Ceiling panel and method for manufacturing the same

Abstract

To provide a woody top plate having integrated feeling that does not express a boundary line between a substrate and an apron on a front end surface.SOLUTION: A top plate 10 is formed by a plate-shaped woody base material 12 in which a backer material 15 is adhered to each of front and back (top and bottom) surfaces of a core material 13, and a woody apron 14 joined to a bottom side end of the base material 12. A core material 13 of the base material 12 is made of MDF or the like, and the backer material 15 is made of kraft paper impregnated with a resin material, thereby increasing the strength of the base material 12. No backer material is interposed on a joint surface of the base material 12 and the apron 14, and instead, the backer material 15 is bonded to a front end surface of the base material 12 and the front end surface of the apron 14, and the integral feeling of the base material with the apron is ensured.SELECTED DRAWING: Figure 2

Description

Technical Field

[0001] The present invention relates to a top plate having a front overhang on the front end side of a plate-shaped base material and a method for manufacturing the same. More specifically, when the front overhang is joined to the base material, the boundary line appearing on the front side is concealed, and an integrated feeling between the base material and the front overhang can be imparted, and the present invention relates to a top plate suitable for use in counters such as kitchens and washbasin vanities, furniture, etc. and a method for manufacturing the same.

Background Art

[0002] Among the top plates used for kitchen and washbasin vanities, or furniture, etc., there is a type that thickens the appearance seen from the front by providing a front overhang on the front end side. As such a top plate with a front overhang, in addition to an integrated object in which the front end side of the base material constituting the top plate is formed relatively thick, there is also one in which a prismatic member forming the front overhang is joined to the lower surface of the front end side of the base material. Further, there is also known a structure in which an extruded member having a vertical width dimension larger than that of the base material is attached to the front end of the base material to form a front overhang (see, for example, Patent Document 1).

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In the case of the above-described integrated object of the base material and the front overhang, there is an advantage that their boundary does not exist on the front end surface of the top plate. However, when provided as a molded product made of resin, there is a restriction that molding by a mold is required. Moreover, when forming an integrated top plate made of a wood-based material, it takes time and effort to process the front overhang region, requires skill in manufacturing, and has the disadvantage that the manufacturing cost also increases.

[0005] In addition, in a configuration where the base material and the overhang are separate members and these are joined, while cost reduction can be achieved compared to an integral body, there is a disadvantage in that the boundary associated with the joining linearly appears on the front end surface of the top plate, and a sense of unity between the base material and the overhang cannot be obtained.

[0006] Furthermore, the configuration described in Patent Document 1 enables the replacement of the extruded profile, but on the other hand, since the base material and the overhang are made of different materials, a sense of unity cannot be obtained. Moreover, due to the configuration using the extruded profile, the overhang cannot be made of a wood-based material.

[0007] [Object of the Invention] The present invention has been devised by paying attention to such disadvantages, and an object thereof is to provide a wood-based top plate in which a boundary line when joining a base material and an overhang does not appear on the front end surface, and a manufacturing method thereof. Another object of the present invention is to provide a top plate and a manufacturing method thereof that can impart a sense of unity even as a structure for joining an overhang to a base material. Furthermore, an object of the present invention is to provide a top plate and a manufacturing method thereof that have a certain strength even when using, for example, a wood-based base material as a material, and have a low risk of deformation or the like.

Means for Solving the Problems

[0008] To achieve the above object, the present invention adopts the configuration described in the claims. Specifically, it is a top plate including a base material in which backing materials are adhered to both the front and back surfaces of a wood-based plate-like core material, and a wood-based overhang joined to the lower surface side of the end portion of the base material, adopting a configuration in which a coating film is formed on the front end surface of the base material and the front end surface of the overhang.

[0009] In the present invention, it is preferable to adopt a configuration in which the backing material does not intervene on the joining surface between the base material and the overhang.

