Interior panel

Abstract

To provide an interior panel capable of stably attaching components to the back side of one side end portion while improving the flame retardant on at least one side end portion in addition to flame retardancy on the indoor side.SOLUTION: An interior panel 1 is installed with the back side facing the interior base 3 side. A surface layer 10 is provided on the indoor side of a panel core layer 20, and includes a flame retardant layer 13 and a decorative layer 11 provided on the indoor side of the flame retardant layer. An end face 24 formed in an intersecting shape with an interior side surface 21 of at least one side end portion 23 of the panel core layer and a back surface 22 formed in an intersecting shape with the end surface are covered by an extension part 10b of the surface layer that extends in a series from a part covering the side surface of the room. On the back side of one side end portion 2 of the interior panel, a coating layer 11a of the decorative layer covering the back surface of the panel core layer at the extending portion is polished away to form a component mounting portion 2a.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates to interior panels that form ceilings, walls, etc. of buildings. [Background technology]

[0002] Conventionally, interior panels that make up the ceilings and walls of buildings have sometimes been required to be flame-retardant (non-combustible). Some of these interior panels have a construction in which a non-combustible layer or a decorative layer is provided on the interior side of various substrates, but there has been concern that the non-combustible performance will be reduced if the substrate is exposed at the end surface. For example, Patent Document 1 below discloses an interior panel in which the end face and back surface of one end of a foamed resin layer are covered by an extended portion of a surface layer including a fiber-reinforced resin layer, a flame-retardant layer, and a decorative layer that extend continuously from a portion covering the interior side surface. Furthermore, Patent Document 2 listed below discloses a ceiling panel in which a surface layer including a flame-retardant layer and a decorative sheet is provided on the indoor side of a foamed resin-based base material, and magnets, hooking parts, and hooked parts are attached to the back side of the end portions. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent Publication No. 2021-38514 [Patent Document 2] Japanese Patent Publication No. 2020-139313 Summary of the Invention [Problem to be solved by the invention]

[0004] According to the interior panel described in Patent Document 1, the end face and back surface of one side end are covered with an extended portion of the surface layer including a flame-retardant layer, which makes it possible to improve the flame retardancy of the one side end. However, when a component such as a magnet, a hooking portion, or a hooked portion as described in Patent Document 2 is attached to the back surface of one side end of such an interior panel with an adhesive, there is a concern that the decorative layer may peel off easily depending on the type of decorative layer, since the decorative layer is located on the outermost layer of the back surface of the one side end.

[0005] The present disclosure has been made in consideration of the above-mentioned situation, and aims to provide an interior panel that is capable of improving the flame retardancy of at least one side end in addition to the flame retardancy on the indoor side, while also allowing components to be stably attached to the back side of the one side end. [Means for solving the problem]

[0006] In order to achieve the above-mentioned object, the interior panel of the present disclosure is an interior panel that is installed with its back side facing the interior base, and has a surface layer on the interior side of the panel core layer, which includes a flame-retardant layer and a decorative layer provided on the interior side of the flame-retardant layer, and at least one end face of the panel core layer that is perpendicular to the interior side face and a back face that is perpendicular to the end face are covered by an extended portion of the surface layer that extends continuously from a portion that covers the interior side face, and on the back face of one end face of the interior panel, the coating layer of the decorative layer at the extended portion that covers the back face of the panel core layer is polished away to form a component mounting portion. [Effects of the Invention]

[0007] The interior panel of the present disclosure has the above-described configuration, which makes it possible to improve the flame retardancy of at least one side end in addition to the flame retardancy on the interior side, while also allowing components to be stably attached to the back side of the one side end. [Brief explanation of the drawings]

[0008] [Figure 1]1 is a partially cutaway, schematic vertical cross-sectional view schematically illustrating an example of an interior panel according to an embodiment of the present disclosure. [Figure 2] 1(a) to 1(c) are partially cutaway schematic vertical cross-sectional views showing an example of a manufacturing method for the interior panel, and 1(d) is a partially cutaway schematic enlarged vertical cross-sectional view corresponding to the X1 portion in 1(c). [Figure 3] 1(a) and 1(c) are partially cutaway schematic vertical cross-sectional views showing an example of a manufacturing method for the interior panel, and 1(b) is a partially cutaway schematic enlarged vertical cross-sectional view corresponding to the X2 portion in 1(a). [Figure 4] (a) and (b) are partially cutaway schematic vertical cross-sectional views showing an example of a manufacturing method for the interior panel, and (c) is a partially cutaway schematic enlarged vertical cross-sectional view corresponding to the X3 portion in (b). [Figure 5] 1(a) is a schematic vertical cross-sectional view, partly broken away, showing an example of a manufacturing method for the interior panel, and FIG. 1(b) is a schematic exploded plan view, partly broken away, omitting a part of the interior panel. [Figure 6] 1(a) is a schematic vertical cross-sectional view, partly cut away, showing an example of a manufacturing method for the interior panel, and FIG. 1(b) is a schematic plan view, partly cut away, omitting a part of the interior panel. [Figure 7] (a) to (d) are schematic diagrams showing a modified example of the same interior panel, (a) and (b) are partially cutaway, enlarged, schematic vertical cross-sectional views corresponding to FIG. 3(b), and (c) and (d) are partially cutaway, enlarged, schematic vertical cross-sectional views corresponding to FIG. 4(c). DETAILED DESCRIPTION OF THE INVENTION

[0009] Hereinafter, embodiments of the present disclosure will be described with reference to the drawings. In some drawings, some of the detailed reference numerals used in other drawings are omitted. In the following embodiment, directions such as the up-down direction will be described based on the state in which a ceiling panel, which is an example of an interior panel according to this embodiment, is installed. 1 to 7 are diagrams that schematically show an example and modified examples of an interior panel according to the present embodiment, and an example of a method for manufacturing the interior panel.

