panel

Abstract

To provide a panel in which a panel strength can be increased while suppressing significant increase in panel weight.SOLUTION: A panel includes a core material and a face material. The core material includes a base material and a reinforcement material constituted of a material higher in strength than the base material. The base material and the reinforcement material are each bonded to the face material.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present invention relates to a panel that can be used as a luggage board or the like installed in a luggage compartment of a vehicle.

Background Art

[0002] Patent Document 1 discloses a panel configured by attaching a thin steel plate to a hollow plate.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In Patent Document 1, the strength is increased by attaching a steel plate to a hollow plate, but there are still cases where the strength is insufficient. To increase the strength, the thickness of the steel plate can be increased, but in that case, the weight of the panel will increase significantly.

[0005] The present invention has been made in view of such circumstances, and provides a panel capable of increasing the panel strength while suppressing a significant increase in the panel weight.

Means for Solving the Problems

[0006] According to the present invention, the following inventions are provided. (1) A panel including a core material and a face material, wherein the core material includes a base material and a reinforcing material made of a material having a higher strength than the base material, and the base material and the reinforcing material are each adhered to the face material. (2) The panel according to (1), wherein the base material and the reinforcing material are made of a foam, and the foaming ratio of the foam constituting the reinforcing material is lower than the foaming ratio of the foam constituting the base material. (3) A panel according to (1) or (2), wherein the reinforcing member comprises a column portion and flange portions provided at one or both ends of the column portion, and the flange portions are bonded to the surface material. (4) A method for manufacturing a panel, comprising a panel fixing step of pressing the panel material against the core material to bond the panel material to the core material, wherein the core material comprises a base material and a reinforcing material made of a material with higher strength than the base material, and the panel material is bonded to both the base material and the reinforcing material. A method according to (5)(4), wherein the surface material fixing step is performed with a spacer positioned so as to overlap the reinforcing material, and the spacer is made of a material that is more easily compressible than the reinforcing material in the state prior to the surface material fixing step. A method according to (6), (4), or (5), wherein the reinforcing member is configured to move relative to the base material in the thickness direction of the core material by the force applied to the surface material during pressing.

[0007] In the panel of the present invention, the core material is composed of a base material and a reinforcing material, and the reinforcing material is bonded to the surface material. In this configuration, the strength can be increased by placing the reinforcing material only where strength is required, so the amount of reinforcing material used can be minimized. Therefore, the panel strength can be increased while suppressing a significant increase in the panel weight. [Brief explanation of the drawing]

[0008] [Figure 1] Figure 1A is a perspective view of panel 1 of one embodiment of the present invention, and Figure 1B is a perspective view of core material 2. [Figure 2] This is a magnified view of the end face in region A in Figure 1A. [Figure 3] This is a perspective view showing the state in which both longitudinal ends of panel 1 are supported by support members 7. [Figure 4] Figures 4A to 4D are diagrams corresponding to Figure 2, respectively, showing the second to fifth embodiments. [Figure 5]Figure 5A shows the core material 2 used in the sixth embodiment, and Figure 5B is an enlarged view of the reinforcing material 5 in Figure 5A. [Figure 6] Figure 6A shows the core material 2 used in the sixth embodiment, with the reinforcing material 5 and spacer 9 protruding from the base material 4, and Figure 6B shows the state after the core material 2 is sandwiched between a pair of facing materials 3a and 3b and pressed. [Modes for carrying out the invention]

[0009] Embodiments of the present invention will be described below. The various features shown in the embodiments below can be combined with each other. Furthermore, each feature can stand alone as an independent invention.

[0010] 1. First Embodiment 1-1. Structure of Panel 1 As shown in Figures 1 and 2, a panel 1 according to one embodiment of the present invention comprises a core material 2 and a surface material 3. The panel 1 is preferably substantially rectangular in shape. The panel 1 can be used as a luggage board or the like, installed in the cargo area of ​​a vehicle.

