JP6761985B2 - Surface decorative panel, decorative panel equipped with this, and surface decorative panel manufacturing method - Google Patents

Description

The present invention relates to a surface decorative panel used as a surface material for an interior panel or furniture, a decorative panel provided with the surface decorative panel, and a method for manufacturing the surface decorative panel.

Conventionally, a surface decorative panel used as a surface material for interior panels and furniture has a structure in which a decorative sheet such as a resin film or a veneer is laminated on a wood-based base material such as MDF (medium density fiberboard). It has been known. In such a case, there is a problem that deformation such as warpage and dimensional change due to moisture absorption and desorption is likely to occur.
For example, Patent Document 1 below discloses a composite plastic structural plate formed by laminating a flat thermoplastic resin sheet, a metal plate, or the like on one side of a thermoplastic resin sheet having a large number of irregularities.

Japanese Unexamined Patent Publication No. 10-156985

However, in the composite plastic structural plate described in Patent Document 1, since the layer having a large number of irregularities is made of a thermoplastic resin, it is considered that the irregularities are easily crushed when a load is applied in the thickness direction. , Further improvement is desired.

The present invention has been made in view of the above circumstances, and is a surface decorative panel capable of improving plane compression strength while being able to suppress deformation such as warpage and dimensional change, a decorative panel provided with the same, and the like. It is an object of the present invention to provide a method for producing a surface decorative panel capable of effectively producing a various surface decorative panel.

In order to achieve the above object, the surface decorative panel according to the present invention includes a surface sheet provided with a decorative single plate, a decorative printing paper or a resin film forming a decorative layer on one side in the thickness direction of the thermoplastic resin sheet. , The surface sheet is provided on the other side in the thickness direction, has a large number of protrusions protruding toward one side in the thickness direction so as to form a recess opening on the other side in the thickness direction, and is a fiber sheet. It is characterized by comprising an uneven fiber reinforced resin layer containing a thermosetting resin as a resin main component.

Further, in order to achieve the above object, the decorative panel according to the present invention is characterized by including a panel core material and a surface decorative panel according to the present invention attached to the panel core material. ..

Further, in order to achieve the above object, in the surface decorative panel manufacturing method according to the present invention, a decorative single plate, decorative printing paper or resin film forming a decorative layer is provided on one side of the thermoplastic resin sheet in the thickness direction. The surface sheet has a large number of protrusions protruding toward one side in the thickness direction so that a recess opening on the other side in the thickness direction is formed on the other side in the thickness direction, and includes a fiber sheet. It is characterized in that a surface decorative panel is manufactured by laminating and integrating an uneven fiber reinforced resin layer containing a thermosetting resin as a resin main component.

Further, in order to achieve the above object, in the surface decorative panel manufacturing method according to the present invention, a decorative single plate, a decorative printing paper or a resin film forming a decorative layer is provided on one side of the thermoplastic resin sheet in the thickness direction. A large number of surface sheets projecting toward one side in the thickness direction so that a sheet-like fiber-reinforced resin layer containing the fiber sheet and a recess opening on the other side in the thickness direction are formed on the other side in the thickness direction. It is characterized in that a surface decorative panel is manufactured by laminating and integrating an uneven fiber reinforced resin layer having a convex portion of the above and containing a fiber sheet and containing a thermosetting resin as a resin main component.

The surface decorative panel according to the present invention and the decorative panel provided with the surface decorative panel have the above-described configuration, so that deformation such as warpage and dimensional change can be suppressed, and plane compression strength can be improved. .. In addition, the surface decorative panel manufacturing method according to the present invention can effectively manufacture such a surface decorative panel.

(A) and (b) schematically show an example of a surface decorative panel according to an embodiment of the present invention and an example of a decorative panel provided with the same, and (a) shows X- in FIG. 2 (a). The partially broken schematic cross-sectional view corresponding to the X-ray view, (b) is the partially broken schematic disassembled cross-sectional view corresponding to (a). (A) is a schematic front view of the decorative panel, and (b) is a schematic front view schematically showing an example of a panel core material included in the decorative panel. (A) to (d) are partial fracture schematic vertical sectional views schematically showing an example of a surface decorative panel manufacturing method according to an embodiment of the present invention. (A) to (e) are partial fracture schematic vertical cross-sectional views schematically showing an example of the same surface decorative panel manufacturing method. (A) to (d) are partial fracture schematic vertical cross-sectional views schematically showing an example of the same surface decorative panel manufacturing method. (A) to (c) are partial fracture schematic plan views schematically showing an example of the uneven fiber reinforced resin layer provided in the surface decorative panel. (A) and (b) are schematic vertical cross-sectional views of a partially broken portion schematically showing an example of a surface decorative panel manufacturing method according to another embodiment of the present invention, and (c) is another embodiment of the present invention. It is a partial fracture schematic vertical sectional view schematically showing an example of the surface decorative panel which concerns on. (A) and (b) are schematic vertical sectional views schematically showing an example of a surface decorative panel according to another embodiment of the present invention.

