Interior panels

Abstract

To provide an interior panel capable of improving the appearance of a corner part on the interior side at 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 an interior base 3 side. At the indoor side of a foamed resin layer 20, a surface layer 10 is provided which includes a fiber-reinforced resin layer 14, a flame retardant layer 13 provided at the indoor side of the fiber-reinforced resin layer, and a decorative layer 11 provided at the indoor side of the flame retardant layer. An end surface 24 which is perpendicular to an indoor side surface 21 of at least one side end portion 23 of the foamed resin layer and a back surface 22 that is formed in an intersecting shape to the end surface are covered by an extension part 10b of the surface layer that extends in a series from a part covering the room side surface. At a position corresponding to an indoor corner part 24a of the end face of the one side end portion of the extension part, a bent groove 27 is provided in which the fiber-reinforced resin layer is removed and the flame retardant layer is exposed at a groove bottom 27a.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present disclosure relates to interior panels that make up the ceilings and walls of buildings.

Background Art

[0002] Conventionally, interior panels that make up the ceilings and walls of buildings have sometimes been required to have flame retardancy (non-combustibility). As such interior panels, there are some that are configured to have a non-combustible layer or a decorative layer provided on the indoor side surface of a heat-insulating base material made of a resin foam from the perspective of weight reduction. However, there has been a concern that the non-combustible performance will deteriorate if the base material is exposed at the end face. For example, Patent Document 1 below discloses an interior panel covered by an extension part of a surface layer including a fiber-reinforced resin layer, a flame retardant layer, and a decorative layer, in which the end faces and the back surfaces of one side end parts of a foamed resin layer extend in series from a part covering the indoor side surface. This interior panel is configured to have a bending groove whose groove bottom is located within the fiber-reinforced resin layer at a position corresponding to the indoor side surface side corner of the end face of one side end part in the extension part.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] However, in the interior panel described in Patent Document 1 above, a fiber-reinforced resin layer exists on the groove bottom side of the bending groove. Depending on the type of the decorative layer, such as when there is a concern that the ridge line becomes unclear when bent at this part due to the rigidity of the fiber-reinforced resin layer on the groove bottom side, or when the decorative layer is a decorative sheet that is easily broken, there is a concern that the decorative layer on the surface side breaks at the indoor side corner.

[0005] This disclosure has been made in view of the above circumstances and aims to provide an interior panel that can improve flame retardancy at least at one end in addition to flame retardancy on the interior side, while also improving the appearance of the interior corner at one end. [Means for solving the problem]

[0006] To achieve the above objective, the interior panel according to this disclosure is an interior panel installed with its back side facing the interior substrate side, wherein a surface layer is provided on the interior side of a foamed resin layer, the surface layer includes a fiber-reinforced resin layer, a flame-retardant layer provided on the interior side of the fiber-reinforced resin layer, and a decorative layer provided on the interior side of the flame-retardant layer, the end face perpendicular to the interior side surface of at least one end of the foamed resin layer and the back surface perpendicular to the end face are covered by an extended portion of the surface layer that extends in a continuous manner from the portion covering the interior side surface, and a bent groove is provided at a position corresponding to the interior corner of the end face of the one end in the extended portion, where the fiber-reinforced resin layer is removed and the flame-retardant layer is exposed at the bottom of the groove. [Effects of the Invention]

[0007] The interior panel relating to this disclosure, with the configuration described above, makes it possible to improve flame retardancy at least at one end in addition to flame retardancy on the interior side, while also improving the appearance of the interior corner at one end. [Brief explanation of the drawing]

[0008] [Figure 1] This is a schematic, partially broken longitudinal cross-sectional view showing an example of an interior panel according to one embodiment of the present disclosure. [Figure 2] (a) to (c) are schematic cross-sectional views with partial breaks illustrating an example of the manufacturing method of the interior panel, and (d) is a partially broken, enlarged cross-sectional view with partial breaks corresponding to the X1 portion in (c). [Figure 3](a) and (c) are schematic partially broken longitudinal section views illustrating an example of a manufacturing method for the interior panel, and (b) is a partially broken, enlarged longitudinal section view corresponding to section X2 in (a). [Figure 4] (a) and (b) are schematic cross-sectional views with partial breaks illustrating an example of a manufacturing method for the interior panel, and (c) is a partially broken, enlarged cross-sectional view with partial breaks corresponding to section X3 in (b). [Figure 5] (a) is a schematic partially broken longitudinal section view illustrating an example of the manufacturing method of the interior panel, and (b) is a partially broken schematic exploded plan view with a portion of the interior panel omitted. [Figure 6] (a) is a schematic partially broken longitudinal section view illustrating an example of the manufacturing method of the interior panel, and (b) is a partially broken schematic plan view of the interior panel with a portion omitted. [Figure 7] (a) to (d) schematically show a modified example of the interior panel, with (a) and (b) being partially broken schematic enlarged longitudinal cross-sectional views corresponding to Figure 3(b), and (c) and (d) being partially broken schematic enlarged longitudinal cross-sectional views corresponding to Figure 4(c), respectively. [Modes for carrying out the invention]