[0011] The core material 2 is preferably a plate-shaped member. The thickness of the core material 2 is, for example, 5 to 25 mm, preferably 8 to 20 mm. Specifically, this thickness may be, for example, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 20, 25 mm, and may be within the range of any two of the values ​​exemplified here. The thickness of the core material 2 refers to the distance at the point where the distance between the opposing first and second main surfaces 2a, 2b of the core material 2 is greatest. Preferably, the core material 2 is provided with recesses, and the facing material 3 is fixed within these recesses. This prevents the facing material 3 from peeling off the core material 2. The core material 2 comprises a base material 4 and a reinforcing material 5.

[0012] The base material 4 may be a foam or a non-foamed material. Furthermore, the base material 4 may be a hollow body or a solid body.

[0013] Examples of the base material 4 include a bead foam molded body obtained by bead foam molding, a foamed or non-foamed sheet molded body obtained by imparting uneven shapes to a single foamed or non-foamed resin sheet, a foamed or non-foamed hollow molded body obtained by molding a foamed or non-foamed tubular parison or two resin sheets, and the like.

[0014] The bead foam molded body can be composed of, for example, foamed polystyrene, foamed acrylonitrile styrene, foamed polypropylene, etc. The foaming ratio thereof is, for example, 20 to 50 times, specifically, for example, 20, 25, 30, 35, 40, 45, 50 times, and may be within the range between any two of the numerical values exemplified here.

[0015] The foamed parison or foamed resin sheet can be composed of polyolefins such as polyethylene and polypropylene. The foaming ratio of the molded body using this is, for example, 1.1 to 8 times, specifically, for example, 1.1, 1.5, 2, 3, 4, 5, 6, 7, 8, and may be within the range between any two of the numerical values exemplified here.

[0016] The reinforcing material 5 is composed of a material having higher strength than the base material 4. Examples of the reinforcing material 5 include metal, wood, resin, etc. The plastic may be a foamed body or a non-foamed body. In this specification, "strength" means Young's modulus at 25°C. The value of {strength of reinforcing material 5 / strength of base material 4} is, for example, 1.1 or more, preferably 1.5 or more, and preferably 2 or more. This value is, for example, 1.1 to 1000, specifically, for example, 1.1, 1.5, 2, 3, 4, 5, 6, 7, 8, 9, 10, 20, 50, 100, 1000, and may be within the range between any two of the numerical values exemplified here or any value or more.

[0017] In this embodiment, the base material 4 and the reinforcing material 5 are formed of a foam, and the foaming ratio of the reinforcing material 5 is lower than that of the base material 4. Since the foam has higher strength when the foaming ratio is lower, by making the foaming ratio of the reinforcing material 5 lower than that of the base material 4, the strength of the reinforcing material 5 can be made higher than that of the base material 4. Further, it is preferable that the base material 4 and the reinforcing material 5 are made of the same resin. In this case, since the base material 4 and the reinforcing material 5 are easily welded, for example, it is easy to integrate the base material 4 and the reinforcing material 5 by insert molding. If the foaming ratio of the reinforcing material 5 is M1 and the foaming ratio of the base material 4 is M2, then M1 / M2 is, for example, 0.1 to 0.9, specifically, for example, 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, and it may be within the range between any two of the values exemplified herein or any value or more thereof.

[0018] The specific gravity of the reinforcing material 5 is usually larger than that of the base material 4. The value of {specific gravity of the reinforcing material 5 / specific gravity of the base material 4} is, for example, 1.1 or more. This value is, for example, 1.1 to 1000, specifically, for example, 1.1, 1.5, 2, 3, 4, 5, 6, 7, 8, 9, 10, 20, 50, 100, 1000, and it may be within the range between any two of the values exemplified herein or any value or more thereof.