Hereinafter, embodiments of the present invention will be described with reference to the drawings.
1 to 6 are diagrams schematically showing an example of a surface decorative panel according to the first embodiment, an example of a decorative panel provided with the surface decorative panel, and an example of a surface decorative panel manufacturing method.

As shown in FIGS. 3 to 5, the surface decorative panel 20 according to the present embodiment includes a surface sheet 21 provided with a decorative layer 23 on one side of the thermoplastic resin sheet 22 in the thickness direction, and the surface sheet 21. A concave-convex fiber reinforced resin layer 32 provided on the other side in the thickness direction is provided. Further, the uneven fiber reinforced resin layer 32 includes a fiber sheet 30 and is configured to contain a thermosetting resin as a resin main component.
Further, as shown in FIG. 1, the decorative panel 1 according to the present embodiment has a configuration in which the surface decorative panel 20 is attached to the panel core material 10. Further, the surface decorative panels 20 and 20 are provided on both sides of the panel core material 10 in the panel thickness direction.

As shown in FIG. 2A, the decorative panel 1 has a substantially rectangular flat plate shape that is long in one direction. When both sides in the thickness direction are decorative surfaces as in the present embodiment, the decorative panel 1 is used as a fitting panel for opening / closing an entrance / a storage opening, a partition panel for a partition, a furniture component, or the like. May be. Further, instead of the mode in which both sides in the thickness direction are decorative surfaces in this way, the surface decorative panel 20 may be provided only on one side in the panel thickness direction of the panel core material 10. In this case as well, it can be used for the same purposes as described above. Further, the decorative panel 1 may be used to form a part of the panel, for example, a frame portion or a mirror plate portion of a frame-shaped panel. Further, the decorative panel 1 includes a ceiling panel, a wall panel (partition wall panel), a waist wall panel, a floor panel, a baseboard panel, a peripheral panel, an opening frame panel, etc., whose anti-decorative surface side is arranged toward the mounting base side. It may be used as.

Further, the length dimension (vertical dimension, height dimension), width dimension, thickness dimension, etc. of the decorative panel 1 may be appropriately set according to the application of the decorative panel 1.
For example, when the decorative panel 1 is used as a fitting panel, the vertical dimension (door height dimension) of the decorative panel 1 is about 1800 mm to 3000 mm, the door width dimension is about 600 mm to 1200 mm, and the door thickness dimension. May be about 20 mm to 40 mm. Further, in this case, a handle or a puller for opening / closing is provided at an appropriate position of the decorative panel 1, a locking device, a rotary connecting member such as a hinge, a running member such as a runner or a door roller, a guide groove, etc. You may do it.

As shown in FIG. 2B, the panel core material 10 has a configuration in which the core material 16 is housed in a space surrounded by a frame body 11 including four peripheral frames 12, 13, 13, and 14.
The frame body 11 includes an upper horizontal frame 12, a pair of left and right vertical frames 13, 13 and a lower horizontal frame 14 that form a four-circumferential frame 12, 13, 13, 14. Further, the frame body 11 includes a plurality of horizontal rails 15 and 15 provided at vertical intervals so as to be bridged between the left and right vertical frames 13 and 13. Further, in the figure example, an example is shown in which a crosspiece is laminated on the upper side of the lower horizontal frame 14. Further, an example is shown in which a base member serving as a processing base for mounting holes of a traveling member such as a door roller is laminated on the upper side of both left and right (longitudinal directions) ends of the lower horizontal frame 14. Depending on the application of the decorative panel 1, a running member such as a runner, a handle, or a locking device as described above may be placed on the lower side of the left and right ends of the upper horizontal frame 12 or on the inner side of one of the vertical frames 13. It is also possible to provide a processing base for mounting holes such as, or a mounting base. Further, a similar crosspiece may be provided on the lower side of the upper horizontal frame 12. Further, the frame body 11 may be provided with a long vertical rail in the vertical direction instead of or in addition to the mode in which the horizontal rail 15 is provided.

Further, these four peripheral frames 12, 13, 13, 14 and the cross rail 15 are substantially square columnar, and the dimensions along the panel thickness direction are substantially the same so that both sides in the panel thickness direction are substantially the same plane. It is a dimension. Further, in the figure example, an example is shown in which the dimensions of the four peripheral frames 12, 13, 13, 14 and the cross rail 15 along the panel thickness direction and the width dimensions orthogonal to the length dimensions are substantially the same as each other. ..
These four circumference frames 12, 13, 13, 14 and the cross rail 15 are made of wood laminated board such as plywood or LVL (single board laminated material), wood board such as PB (particle board), MDF (medium density fiberboard) or the like. It may be formed from a wood-based material such as a wood fiber board such as a hard board. Further, the wood-based material may be a wood powder / plastic composite material (WPC) in which a synthetic resin-based material contains wood flour, an inorganic filler, a compatibilizer, a colorant, or the like in a predetermined content ratio. Further, the frame body 11 is not limited to the one formed from such a wood-based material, and may be formed from a synthetic resin-based material or a metal-based material.