[0009] Embodiments of this disclosure will be described below with reference to the drawings. In some of the figures, some of the detailed symbols used in other figures have been omitted. In the following embodiments, directions such as the vertical direction will be explained based on the state in which a ceiling panel, as an example of an interior panel according to this embodiment, has been installed. Figures 1 to 7 schematically show an example and a modified example of an interior panel according to this embodiment, as well as 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 Figure 1, it is installed with its back side 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 provided on the interior side of the foamed resin layer 20. With this configuration, it is possible to reduce the weight compared to wood-based boards or gypsum boards. The ceiling substrate 3 to which this ceiling panel 1 is fixed may be a wooden ceiling substrate or a steel ceiling substrate. Alternatively, the ceiling substrate 3 may be a so-called lightweight ceiling substrate made of light steel. In the illustrated example, the ceiling substrate 3 is shown as a channel-shaped steel joist. This ceiling substrate 3 may also constitute a so-called suspended ceiling, suspended via appropriate joist hangers and suspension members such as hangers and suspension bolts that suspend the joist hangers, and may be configured in various ways.

[0011] This ceiling panel 1 may be installed as a ceiling in relatively small buildings such as residences and offices, or as a ceiling in various relatively large buildings such as gymnasiums, halls, shopping malls, factories, and schools. This ceiling panel 1 has a unit area (1m²). 2 The mass per ) may be 2.0 kg or less. The mass of this ceiling panel 1 is calculated as follows: The mass of the entire ceiling system, including the ceiling base 3 made of the light ceiling base as described above, is 2.0 kg / m 2 The mass may be as follows. Note that 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, wall substrates such as studs and joists should be used as the interior substrate.

[0012] As shown in Fig. 5(b), this ceiling panel 1 is substantially square-shaped in plan view (when viewed in the thickness direction). This ceiling panel 1 may be substantially square-shaped or substantially rectangular-shaped in plan view. The size of this ceiling panel 1 in the plan view may be an appropriate size from the viewpoints of handling property, constructability, etc. For example, the length of one side may be 0.3 m or more and may be 2.5 m or less. In the ceiling panel 1 that is substantially rectangular-shaped, 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 ceiling panel 1 that is substantially square-shaped, the length of one side may be 0.6 m or more and 1.5 m or less, and may also be about 0.8 m to 1.2 m. The thickness of this ceiling panel 1 may be about 2.5 mm to 15.0 mm depending on the layer structure, etc., preferably about 3.0 mm to 12.0 mm, and more preferably about 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 this flame-retardant layer 13. With such a configuration, the flame retardancy on the indoor side can be improved. In this embodiment, the surface layer 10 includes a fiber-reinforced resin layer 14 provided on the interior base side (base side) of the flame-retardant layer 13. That is, the flame-retardant layer 13 is provided on the indoor side of the fiber-reinforced resin layer 14. With such a configuration, the fiber-reinforced resin layer 14 functions as a reinforcing layer, and the bending rigidity and dimensional stability of the entire ceiling panel 1 can be improved. Thereby, while achieving weight reduction, sagging after construction can be effectively suppressed, making it suitable as the ceiling panel 1.

[0014] The end face 24 and the back surface 22 of at least one end 23 of the foamed resin layer 20, which are perpendicular to the interior side surface 21, are covered by an extended portion 10b of the surface layer 10 that extends in a continuous manner from the portion covering the interior side surface 21. With this configuration, the flame retardancy of at least one end 2 of the ceiling panel 1 and the back surface can be improved. As a result, even if a fire occurs on the interior side when adjacent ceiling panels 1,1 are installed with their end faces facing each other, the combustion from the end face can be delayed compared to a configuration in which the foamed resin layer 20 is exposed at the end face. In addition, moisture absorption from the end face 24 can be suppressed compared to a configuration in which the end face 24 of the foamed resin layer 20 is exposed. In this embodiment, the fiber-reinforced resin layer 14 is also provided in a continuous manner on the end face and the back surface of one end 2, so the bending rigidity of one end 2 can be improved. Furthermore, since the surface layer 10 is provided in a continuous manner from the interior side surface to the end face and back surface of this one end portion 2, the appearance of the interior corner (edge) can be improved compared to, for example, a method of covering the end face 24 by attaching an edge sheet. In addition, peeling of the surface layer 10 can be suppressed. Moreover, if, for example, fasteners such as screws are attached to the portion where the extended portion 10b (end back surface layer 10d) is provided on the back surface of the one end portion 2, the fastener retention force can also be improved.