[0010] The interior panel according to this embodiment constitutes a ceiling panel 1, and as shown in Fig. 1, is installed with its back surface facing the ceiling substrate 3, which serves as the interior substrate. This ceiling panel 1 comprises a foamed resin layer 20 that constitutes the panel core layer, and a surface layer 10 that is provided on the indoor side of this foamed resin layer 20. With this configuration, it is possible to achieve a lighter weight than wood boards or gypsum boards. The ceiling substructure 3 to which this ceiling panel 1 is fixed may be a wooden ceiling substructure or a steel ceiling substructure. The ceiling substructure 3 may also be a so-called light ceiling substructure made of light steel material. In the example shown, the ceiling substructure 3 is a channel-shaped steel joist. This ceiling substructure 3 may be a so-called suspended ceiling suspended via appropriate joist supports or hanging members such as hanging beams or hanging bolts that suspend the joist supports, or may have various other configurations.

[0011] This ceiling panel 1 may be installed as a ceiling for relatively small buildings such as residences and offices, or may be installed as a ceiling for various relatively large buildings such as gymnasiums, halls, shopping malls, factories, and schools. This ceiling panel 1 has a unit area (1m 2 The mass of the ceiling panel 1 may be set to 2.0 kg / m or less. The mass of the entire ceiling system including the ceiling substrate 3 made of the light ceiling substrate as described above may be set to 2.0 kg / m or less. 2 The mass may be as follows: The interior panel according to this embodiment is not limited to the ceiling panel 1, but may also be a wall panel. In this case, the wall substrate such as studs and studs may be regarded as the interior substrate.

[0012] As shown in FIG. 5(b), the ceiling panel 1 has a substantially rectangular shape in plan view (thickness direction). The ceiling panel 1 may have a substantially square or rectangular shape in plan view. The size of the ceiling panel 1 in plan view may be an appropriate size from the viewpoints of ease of handling and installation. For example, the length of one side may be 0.3 m or more and 2.5 m or less. In the substantially rectangular ceiling panel 1, the length of the short side may be 0.3 m or more and the length of the long side may be 2.5 m or less. In the substantially square ceiling panel 1, the length of one side may be 0.6 m or more and 1.5 m or less, and may be approximately 0.8 m to 1.2 m. The thickness of the ceiling panel 1 may vary depending on the layer structure, etc., and may be, for example, approximately 2.5 mm to 15.0 mm, preferably approximately 3.0 mm to 12.0 mm, and more preferably approximately 3.0 mm to 6.0 mm.

[0013] As shown in FIG. 1 , the surface layer 10 includes a flame-retardant layer 13 provided on the indoor side of the foamed resin layer 20 and a decorative layer 11 provided on the indoor side of the flame-retardant layer 13. This configuration improves the flame retardancy on the indoor side. In this embodiment, the surface layer 10 includes a fiber-reinforced resin layer 14 provided on the interior substrate side (substrate side) of the flame-retardant layer 13. In other words, the flame-retardant layer 13 is provided on the indoor side of the fiber-reinforced resin layer 14. This configuration allows the fiber-reinforced resin layer 14 to function as a reinforcing layer, improving the bending rigidity and dimensional stability of the entire ceiling panel 1. This effectively suppresses sagging after installation while achieving a lightweight ceiling panel 1, making it suitable for use as a ceiling panel 1.

[0014] At least one end 23 of the foamed resin layer 20 has an end 24 perpendicular to the indoor side surface 21, and a back surface 22 perpendicular to the end 24. The extended portion 10b of the surface layer 10 extends continuously from the portion covering the indoor side surface 21 and covers the end 24. This configuration improves the flame retardancy of at least the end surface and back surface of the one end 2 of the ceiling panel 1. This configuration can delay combustion from the end surface compared to a configuration in which the end surface of the foamed resin layer 20 is exposed, even in the event of a fire occurring on the indoor side when the end surfaces of the one end 2 of adjacent ceiling panels 1, 1 are installed facing each other. Furthermore, moisture absorption from the end surface 24 can be suppressed compared to a configuration in which the end surface 24 of the foamed resin layer 20 is exposed. In this embodiment, the fiber-reinforced resin layer 14 is provided continuously on the end surface and back surface of the one end 2, thereby improving the bending rigidity of the one end 2. Furthermore, since the surface layer 10 is provided continuously from the interior side to the end face and back surface of this one side end 2, the appearance of the corners (edges) on the interior side can be improved compared to, for example, covering the end face 24 by adhering an edge sheet. Peeling of the surface layer 10 can also be suppressed. Furthermore, for example, if a fastener such as a screw is fastened to the portion of the back surface of one side end 2 where the extension portion 10b (end back surface layer 10d) is provided, the fastener holding force can also be improved.

[0015] 5 and 6, on the back surface of one side end 2 of the ceiling panel 1, the coating layer 11a of the decorative layer 11 in the extension portion 10b covering the back surface 22 of the foamed resin layer 20 is ground away to form a component mounting portion 2a. With this configuration, the coating layer 11a, which has releasability for stain resistance and the like, is ground away, so that even when a component such as a fixing member 30 described below is attached with adhesive 9, it is difficult for the component to peel off, and the component can be stably attached. At a position corresponding to the indoor-side corner 24a of the end face 24 of the one side end 23 of the extended portion 10b, a bent groove (first bent groove) 27 is provided, in which the fiber-reinforced resin layer 14 is removed and the flame-retardant layer 13 is exposed at the groove bottom 27a (see FIG. 3(b)). With this configuration, the extended portion 10b is thinner at the location where the first bent groove 27 is provided than at other locations, making it easier to bend at that location. In addition, the fiber-reinforced resin layer 14 is not present on the groove bottom 27a side. This prevents the rigidity of the fiber-reinforced resin layer 14 from making the ridgeline unclear, and prevents the surface-side decorative layer 11 from breaking at the indoor-side corner even if the surface-side decorative layer 11 is prone to breaking, thereby improving the appearance of the corner. A second bending groove 29 is provided in the extending portion 10b at a position corresponding to the base-side corner 24b of the end surface 24 of the one side end 23. With this configuration, as in the above, the extending portion 10b becomes thinner at the portion where the second bending groove 29 is provided than at other portions, and the extending portion 10b becomes easier to bend at that portion.