Further, in the present embodiment, as shown in FIGS. 1 (b) and 2 (b), the difference between the surface decorative panels 20 and 20 described later is on the outer surface of both vertical frames 13 and 13 facing outward in the panel width direction. The insertion grooves 13a and 13a into which the insert pieces 20c and 20c are inserted are provided over the entire length. The insertion grooves 13a and 13a on both sides in the panel width direction are provided so as to open toward the outside in the panel width direction. Further, these insertion grooves 13a and 13a are provided so as to be located substantially at the center in the panel thickness direction of the vertical frames 13 and 13. The groove depth dimension along the panel width direction of the insertion grooves 13a and 13a and the groove width dimension along the panel thickness direction are the insertability and retention of the insertion pieces 20c and 20c of the surface decorative panels 20 and 20. From the viewpoint of the above, the dimensions may be appropriate.

As shown in FIG. 2B, the core material 16 of the panel core material 10 is housed so as to be filled in the space surrounded by the frame body 11. In the present embodiment, the spaces in the four-circumferential frames 12, 13, 13, and 14 are vertically partitioned by a plurality of cross rails 15, 15 provided at intervals in the vertical direction (panel longitudinal direction) as described above. The core material 16 is housed in each of the above. The dimensions of the core material 16 along the panel thickness direction are substantially the same as the dimensions of the frame body 11 along the panel thickness direction. Such a core material 16 may be a foam molded body molded from a foamed resin-based material such as urethane foam, but in the present embodiment, a large number of hollow tubular cells that open on both sides in the panel thickness direction. The honeycomb-shaped core material 16 is made of an aggregate of the above. That is, the core material 16 is a so-called paper core. Further, such a core material 16 may be formed by stacking and adhering paper materials such as corrugated cardboard base paper and kraft paper with an adhesive. Further, the core material 16 may be such a paper material further impregnated with a reinforcing resin such as an epoxy resin, and in addition, a metal-based material such as an aluminum material, a hard polyvinyl chloride resin, or a polypropylene resin. It may be formed from a synthetic resin-based material such as.

Further, in the figure example, the hollow tubular cell of the core material 16 is schematically shown, and a corrugated portion (corrugated portion) is provided between thin sheets along the thickness direction in the panel width direction. However, it is not limited to such an aspect. The core material 16 has various cell shapes such as a hollow tubular cell having a honeycomb shape (hexagonal shape), a square shape, and a cylindrical shape. It may be the one that is said to be. Further, the core material 16 may be fixed to the frame 11 with a stopper such as a staple or an adhesive. The cell size (cell diameter, cell width) of the hollow tubular cell of the core material 16 may be an appropriate size from the viewpoint of weight reduction, strength, etc., or may be 1 mm or more and 100 mm or less. Preferably, it may be 5 mm or more and 15 mm or less.

The surface decorative panel 20 has a thin plate shape. The surface decorative panel 20 has a thickness similar to that of a surface material based on a wood-based material such as MDF, which has been conventionally used as a surface material constituting the decorative surface of various decorative panels 1, (for example, about 3 mm). ), But it may also have an appropriate thickness depending on the application and the like. For example, the thickness of the surface decorative panel 20 may be about 0.5 mm to 5.0 mm, preferably 1.0 mm or more and 3.0 mm or less, and more preferably 1.5 mm or more and 2.0 mm or less. May be good.
In the present embodiment, the decorative layer 22 constituting the surface sheet 21 of the surface decorative panel 20 is a decorative sheet 22 in the form of a thin sheet. The decorative sheet 22 includes a single plate (decorative single plate) such as a veneer formed from natural wood (named wood), a decorative printing paper on which various patterns (patterns) such as a wood grain pattern are printed, or a synthetic resin type. It may be a resin sheet (film) or the like. Examples of the resin film include vinyl chloride resin film, polyethylene resin film, polyethylene terephthalate resin film, polypropylene resin film, polycarbonate resin film, acrylic resin film, urethane resin film and the like. Further, as the thickness of the resin film, for example, the range of 0.02 mm to 1.0 mm, preferably 0.05 mm to 0.2 mm, and more preferably 0.06 mm to 0.12 mm is exemplified.

