Interior panel

Abstract

In an interior panel 1 comprising a porous base material layer 2 having a thin shape and an open-cell structure, and sheets 3, 5 covering both surfaces in the thickness direction of the porous base material layer 2, one surface side non-through holes 6 communicating with the porous base material layer 2 from the sheet 3 on one surface side in the thickness direction of the porous base material layer 2, and the other surface side non-through holes 7 communicating with the porous base material layer 2 from the sheet 5 on the other surface side in the thickness direction of the porous base material layer 2 are formed, and the one surface side non-through holes 6 and the other surface side non-through holes 7 are formed at positions not overlapping each other as viewed from the thickness direction of the porous base material layer 2.

Description

Interior panels

[0001] This disclosure relates to interior panels that make up ceilings, walls, and other parts of a building.

[0002] Conventionally, interior panels such as ceiling panels used in suspended ceilings have been made lighter by constructing a base layer from rock wool, fiberglass, foam, etc., and the surface is covered with a sheet to protect the base layer. For example, Patent Document 1 below discloses an interior panel in which a base layer made of foamed resin is covered with a flame-retardant sheet or a glass fiber sheet.

[0003] International Publication No. 2019 / 044985

[0004] However, the interior panels described above have their surfaces covered with a sheet, which obstructs the penetration of sound waves and makes it difficult for them to exhibit sound-absorbing properties. Therefore, there is a need for interior panels that can easily exhibit sound-absorbing properties.

[0005] This disclosure is made in view of the above circumstances and aims to provide an interior panel that easily exhibits sound absorption performance.

[0006] To achieve the above objective, the interior panel according to this disclosure comprises a thin porous substrate layer having an open-cell structure and a sheet covering both sides of the porous substrate layer in the thickness direction, wherein a non-penetrating hole on one side of the sheet communicating with the porous substrate layer is formed from the sheet on one side in the thickness direction of the porous substrate layer, and a non-penetrating hole on the other side of the sheet communicating with the porous substrate layer is formed from the sheet on the other side in the thickness direction of the porous substrate layer, and the non-penetrating hole on one side and the non-penetrating hole on the other side are formed in positions that do not overlap when viewed from the thickness direction of the porous substrate layer.

[0007] The interior panel relating to this disclosure, with its configuration as described above, is designed to easily exhibit sound-absorbing performance.

[0008] A partially broken plan view of an interior panel according to one embodiment of the present disclosure. A partially broken schematic longitudinal section view of the same interior panel corresponding to the view along the line X-X in Figure 1. A partially broken schematic longitudinal section view schematically showing an example of an interior panel according to another embodiment of the present disclosure.

[0009] Embodiments of the present disclosure will be described below with reference to the drawings. As shown in Figures 1 and 2, the interior panel 1 according to the first embodiment comprises a thin porous substrate layer 2 having an open-cell structure and sheets 3 and 5 covering both sides of the porous substrate layer 2 in the thickness direction. The interior panel 1 according to this embodiment is substantially rectangular in shape when viewed from above. The interior panel 1 may be substantially square or substantially rectangular when viewed from above. The size of the interior panel 1 when viewed from above may be an appropriate size from the viewpoint of handling and workability, for example, the length of one side may be 0.3 m or more, or 2.0 m or less. In the case of a substantially rectangular interior panel 1, the length of the short side may be 0.3 m or more, and the length of the long side may be 2.0 m or less. In the case of a substantially square interior panel 1, the length of one side may be 0.6 m or more, 1.5 m or less, or about 0.9 m to 1.2 m. Furthermore, the thickness of the interior panel 1 may be, for example, 2.5 mm to 15.0 mm, preferably 3.0 mm to 8.0 mm, and more preferably 3.5 mm to 5.0 mm, depending on the layer structure and other factors.

[0010] The porous substrate layer 2 occupies most of the interior panel 1. The thickness of this porous substrate layer 2 is preferably 80% to 99% of the thickness of the interior panel 1, and more preferably 85% to 95%. The thickness of this porous substrate layer 2 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. Furthermore, the porous substrate layer 2 may have a uniform thickness throughout, or the central part may be thicker than other parts, with the area around the central part being thinner. In that case, the thickness dimension of the thinnest part may be about 1 / 5 to 1 / 2 of the thickness dimension of the thickest part, for example, about 1.0 mm to 7.0 mm, preferably 1.5 mm or more, and also 3.0 mm or less.