[0016] Specifically, the decorative layer 11 is in the form of a thin sheet having a thickness of about 0.1 mm to 0.5 mm, and constitutes the decorative surface of the ceiling panel 1. In this embodiment, as shown in Fig. 5(a), the decorative layer 11 includes a printed layer 11b and a base layer 11c on the flame-retardant layer 13 side of the coating layer 11a. The coating layer 11a functions as a surface protection layer that protects the printed layer 11b applied to the surface side of the base layer 11c. This coating layer 11a may be formed of an appropriate transparent resin coating layer or resin film, or may be formed as a thin film on the surface of the decorative layer 11 by various methods. This coating layer 11a may have poor adhesion or releasability, making it difficult for the adhesive 9 to adhere to it. The printed layer 11b is a layer that imparts a color and pattern to the decorative layer 11, and may be formed with various patterns such as wood grain by printing. The pigments, additives, etc. contained in the paint used to form the printed layer 11b are preferably inorganic from the viewpoint of ensuring flame retardancy. The substrate layer 11c may be a paper substrate such as base paper made from paper raw materials such as pulp, or so-called titanium paper made by adding titanium oxide to paper raw materials, or may be resin-impregnated paper or a resin film.

[0017] The flame-retardant layer 13 may be appropriately configured so that the ceiling panel 1 satisfies the technical standards for performance required for non-combustible materials, etc., as stipulated in the Building Standards Act. For example, the ceiling panel 1 may be configured to meet the technical standards for "flame-retardant materials," preferably the standards for "semi-non-combustible materials," and more preferably the standards for "non-combustible materials." The flame-retardant layer 13 may be, for example, a thin foil-like metal sheet. The thickness of the metal sheet constituting the flame-retardant layer 13 may be approximately 5 μm to 50 μm, preferably approximately 7 μm to 40 μm, and more preferably approximately 10 μm to 30 μm. The metal sheet constituting the flame-retardant layer 13 may be a sheet made of aluminum, tin, gold, silver, copper, etc., from the viewpoint of ease of bending, etc., and preferably an aluminum sheet. The flame-retardant layer 13 is not limited to the above-described configuration and may have various other configurations. For example, the flame-retardant layer 13 may be a resin-impregnated glass fiber nonwoven fabric plate containing a heat-absorbing metal hydroxide. The decorative layer 11 and the flame-retardant layer 13 are laminated together via an appropriate adhesive layer 12. This adhesive layer 12 may be made of a polyethylene-based adhesive.

[0018] In this embodiment, the fiber reinforced resin layer 14 is a glass fiber reinforced resin layer containing glass fibers. The fiber reinforced resin layer 14 may have the same resin main component as the foamed resin layer 20. The glass fiber sheet 15 constituting the fiber reinforced resin layer 14 has a basis weight of 50 g / m 2 ~300g / m 2 The glass fiber sheet 15 may be a glass cloth. The weight of the glass fiber sheet 15 is preferably 50 g / m 2 ~150g / m 2 More preferably, 50 g / m 2~100g / m 2 Such a glass fiber sheet 15 may be a thin sheet having a thickness of about 0.1 mm to 0.5 mm. Furthermore, a woven fabric of glass fibers is preferable as the glass fiber sheet 15, and for example, a glass cloth which is a plain weave or leno weave woven using glass roving as the warp and weft may be used. The glass fiber sheet 15 is not limited to such a glass cloth, and may also be glass paper or a glass mat. The fiber reinforced resin layer 14 may be formed by impregnating the glass fiber sheet 15 with the resin composition that constitutes the foamed resin layer 20. In other words, the fiber reinforced resin layer 14 may be integrally provided with a part of the foamed resin layer 20. The fiber reinforced resin layer 14 may contain bubbles due to foaming of the resin composition.

[0019] A composite sheet formed by laminating a glass fiber sheet 15 to the ceiling substrate 3 side of the laminated decorative layer 11 and flame-retardant layer 13 with an appropriate adhesive may be laminated to the foamed resin layer 20 by the resin composition that constitutes the foamed resin layer 20. In this case, the flame-retardant layer 13 may be at least partially adhered to the resin composition that has passed through the glass fiber sheet 15 that constitutes the fiber-reinforced resin layer 14. In other words, the resin composition that constitutes the foamed resin layer 20 may be partially adhered to the flame-retardant layer 13 so as to seep out from the glass fiber sheet 15, which has a small basis weight and many pores as described above. The adhesive that laminates the flame-retardant layer 13 and the glass fiber sheet 15 together may be applied to the glass fiber sheet 15 in a manner that allows the resin composition that constitutes the fiber-reinforced resin layer 14 to seep out from the glass fiber sheet 15.