Further, as the thickness of the decorative single plate constituting the decorative sheet 22, for example, the range of 0.2 mm to 1.0 mm is exemplified. When the decorative sheet 22 is used as a decorative single plate, a backing material such as a non-woven fabric may be attached to the back surface side of the decorative single plate via an adhesive. As the adhesive in this case, a water-insoluble adhesive in which moisture does not easily transfer to the decorative single plate is preferably exemplified. Examples of the water-insoluble adhesive include a solution-type acrylic copolymer, a synthetic rubber-based adhesive, and a hot-melt-based adhesive which is a thermoplastic synthetic resin, which are used alone or in combination of two or more. can do. Examples of the hot melt adhesive include ethylene vinyl acetate (EVA) and urethane hot melt (PUR). Further, an epoxy resin-based adhesive, a urethane-based adhesive, a vinyl chloride-based adhesive, a vinyl acetate-based adhesive, or the like may be exemplified alone or in combination of two or more kinds.

Further, the thermoplastic resin sheet 23 constituting the surface sheet 21 of the surface decorative panel 20 is provided in the form of a backing material (backer material) over substantially the entire back surface side of the decorative sheet 22. The thermoplastic resin sheet 23 and the decorative sheet 22 may be laminated and integrated via various adhesives similar to those described above. Further, the thermoplastic resin sheet 23 is configured not to contain the reinforcing fibers contained in the fiber reinforced resin layer 26 and the uneven fiber reinforced resin layer 32, which will be described later.
Further, the resin constituting the thermoplastic resin sheet 23 may be various thermoplastic resins such as polypropylene resin, ABS resin, polyvinyl chloride resin, polyethylene resin and polyester resin, and preferably polypropylene resin or ABS resin. ..

Further, the thickness of the thermoplastic resin sheet 23 is appropriately adjusted from the viewpoint of improving the surface appearance (surface smoothness) including the appearance of the bent corners of the surface decorative panel 20 and from the viewpoint of dimensional stability, productivity and the like. It may be the thickness. For example, the thickness of the thermoplastic resin sheet 23 may be about 0.03 mm to 1.0 mm, preferably about 0.05 mm to 0.5 mm, and more preferably about 0.15 mm to 0.4 mm. Good. If the thickness of the thermoplastic resin sheet 23 is too small, the surface appearance tends to deteriorate, and if the thickness of the thermoplastic resin sheet 23 is too large, the effect of thermal expansion by the thermoplastic resin sheet 23 is large. Tends to be.

Further, in the present embodiment, the sheet-shaped fiber reinforced resin layer 26 including the fiber sheet 25 is interposed between the surface sheet 21 and the uneven fiber reinforced resin layer 32.
As shown in FIGS. 3C and 3D, the fiber-reinforced resin layer 26 has a structure in which the fiber sheet 25 is impregnated with the uncured resin composition 24 and the resin composition 24 is cured. The thickness of the fiber reinforced resin layer 26 may be an appropriate thickness depending on the type, basis weight, thickness, etc. of the fiber sheet 25 selected according to the application of the surface decorative panel 20 (decorative panel 1). Good.
The thickness of the fiber reinforced resin layer 26 may be, for example, about 0.1 mm to 1.0 mm, preferably about 0.2 mm to 0.6 mm.

Examples of the fiber sheet 25 include woven fabrics of reinforcing fibers such as glass fibers, carbon fibers, and mineral fibers, non-woven fabrics, and mats. Examples of the glass fiber woven fabric include a plain weave woven by using glass roving for the warp and weft, a glass cloth which is a woven fabric such as a leno weave, and the like. As the non-woven fabric of glass fiber, for example, glass fiber having a length of about 10 mm is dispersed in water, then scooped, dehydrated and sheeted by a wet paper making method, and an adhesive such as epoxy resin or acrylic resin is applied. Glass paper and the like are exemplified. As the glass fiber mat, glass strands cut into long fibers (for example, about 30 mm in length, preferably about 50 mm in length) are evenly dispersed in a non-directional manner, and a mat is used with a binder such as a polyester binder. An example is a glass mat or the like which is molded into a shape.

Further, as the thickness of the fiber sheet 25, for example, the range of 0.1 mm to 0.5 mm is exemplified. When the fiber sheet 25 is a glass mat, the thickness may be about 0.3 mm to 0.5 mm, and when the fiber sheet 25 is a glass cloth, the thickness may be about 0.1 mm to 0.3 mm. May be. Further, as the density of the glass cloth, for example, 30 to 120 pieces / 25 mm is exemplified. Further, as the count (thickness) of the glass thread constituting the glass cloth, for example, the range of 67 to 135 tex (g / 1000 m) is exemplified.
As the basis weight of the fiber sheet 25, for example, a range of 100 g / m ² or more and 700 g / m ² or less is exemplified, and it may be preferably 150 g / m ² or more. According to this, it is possible to impart appropriate strength to the fiber reinforced resin layer 26, but it is possible to reduce the weight.
If the basis weight of the fiber sheet 25 is too small, the strength tends to decrease, while if it is too large, it tends to be heavy. When a glass cloth is used as the fiber sheet 25, the basis weight may be 200 g / m ² or more. When glass paper is used as the fiber sheet 25, the basis weight may be 50 g / m ² or more. When a glass mat is used as the fiber sheet 25, the basis weight may be 100 g / m ² or more. Further, as the fiber sheet 25, a glass mat or a glass cloth is preferable among such glass fiber sheets.