[0019] The reinforcing material 5 is preferably an elongated member. If the length in the longitudinal direction is L and the outer diameter of the circumscribed circle at the site where the outer diameter of the circumscribed circle in the cross section perpendicular to the longitudinal direction is the largest is D, then L / D is preferably 5 or more, more preferably​​​The reinforcing material 5 can be provided at any position and of any size within the core material 2. However, since the reinforcing material 5 usually has a higher specific gravity than the base material 4, it is preferable to use the minimum necessary amount of reinforcing material 5 in order to suppress weight increase. If the volume of the core material 2 is V1 and the volume of the reinforcing material 5 is V2, then V2 / V1 is preferably 0.5 or less, and more preferably 0.3 or less. V2 / V1 is, for example, 0.001 to 0.5, specifically, for example, 0.001, 0.01, 0.1, 0.2, 0.3, 0.4, 0.5, and may be within the range between any two of the values ​​exemplified here or less than or equal to any two of them. If the mass of the core material 2 is W1 and the mass of the reinforcing material 5 is W2, then W2 / W1 is preferably 0.8 or less, more preferably 0.5 or less, and more preferably 0.3 or less. W2 / W1 is, for example, 0.001 to 0.8, specifically, for example, 0.001, 0.01, 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, and may be within the range between any two of the numbers exemplified here, or less than or equal to any two of them.

[0021] In one example, the reinforcing member 5 is positioned such that its longitudinal direction aligns with the longitudinal or transverse direction of the core material 2. If the length of the core material 2 along the longitudinal direction of the reinforcing member 5 is LC, and the length of the reinforcing member 5 in the longitudinal direction is L, then L / LC is preferably 0.5 or greater, and preferably 0.8 or greater. In this case, the strength of the panel 1 can be increased over a wide area of ​​the panel 1. L / LC is, for example, 0.5 to 1.0, specifically, for example, 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, and may be within the range of any two of the values ​​exemplified here.

[0022] The thickness of the reinforcing material 5 relative to the thickness of the core material 2 is, for example, 0.1 to 1.0, specifically, for example, 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, and 1.0, and may be within the range of any two of the values ​​exemplified here.

[0023] The length of the core material in the short direction (length perpendicular to both the longitudinal and thickness directions) is, for example, 10 to 100 mm, and preferably 20 to 40 mm. Specifically, this length may be, for example, 10, 20, 30, 40, 50, 60, 70, 80, 90, or 100 mm, and may be within the range of any two of the values ​​exemplified here.

[0024] For example, if the length of the core material 2 in the longitudinal direction is LL, and the distance of the reinforcing member 5 from the center of the core material 2 in the longitudinal direction is D, it is preferable to position the reinforcing member 5 so that its longitudinal direction is aligned with the short direction of the core material 2 at a position where D / LL is between 0.20 and 0.45. As shown in Figure 3, when a relatively large load 8 is placed near the center of the longitudinal direction of the panel 1 while both ends of the panel 1 in the longitudinal direction are supported by support members 7, the panel 1 tends to buckle at a position where D / LL is between 0.20 and 0.45. Therefore, by providing the reinforcing member 5 at such a position, buckling of the panel 1 can be suppressed. Specifically, D / LL may be, for example, 0.20, 0.25, 0.30, 0.35, 0.40, or 0.45, and may also be within the range of any two of the values ​​exemplified here.

[0025] The reinforcing material 5 may be provided along the entire thickness of the core material 2, or it may be provided only along a portion of the thickness. The reinforcing material 5 may be exposed on only one side of the core material 2, or it may be exposed on both sides of the core material 2.

[0026] On the surface where the reinforcing material 5 is exposed, it is preferable that the base material 4 and the reinforcing material 5 are flush. This makes it easier to bond the base material 4 and the reinforcing material 5 to the surface material 3.