[0011] The porous substrate layer 2 according to this embodiment is composed of a porous resin composition having an open-cell structure. Specifically, foamed polyurethane resin may be used. This porous substrate layer 2 is not limited to foamed polyurethane, and may be, for example, polystyrene resin, polyethylene resin, polypropylene resin, melamine resin, phenolic resin, etc. The porous substrate layer 2 may have flame retardancy by containing an appropriate flame retardant. The density of this porous substrate layer 2 is 5 kg / m³. ３ ~60 kg / m ３ It may be to a certain extent. The foamed polyurethane resin constituting the porous substrate layer 2 is preferably a foamed polyurethane resin with a foaming ratio of 10 to 30 times, and more preferably 15 to 25 times. With such a configuration, weight reduction can be achieved. Since the porous substrate layer 2 is made of a porous material, it has sound-absorbing properties.

[0012] As shown in Figure 1, the interior panel 1 is constructed so as to cover both sides of the porous substrate layer 2 in the thickness direction, with a one-sided sheet 3 provided on one side in the thickness direction of the porous substrate layer 2 and a other-sided sheet 5 provided on the other side in the thickness direction of the porous substrate layer 2. The one-sided sheet 3 may include a flame-retardant sheet 4a. The one-sided sheet 3 may also be a composite sheet in which a glass fiber sheet 4b is laminated and integrated on the outer side (the side different from the porous substrate layer 2) in the thickness direction of the flame-retardant sheet 4a. The flame-retardant sheet 4a may be configured appropriately so that the interior panel 1 meets the technical standards for performance required for non-combustible materials, etc., as stipulated in the Building Standards Act. For example, the interior 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". For example, a thin sheet-like foil-like metal sheet, such as an aluminum sheet, may be used. The thickness of the aluminum sheet used as the flame-retardant sheet 4a may be about 5 μm to 50 μm, preferably about 7 μm to 40 μm, and more preferably about 10 μm to 30 μm.

[0013] The glass fiber sheet 4b is a thin sheet with a thickness of approximately 0.1 mm to 0.5 mm. This glass fiber sheet 4b may also be glass nonwoven fabric (glass paper) with a basis weight of 20 g / m². ２ ~250g / m ２ It may be a weight of approximately 30 g / m², preferably 30 g / m². ２ ~100g / m ２ It may be of a certain degree. Furthermore, the glass fiber sheet 4b and the flame-retardant sheet 4a may be laminated and integrated together with an appropriate adhesive or the like. Also, the one-sided sheet 3 is not limited to the above configuration, and various other configurations can be used. For example, it may be a resin-impregnated glass fiber nonwoven fabric board containing an endothermic metal hydroxide.

[0014] Furthermore, the surface of the sheet 3 on one side of the interior panel 1 may be a decorative surface that has been treated with appropriate surface finishing such as printing or painting. For example, the glass fiber sheet 4b may constitute the decorative layer. Alternatively, one side of the interior panel may be a base surface to which an appropriate decorative sheet is attached. Note that the decorative layer is not limited to the glass fiber sheet 4b, but may be other sheet materials that have been treated with appropriate surface finishing such as printing or painting, or may be formed by printing, painting, etc. Furthermore, the pigments, additives, etc., contained in the paint used for printing the decorative layer are preferably inorganic in order to ensure flame retardancy. In this embodiment, it is preferable that the interior panel 1 is installed so that the sheet 3 on one side faces the interior side. As a result, if a disaster occurs on the interior side, the sheet 3 on the interior side is flame retardant, which can delay the combustion of the porous base material layer 2. Furthermore, in this embodiment, the interior panel 1 having the glass fiber sheet 4b can further improve bending rigidity and dimensional stability.