The fiber sheet 25 includes a laminated sheet of the above-mentioned glass fiber woven fabric, non-woven fabric or mat (glass fiber sheet), or a glass fiber sheet and a plant fiber woven fabric, non-woven fabric, film, paper or mat. And may be laminated. The plant fiber is not particularly limited as long as it is a plant fiber mat or a plant fiber used for papermaking, but in consideration of the strength, durability, dimensional stability, etc. of the fiber sheet 25, hemp-based natural fiber, palm fiber, or agricultural waste It is preferable that any one or more of the physical fibers are used.
The resin composition 24 impregnated in the fiber sheet 25 is exemplified by a non-foaming or low-foaming resin. For example, as the resin main component of the resin composition 24, various thermosetting resins such as urethane (polyurethane) resin and phenol resin are used alone or in combination of two or more.

The foaming ratio of the resin composition 24 constituting the fiber-reinforced resin layer 26 depends on the type thereof, but may be a low foaming ratio having a foaming ratio of 7 times or less, more preferably 5 times or less. Further, the resin composition 24 may have a foaming ratio of 1 to 5 times, more preferably 1 to 3 times, still more preferably 1 to 2 times.
Further, the resin composition 24 may be a low-temperature curable thermosetting resin that cures at a relatively low temperature (for example, 40 ° C. or higher and 90 ° C. or lower, preferably 80 ° C. or lower). According to this, it is possible to cure at a low temperature, it is possible to reduce the heat load on the surface sheet 21, and it is possible to suppress deterioration of the surface appearance.
Further, urethane resin is preferably adopted as the resin main component of the resin composition 24. According to this, the adhesiveness to the surface sheet 21 described later is excellent, and the impregnation property to the fiber sheet 25 is also excellent. As such a urethane resin, an ether-based urethane resin or a castor oil-based urethane resin having water resistance is preferably exemplified. Various additives such as a curing agent and a flame-retardant material can be added to the resin composition 24.

The amount of the resin composition 24 is appropriately set from the viewpoints of the thickness and basis weight of the fiber sheet 25, the desired thickness of the fiber reinforced resin layer 26, the strength and dimensional stability of the surface decorative panel 20, cost, and the like. May be good. For example, the amount of the resin composition 24 impregnated in the fiber sheet 25 may be 80 g / m ² or more, preferably 100 g / m ² or more. Further, from the viewpoint of weight reduction and cost, the amount of the resin composition 24 impregnated in the fiber sheet 25 may be 400 g / m ² or less, preferably 250 g / m ² or less. The amount of the resin composition 24 may be a relatively small amount so that the fiber sheet 25 can be impregnated and flattened. The amount of the resin composition 24 may be, for example, about 1/2 to 2 times the basis weight of the fiber sheet 25, and preferably 1.5 times or less.
Further, the impregnation of the resin composition 24 into the fiber sheet 25 may be performed by immersing the fiber sheet 25 in a container for storing the resin composition 24 and then appropriately squeezing out the excess, or spraying the fiber sheet 25. It may be applied by a roller or the like. Alternatively, as in the manufacturing method example described later, the fiber sheet is applied to the resin composition 24 coated by a spray, a roller, or the like on the other side in the thickness direction, which is the back surface side of the thermoplastic resin sheet 23 constituting the front surface sheet 21 described above. By laminating 25, the fiber sheet 25 may be impregnated with the resin composition 24 as a result.

As shown in FIGS. 4 (b) and 4 (c), the uneven fiber reinforced resin layer 32 is obtained by impregnating the fiber sheet 30 with the uncured resin composition 31 in the same manner as the fiber reinforced resin layer 26. Is considered to be a cured structure.
In the present embodiment, the resin main component of the resin composition 31 constituting the uneven fiber reinforced resin layer 32 is the same as the resin main component of the resin composition 24 constituting the fiber reinforced resin layer 26. That is, the resin main component of the resin composition 31 constituting the uneven fiber reinforced resin layer 32 may be preferably a urethane resin. According to this, the impregnation property into the fiber sheet 30 is also excellent as described above. Further, the resin composition 31 constituting the uneven fiber reinforced resin layer 32 may be a low-temperature curable thermosetting resin as described above.
Further, the fiber sheet 30 included in the uneven fiber reinforced resin layer 32 may be any of those exemplified as the fiber sheet 25 of the fiber reinforced resin layer 26 described above. The fiber sheet 30 may preferably be a glass mat or a glass cloth among the glass fiber sheets as described above, or may be the same as or the same type as the fiber sheet 25 of the fiber reinforced resin layer 26, or may be different. May be good.