[0027] The facing material 3 is a plate-shaped member that is fixed to the core material 2 by bonding it to the base material 4 and the reinforcing material 5. By bonding the facing material 3 not only to the base material 4 but also to the reinforcing material 5, the facing material 3 and the reinforcing material 5 are integrated, the reinforcing effect due to the presence of the reinforcing material 5 is significantly enhanced, and interference between the reinforcing material 5 and other members during vibration, which generates abnormal noise, is suppressed. The facing material 3 can be made of a material with a higher strength per unit thickness than the base material 4, and can be made of, for example, metal (aluminum, iron, etc.) or fiber-reinforced resin. The thickness of the facing material 3 is, for example, 0.1 to 3 mm, and preferably 0.3 to 1.5 mm. Specifically, this depth can be, for example, 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9, 1.0, 1.5, 2.0, 2.5, or 3.0 mm, and may be within the range of any two of the values ​​exemplified here. In this specification, unless otherwise specified, values ​​such as thickness and depth refer to average values.

[0028] The facing material 3 can be bonded to the substrate 4 and the reinforcing material 5 via an adhesive layer 6. Examples of adhesives that make up the adhesive layer 6 include urethane-based adhesives and olefin-based adhesives. The thickness of the adhesive layer 6 is, for example, 0.01 to 0.5 mm, specifically, for example, 0.01, 0.05, 0.1, 0.2, 0.3, 0.4, and 0.5 mm, and may be within the range of any two of the values ​​exemplified here.

[0029] The surface material 3 may be provided on only one of the first and second main surfaces 2a and 2b of the core material 2, or it may be provided on both the first and second main surfaces 2a and 2b.

[0030] 1-2. Manufacturing method of Panel 1 Panel 1 can be manufactured by the following method.

[0031] (1) Core material preparation process In the core preparation process, the core material 2 is prepared. The core material 2 can be formed by insert molding, in which a reinforcing material 5 is inserted when molding the base material 4, or by preparing the base material 4 and the reinforcing material 5 separately and then joining them together (fitting, bonding, welding, etc.).

[0032] (2) Surface material fixing process In the panel fixing process, the base material 4 and the reinforcing material 5 are bonded to the panel 3, respectively. This bonding can be achieved by applying adhesive to the base material 4 and the reinforcing material 5 (e.g., spray application, bead application), and then pressing the panel 3 against the core material 2 (i.e., the base material 4 and the reinforcing material 5). This pressing can be performed, for example, using a roll press machine. A roll press machine can press an object with a pair of rollers that rotate in opposite directions. Alternatively, this pressing can be performed by pressing the core material 2 while it is sandwiched between the pair of panel materials 3.

[0033] 2. Second Embodiment A second embodiment of the present invention will be described using Figure 4A. This embodiment is similar to the first embodiment, with the main difference being the configuration of the reinforcing member 5. The differences will be explained below.

[0034] In this embodiment, the reinforcing member 5 is H-shaped and comprises a column portion 5a and flange portions 5b and 5c provided at both ends of the column portion 5a, with both flange portions 5b and 5c being bonded to the surface material 3.

[0035] The H-shaped reinforcing material 5 has a high strength-enhancing effect per unit volume, so by using a reinforcing material of this shape, the strength of the panel 1 can be significantly increased. Furthermore, in this embodiment, since the flange portions 5b and 5c are bonded to the surface material 3, the strength-enhancing effect is even more pronounced.

[0036] The thickness of the flange portions 5b and 5c is, for example, 0.5 to 5 mm, preferably 1 to 3 mm. Specifically, this thickness may be, for example, 0.5, 1.0, 1.5, 2.0, 2.5, 3.0, 3.5, 4.0, 4.5, or 5.0 mm, and may be within the range of any two of the values ​​exemplified here.

[0037] 3. Third Embodiment A third embodiment of the present invention will be described using Figure 4B. This embodiment is similar to the second embodiment, with the main difference being the manner in which the reinforcing material 5 is bonded to the facing material 3. The differences will be explained below.

[0038] In this embodiment, the configuration of the reinforcing member 5 is the same as in the second embodiment, but only the flange portion 5b is bonded to the surface material 3, while the flange portion 5c is not bonded to the surface material 3. Even with this configuration, the effects of improved strength and suppression of abnormal noise are achieved.