[0015] As shown in Figures 5 and 6, on the back surface of one end portion 2 of the ceiling panel 1, the coating layer 11a of the decorative layer 11 of the extended portion 10b covering the back surface 22 of the foamed resin layer 20 is polished off to form a component mounting portion 2a. With this configuration, since the coating layer 11a, which has release properties for stain prevention, etc., is polished off, it becomes difficult for components such as the fixing member 30 described later to peel off when attached with adhesive 9, and components can be attached stably. At a position corresponding to the indoor-side corner 24a of the end face 24 of one-side end 23 in the extending portion 10b, a bent groove (first bent groove) 27 is provided where 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 such a configuration, the extending portion 10b becomes thinner than other portions at the portion where the first bent groove 27 is provided, and it becomes easier to bend at that portion. Also, the fiber-reinforced resin layer 14 does not exist on the groove bottom 27a side. For this reason, even when the ridgeline becomes unclear due to the rigidity of the fiber-reinforced resin layer 14 or the decorative layer 11 on the surface side is likely to break, it is possible to suppress the decorative layer 11 on the surface side from breaking at the indoor-side corner, and the appearance of the corner can be improved. A second bent groove 29 is provided at a position corresponding to the base-side corner 24b of the end face 24 of one-side end 23 in the extending portion 10b. With such a configuration, similarly to the above, the extending portion 10b becomes thinner than other portions at the portion where the second bent groove 29 is provided, and it becomes easier to bend at that portion.

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

[0017] The flame-retardant layer 13 may be configured in a manner that is appropriate so that the ceiling panel 1 meets the technical standards for performance required for non-combustible materials as stipulated in the Building Standards Act. For example, the ceiling panel 1 may be configured to meet the standard for "flame-retardant material" in the technical standards, preferably to meet the standard for "semi-non-combustible material," and more preferably to meet the standard for "non-combustible material." 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 about 5 μm to 50 μm, preferably about 7 μm to 40 μm, and more preferably about 10 μm to 30 μm. The metal sheet constituting the flame-retardant layer 13 may be made of aluminum, tin, gold, silver, copper, etc., from the viewpoint of ease of bending, and preferably an aluminum sheet. The flame-retardant layer 13 is not limited to the configuration described above, and may have various other configurations. For example, the flame-retardant layer 13 may be a resin-impregnated glass fiber nonwoven fabric board containing an endothermic metal hydroxide. The decorative layer 11 and the flame-retardant layer 13 are laminated and integrated via an appropriate adhesive layer 12. This adhesive layer 12 may be formed from 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 main resin component of this fiber-reinforced resin layer 14 may be the same as the main resin component of the foamed resin layer 20. The glass fiber sheet 15 that makes up this fiber-reinforced resin layer 14 has a basis weight of 50 g / m². 2 ~300g / m 2 Glass cloth may also be used. The basis weight of the glass fiber sheet 15 is preferably 50 g / m². 2 ~150g / m 2 But often, comfortably, 50g / m 2~100g / m 2 However, this is also acceptable. The glass fiber sheet 15 may be a thin sheet with a thickness of about 0.1 mm to 0.5 mm. Furthermore, the glass fiber sheet 15 is preferably a woven fabric of glass fibers, for example, a glass cloth which is a plain weave or leno weave fabric woven using glass roving for the warp and weft threads. The glass fiber sheet 15 is not limited to such glass cloth, but may also be glass paper or glass mat. The fiber-reinforced resin layer 14 may be formed by impregnating a 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 on a part of the foamed resin layer 20. This fiber-reinforced resin layer 14 may contain air bubbles due to the foaming of the resin composition.

[0019] A composite sheet in which a glass fiber sheet 15 is laminated and integrated with the ceiling substrate 3 side of the laminated decorative layer 11 and flame retardant layer 13 using an appropriate adhesive may be laminated and integrated with the foamed resin layer 20 using the resin composition that constitutes the foamed resin layer 20. In this case, the flame retardant layer 13 may be at least partially bonded 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 bonded to the flame retardant layer 13 in such a way that it seeps out from the glass fiber sheet 15, which has a small basis weight and many gaps as described above. The adhesive used to laminate and integrate the flame retardant layer 13 and the glass fiber sheet 15 may be applied to the glass fiber sheet 15 in such a way that it allows the resin composition that constitutes the fiber-reinforced resin layer 14 to seep out from the glass fiber sheet 15.

[0020] In this embodiment, as shown in Figure 1, the ceiling panel 1 includes a back surface layer 16 which comprises a back surface fiber-reinforced resin layer 18 provided on the ceiling substrate 3 side that is the back surface 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 sandwiched between fiber-reinforced resin layers 14 and 18 that constitute reinforcing layers on both sides in the thickness direction. The fiber-reinforced resin layer 18 on the back side may have the same main resin component as the fiber-reinforced resin layer 14 that constitutes the surface layer 10 described above. Also, similarly to the above, the fiber-reinforced resin layer 18 on the back side may be formed by impregnating the glass fiber sheet 19 with the resin composition that constitutes the foamed resin layer 20. Similar to the above, the fiber-reinforced resin layer 18 on the back side may contain air bubbles due to the foaming of the resin composition.