Further, the basis weight of the fiber sheet 30 contained in the uneven fiber reinforced resin layer 32 may be an appropriate basis weight from the same viewpoint as described above, and a range of 100 g / m ² or more and 700 g / m ² or less is exemplified, and preferably. It may be 150 g / m ² or more. According to this, it is possible to impart appropriate strength to the uneven fiber reinforced resin layer 32 as described above, but it is possible to reduce the weight. Further, the basis weight of the fiber sheet 30 may be substantially the same as that of the fiber sheet 25 of the fiber reinforced resin layer 26, or may be different.
From the same viewpoint as described above, the amount of the resin composition 31 impregnated in the fiber sheet 30 may be an appropriate amount, may be 80 g / m ² or more and 300 g / m ² or less, and preferably 100 g / m ² or more and 250 g. It may be less than / m ² . Further, the amount of the resin composition 31 may be about 1/2 to 2 times, preferably 1.5 times or less the basis weight of the fiber sheet 30 as described above. Further, the amount of the resin composition 31 may be substantially the same as or different from the amount of the resin composition 24 of the fiber reinforced resin layer 26.

Further, the uneven fiber reinforced resin layer 32 has a front surface side (fiber) on one side in the thickness direction so that a recess 33 that opens on the back surface side (anti-fiber reinforced resin layer side) on the other side in the thickness direction is formed. It has a structure in which a convex portion 34 protruding toward the reinforced resin layer 26 side) is provided and has an embossed plate shape.
In the present embodiment, as shown in FIG. 4 (e), the surface side (fiber reinforced resin layer 26 side) portion that is the tip portion of the convex portion 34 in the protruding direction (bottom of the concave portion 33) is referred to as the fiber reinforced resin layer 26. It is a parallel surface side flat plate part. Further, the concave portions 33 and the convex portions 34 are provided at intervals from each other so that the back surface side flat plate portion parallel to the fiber reinforced resin layer 26 is formed around the concave portions 33 and the convex portions 34. It is said. Further, the thickness dimension of the side peripheral wall portion connected to the tip end portion (bottom portion of the concave portion 33) of the convex portion 34 is substantially the same as the thickness of the front surface side flat plate portion and the back surface side flat plate portion.
The thickness dimension of each part of the uneven fiber reinforced resin layer 32 may be substantially the same as the thickness of the fiber reinforced resin layer 26, or may be different.

Further, the protruding dimension of the convex portion 34 (the protruding dimension from the surface of the back surface side flat plate portion toward the front surface side) is the moldability and the total thickness of the desired uneven fiber reinforced resin layer 32 (on the back surface side of the back surface side flat plate portion). The thickness may be appropriate depending on the thickness from the facing surface to the tip surface of the convex portion 34 in the protruding direction). The protruding dimension of the convex portion 34 may be about 1.5 to 4 times the thickness of each portion of the concave-convex fiber reinforced resin layer 32 (thickness of the flat plate portion on the back surface side, etc.), preferably 2.5 times or less. May be. Further, the total thickness of the uneven fiber reinforced resin layer 32 may be ½ or more of the thickness of the surface decorative panel 20 from the viewpoint of reducing the weight while ensuring the thickness.
Further, in the present embodiment, a large number of concave portions 33 and convex portions 34 have the same size and shape. Further, the opening of the tip portion of the convex portion 34 and the concave portion 33 has a substantially circular shape when viewed in the thickness direction (direction along the thickness direction of the surface decorative panel 20) (see FIG. 6A). That is, the convex portion 34 has a substantially cylindrical shape with the front surface side flat plate portion as the bottom portion.

Further, in the present embodiment, the convex portion 34 has a substantially truncated cone shape that tapers toward the tip side in the protruding direction. That is, the side peripheral wall portion of the convex portion 34 is not orthogonal to the back surface side flat plate portion, but is inclined. The inclination angle of the side peripheral wall portion with respect to the back surface side flat plate portion (the angle (inner angle) formed by the same virtual surface as the surface facing the back surface side of the back surface side flat plate portion and the inner surface of the side peripheral wall portion) determines the moldability and the plane compression strength. An appropriate angle may be used from the viewpoint of improvement. For example, the inclination angle of the side peripheral wall portion with respect to the back surface side flat plate portion may be 45 degrees or more and less than 90 degrees, preferably 50 degrees or more and 80 degrees or less. In the illustrated example, an example is shown in which the inclination angle of the side peripheral wall portion with respect to the back surface side flat plate portion is about 55 degrees.

Further, in the present embodiment, as shown in FIG. 6A, a large number of convex portions 34 are provided so as to have a regular arrangement. A large number of the convex portions 34 may be provided in a square arrangement, a lattice arrangement, or a staggered arrangement, or may be provided at substantially equal intervals (at a substantially equal pitch). In the illustrated example, a large number of convex portions 34 are provided so as to form a hexagonal lattice. With such a configuration, a relatively large number of convex portions 34 (concave portions 33) can be efficiently provided.
The pitch of the convex portion 34 and the diameter of the convex portion 34 (outer diameter of the base end portion) are the moldability, the bondability between the uneven fiber reinforced resin layer 32 and the fiber reinforced resin layer 26, and the uneven fiber reinforced resin layer 32. It may be set as appropriate from the viewpoint of bondability with the bonding target on the back surface side of the and.