[0039] 4. Fourth Embodiment A fourth embodiment of the present invention will be described using Figure 4C. This embodiment is similar to the third embodiment, with the main difference being the configuration of the reinforcing member 5. The differences will be explained below.

[0040] In this embodiment, the reinforcing member 5 has a flange portion 5b at one end of the column portion 5a, and no flange portion at the other end of the column portion 5a. The flange portion 5b is bonded to the surface material 3. The other end of the column portion 5a may or may not be bonded to the surface material. Even with this configuration, the effects of improved strength and suppression of abnormal noise are achieved.

[0041] 5. Fifth Embodiment A fifth embodiment of the present invention will be described using Figure 4D. This embodiment is similar to the fourth embodiment, with the main difference being the configuration of the reinforcing member 5. The differences will be explained below.

[0042] In this embodiment, the reinforcing member 5 has a flange portion 5b at one end of the column portion 5a, and no flange portion at the other end of the column portion 5a. The flange portion 5b is bonded to the face material 3. The other end of the column portion 5a does not reach the face material 3, but extends partway to the core material 2. Even with this configuration, the effects of improved strength and suppression of abnormal noise are achieved.

[0043] 6. Sixth Embodiment A sixth embodiment of the present invention will be described using Figures 5 and 6. This embodiment is similar to the second embodiment, and the differences will be described below.

[0044] (Problems that this embodiment aims to solve) As in the second embodiment, if the thickness of the base material 4 and the reinforcing material 5 are equal and the reinforcing material 5 is provided along the entire thickness of the base material 4, then if the thickness of the base material 4 becomes smaller than the standard value due to manufacturing variations or the like, when the face material 3 is pressed against the core material 2, the face material 3 will be pressed strongly against the reinforcing material 5, and the force pressing against the base material 4 will be weak, which may result in poor adhesion. This problem is particularly noticeable when the reinforcing material 5 is made of a material that is not easily compressed. When the reinforcing material 5 is made of a material that is not easily compressed, the reinforcing material 5 is hardly compressed even when pressed, and the force pressing the face material 3 against the base material 4 does not become strong.

[0045] To avoid such problems, it is also possible to make the standard thickness of the base material 4 greater than that of the reinforcing material 5, and then compress and deform the base material 4 to bond the surface material 3 to both the base material 4 and the reinforcing material 5. If the expected variation in the thickness of the base material 4 is ±1 mm, for example, the thickness of the base material 4 can be set to 20 mm and the thickness of the reinforcing material 5 to 19 mm. In this case, the base material 4 is prevented from becoming thinner than the reinforcing material 5, so the occurrence of poor adhesion between the surface material 3 and the base material 4 can be suppressed.

[0046] However, the thickness of the base material 4 may be thicker than the standard value. In this case, the base material 4 cannot be sufficiently compressed and deformed during pressing, making it difficult for the force applied to the surface material 3 to be applied to the reinforcing material 5, which creates a new problem where poor adhesion between the surface material 3 and the reinforcing material 5 is likely to occur.

[0047] Therefore, if there is variation in the thickness of the base material 4, it is not easy to reliably adhere the facing material 3 to both the base material 4 and the reinforcing material 5.

[0048] (First means: Spacer 9) As a first means to solve the above problems, in this embodiment, as shown in Figure 5A, the standard value of the thickness of the base material 4 is made greater than the thickness of the reinforcing material 5, and with the spacer 9 placed so as to overlap the reinforcing material 5, the surface material fixing process is performed as shown in Figure 6B. The spacer 9 is made of a material that is more easily compressed than the reinforcing material 5 in the state before the bonding process in which the surface material 3 is bonded to the core material 2 (i.e., before it is compressed and deformed). The ease of compression deformation can be evaluated, for example, based on the 10% compressive stress measured in accordance with JIS K 7220.