[0015] On the other hand, the other surface side sheet 5 may include a sheet similar to the above-mentioned flame-retardant sheet 4a. That is, the other surface side sheet 5 may be a metal (aluminum) sheet. In addition, in the illustrated example, a glass fiber sheet constituting a reinforcing layer is provided on the porous substrate layer 2 side of each of the one surface side sheet 3 and the other surface side sheet 5. The glass fiber sheets on both sides in the thickness direction of the porous substrate layer 2 may be impregnated with the resin composition constituting the porous substrate layer 2 to form a glass fiber reinforced resin layer. The basis weight of this glass fiber sheet is preferably 50 g / m ２ to 150 g / m ２ , more preferably 50 g / m ２ to 100 g / m ２ . Such a glass fiber sheet may be a thin sheet having a thickness of about 0.1 mm to 0.5 mm. Further, as the glass fiber sheet, a woven fabric of glass fibers is preferable, and for example, it may be a glass cloth which is a woven fabric such as plain weave or leno weave woven by using glass rovings for warp and weft. The use of glass cloth makes it difficult to cause thermal deformation. It should be noted that the glass fiber sheet is not limited to such glass cloth, and may be glass paper or glass mat.

[0016] With the above configuration, in the interior panel 1 according to the present embodiment, the glass fiber sheets (glass fiber reinforced resin layers) on both sides in the thickness direction of the porous substrate layer 2 serve as reinforcing layers, so that flexural rigidity and dimensional stability are improved. In addition, the other surface side sheet 5 is not limited to the one having the above configuration, and various other configurations can be adopted. For example, similar to the one surface side sheet 3, it may be a composite sheet in which a flame-retardant sheet and a glass fiber sheet are laminated and integrated. With this configuration, both sides have the same sheet structure, so there is no need to worry about the mounting direction during construction, which improves convenience. Further, the four circumferential side end surfaces of the porous base material layer 2 may also be covered by the one surface side sheet 3.

[0017] As shown in Figures 1 and 2, the interior panel 1 according to this embodiment has a one-sided non-penetrating hole 6 that communicates with the porous substrate layer 2 from a one-sided sheet 3 provided on one side in the thickness direction of the thin porous substrate layer 2, and a other-sided non-penetrating hole 7 that communicates with the porous substrate layer 2 from a other-sided sheet 5 provided on the other side in the thickness direction of the porous substrate layer 2. With this configuration, air entering the one-sided non-penetrating hole 6 encounters resistance at the porous surface of the porous substrate layer 2, and the energy of the air vibration (i.e., sound energy) is converted into thermal energy, and sound generated on one side of the interior panel 1 is absorbed. Since the interior panel 1 according to this embodiment has non-penetrating holes 6 and 7 on both sides in the thickness direction, air entering the one-sided non-penetrating hole 6 escapes to the other-sided through-hole 7 through the porous substrate layer 2 which has a continuous cell structure and is breathable, and sound is absorbed in the other-sided non-penetrating hole 7 as well. Therefore, the sound absorption performance is further enhanced.

[0018] The non-penetrating holes 6 on one side are open on one side of the interior panel 1. The non-penetrating holes 6 on one side penetrate the sheet 3 on one side, and are formed so that the bottom of the hole is located in the porous substrate layer 2. The non-penetrating holes 7 on the other side are open on the other side of the interior panel 1. The non-penetrating holes 7 on the other side penetrate the sheet 5 on the other side, and are formed so that the bottom of the hole is located in the porous substrate layer 2. In other words, these non-penetrating holes 6 on one side and non-penetrating holes 7 on the other side are recesses (bottomed holes) formed so as not to penetrate the interior panel 1 in the thickness direction. The non-penetrating holes 6 on one side and non-penetrating holes 7 on the other side are provided at equal intervals from each other throughout the entire sheet 3 on one side or the sheet 5 on the other side, making it easy to maintain a consistent sound absorption performance at any position on the interior panel without compromising aesthetics. However, this is not the only option; the non-penetrating holes 6 on one side and non-penetrating holes 7 on the other side are formed in positions that do not overlap when viewed from the thickness direction of the porous substrate layer 2. The diagram shows an example where the non-through holes 6 on one side and the non-through holes 7 on the other side are both circular and arranged in parallel on their respective surfaces (where imaginary lines connecting the centers of the non-through holes vertically and horizontally intersect at a 90-degree angle). It also shows an example where the pitches P1 and P2 (distance between the centers of adjacent non-through holes) of the non-through holes 6 and 7 are the same, and they are positioned so that they are offset by half a pitch vertically and horizontally from each other. In other words, it shows an example where the other non-through hole (non-through hole 7 on the other side) is positioned at the center of the length of an imaginary line diagonally connecting two non-through holes (non-through holes 6 on the one side) that are arranged in parallel vertically and horizontally. The opening ratio (opening ratio) of the non-through holes 6 and 7 on the other side may be 3.5% or more. For example, if non-penetrating holes 6 on one side and non-penetrating holes 7 on the other side are arranged in parallel on each side as shown in the figure, with each hole having a diameter of 0.9 mm and each pitch P1 and P2 of 4.2 mm, the porosity ratio will be approximately 3.6%. By increasing the porosity ratio of the non-penetrating holes 6 on one side and non-penetrating holes 7 on the other side, the distance between the non-penetrating holes 6 on one side and non-penetrating holes 7 on the other side via the porous substrate layer 2 becomes smaller, thus improving sound absorption performance.The opening ratio of the non-through holes 6 on one side and the non-through holes 7 on the other side is preferably 3.5% to 10%, and more preferably 7% to 10%. This further improves sound absorption. By having an opening ratio of 10% or less for the non-through holes 6 on one side and the non-through holes 7 on the other side, a decrease in the rigidity of the interior panel 1 is suppressed.