[0020] 1, the ceiling panel 1 in this embodiment has a back surface layer 16 including a back surface fiber-reinforced resin layer 18 provided on the ceiling substrate 3 side, which is the back surface side of the foamed resin layer 20, and a back surface flame-retardant layer 17 provided on the ceiling substrate 3 side of the back surface fiber-reinforced resin layer 18. In other words, the foamed resin layer 20 is configured to be sandwiched between the fiber-reinforced resin layers 14, 18 that constitute the reinforcing layers on both sides in the thickness direction. This back-side fiber-reinforced resin layer 18 may have the same main resin component as the foamed resin layer 20, similarly to the fiber-reinforced resin layer 14 constituting the surface layer 10 described above. As described above, this back-side fiber-reinforced resin layer 18 may be formed by impregnating a glass fiber sheet 19 with the resin composition constituting the foamed resin layer 20. As described above, this back-side fiber-reinforced resin layer 18 may contain bubbles due to foaming of the resin composition.

[0021] The back-side flame-retardant layer 17 may be the same as the above-described flame-retardant layer 13 or may be a metal sheet. The back-side flame-retardant layer 17 may also function as an exudation-suppressing layer that suppresses the exudation of the resin composition constituting the back-side fiber-reinforced resin layer 18. The back-side flame-retardant layer 17 may be a thinner sheet than the above-mentioned flame-retardant layer 13. For example, the thickness of the back-side flame-retardant layer 17 may be about 2 / 5 to 3 / 5 of the thickness of the flame-retardant layer 13. The composite sheet, in which the glass fiber sheet 19 constituting the back-side fiber-reinforced resin layer 18 is laminated to the back-side flame-retardant layer 17 with an appropriate adhesive, may be laminated to the foamed resin layer 20 with the resin composition constituting the foamed resin layer 20. In this case, the back-side flame-retardant layer 17 may be at least partially adhered to the resin composition that has passed through the glass fiber sheet 19 constituting the back-side fiber-reinforced resin layer 18. That is, the back-side flame-retardant layer 17 may be partially adhered to the back-side flame-retardant layer 17 so that the resin composition constituting the foamed resin layer 20 seeps out from the glass fiber sheet 19, which has a small basis weight and many pores as described above. Furthermore, the adhesive for laminating the back-side flame-retardant layer 17 to the glass fiber sheet 19 may be applied to the glass fiber sheet 19 so as to allow the resin composition constituting the back-side fiber-reinforced resin layer 18 to seep out from the glass fiber sheet 19. The back layer 16 may be provided so as to cover the entire back surface 22 of the foamed resin layer 20.

[0022] The foamed resin layer 20 occupies the majority of the ceiling panel 1. The thickness of the foamed resin layer 20 is preferably 80% to 99%, and more preferably 85% to 95%, of the thickness of the ceiling panel 1. The thickness of the foamed resin layer 20 may be, for example, about 2.3 mm to 14.8 mm, preferably about 2.5 mm to 11.5 mm, and more preferably about 2.5 mm to 5.5 mm. The resin composition constituting the foamed resin layer 20 may be a foamed polyurethane resin having an expansion ratio of 10 to 30 times. The expansion ratio of the resin composition constituting the foamed resin layer 20 may preferably be about 15 to 25 times. The resin composition constituting the foamed resin layer 20 may be a flame-retardant polyurethane resin composition. Such a flame-retardant polyurethane resin composition may contain a polyisocyanate compound, a polyol compound, a catalyst, a blowing agent, a foam stabilizer, and additives. Such a flame-retardant polyurethane resin composition may further contain a flame retardant, a filler, or an inorganic filler. Examples of resins constituting the foamed resin layer 20 include polyurethane resins, polystyrene resins, polyethylene resins, polypropylene resins, phenolic resins, and epoxy resins.

[0023] The extension portion 10b is provided so as to cover the ceiling substrate 3 side of the back surface layer 16 that extends up to the substrate-side corner portion 24b of the end surface 24 of one side end portion 23 of the foamed resin layer 20. This extending portion 10b forms the indoor side surface of the ceiling panel 1 and extends continuously from the indoor side surface layer 10a which forms the portion covering the indoor side surface 21 of the foamed resin layer 20. This extending portion 10b includes an end surface layer 10c which covers the end surface 24 of one side end 23 of the foamed resin layer 20, and an end back surface layer 10d which covers the back surface of one side end 2 (ceiling substrate 3 of back surface layer 16). The extending portions 10b including the end surface layer 10c and the end back surface layer 10d are provided on both side end portions 2,2 in a first direction (e.g., the panel width direction) of the ceiling panel 1, but are not provided on both side end portions 2,2 in a second direction (e.g., the panel longitudinal direction) perpendicular to the first direction (see FIG. 5(b)). In other words, at both side end portions 2,2 in the second direction of the ceiling panel 1, the end faces 24 of the foamed resin layer 20 are not covered by the extending portions 10b. Instead of this embodiment, the extending portions 10b including the end surface layer 10c and the end back surface layer 10d may be provided on the side end portions 2,2,2,2 around the four periphery of the ceiling panel 1. The side end portions 2, 2 on both sides in the first direction have the same configuration, so the following will describe the details of one side end portion 2 as an example.

[0024] The end faces of the side end portions 2 are perpendicular to the interior side and back surface (base side) of the ceiling panel 1. Here, perpendicular does not necessarily mean that the angle between the end faces and the interior side and back surface is 90 degrees, but also includes angles of, for example, about 85 to 95 degrees. When installing the ceiling panels 1, 1 with the end faces of adjacent panels abutting against each other, the angle between the end faces and the interior side may be less than 90 degrees (for example, 85 to 89 degrees). The end faces 24 of the side end portions 23 of the foamed resin layer 20 are orthogonal to the interior side surface 21 and the back surface 22 of the foamed resin layer 20, as described above. In this embodiment, as shown in FIG. 3(b), a notch 25 opening at the end face 24 is provided at the interior corner 24a of the end face 24. This notch 25 is groove-shaped and opens toward the extension direction of the extension portion 10b when the extension portion 10b is in an unfolded state (unfolded state), extending along the side end portion 23. The depth of the notch 25 along the extension direction and the width of the notch 25 along the panel thickness direction may be, for example, approximately 0.1 mm to 1.0 mm. While the illustrated example shows an example in which the depth of the notch 25 is greater than the width, this is not a limitation. Furthermore, although the bottom side of the notch 25 is substantially V-shaped when viewed in the longitudinal direction of the groove, this is not a limitation.