[0021] The flame-retardant layer 17 on the back side may be the same as the flame-retardant layer 13 described above, or it may be a metal sheet. This flame-retardant layer 17 on the back side may also function as an elution-inhibiting layer that suppresses the elution of the resin composition constituting the fiber-reinforced resin layer 18 on the back side. The flame-retardant layer 17 on the back side may be a thinner sheet than the flame-retardant layer 13 described above. For example, the thickness of the flame-retardant layer 17 on the back side may be about 2 / 5 to 3 / 5 the thickness of the flame-retardant layer 13. A composite sheet, in which a glass fiber sheet 19 constituting the back-side fiber-reinforced resin layer 18 is laminated and integrated with the back-side flame-retardant layer 17 using an appropriate adhesive, may be laminated and integrated with the foamed resin layer 20 using the resin composition constituting the foamed resin layer 20. In this case, the back-side flame-retardant layer 17 may be at least partially bonded to the resin composition that has passed through the glass fiber sheet 19 constituting the back-side fiber-reinforced resin layer 18. In other words, the resin composition constituting the foamed resin layer 20 may be partially bonded to the back-side flame-retardant layer 17 in such a way that it seeps out from the glass fiber sheet 19, which has a small basis weight and many gaps as described above. Furthermore, the adhesive used to laminate and integrate the back-side flame-retardant layer 17 and the glass fiber sheet 19 may be applied to the glass fiber sheet 19 in such a way that it allows 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 most of the ceiling panel 1. The thickness of this foamed resin layer 20 is preferably 80% to 99% of the thickness of the ceiling panel 1, and more preferably 85% to 95%. The thickness of this foamed resin layer 10 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 this foamed resin layer 20 may be a foamed polyurethane resin with a foaming ratio of 10 to 30 times. The foaming ratio of the resin composition constituting this 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 include 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 resin, polystyrene resin, polyethylene resin, polypropylene resin, phenolic resin, epoxy resin, and the like.

[0023] The extended portion 10b is provided so as to cover the ceiling substrate 3 side of the back layer 16, which extends to the substrate-side corner 24b of the end face 24 of the end face 23 of one side of the foamed resin layer 20. This extended portion 10b is a continuous extension from the interior side layer 10a, which constitutes the interior side surface of the ceiling panel 1 and covers the interior side surface 21 of the foamed resin layer 20. This extended portion 10b includes an end face layer 10c that covers the end face 24 of one side end 23 of the foamed resin layer 20, and an end back layer 10d that covers the back side (ceiling base 3 of the back layer 16) of one side end 2. The extended portion 10b, including the end face layer 10c and the end back surface layer 10d, is provided at both ends 2,2 of the ceiling panel 1 in the first direction (e.g., the panel width direction), but not at both ends 2,2 of the ceiling panel 1 in the second direction perpendicular to the first direction (e.g., the panel longitudinal direction) (see Figure 5(b)). In other words, at both ends 2,2 of the ceiling panel 1 in the second direction, the end face 24 of the foamed resin layer 20 is not covered by the extended portion 10b. Alternatively, the extended portion 10b, including the end face layer 10c and the end back surface layer 10d, may be provided at the four perimeter side ends 2,2,2,2 of the ceiling panel 1. Since the side ends 2,2 on both sides in the first direction have similar configurations, the details will be explained below using one side end 2 as an example.

[0024] The end face of side end 2 is perpendicular to the interior side and back (substrate side) of the ceiling panel 1. Here, perpendicular means that the angle between the end face and the interior side and back is not limited to 90 degrees, but also includes, for example, angles of about 85 to 95 degrees. When installing adjacent ceiling panels 1,1 with their end faces in contact with each other, the angle between the end face and the interior side may be less than 90 degrees (for example, 85 to 89 degrees). The end face 24 of the side edge 23 of the foamed resin layer 20 is perpendicular to the indoor side surface 21 and back surface 22 of the foamed resin layer 20, as described above. In this embodiment, as shown in Figure 3(b), a notch 25 that opens on the end face 24 is provided at the indoor side corner 24a of the end face 24. This notch 25 opens in the direction of extension of the extension portion 10b when the extension portion 10b is not bent (unfolded state) and is provided in a groove shape along the entire length of the side edge 23. The groove depth dimension along the extension direction and the groove width dimension along the panel thickness direction of this notch 25 may be, for example, about 0.1 mm to 1.0 mm. In the example shown, the groove depth dimension of the notch 25 is shown to be greater than the groove width dimension, but the embodiment is not limited to this. Also, in the example shown, the groove bottom side of the notch 25 is shown to be approximately V-shaped when viewed in the longitudinal direction of the groove, but the embodiment is not limited to this.