[0049] By providing the spacer 9, even when the base material 4 is thicker than the reinforcing material 5, the force applied to the surface material 3 is more easily applied to the reinforcing material 5, thereby suppressing the occurrence of adhesion defects between the surface material 3 and the reinforcing material 5. Furthermore, since the spacer 9 is made of a material that is more easily compressed than the reinforcing material 5, as shown in Figure 6A, when the total thickness of the reinforcing material 5 and the spacer 9 is greater than the thickness of the base material 4 and the spacer 9 protrudes from the base material 4, as shown in Figure 6B, the amount of protrusion of the spacer 9 is reduced by the compression deformation of the spacer 9, thereby suppressing the occurrence of adhesion defects between the surface material 3 and the base material 4.

[0050] It is preferable that the spacer 9 is made of a material that is more easily compressible than the base material 4. Since the spacer 9 is thinner than the base material 4, when the spacer 9 and the base material 4 are compressed to the same thickness, the spacer 9 will have a higher compression ratio, and the hardening due to compression will be more pronounced. For this reason, when the facing material 3b is pressed against the spacer 9 and the spacer 9 is compressed and deformed, the shape of the spacer 9 is likely to be imprinted on the facing material 3b. This problem can be mitigated by making the spacer 9 from a material that is more easily compressible than the base material 4.

[0051] The spacer 9 can be made of, for example, foam. In this case, the ease with which the spacer 9 is compressed can be changed by changing the magnification of the foam.

[0052] The spacer 9 is preferably plate-shaped. If the thickness of the reinforcing material 5 is T1 and the thickness of the spacer 9 is T2, then T2 / T1 is preferably 0.01 to 0.5. If this value is too small, the effect of providing the spacer 9 tends to be insufficient, and if this value is too large, the reinforcing effect of the reinforcing material 5 tends to be insufficient. Specifically, T2 / T1 may be, for example, 0.01, 0.02, 0.05, 0.1, 0.2, 0.3, 0.4, 0.5, or within the range of any two of the values ​​exemplified here.

[0053] The thickness of the reinforcing material 5 is preferably thinner than that of the base material 4. Furthermore, the combined thickness of the reinforcing material 5 and the spacer 9 is preferably equal to the thickness of the base material 4, but it may be slightly thicker or thinner than the base material 4. The difference between the combined thickness of the reinforcing material 5 and the spacer 9 and the thickness of the base material 4 is, for example, 1 mm or less, and preferably 0.5 mm or less. If the thickness of the base material 4 is T3, then (T1+T2) / T3 is, for example, 0.95 to 1.05, and preferably 0.98 to 1.02.

[0054] The spacer 9 may or may not be bonded to the reinforcing material 5. Also, on the surface where the spacer 9 is not placed (the first main surface 2a in this embodiment), it is sufficient that the reinforcing material 5 is bonded to the surface material 3a, and the spacer 9 may or may not be bonded to the surface material 3b. The spacer 9 may or may not be bonded to the reinforcing material 5.

[0055] (Second means: The reinforcing material 5 is movable relative to the base material 4) As a second means to solve the above problems, in this embodiment, when the facing material 3 is pressed against the core material 2, the reinforcing material 5 is configured to move in the thickness direction of the core material 2 relative to the base material 4 due to the force applied to the facing material 3. The second means can be used alone, but it is preferable to use it together with the first means.

[0056] As shown in Figure 6A, if the reinforcing member 5 protrudes from the base material 4 on the first main surface 2a side of the core material 2, even if a spacer 9 is placed on the second main surface 2b side, the protrusion of the reinforcing member 5 on the first main surface 2a side may not be eliminated during the surface material fixing process. In this embodiment, when the reinforcing member 5 is pressed by the surface material 3, the reinforcing member 5 moves in the thickness direction of the core material 2 relative to the base material 4, and the protrusion of the reinforcing member 5 is mitigated. This suppresses the occurrence of poor adhesion between the surface material 3 and the base material 4.