[0025] 3(b), the first bending groove 27 provided in the extending portion 10b is positioned at the corner between the extending portion 10b in an unfolded state (unfolded state) and the end surface 24. The second bending groove 29 is positioned at the boundary between the end surface layer 10c of the extending portion 10b and the end back surface layer 10d. In other words, the dimension from the first bending groove 27 to the second bending groove 29 along the extending direction (groove width direction) of the extending portion 10b corresponds to the thickness of the foamed resin layer 20. These first bent grooves 27 and second bent grooves 29 are formed in a groove-like shape throughout the panel so that when the extension portion 10b is in an unfolded state, they open toward one side in the panel thickness direction (toward the ceiling substructure 3) and extend parallel to each other along the side end portion 2 (2A). 4(c), the first bent groove 27 is filled with adhesive resin 6A that bonds the extension portion 10b to the end face 24 and the back surface 22. With this configuration, even when the width dimension W1 of the first bent groove 27 is relatively large, the adhesive resin 6A is filled in the portion where the fiber-reinforced resin layer 14 has been removed, making it less likely that steps will occur on the end face of the one side end portion 2, and the indoor-side corner can also be reinforced by the adhesive resin 6A.

[0026] The width W1 of the groove bottom 27a of the first bent groove 27 may be 0.1 mm or more. This configuration can reduce the influence of the fiber-reinforced resin layer 14, make it easier to bend, and improve the appearance of the indoor corner. In other words, the width W1 of the flame-retardant layer 13 exposed at the groove bottom 27a of the first bent groove 27 may be 0.1 mm or more. The width W1 of the flame-retardant layer 13 exposed at the groove bottom 27a of the first bent groove 27 may be 0.3 mm or more, or 0.5 mm or more. The first bent groove 27 has a substantially rectangular shape when viewed in the longitudinal direction of the groove. That is, the width W1 of the groove bottom 27a and the width of the groove opening side of the first bent groove 27 are substantially the same. Instead of this configuration, the width of the first bent groove 27 may increase toward the groove opening side. The first bent grooves 27 only need to have a width dimension W1 of the flame-retardant layer 13 exposed at the groove bottom 27a of 0.1 mm or more, and at the groove bottom 27a, a part of the fiber-reinforced resin layer 14 may remain on one side in the groove width direction of the exposed flame-retardant layer 13. In other words, at the groove bottom 27a of each first bent groove 27, the part where the flame-retardant layer 13 is exposed and the part where a part of the fiber-reinforced resin layer 14 remains may be adjacent to each other in the groove width direction.

[0027] The second bent grooves 29 are provided so that their groove bottoms 29a are located within the fiber-reinforced resin layer 14. The second bent grooves 29 may be provided so that a portion of the glass fiber sheet 15 constituting the fiber-reinforced resin layer 14 remains on the groove bottom 29a side. The second bent grooves 29 are generally V-shaped when viewed in the longitudinal direction of the groove. That is, the width of the second bent grooves 29 increases from the groove bottom 29a toward the groove opening. The thickness of the fiber-reinforced resin layer 14 on the groove bottom 29a side of the portion of the extended portion 10b where the second bent grooves 29 are provided may be half or less, or one-third or less, of the thickness of the fiber-reinforced resin layer 14 in other portions of the extended portion 10b. The extension portion 10b may be composed of only the surface layer 10 including the fiber-reinforced resin layer 14, or may have a portion of the foamed resin layer 20 on the back surface side, or may have a portion of the fiber-reinforced resin layer 14 removed. The dimension (width) of the end back surface layer 10d of the extension portion 10b along the extension direction may be an appropriate dimension from the viewpoints of strength of the side end portion 2, prevention of peeling, weight reduction, etc. For example, the width dimension of this end back surface layer 10d may be approximately 1 to 15 times, and preferably approximately 2 to 10 times, the thickness dimension of the ceiling panel 1. A recessed step for receiving this end back surface layer 10d may be provided on the back surface side of the side end portion 2.

[0028] As shown in FIG. 5(b), the component mounting portion 2a on the rear surface of the side end portion 2 of the ceiling panel 1 is provided on the rear surface layer 10d of the end portion of the extension portion 10b. This component mounting portion 2a may have a rough surface. With this configuration, the anchoring effect of the fine irregularities on the roughened component mounting portion 2a can improve the adhesive strength of the component to the component mounting portion 2a. The component mounting portion 2a may have a rough surface with a matte finish (grained), fuzziness, or polishing scratches (polishing marks). The surface roughness (surface roughness) of this component mounting portion 2a may be set appropriately so that the anchoring effect of the fine irregularities can improve the adhesive strength. As shown in FIG. 6(a), any one of the printed layer 11b, the base layer 11c, and the flame-retardant layer 13 may be exposed in the component mounting portion 2a. This configuration allows components to be attached via adhesive 9 to any one of the printed layer 11b, the base layer 11c, and the flame-retardant layer 13, which are more easily compatible with the adhesive 9 than the coating layer 11a, thereby ensuring stable component attachment. In the illustrated example, the base layer 11c is exposed in the component mounting portion 2a. That is, the component mounting portion 2a is formed by polishing away the coating layer 11a and the printed layer 11b. The illustrated example shows an example in which a portion of the base layer 11c is also polished away. If the base layer 11c is a paper base as described above, the polished surface of the base layer 11c (the surface facing the substrate) can be made rough with a fuzzy texture. Alternatively, the printed layer 11b or the flame-retardant layer 13 may be exposed in the component mounting portion 2a.