[0025] The first bending groove 27 provided in the extended portion 10b is positioned at the inner corner between the extended portion 10b and the end face 24 in the unbent state (unfolded state), as shown in Figure 3(b). The second bending groove 29 is positioned at the boundary between the end face layer 10c and the end back layer 10d of the extended portion 10b. In other words, the dimensions along the extension direction (groove width direction) of the extended portion 10b from the first bending groove 27 to the second bending groove 29 are dimensions corresponding to the thickness of the foamed resin layer 20. These first bending groove 27 and second bending groove 29 are provided in a groove-like manner throughout the entire surface, opening toward one side in the panel thickness direction (towards the ceiling substrate 3) when the extended portion 10b is unfolded, and extending parallel to each other along the side end portion 2 (2A). As shown in Figure 4(c), the first bending groove 27 is filled with adhesive resin 6A to bond the extended portion 10b to the end face 24 and the back surface 22. With this configuration, even when the width dimension W1 of the first bending groove 27 is relatively large, the adhesive resin 6A is filled in the area where the fiber-reinforced resin layer 14 has been removed, making it less likely for steps or other unevenness to occur at the end face of one end portion 2, and the indoor side corner can also be reinforced with adhesive resin 6A.

[0026] The width dimension W1 of the groove bottom 27a of the first bending groove 27 may be 0.1 mm or more. With this configuration, the influence of the fiber-reinforced resin layer 14 can be reduced, making it easier to bend and improving the appearance of the interior corner. In other words, the width dimension W1 of the flame-retardant layer 13 exposed at the groove bottom 27a of the first bending groove 27 may be 0.1 mm or more. The width dimension W1 of the flame-retardant layer 13 exposed at the groove bottom 27a of the first bending groove 27 may be 0.3 mm or more, or 0.5 mm or more. The first bent groove 27 is approximately rectangular in shape when viewed in the longitudinal direction of the groove. That is, the width dimension W1 of the groove bottom 27a of the first bent groove 27 is approximately the same as the width dimension on the groove opening side. Alternatively, the width dimension of the first bent groove 27 may increase towards the groove opening side. The first bent groove 27 only needs to have a width dimension W1 of 0.1 mm or more of the flame retardant layer 13 exposed at the groove bottom 27a, and a portion of the fiber-reinforced resin layer 14 may remain on one side in the groove width direction of the exposed flame retardant layer 13 at the groove bottom 27a. In other words, at the groove bottom 27a of the first bent groove 27, the portion where the flame retardant layer 13 is exposed and the portion where a portion of the fiber-reinforced resin layer 14 remains may be provided adjacent to each other in the groove width direction.

[0027] The second bending groove 29 is provided such that its groove bottom 29a is located within the fiber-reinforced resin layer 14. The second bending groove 29 may be provided such 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 bending groove 29 is approximately V-shaped when viewed in the longitudinal direction of the groove. In other words, the width dimension of the second bending groove 29 increases from the groove bottom 29a toward the groove opening side. 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 bending groove 29 is provided may be 1 / 2 or less, or 1 / 3 or less, of the thickness of the fiber-reinforced resin layer 14 in other parts of the extended portion 10b. The extended portion 10b may consist only of the surface layer 10 including the fiber-reinforced resin layer 14, but a portion of the foamed resin layer 20 may be provided on the back side, and a portion of the fiber-reinforced resin layer 14 may be cut off. The dimension (width dimension) of the end back layer 10d of the extended portion 10b along the extension direction may be set to an appropriate dimension from the viewpoint of strength of the side end 2, from the viewpoint of suppressing peeling, from the viewpoint of reducing weight, etc. For example, the width dimension of this end back layer 10d may be about 1 to 15 times the thickness dimension of the ceiling panel 1, preferably about 2 to 10 times. A recessed step portion to receive this end back layer 10d may be provided on the back side of the side end 2.

[0028] As shown in Figure 5(b), the component mounting portion 2a on the back surface of the side end portion 2 of the ceiling panel 1 is provided on the back surface layer 10d of the extended portion 10b. The component mounting portion 2a may have a rough surface. With this configuration, the adhesive strength of the component to the component mounting portion 2a can be improved by the anchoring effect of the fine irregularities of the rough surface of the component mounting portion 2a. The component mounting portion 2a may have a rough surface such as a textured (grained), fuzzy, or polished (polished) surface. The surface roughness (surface roughness) of the component mounting portion 2a may be set appropriately so that the adhesive strength can be improved by the anchoring effect of the fine irregularities. As shown in Figure 6(a), the component mounting portion 2a may have any of the printed layer 11b, the base material layer 11c, or the flame retardant layer 13 exposed. With this configuration, the component can be attached via the adhesive 9 to any of the printed layer 11b, base material layer 11c, or flame retardant layer 13, which the adhesive 9 adheres to more easily than the coated layer 11a, thus enabling stable attachment of the component. In the illustrated example, the component mounting portion 2a is configured with the base material layer 11c exposed. In other words, the component mounting portion 2a is formed by grinding away the coated layer 11a and the printed layer 11b. In the illustrated example, a part of the base material layer 11c is also shown to have been ground away. If the base material layer 11c is made of paper as described above, the surface of the ground base material layer 11c (the side facing the substrate) can be made into a rough surface with a so-called fuzzy texture. Alternatively, the component mounting portion 2a may have either the printed layer 11b or the flame retardant layer 13 exposed.

