fifth embodiment shown in FIG. 9, the size of the storage section filler 8a can be made smaller than the storage section filling section S3 (which is a space surrounded on all four sides by horizontal bars 11 and vertical bars 12, which becomes the storage section 6 in this embodiment). In this case, a small gap S5 is formed between the inner surface of the storage section void section S3 and the outer surface of the storage section filler 8a. However, since this gap S5 is small, it does not affect the adhesive molding of the panel body 3 by press processing.

[0019] The method for manufacturing such a panel body 3 by press working is as follows: a step of interposing a sheet material 13 between a portion of the surface material 9 where the storage section 6 is to be formed and the filler material 8, prior to the step of interposing the filler material 8 between the front and back surface materials 9, 10 to which the adhesive is applied; a step of adhering the filler 8 to the front and back surface materials 9 and 10 with an adhesive, followed by removing the opening-corresponding portion 10a of the back surface material 10 and the storage portion filler 8a at the corresponding portion while leaving the sheet material 13 adhered to the front surface material 9; Since the panel body 3 is provided with a sheet material, the manufacturing process does not become complicated since it is only necessary to insert the sheet material, and further, as mentioned above, the formation of the storage section 6 is simplified. Further, as a method for manufacturing the panel body 3 by press working, A process of interposing a filler 8 between the front and back surfaces 9, 10 to which the adhesive is applied; A process of bonding the filler to the front and back surfaces 9 and 10 via an adhesive; a step of removing a portion of one face material 9 to which the filler 8 is adhered, where a space is to be formed, and a step of removing the filler 8a adhered to the other face material 10 in a portion corresponding to the space; A step of adhering an auxiliary surface material 13 to the bottom surface of the space portion from which the filler material 8a has been removed; In this case, too, there is an advantage that the storage section 6 provided with the auxiliary panel 13 can be easily formed without complicating the process of manufacturing the panel body 3, as described above.

[0020] Of course, the present invention is not limited to the above-mentioned embodiment, and the above-mentioned embodiment has an intermediate auxiliary surface material provided on the inner surface of the front panel 9 which forms the bottom of the storage section 6 which is a space, but the present invention is not limited to this and may be attached to the outer surface of the front panel 9 as auxiliary surface material 14, as in the sixth embodiment shown in Fig. 10(A). In this case, by making the auxiliary surface material 14 larger than the portion corresponding to the storage section 6 in this case, it is possible to reinforce the peripheral portion of the space as well, and in this case the auxiliary surface material 14 may be attached to the entire outer surface of the front panel 9 if necessary. Furthermore, it can be implemented in a seventh embodiment shown in Figure 10(B), in which auxiliary surface materials 14 are attached to both outer surfaces of the front and back surface materials 9, 10, or in an eighth embodiment shown in Figure 10(C), in which an auxiliary surface material 13 is further attached to the inner surface of the front panel 9 and an auxiliary surface material 14 is further attached to both outer surfaces of the front and back surface materials 9, 10. In particular, when the surface panel 9 is made of a hygroscopic material such as fiberboard (for example, medium-density fiberboard (MDF)), forming the storage section 6 has the advantage that the surface panel 9 in the area of ​​the storage section 6 can be prevented from subsequently (over time) absorbing moisture and deforming by providing the auxiliary surface material 14 on the surface panel 9 (and / or the back surface material 10) as described above. Furthermore, when the auxiliary surface material 14 is affixed to the outer surface of the surface panel 9, the auxiliary surface material 14 can be a decorative panel, which has the advantage of giving the surface panel 9 an aesthetically pleasing appearance while reinforcing the storage section 6 area. [Industrial Applicability]

[0021] The present invention can be utilized as a panel body provided to divide an indoor space to form a toilet booth or the like, and as a manufacturing method for the panel body. [Explanation of symbols]

[0022] 1 Toilet booth 3 Depth Panel Body 5 External device 6 Storage area 6a aperture 8 Filler 8a Filler for storage area 9 Surface material 10 Backing material 10a Opening equivalent part 13 Sheet material S3 Storage compartment filling section

Claims

1. A panel body formed by pressing a front and back surface material and a filler material interposed between the front and back surface materials together with an adhesive, The panel body has a storage section formed in a rectangular shape by upper and lower horizontal bars and left and right vertical bars, The pressed panel body is configured such that one of the front and back surface materials of the storage section and the storage section filler are removed, so that the inner surface of the other surface material of the storage section becomes the bottom surface, and the removed surface portion becomes an opening to form a groove-shaped storage section, The panel body before being pressed, A panel body characterized in that an auxiliary panel is placed on the inner surface of the storage section of the other panel, and a storage section filler is incorporated in a manner covering the auxiliary panel.

2. A panel body as described in claim 1, characterized in that the opening of the storage section is set to a dimension smaller than the storage section, and the auxiliary surface material is set to a dimension between the opening of the storage section and the storage section.

3. 3. The panel body according to claim 1, wherein the auxiliary surface material is also provided between one of the surface materials and the filling material.

4. 2. The panel body according to claim 1, wherein the auxiliary surface material is made of a material selected from the group consisting of a metal plate, gypsum, calcium silicate, and melamine.

5. A panel body formed by pressing a front and back surface material and a filler material interposed between the front and back surface materials together with an adhesive, The panel body has a storage section formed in a rectangular shape by upper and lower horizontal bars and left and right vertical bars, The method for manufacturing the pressed panel body includes removing one of the front and back surface materials of the storage section and the storage section filler, so that the inner surface of the other surface material of the storage section becomes a bottom surface, and the removed surface portion becomes an opening to form a groove-shaped storage section, As a process before pressing, A process of placing horizontal and vertical bars for forming a storage section on one of the front and back surface materials, and placing an auxiliary surface material on a portion that will become the bottom of the storage section; - A step of incorporating the storage section filler into the auxiliary surface material placed in a state where it covers the storage section filler; After pressing, the following process is carried out: - A step of removing a portion of the other face plate that will become an opening for the storage portion; - Removing the storage filler that is not adhered to the auxiliary surface material; A method for manufacturing a panel body, comprising the steps of:

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