[0029] In this component mounting portion 2a, at least the coating layer 11a may be removed at least in the area where the adhesive 9 for fixing the component is applied. In FIG. 5(b), the areas where the component mounting portions 2a are formed are conveniently indicated by matte hatching. In the illustrated example, the component mounting portions 2a are provided along the entire length (entire in the second direction) of the back surface of the end portion 2, but they may also be provided at intervals on the back surface of the end portion 2. The width of the component mounting portions 2a along the first direction may be approximately 3 mm to 20 mm, or approximately 10 mm to 15 mm, depending on the dimensions of the components to be fixed with the adhesive 9. The width of the component mounting portions 2a may be smaller than the width of the end back surface layer 10d. In the illustrated example, the component mounting portions 2a are provided so as not to reach the corners of the substrate on the end surface of the end portion 2. This configuration prevents the corners of the substrate from being affected by polishing. The dimension along the first direction from the end surface of the end portion 2 to the component mounting portions 2a may be approximately 1 mm to 5 mm.

[0030] As shown in Figures 1 and 6(a), the fixing member 30 includes an attachment portion 32 attached to the component mounting portion 2a with adhesive 9, and a fixed portion 36 extending from the attachment portion 32 toward the outside of the panel and fixed to a target object. With this configuration, the side end portion 2 of the ceiling panel 1 can be fixed to the target object by the fixed portion 36. The fixed portion 36 also extends from the attachment portion 32 toward the outside of the panel. Therefore, when the fixed portion 36 is fixed to the target object, a moment acts due to the weight of the ceiling panel 1 in a direction that would peel the attachment portion 32 off. However, because the attachment portion 32 is attached to the component mounting portion 2a as described above, peeling can be suppressed. This fixing member 30 includes a panel-side member 31 having an attachment portion 32 and a base-side member 34 having a fixed portion 36. Instead of providing the attachment portion 32 and the fixed portion 36 separately in this manner, they may be provided integrally.

[0031] As shown in FIGS. 5(b) and 6(b), the panel side member 31 is elongated along the side edge 2. The mounting portion 32 of the panel side member 31 is flat and has a thickness parallel to the panel thickness direction. It is aligned with the component mounting portion 2a and fixed with an adhesive 9. The adhesive 9 may be, for example, a polyethylene (PE)-based or ethylene vinyl acetate (EVA)-based hot melt adhesive, or various other adhesives such as a silicone adhesive, an acrylic adhesive, or an epoxy adhesive. The illustrated example shows an example in which the mounting portion 32 has a plurality of elongated through-holes spaced apart along the longitudinal direction (second direction) of the mounting portion 32. In addition to the adhesive 9, the mounting portion 32 may be attached to the side edge 2 with an appropriate attachment member or fastener such as a screw. For example, both longitudinal ends of the mounting portion 32 may be fastened with fasteners to insert pieces of an attachment member inserted into the layer of the side edge 2. 1, the panel-side member 31 is provided with a fixed portion 33 to which a base-side member 34 is fixed. The fixed portion 33 is provided so as to be continuous with the outer side of the panel of the attached portion 32. The fixed portion 33 includes a portion that extends obliquely from the outer panel end of the attached portion 32 toward the outside of the panel and the base side via a portion that rises in the panel thickness direction from the outer panel end of the attached portion 32, and a portion that is provided at the outer panel portion of this extended portion and is bent in a convex curve. The panel-side member 31 is provided so as not to protrude outside the panel from the end face of the side end 2.

[0032] The substrate-side member 34 includes a fixing portion 35 that is fixed to the fixing portion 33 of the panel-side member 31, and a fixing portion 36 that is fixed to the ceiling substrate 3 to be fixed thereto. The fixing portion 35 is fixed by fastening a fastener to an oblique portion that is aligned with the obliquely extending portion of the fixed portion 33 of the panel side member 31. A hanging piece portion is provided at the panel outer end of the oblique portion of this fixing portion 35 so as to be continuous with the extending portion that extends toward the outside of the panel and hangs down toward the side end portion 2. The surface of this hanging piece portion facing the outside of the panel is approximately flush with the end face of the side end portion 2, and its lower end portion abuts against the side end portion 2. The fixed portion 36 extends further outward from the end of the extending portion of the fixing portion 35. This fixed portion 36 is flat and has a thickness that is the same as the panel thickness direction. The fixed portions 36, 36 of the side ends 2, 2 of adjacent ceiling panels 1, 1 are overlapped and aligned along the underside of the ceiling substrate 3, and are fixed to the ceiling substrate 3 by fasteners 4. In the illustrated example, one of the fixed portions 36, 36 of the side ends 2, 2 of adjacent ceiling panels 1, 1, which is located on the ceiling substrate 3 side, is positioned on the substrate side in accordance with the thickness dimension of the other fixed portion 36. This one fixed portion 36 is held so as to be sandwiched between the other fixed portion 36 and the ceiling substrate 3.