For example, the diameter of the convex portion 34 (outer diameter of the base end portion) may be about 2 mm to 15 mm, or may be about 3 mm to 8 mm. Further, the pitch of the convex portions 34 (the dimension between the centers (centers) of the adjacent convex portions 34, 34 when viewed in the thickness direction) is set to be larger than the diameter of the convex portions 34 (outer diameter of the base end portion). For example, it may be about 1.2 times to 5 times, preferably about 1.5 times to 3 times.
Further, for example, the concave portions 33 and the convex portions 34 are provided so that the total area of the tip surfaces of a large number of convex portions 34 is 10% or more of the area of the concave-convex fiber reinforced resin layer 32 viewed in the thickness direction. It may be configured as a new type. Further, the concave portion 33 and the convex portion 34 are provided so that the total area of the surface of the flat plate portion on the back surface side facing the back surface side is 60% or more of the area of the concave-convex fiber reinforced resin layer 32 viewed in the thickness direction. May be.

FIG. 6A exemplifies the uneven fiber reinforced resin layer 32 in which the pitch of the convex portion 34 is substantially twice the diameter of the convex portion 34 (outer diameter of the base end portion).
Further, FIG. 6B exemplifies the uneven fiber reinforced resin layer 32A in which the pitch of the convex portion 34A is approximately 1.5 times the diameter of the convex portion 34A (outer diameter of the base end portion).
Further, FIG. 6C exemplifies the uneven fiber reinforced resin layer 32B in which the pitch of the convex portion 34B is approximately 4/3 times the diameter of the convex portion 34B (outer diameter of the base end portion). The uneven fiber reinforced resin layers 32A and 32B shown in FIGS. 6 (b) and 6 (c) may be provided on the surface decorative panel 20 instead of the uneven fiber reinforced resin layer 32.
Further, the diameters, pitches, and arrangements of the convex portions 34, 34A, and 34B are not limited to the above examples, and various modifications are possible.
Further, the shapes of the convex portions 34, 34A, 34B (concave portions 33) when viewed in the thickness direction are not limited to the above examples, and may be a polygonal shape or the like. That is, the convex portions 34, 34A, 34B may be formed into a substantially polygonal columnar shape, a substantially polygonal pyramid-shaped shape, or the like.

In the present embodiment, as shown in FIG. 1, the surface decorative panel 20 having the above-described configuration is provided on both sides of the panel core material 10 in the panel thickness direction so that seams are located on both end faces in the panel width direction. It is configured to be provided in pairs. That is, the configuration is such that two surface decorative panels 20 and 20 are provided. Further, on these two surface decorative panels 20 and 20, the four peripheral surfaces (panel thickness) of the panel core material 10 are arranged so that the four peripheral surfaces (both sides in the thickness direction and both end surfaces in the width direction) of the decorative panel 1 are decorative surfaces. Both sides in the direction and both ends in the width direction of the panel) are provided.
Further, in the present embodiment, the bent grooves 37 and 38 are provided on the back surface side of the front surface decorative panels 20 and 20 so that the groove bottom is located on the thermoplastic resin sheet 23.
These surface decorative panels 20 and 20 have the same structure as each other, and are bent grooves (corner bent grooves) 37, 37, 37 on the back surface side so as to be positioned according to the corners of the panel core material 10. , 37 are provided. Further, in the present embodiment, on the back surface side of the front surface decorative panels 20, 20, in addition to the corner bent grooves 37, 37, 37, 37, both opening edges of the insertion grooves 13a, 13a of the panel core material 10 are provided. The end bending grooves 38, 38, 38, 38 are provided so as to be positioned according to the above.

The corner bent grooves 37 and the end bent grooves 38 are provided on the back surface side of the front surface decorative panels 20 and 20 so as to leave at least the decorative sheet 22.
In each of the surface decorative panels 20 and 20, at least the portion of the decorative sheet 22 remaining in the corner bent groove 37 and the end bent groove 38 functions like a hinge portion (bent portion), and these It is said that it can be bent at the site.
Further, in the present embodiment, the corner bent groove 37 and the end bent groove 38 are provided so that the groove bottom is located on the thermoplastic resin sheet 23 (see FIG. 1 (b)). That is, the corner bent grooves 37 and the end bent grooves 38 are formed so that the bottom of the groove stays on the thermoplastic resin sheet 23 and does not reach the decorative sheet 22, and the uneven fiber reinforced resin layer 32 and the fiber reinforced resin layer. The structure is provided over the entire thickness direction of 26.