[0029] In this component mounting portion 2a, it is sufficient that at least the coating layer 11a is removed in the area where the adhesive 9 used to fix the component is applied. In Figure 5(b), the area where the component mounting portion 2a is formed is conveniently indicated by textured hatching. In the example shown, the component mounting portion 2a is provided along the entire length (the entire second direction) of the back surface of the side end portion 2, but it may also be provided at intervals on the back surface of the side end portion 2. The width dimension of this component mounting portion 2a along the first direction depends on the dimensions of the component to be fixed with adhesive 9, but it may be about 3 mm to 20 mm or about 10 mm to 15 mm. The width dimension of this component mounting portion 2a may be smaller than the width dimension of the back surface layer 10d of the end portion. In the example shown, the component mounting portion 2a is provided so as not to reach the base side corner of the end face of the side end portion 2. With this configuration, the effects of polishing will not occur on the base side corner. The dimension along the first direction from the end face of the side end portion 2 to the component mounting portion 2a may be about 1 mm to 5 mm.

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

[0031] As shown in Figures 5(b) and 6(b), the panel side member 31 is elongated along the side end 2. The mounting portion 32 of this panel side member 31 is flat with its thickness direction being the same as the panel thickness direction, and is fixed to the component mounting portion 2a with adhesive 9. This adhesive 9 may be a hot melt adhesive such as polyethylene (PE) or ethylene vinyl acetate (EVA), or various other adhesives such as silicone adhesive, acrylic adhesive, or epoxy adhesive. In the illustrated example, the mounting portion 32 is shown to have multiple elongated through holes spaced apart in the longitudinal direction (second direction) of the mounting portion 32. In addition to the adhesive 9, this mounting portion 32 may be attached to the side end 2 by appropriate mounting members or fasteners such as screws. For example, both longitudinal ends of the mounting portion 32 may be fastened to the insertion pieces of a mounting member inserted into the layer of the side end 2 with fasteners. As shown in Figure 1, the panel-side member 31 is provided with a fixing portion 33 to which the base-side member 34 is fixed. This fixing portion 33 is provided so as to be continuous with the outside of the panel of the mounting portion 32. This fixing portion 33 includes a portion that extends diagonally outward from the outer edge of the panel of the mounting portion 32 in the panel thickness direction, and a portion that is provided on the outer panel portion of this extended portion and is bent in a protruding curved shape. This panel-side member 31 is provided so as not to protrude outward from the end face of the side end 2.

[0032] The base-side member 34 includes a fixing portion 35 that is fixed to the fixed portion 33 of the panel-side member 31, and a fixed portion 36 that is fixed to the ceiling base 3 to be fixed. 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. The outer end of the oblique portion of this fixing portion 35 is provided with a hanging piece that hangs down toward the side end 2 via an extending portion that extends toward the outside of the panel. The surface of this hanging piece that faces toward the outside of the panel is substantially flush with the end surface of the side end 2, and its lower end is in contact with the side end 2. The fixed portion 36 is provided to extend further outward from the end of the extended portion of the fixing portion 35. This fixed portion 36 is a flat plate with its thickness direction in the same direction as the panel thickness. The fixed portions 36, 36 of the side ends 2, 2 of adjacent ceiling panels 1, 1 are overlapped and aligned along the lower surface of the ceiling substrate 3, and 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 that faces the ceiling substrate 3 is provided so as to be positioned on the substrate side according to the thickness dimension of the other. This one fixed portion 36 is held between the other fixed portion 36 and the ceiling substrate 3.

[0033] As described above, when the side ends 2,2 of adjacent ceiling panels 1,1 are fixed to the ceiling substrate 3 via fixing members 30,30, a gap resembling a slit is formed between the end faces of the opposing side ends 2,2 of adjacent ceiling panels 1,1. Alternatively, the end faces of the opposing side ends 2,2 of adjacent ceiling panels 1,1 may be butted together during installation. The fixing member 30 that secures the side end 2 of the ceiling panel 1 to the ceiling base 3 is not limited to the configuration described above, and may have various other configurations. The parts that can be attached to the parts mounting part 2a are not limited to the fixing member 30 described above. For example, it may be a hooking member provided on one of two adjacent ceiling panels 1 and a hooking member provided on the other that can be hooked onto it, or it may be a magnet that is attracted to the object by magnetic force, or a holder that holds the magnet, or any other part.