[0033] When the side edges 2, 2 of adjacent ceiling panels 1, 1 are fixed to the ceiling substrate 3 via the fixing members 30, 30 as described above, a see-through gap is formed between the end faces of the opposing side edges 2, 2 of the adjacent ceiling panels 1, 1. Instead of this configuration, the end faces of the opposing side edges 2, 2 of the adjacent ceiling panels 1, 1 may be butted together during construction. The fixing member 30 that fixes the side edge 2 of the ceiling panel 1 to the ceiling substrate 3 is not limited to the configuration described above, and may have various other configurations. The component attached to the component attachment portion 2a is not limited to the fixing member 30 described above. For example, it may be a hooked member provided on one of the adjacent ceiling panels 1 or a hooking member provided on the other panel that is hooked onto the hooked member, a magnet that is attracted to an object by magnetic force, a holder that holds a magnet, or various other components.

[0034] 5(b) and 6(b), the ceiling panel 1 includes end covers 37, 37 that cover the end faces 24 of the foamed resin layer 20 at each side end 2, 2 on both sides in the second direction. With this configuration, the end faces 24, 24 of the foamed resin layer 20 on both sides in the second direction that are not covered by the extending portion 10b as described above can be covered by the end covers 37, 37. These end covers 37, 37 are provided over the entire length of each side end 2, 2 on both sides in the second direction of the ceiling panel 1 so as to extend in the first direction. These end covers 37, 37 may be metal profiles having a substantially U-shape with recesses for receiving each side end 2, 2 of the ceiling panel 1. The panel side member 31 of the fixing member 30 described above is provided so as to be positioned between the end covers 37, 37 on both sides in the second direction. Instead of a configuration in which such end covers 37, 37 are provided, the end faces 24, 24 of the foamed resin layer 20 on both sides in the second direction may be covered with an appropriate edge sheet or the like.

[0035] Next, an example of a method for manufacturing the ceiling panel 1 as an example of an interior panel according to this embodiment will be described with reference to the drawings. In this manufacturing method, as shown in FIG. 2(a), a resin composition constituting the foamed resin layer 20A may be supplied between the front layer 10A and the back layer 16A to form the panel body 1A. Then, as shown in FIG. 2(b), the four peripheries of the panel body 1A are cut to an appropriate size. Alternatively, as shown in FIGS. 2(c) and 2(d), the foamed resin layer 20A may be cut from the back side of the side end 2A of the panel body 1A to form the first bent groove 27 and the second bent groove 29. Cutting blades 5, 5A that cut the foamed resin layer 20A from the back side of the side end 2A may form slit-shaped grooves (first groove 26 and second groove 28) 26, 28 in the side end 2A, and the first bent groove 27 and the second bent groove 29 may be formed at the bottoms of these grooves. In the illustrated example, the cutting edge of the cutting blade 5 that forms the first bent groove 27 has a cylindrical outer peripheral surface corresponding to the groove bottom 27a of the first bent groove 27. In this example, the cutting edge of the cutting blade 5A that forms the second bent groove 29 is formed in a pointed shape corresponding to the shape of the second bent groove 29.

[0036] 3(a) and 3(b), the foamed resin layer 20A on the back surface side of the side end portion 2A may be cut away to form the extended portion 10b. At this time, the foamed resin layer 20A may be cut away by aligning the cutting blade 5B along the back surface side of the extended portion 10b so as to form the above-mentioned incision 25. By cutting away the foamed resin layer 20A on the back surface side of the side end portion 2A in this manner, the extended portion 10b is formed, in which the first bent groove 27 and the second bent groove 29, which form the groove bottom sides of the first groove 26 and the second groove 28, are formed. 3(c), an adhesive 6 is applied to the side edge 2A of the panel body 1A to fold and adhere the extended portion 10b. Similar to the adhesive 9, various adhesives may be used for this adhesive 6. The adhesive 6 may be applied to the back surface and end surface of the side edge 2 so that the adhesive resin 6A formed upon curing fills the first folding groove 27 as described above, or a portion of the adhesive applied to the back surface may hang down and be attached to the end surface 24.

[0037] Then, as shown in Figures 4(a) and (b), the extended portion 10b may be folded at each of the folding grooves 27, 29 using an appropriate guide roller 7, and the end back surface layer 10d may be folded back so as to overlap the back surface layer 16, and the adhesive 6 may be hardened. Next, as shown in FIGS. 5(a) and 5(b), the coating layer 11a of the decorative layer 11 on the back surface of the side end portion 2 may be polished and removed with an appropriate polishing member 8 to form the component mounting portion 2a. 5(b) and 6(a) and (b), a panel-side member 31 may be fixed to the component mounting portion 2a with an adhesive 9. Also, as shown in Fig. 1, a base-side member 34 may be fixed to the panel-side member 31 with a fastener. The above manufacturing process is merely an example and can be modified as appropriate.

[0038] Next, a modified example will be described. In each of the following modified examples, differences from the previously described example will be mainly described, and the same components will be denoted by the same reference numerals and their description will be omitted or simplified. In each of the following modified examples, description of the same effects as those of the previously described example will also be omitted or simplified.

[0039] 7(a) and 7(c) are diagrams that schematically show a ceiling panel 1C as an example of an interior panel according to a first modified example. In this modification, the first bent groove 27A is formed so that the groove bottom 27Aa faces a part of the end surface 24 that is continuous with the indoor corner portion 24a. With this configuration, it is possible to more effectively reduce the influence of the fiber reinforced resin layer 14. In this modification, the first bent groove 27A is formed in the extending portion 10b of the panel body 1B that becomes the ceiling panel 1C so that the width dimension W2 is larger than that of the above-described example. The width dimension W2 of this first bent groove 27A may be approximately 1 / 10 to 2 / 3 of the width dimension of the end surface layer 10c of the extending portion 10b (the thickness dimension of the foamed resin layer 20). In the illustrated example, the width dimension W2 of the first bent groove 27A is approximately 1 / 2 of the width dimension of the end surface layer 10c of the extending portion 10b. As in the above, the first bent groove 27A is filled with adhesive resin 6B.