[0019] The opening ratio of the non-through holes 6 on one side refers to the ratio (percentage) of the area of ​​all non-through holes 6 on one side to the area of ​​one side of the interior panel 1 in the thickness direction, as viewed from one side in a plan view along the thickness direction of the interior panel 1. The opening ratio of the non-through holes 7 on the other side refers to the ratio (percentage) of the area of ​​all non-through holes 7 on the other side to the area of ​​the other side of the interior panel 1 in the thickness direction, as viewed from the other side in a plan view along the thickness direction of the interior panel 1. In addition, although the hole diameters of the non-through holes 6 on one side and the non-through holes 7 on the other side are set to 0.9 mm as an example above, the hole diameters are not particularly limited and may be preferably around 50 μm to 10.0 mm, and more preferably around 0.3 mm to 1.0 mm. In particular, by setting the hole diameters of the non-through holes 6 on one side and the non-through holes 7 on the other side to 1.0 mm or less, the flame retardancy of the interior panel 1 is improved. Furthermore, the pitches P1 and P2 of the non-through holes 6 on one side and the non-through holes 7 on the other side can be set to appropriate pitches depending on the hole diameter and arrangement pattern so that the opening ratio is as described above.

[0020] In this embodiment, the non-through holes 6 on one side and the non-through holes 7 on the other side are each formed in a circular shape when viewed from the thickness direction of the porous substrate layer 2. The shape of the non-through holes 6 on one side and the non-through holes 7 on the other side is not limited to a circular shape, but can be any shape such as an ellipse, a rounded square, an elongated hole, or a polygon. In the illustrated example, the hole diameters of the multiple non-through holes 6 on one side and the multiple non-through holes 7 on the other side are shown to be the same diameter, but holes with different diameters may be included. Furthermore, the arrangement pattern of the non-through holes 6 on one side and the non-through holes 7 on the other side is not limited to a parallel pattern as shown in the illustrated example, but can be staggered (60-degree staggered or 45-degree staggered), or various other patterns.

[0021] In this embodiment, the non-penetrating holes 6 on one side and the non-penetrating holes 7 on the other side are formed to a depth of approximately 75% of the thickness of the porous substrate layer 2. That is, the depth dimension of the non-penetrating holes 6 on one side along the panel thickness direction and the depth dimension of the non-penetrating holes 7 on the other side along the panel thickness direction are approximately the same. The greater the depth of the non-penetrating holes 6 on one side and the non-penetrating holes 7 on the other side, the larger the area over which air is resisted by the porous substrate layer 2, resulting in greater sound absorption. For the reasons mentioned above, the depth of the non-penetrating holes 6 on one side and the non-penetrating holes 7 on the other side is preferably 50% or more of the thickness of the porous substrate layer 2, and more preferably 75% or more of the thickness of the porous substrate layer 2. From the viewpoint of moldability, etc., the depth of the non-penetrating holes 6 on one side and the non-penetrating holes 7 on the other side may be 95% or less of the thickness of the porous substrate layer 2, or 90% or less, so as not to penetrate the interior panel 1. Furthermore, if the depth of the non-penetrating holes 6 on one side and the non-penetrating holes 7 on the other side exceeds 50% of the thickness of the porous substrate layer 2, at least a portion of the non-penetrating holes 6 on one side and the non-penetrating holes 7 on the other side will overlap in a direction perpendicular to the thickness of the porous substrate layer 2. This makes it easier for air to flow through the non-penetrating holes 6 on one side and the non-penetrating holes 7 on the other side via the porous substrate layer 2, thereby improving sound absorption performance.