[0034] As shown in Figures 5(b) and 6(b), the ceiling panel 1 is equipped with end face covers 37, 37 that cover the end faces 24 of the foamed resin layer 20 at each side end 2, 2 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 extended portion 10b as described above can be covered by the end face covers 37, 37. These end face covers 37, 37 are provided along the entire length of each side end 2, 2 on both sides of the ceiling panel 1 in the second direction, extending in the first direction. These end face covers 37, 37 may be metal profiles in 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 located between the end face covers 37, 37 on both sides in the second direction. Instead of this configuration with end face covers 37, 37, 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 manufacturing method for the ceiling panel 1, which is 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 Figure 2(a), the resin composition constituting the foamed resin layer 20A may be supplied between the surface layer 10A and the back layer 16A to form the panel body 1A. Then, as shown in Figure 2(b), the four sides of the panel body 1A are cut to an appropriate size. Alternatively, as shown in Figures 2(c) and (d), the first bend groove 27 and the second bend groove 29 may be formed by cutting the side end 2A of the panel body 1A so as to divide the foamed resin layer 20A from the back side. Slit-shaped grooves (first groove 26 and second groove 28) 26, 28 may be formed in the side end 2A by cutting blades 5, 5A that divide the foamed resin layer 20A from the back side of the side end 2A, and the first bend groove 27 and the second bend groove 29 as described above may be formed at the bottom of these grooves. In the illustrated example, the cutting edge of the cutting blade 5 that forms the first bend groove 27 is shown as a cylindrical outer surface corresponding to the groove bottom 27a of the first bend groove 27. This example shows a cutting edge 5A that forms the second bending groove 29, with the cutting edge shaped to be pointed according to the shape of the second bending groove 29.

[0036] Furthermore, as shown in Figures 3(a) and (b), the foamed resin layer 20A on the back side of the side end portion 2A may be cut to form the extended portion 10b. In this case, the cutting blade 5B may be guided along the back side of the extended portion 10b to cut the foamed resin layer 20A so that the above-described notch 25 is formed. By cutting the foamed resin layer 20A on the back side of the side end portion 2A in this way, the extended portion 10b is formed in which the first bent groove 27 and the second bent groove 29, which become the groove bottom sides of the first groove 26 and the second groove 28, are formed. Then, as shown in Figure 3(c), adhesive 6 is applied to the side end portion 2A of the panel body 1A to bend and bond the extended portion 10b. This adhesive 6, like adhesive 9, may be any type of adhesive. This adhesive 6 may be applied to the back surface and end surface of the side end portion 2 so that the adhesive resin 6A formed by curing fills the first bending groove 27 as described above, or a portion applied to the back surface may drip and adhere to the end surface 24.

[0037] Then, as shown in Figures 4(a) and (b), the extended portion 10b may be bent at each bending groove 27, 29 using an appropriate guide roller 7, the end back layer 10d may be folded over the back layer 16, and the adhesive 6 may be cured. Next, as shown in Figures 5(a) and (b), the coating layer 11a of the decorative layer 11 on the back surface of the side end portion 2 may be polished off with an appropriate polishing member 8 to form the component mounting portion 2a. Furthermore, as shown in Figures 5(b) and 6(a),(b), the panel-side member 31 may be fixed to the component mounting portion 2a with adhesive 9. Alternatively, as shown in Figure 1, the base-side member 34 may be fixed to the panel-side member 31 with fasteners. The above manufacturing process is merely an example and can be modified as appropriate.

[0038] Next, I will explain some variations. In each of the following modifications, the differences from the previously described example will be explained primarily. Similar components will be denoted by the same reference numerals, and their explanations will be omitted or simplified. In each of the following modifications, the effects and benefits achieved in the same manner as in the previously described example will also be omitted or simplified.

[0039] Figures 7(a) and 7(c) schematically show a ceiling panel 1C as an example of an interior panel according to the first modified example. In this modified example, the first bent groove 27A is formed such that the groove bottom 27Aa faces a portion of the end face 24 that is connected to the indoor side corner 24a. With this configuration, the influence of the fiber-reinforced resin layer 14 can be made less effective. In this modified example, a first bending groove 27A is formed in the extended portion 10b of the panel body 1B, which will become the ceiling panel 1C, such that its width W2 is larger than in the example described above. The width W2 of this first bending groove 27A may be about 1 / 10 to 2 / 3 of the width of the end face layer 10c of the extended portion 10b (the thickness of the foamed resin layer 20). In the illustrated example, an example is shown where the width W2 of the first bending groove 27A is about 1 / 2 of the width of the end face layer 10c of the extended portion 10b. Furthermore, as described above, adhesive resin 6B is filled into this first bending groove 27A.

[0040] Figures 7(b) and 7(d) schematically show a ceiling panel 1E as an example of an interior panel according to the second modified example. In this modified example, the flame-retardant layer 13 is exposed at the groove bottom 29Aa of the second bent groove 29A. With this configuration, since the fiber-reinforced resin layer 14 is not present on the groove bottom 29Aa side, it is possible to suppress the blurring of the ridge line due to the rigidity of the fiber-reinforced resin layer 14, and the fracture of the decorative layer 11 on the surface side at the corner on the substrate side, thereby improving the appearance of the corner. In other words, in this modified example, the flame-retardant layer 13 is exposed at the groove bottoms 27a and 29Aa of both the first bent groove 27 and the second bent groove 29A. This second bent groove 29A, like the first bent groove 27 described above, is roughly rectangular in shape when viewed in the longitudinal direction of the groove. The width dimension W3 of this second bent groove 29A may be 0.1 mm or more, as described above, for the flame-retardant layer 13 exposed at the bottom of the groove 29Aa. Furthermore, similar to the above, adhesive resin 6C is also filled into this second bending groove 29A.