[0040] 7(b) and (d) are diagrams that schematically show a ceiling panel 1E as an example of an interior panel according to a second modified example. In this modified example, the flame-retardant layer 13 is exposed at the groove bottoms 29Aa of the second bent grooves 29A. With this configuration, the fiber-reinforced resin layer 14 is not present on the groove bottom 29Aa side, which prevents the rigidity of the fiber-reinforced resin layer 14 from making the ridge lines unclear and prevents the decorative layer 11 on the surface side from breaking at the corners on the base side, thereby improving the appearance of the corners. In other words, in this modified example, the flame-retardant layer 13 is exposed at the groove bottoms 27a, 29Aa of both the first bent groove 27 and the second bent groove 29A. The second bent groove 29A has a substantially rectangular shape when viewed in the longitudinal direction of the groove, similar to the above-described first bent groove 27. As for the width dimension W3 of the second bent groove 29A, the width dimension W3 of the flame-retardant layer 13 exposed at the groove bottom 29Aa may be 0.1 mm or more, similar to the above. As in the above, the second bent groove 29A is also filled with adhesive resin 6C.

[0041] The different configurations described in the above examples may be appropriately modified, rearranged, or combined as needed. In the above examples, the fiber reinforced resin layers 14, 18 on both sides of the foamed resin layer 20 in the thickness direction are formed by impregnating the glass fiber sheets 15, 19 with the resin composition that constitutes the foamed resin layer 20, but this is not limited to this. One or both of the fiber reinforced resin layers 14, 18 on both sides of the foamed resin layer 20 in the thickness direction may be formed separately from the foamed resin layer 20 and laminated together with an appropriate adhesive. In each of the above examples, a back surface layer 16 including a back surface fiber reinforced resin layer 18 and a back surface flame retardant layer 17 is provided on the ceiling substrate 3 side of the foamed resin layer 20, but it is also possible to have a configuration in which both or one of the back surface fiber reinforced resin layer 18 and the back surface flame retardant layer 17 is not provided. In each of the above examples, the flame-retardant layer 13 is exposed at the groove bottoms 27a, 27Aa of the first bent grooves 27, 27A, but the first bent grooves 27, 27A may be generally similar to the second bent grooves 29 or may have other shapes. In the above example, the panel core layer is a foamed resin layer 20, but it may also be a fiber-based core layer made from mineral fibers such as glass wool or rock wool, or gypsum board, calcium silicate board, or wood-based board. In the above example, the fiber reinforced resin layer 14 is provided on the surface layer 10, but the fiber reinforced resin layer 14 may not be provided. The above-described configurations of the respective parts of the ceiling panels 1, 1C, and 1E according to this embodiment are merely examples, and various other modifications are possible.

[0042] <Additional Notes> The above description of the embodiment discloses the following technology relating to an interior panel that is installed with its back surface facing the interior substrate. <Technology 1> The interior panel is configured such that a surface layer including a flame-retardant layer and a decorative layer provided on the interior side of the panel core layer is provided on the interior side of the panel. At least one end face of the panel core layer that is perpendicular to the interior side face and a back face that is perpendicular to the end face are covered by an extended portion of the surface layer that extends continuously from a portion covering the interior side face. On the back face of one end of the interior panel, the coating layer of the decorative layer at the extended portion covering the back face of the panel core layer is polished and removed to form a component mounting portion. <Technology 2> The interior panel according to Art. 1, wherein the part mounting portion has a rough surface. <Technology 3> An interior panel according to Technology 1 or Technology 2, wherein the decorative layer has a printed layer and a base material layer on the flame-retardant layer side of the coating layer, and any one of the printed layer, the base material layer and the flame-retardant layer is exposed in the part mounting portion. <Technology 4> The interior panel is a ceiling panel, and includes an attachment portion attached to the component attachment portion with an adhesive, and a fixed portion extending from the attachment portion toward the outside of the panel and fixed to a fixing object. The interior panel according to any one of Techniques 1 to 3. [Explanation of symbols]

[0043] 1, 1C, 1E Ceiling panel (interior panel) 2 side ends 2a Parts mounting section 9. Adhesive 10 Surface layer 10b Extension part (surface layer) 11 Cosmetic layer 11a Coat layer 11b Printing layer 11c Base layer 13 Flame retardant layer 20 Foamed resin layer (panel core layer) 21 Interior side 22 Back side 23 Side edge 24 End face 32 Mounting part 36 Fixed part 3 Ceiling base (interior base)

Claims

1. An interior panel that is installed with the back side facing the interior substrate, A surface layer including a flame-retardant layer and a decorative layer provided on the indoor side of the flame-retardant layer is provided on the indoor side of the panel core layer, An interior panel characterized in that an end face of at least one side end of the panel core layer that is perpendicular to the interior side surface and a back surface that is perpendicular to the end face are covered by an extended portion of the surface layer that extends continuously from the portion covering the interior side surface, and a component mounting portion is formed on the back surface of one side end of the interior panel by polishing away the coating layer of the decorative layer of the extended portion that covers the back surface of the panel core layer.

2. In claim 1, An interior panel characterized in that the component mounting portion has a rough surface.

3. In claim 1, The decorative layer includes a printed layer and a base material layer on the flame-retardant layer side of the coating layer, and any one of the printed layer, the base material layer, and the flame-retardant layer is exposed in the component mounting portion.

4. In any one of claims 1 to 3, The interior panel is a ceiling panel, and is characterized by comprising: an attachment portion attached to the component attachment portion with an adhesive; and a fixed portion extending from the attachment portion toward the outside of the panel and fixed to a fixing object.

Images