[0057] The above configuration can be achieved, for example, as shown in Figures 5A to 5B, when the protruding portion 4a of the base material 4 is positioned between the flange portions 5b and 5c of the reinforcing material 5, by making the distance D1 between the inner surfaces of the flange portions 5b and 5c larger than the thickness T4 of the protruding portion 4a.

[0058] D1 / T4 is, for example, 1.01 to 1.2, specifically, for example, 1.01, 1.05, 1.1, 1.15, 1.2, and may be within the range of any two of the numbers exemplified here.

[0059] While this configuration allows the reinforcing material 5 to be movable relative to the base material 4, the base material 4 and the reinforcing material 5 can easily separate before the surface material fixing process, making them difficult to handle during the manufacturing process.

[0060] Therefore, as shown in Figure 5B, the flange portions 5b and 5c are provided with claws 5b1 and 5c1 that protrude from the inner surface. By allowing the claws 5b1 and 5c1 to bite into the protruding portion 4a, it becomes more difficult to separate the base material 4 and the reinforcing material 5. In addition, in areas other than those with claws 5b1 and 5c1, there is a gap between the inner surface of the flange portions 5b and 5c and the protruding portion 4a. Therefore, when a force in the thickness direction of the core material 2 is applied to the reinforcing material 5, the amount of biting into one of the claws 5b1 or 5c1 increases, allowing the reinforcing material 5 to move relative to the base material 4 in the thickness direction of the core material 2.

[0061] 7. Other Embodiments If necessary, a surface material may be provided to cover the core material 2 and the facing material 3. This improves the aesthetic appearance and prevents the facing material 3 from peeling off from the core material 2. In one example, the surface material is a nonwoven fabric and can be bonded to the facing material 3 and the core material 2 via an adhesive layer. [Explanation of Symbols]

[0062] 1: Panel 2: Core material 2a: 1st principal surface 2b: 2nd principal surface 3: Surface material 3a: Surface material 3b: Surface material 4: Base material 4a:Protrusion 5: Reinforcement material 5a: Pillar part 5b: Flange section 5b1: Nail 5c: Flange section 5c1: Claw 6: Adhesive layer 7: Support member 8: Luggage 9: Spacer

Claims

1. A panel comprising a core material and a surface material, The core material comprises a base material and a reinforcing material made of a material with higher strength than the base material. The base material and the reinforcing material are each bonded to the surface material. The aforementioned surface material is made of metal. The aforementioned substrate is made of foam, A panel in which the base material and the reinforcing material are each bonded to the surface material via an adhesive layer made of an adhesive.

2. A panel according to claim 1, The aforementioned reinforcing material is made of foam, A panel in which the foaming ratio of the foam constituting the reinforcing material is lower than that of the foam constituting the base material.

3. The panel according to claim 2, A panel in which the base material and the reinforcing material are made of the same resin.

4. A panel according to any one of claims 1 to 3, The reinforcing material comprises a column portion and flange portions provided at one or both ends of the column portion, the flange portions being bonded to the surface material, the panel.

5. A method for manufacturing a panel, The process includes a surface material fixing step in which the surface material is pressed against the core material to bond the surface material to the core material, The core material comprises a base material and a reinforcing material made of a material with higher strength than the base material. The surface material is bonded to both the base material and the reinforcing material. The aforementioned surface material is made of metal. The aforementioned substrate is made of foam, A method wherein the base material and the reinforcing material are each bonded to the surface material via an adhesive layer composed of an adhesive.

6. The method according to claim 5, The aforementioned reinforcing material is made of foam, The foaming ratio of the foam constituting the reinforcing material is lower than that of the foam constituting the base material. A method wherein the base material and the reinforcing material are made of the same resin.

7. The method according to claim 5, The aforementioned panel fixing process is carried out with spacers positioned so as to overlap the reinforcing material. The method wherein the spacer is made of a material that is more easily compressible than the reinforcing material in the state prior to the surface material fixing step.

8. The method according to claim 5, A method wherein the reinforcing material is configured to move relative to the base material in the thickness direction of the core material by the force applied to the surface material during the pressing process.

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