[0022] The non-penetrating holes 6 on one side and the non-penetrating holes 7 on the other side are formed in positions that do not overlap when viewed from the thickness direction of the porous substrate layer 2. This configuration allows for a larger depth of the non-penetrating holes. If they were formed in overlapping positions, it would only be possible to form non-penetrating holes to a depth that prevents them from communicating with each other. The porous substrate layer 2 of the interior panel 1 according to this embodiment is made of a porous material having an open-cell structure, and therefore has breathability. As a result, air flowing into either the non-penetrating hole 6 on one side or the non-penetrating hole 7 on the other side passes through the porous substrate layer 2 from the non-penetrating hole 6 on one side to the non-penetrating hole 7 on the other side, creating air circulation through the interior panel 1. This air circulation through ventilation makes it easier to achieve sound absorption performance.

[0023] <Second Embodiment> As shown in Figure 3, the interior panel 1A according to the second embodiment has a configuration in which the depths of the non-penetrating holes 6 on one side and the non-penetrating holes 7 on the other side are different, and only one of the non-penetrating holes 6 on one side and the non-penetrating holes 7 on the other side has a depth of 50% or more of the thickness of the porous substrate layer 2. Even with the above configuration, the interior panel 1A according to the second embodiment can exhibit high sound absorption. For example, by installing the panel so that the side with the non-penetrating holes having a depth of 50% or more of the thickness of the porous substrate layer 2 faces the room, it is possible to absorb more sound generated in the room. In this embodiment as well, the non-penetrating holes 6 on one side and the non-penetrating holes 7 on the other side are formed so that at least a portion of them overlap in a direction perpendicular to the thickness of the porous substrate layer 2. In other words, the sum of the depth dimension of the non-penetrating holes 6 on one side and the depth dimension of the non-penetrating holes 7 on the other side is greater than the thickness of the interior panel 1A. <Other Embodiments> In the above-described examples, at least one of the non-penetrating holes 6 on one side and the non-penetrating holes 7 on the other side has a depth of 50% or more of the thickness of the porous substrate layer 2. However, the configuration is not limited to this, and the configuration does not have to have a depth of 50% or more of the thickness of the porous substrate layer 2.

[0024] 1.1A Interior panel 2. Porous substrate layer 3. One-sided sheet 5. Other-sided sheet 6. Non-penetrating holes on one side 7. Non-penetrating holes on the other side

Claims

1. An interior panel comprising: a thin, thick porous substrate layer having an open-cell structure; and a sheet covering both sides of the porous substrate layer in the thickness direction, wherein a non-penetrating hole on one side of the sheet communicating with the porous substrate layer is formed from the sheet on one side in the thickness direction of the porous substrate layer; and a non-penetrating hole on the other side of the sheet communicating with the porous substrate layer is formed from the sheet on the other side in the thickness direction of the porous substrate layer, and the non-penetrating hole on one side and the non-penetrating hole on the other side are formed in positions that do not overlap when viewed from the thickness direction of the porous substrate layer.

2. The interior panel according to claim 1, characterized in that the non-penetrating holes on one side and the non-penetrating holes on the other side have a depth of 50% or more of the thickness of the porous substrate layer.

3. The interior panel according to claim 1, characterized in that one of the non-penetrating holes on one side and the non-penetrating holes on the other side has a depth of 50% or more of the thickness of the porous substrate layer.

4. An interior panel according to any one of claims 1 to 3, characterized in that the porosity of non-penetrating holes on one side of the porous substrate layer in the thickness direction, and the porosity of non-penetrating holes on the other side of the porous substrate layer in the thickness direction, are each 3.5% or more.

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