[0010] Furthermore, the present invention provides a top plate comprising a base material with backing materials adhered to both the front and back surfaces of a wood-based plate-shaped core material, and a wood-based front overhang joined to the lower surface side of the end portion of the base material, It is also possible to adopt a configuration in which a backing material is adhered to the front end surface of the base material and the front end surface of the front overhang.

[0011] Furthermore, the present invention provides a method for manufacturing a top plate comprising a plate-shaped base material and a front overhang joined to the lower surface side of the end portion of the base material, a step of forming a base material by adhering backing materials to both the front and back surfaces of a wood-based plate-shaped core material, a step of removing the backing material at the location on the lower surface side of the end portion of the base material where the upper surface of at least the wood-based square timber forming the front overhang is joined, a step of joining the upper surface of the square timber to the surface where the backing material has been removed, a method including a step of applying a coating to at least the front end surface of the base material and the front end surface of the front overhang.

[0012] Furthermore, the present invention provides a method for manufacturing a top plate comprising a plate-shaped base material and a front overhang joined to the lower surface side of the end portion of the base material, a step of forming a base material by adhering backing materials to both the front and back surfaces of a wood-based plate-shaped core material, a step of joining the upper surface of the wood-based square timber forming the front overhang to the lower surface side of the end portion of the base material, a method including a step of adhering a backing material to the front end surface of the base material and the front end surface of the front overhang can also be adopted.

Advantages of the Invention

[0013] According to the present invention, by forming a coating film on the front end surface, it is possible to provide a top plate having an integrated feeling between the base material and the front overhang. In particular, according to the configuration in which the backing material on the lower surface side of the end portion of the base material is removed and the front overhang is joined, it is possible to minimize the layer structure in the front overhang region, and by enhancing the adhesion at the joint surface between the base material and the front overhang, it is expected that the boundary that can appear on the front end surface of the top plate can be well concealed by the coating film. In addition, the present invention can ensure a certain strength and reduce manufacturing costs by adopting a base material obtained by adhering a backing material to each of the front and back surfaces of a wood-based core material such as MDF or a front overhang. Furthermore, according to the configuration in which the backing material is adhered to the front end surfaces of the base material and the front overhang, not only does the boundary between the base material and the front overhang not appear on the front end surface, but there is also no need to remove the backing material on the joint surface.

Brief Description of the Drawings

[0014]

Figure 1

Figure 2

Figure 3

Embodiments for Carrying Out the Invention

[0015] Hereinafter, embodiments of the present invention will be described with reference to the drawings. In FIG. 1, a top plate 10 is disposed at the upper end of a cabinet 11 having a box shape. As shown in FIG. 2, this top plate 10 includes a base material 12 and a front overhang 14 joined to the lower surface side of the front end portion (left end portion in FIG. 2) of the base material 12. The base material 12 has a rectangular shape in plan view. In the present embodiment, MDF is used as the core material 13, and a backing material 15 is adhered to each of the front and back (upper and lower) surfaces thereof, thereby preventing warping and improving the strength of the base material 12. Examples of the material of the base material 12 include a core material 13 made of MDF with a thickness of 12 mm and a backing material 15 with a thickness of 1 mm obtained by impregnating kraft paper with phenolic resin. In addition to the above, the backing material 15 can be selected from those obtained by impregnating and laminating kraft paper or titanium paper with resins such as phenolic resin, melamine resin, and diallyl phthalate resin.

[0016] In this embodiment, the front overhang 14 is made of the same material as the base material 12, and a backing material 15 is adhered to the lower surface side in FIG. 2. As the front overhang 14, a prismatic material with a front-to-rear width of, for example, 23 to 25 mm and a thickness of 19 mm is used. The lower surface side portion of the base material 12 (core material 13) where the front overhang 14 becomes the joint surface 13A is a smooth surface obtained by removing the backing material 15 and polishing it. The upper surface of the front overhang 14 is adhered to this joint surface 13A via an appropriate adhesive (not shown).