[0041] The different configurations described in each of the above examples may be modified, rearranged, or combined as appropriate and necessary. In the examples described above, the fiber-reinforced resin layers 14 and 18 on both sides in the thickness direction of the foamed resin layer 20 are shown to be formed by impregnating glass fiber sheets 15 and 19 with the resin composition constituting the foamed resin layer 20, but the embodiment is not limited to this. Both or one of the fiber-reinforced resin layers 14 and 18 on both sides in the thickness direction of the foamed resin layer 20 may be formed separately from the foamed resin layer 20 and laminated together with an appropriate adhesive. In the examples described above, a back layer 16 including a back fiber reinforced resin layer 18 and a back flame retardant layer 17 is provided on the ceiling substrate 3 side of the foamed resin layer 20. However, a configuration in which both or one of the back fiber reinforced resin layer 18 and the back flame retardant layer 17 are not provided is also possible. In the examples described above, the coating layer 11a of the decorative layer 11 is polished off on the back surface of the side end 2 to provide a component mounting portion 2a. However, a configuration without such a component mounting portion 2a is also acceptable. The configurations of the ceiling panels 1, 1C, and 1E described above according to this embodiment are merely examples, and various other modifications are possible.

[0042] <Note> Based on the above description of the embodiments, the following technology relating to interior panels installed with the back side facing the interior substrate is disclosed. <Technology 1> The interior panel has a structure in which a surface layer is provided on the interior side of a foamed resin layer, including a fiber-reinforced resin layer, a flame-retardant layer provided on the interior side of the fiber-reinforced resin layer, and a decorative layer provided on the interior side of the flame-retardant layer. The end face and back surface of at least one end of the foamed resin layer, which are perpendicular to the interior side surface, are covered by an extended portion of the surface layer that extends in a continuous manner from the portion covering the interior side surface. At a position corresponding to the interior corner of the end face of one end of the extended portion, a bent groove is provided in which the fiber-reinforced resin layer is removed and the flame-retardant layer is exposed at the bottom of the groove. <Technology 2> An interior panel as described in Technology 1, wherein the width dimension of the groove bottom of the bent groove is 0.1 mm or more. <Technology 3> The interior panel according to Technology 2, wherein the bent groove is formed such that the bottom of the groove faces a portion of the end face that is connected to the interior corner. <Technology 4> An interior panel according to any one of the three techniques, wherein a bent groove is provided at a position corresponding to the corner on the interior substrate side of the end face of one end of the extended portion, in which the fiber-reinforced resin layer has been removed and the flame-retardant layer is exposed at the bottom of the groove. <Technology 5> An interior panel according to any one of the techniques 1 to 4, wherein an adhesive resin for bonding the extended portion to the end face and back surface is filled in the bending groove. <Technology 6> The interior panel in question is an interior panel described in any one of the following technical descriptions (Technical Descriptions 1 to 5), which is a ceiling panel. [Explanation of Symbols]

[0043] 1,1C,1E Ceiling Panel (Interior Panel) 6A,6B,6C Adhesive resin 10 Surface layer 10b Extension part (surface layer) 11. Makeup layer 13. Flame-retardant layer 14 Fiber-reinforced resin layer 20 Foamed resin layer 21 Interior side 22 Back side 23 Side edge 24 End face 24a Indoor corner 24b Corner on the substrate side (corner on the interior substrate side) 27,27A 1st bending groove (bending groove) 27a,27Aa groove bottom 29A 2nd bending groove (bending groove) 29Aa groove bottom 3. Ceiling substructure (interior substructure) W1, W2 Width dimensions of the groove bottom

Claims

1. An interior panel that is installed with its reverse side facing the interior substrate side, A surface layer is provided on the interior side of the foamed resin layer, which includes a fiber-reinforced resin layer, a flame-retardant layer provided on the interior side of the fiber-reinforced resin layer, and a decorative layer provided on the interior side of the flame-retardant layer. An interior panel characterized in that the end face and back surface of at least one end of the foamed resin layer, which are perpendicular to the interior side surface, are covered by an extended portion of the surface layer that extends in a continuous manner from the portion covering the interior side surface, and a bent groove is provided at the position corresponding to the interior corner of the end face of the one end of the foamed resin layer in the extended portion, where the fiber-reinforced resin layer is removed and the flame-retardant layer is exposed at the bottom of the groove.

2. In claim 1, An interior panel characterized in that the width dimension of the groove bottom of the bent groove is 0.1 mm or more.

3. In claim 2, The interior panel is characterized in that the bent groove is formed such that the bottom of the groove faces a part of the end face that is connected to the interior corner.

4. In claim 1, An interior panel characterized in that a bent groove is provided at a position corresponding to the interior substrate side corner of the end face of one end of the extended portion, where the fiber-reinforced resin layer is removed and the flame-retardant layer is exposed at the bottom of the groove.

5. In any one of claims 1 to 4, An interior panel characterized in that an adhesive resin for bonding the extended portion to the end face and the back surface is filled in the bending groove.

6. In any one of claims 1 to 4, The interior panel is characterized by being a ceiling panel.

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