[0017] After caulking treatment by spray coating is performed at the front end of the boundary between the base material 12 and the front overhang 14, for example, after performing end face polishing treatment with sandpaper of roughness #240, a coating film 20 is formed on at least the front end face of the base material 12 and the front end face of the front overhang 14 by spray coating. As a result, the boundary line between the base material 12 and the front overhang 14 is concealed and does not appear on the front surface.

[0018] Therefore, according to such an embodiment, it is possible to provide a top plate that can exhibit an appearance in which the base material 12 and the front overhang 14 are integrated by obtaining a state in which the boundary between the base material 12 and the front overhang 14 is concealed without being conspicuous. Moreover, by using MDF as the material for the base material 12 and the front overhang 14 for the core material 13 and adhering the backing material 15 thereto, processing can be easily performed and provided at low cost, and sufficient strength can also be ensured.

[0019] The best configuration, method, etc. for implementing the present invention are disclosed in the above description, but the present invention is not limited thereto. That is, the present invention has been particularly illustrated and described with respect to specific embodiments, but those skilled in the art can make various modifications to the above-described embodiments without departing from the scope of the technical idea and purpose of the present invention.

[0020] For example, in the above embodiment, the lower surface of the end portion of the base material 12 that becomes the joint surface of the overhang 14, that is, the surface obtained by removing and polishing the backing material 15 from the lower surface of the core material 13, is used. However, as shown in FIG. 3, the upper surface of the overhang 14 may be joined to the lower surface of the backing material 15 while leaving the backing material 15. And in this configuration, instead of the coating film 20, the backing material 15 can be adhered to the front end surface of the base material 12 and the overhang 14. With such a configuration, even if there are a plurality of boundary lines due to the interposition of the backing material 15 between the base material 12 and the overhang 14, it is possible to provide a top plate with an integrated feeling in which the upper surface and the front end surface are uniformly covered with the backing material 15. Furthermore, a coating film 20 may be formed on the surface of the backing material 15 by spray coating.

[0021] Also, the material, shape, dimensions of the base material 12 and the overhang 14, and the material, thickness, etc. of the backing material 15 in the present invention can be arbitrarily determined.

Explanation of reference numerals

[0022] 10... top plate, 12... base material, 13... core material, 14... overhang, 15... backing material, 20... coating film

Claims

1. A top plate comprising a base material having a backing material adhered to each of the front and back surfaces of a wood-based plate-shaped core material, and a wood-based front overhang joined to the lower surface side of the end of the base material, wherein a coating film is formed on the front end surface of the base material and the front end surface of the front overhang.

2. The top plate according to claim 1, wherein the backing material does not intervene on the joint surface between the base material and the front overhang.

3. A top plate comprising a base material having a backing material adhered to each of the front and back surfaces of a wood-based plate-shaped core material, and a wood-based front overhang joined to the lower surface side of the end of the base material, wherein the backing material is adhered to the front end surface of the base material and the front end surface of the front overhang.

4. A method for manufacturing a top plate comprising a plate-shaped base material and a front overhang joined to the lower surface side of the end of the base material, comprising the steps of: adhering a backing material to each of the front and back surfaces of a wood-based plate-shaped core material to form a base material; removing the backing material at a location on the lower surface side of the end of the base material where at least the upper surface of a wood-based square timber for forming the front overhang is to be joined; joining the upper surface of the square timber to the surface where the backing material has been removed; and applying a coating to at least the front end surface of the base material and the front end surface of the front overhang. A method for manufacturing a top plate, characterized by including the above steps.

5. A method for manufacturing a top plate comprising a plate-shaped base material and a front overhang joined to the lower surface side of the end of the base material, comprising the steps of: adhering a backing material to each of the front and back surfaces of a wood-based plate-shaped core material to form a base material; joining the upper surface of a wood-based square timber for forming the front overhang to the lower surface side of the end of the base material; and adhering a backing material to the front end surface of the base material and the front end surface of the front overhang. A method for manufacturing a top plate, characterized by including the above steps.

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