The thickness of the thermoplastic resin sheet 23 at the portion where the corner bent groove 37 and the end bent groove 38 are provided, that is, the remaining thickness on the groove bottom side functions as a hinge portion as described above. In addition, the thickness may be appropriate depending on the thickness of the decorative sheet 22 and the thickness of the thermoplastic resin sheet 23. In the illustrated example, the remaining thickness on the groove bottom side of the thermoplastic resin sheet 23 is set to about 2/3 of the total thickness of the thermoplastic resin sheet 23, but the thickness is limited to such a thickness. Absent.
Further, the corner bent grooves 37, 37 are formed along the surface side piece 20a of the surface decorative panel 20 along one surface in the thickness direction of the panel core material 10 and each end surface in the width direction of the panel core material 10. It is provided so as to be located at the boundary between the side end face pieces 20b and 20b.
Further, the end bent grooves 38, 38 are located at the boundary between the side end surface piece portions 20b, 20b and the insertion piece portions 20c, 20c to be inserted into the insertion grooves 13a, 13a of the panel core material 10. It is provided as follows. The insertion pieces 20c, 20c, 20c, 20c of the surface decorative panels 20, 20 on both sides in the panel thickness direction are housed so as to be fitted into the insertion grooves 13a, 13a of the panel core material 10.

Further, in the present embodiment, the back surface side of the front surface decorative panel 20 so that the corner portions formed by bending the corner bending grooves 37, 37 in these corner bending grooves 37, 37 are substantially right-angled. It has the configuration provided in. In the illustrated example, these corner bent grooves 37, 37 are shown as an example composed of a single groove having a substantially V-shaped groove shape when viewed in the longitudinal direction of the groove. Instead of such an embodiment, the corner bent grooves 37, 37 are formed so that the corners formed by bending in the corner bent grooves 37, 37 have an R chamfer shape or a C chamfer shape. Each of the above may be composed of a plurality of grooves. Further, the end bending grooves 38, 38 are provided on the back surface side of the front surface decorative panel 20 so that the corners formed by bending the end bending grooves 38, 38 are substantially right-angled. ..
The surface decorative panels 20 and 20 on both sides in the panel thickness direction having the above configuration are attached to the four peripheral surfaces of the panel core material 10, and the four peripheral surfaces of the decorative panel 1 are used as decorative surfaces. The surface decorative panels 20 and 20 may be attached to the panel core material 10 by using an appropriate adhesive or the like as described above.

Next, an example of a surface decorative panel manufacturing method for manufacturing the surface decorative panel 20 according to the present embodiment will be described with reference to FIGS. 3 to 5.
In the same surface decorative panel manufacturing method, the fiber reinforced resin layer 26 and the uneven fiber reinforced resin layer 32 are laminated and integrated on the other side in the thickness direction, which is the back side of the front sheet 21, to manufacture the surface decorative panel 20. Has been done. Further, in the surface decorative panel manufacturing method according to the present embodiment, as shown in FIG. 3, after supplying the uncured resin composition 24 to the back surface side of the front surface sheet 21, the fiber sheet 25 is supplied to the back surface side of the front surface sheet 21. A step of forming the fiber reinforced resin layer 26 is provided. Further, in the same surface decorative panel manufacturing method, a large number of concave portions 33 and convex portions 34 as described above are provided, and the convex portions 34 of the uneven fiber reinforced resin layer 32 including the fiber sheet 30 are formed on the back surface of the fiber reinforced resin layer 26. It has a process of adhering to the side.

Further, in the present embodiment, as shown in FIG. 3D, the surface sheet 21 and the fiber reinforced resin layer 26 are laminated and integrated by using the upper and lower molding dies 2 and 3 whose surfaces facing each other are flat surfaces. The structure is such that the surface layer side sheet body is formed. Further, as shown in FIGS. 4 (c) and 4 (d), upper and lower moldings are provided with a large number of convex portions 4a on one surface side of the surfaces facing each other and a large number of concave portions 5a on the other surface side. Molds 4 and 5 are used to form the uneven fiber reinforced resin layer 32. The upper and lower molding dies (flat plate presses) 2 and 3 and the upper and lower molding dies (concave and convex presses) 4 and 5 may require heating for curing, although it depends on the types of the resin compositions 24 and 31. May be provided with a heater or a medium flow passage through which a heat medium is circulated. That is, the molding dies 2, 3, 4, and 5 may be hot-pressed.

First, as shown in FIG. 3A, the surface sheet 21 is placed on the upper surface of the lower molding die 2 of the upper and lower molding dies 2 and 3 so that the decorative surface faces each other. That is, the front surface sheet 21 is placed on the lower molding die 2 with the thermoplastic resin sheet 23 side, which is the back surface side thereof, arranged on the upper side. Then, as shown in FIG. 3B, the resin composition 24 constituting the fiber reinforced resin layer 26 is supplied to the back surface of the front surface sheet 21. The resin composition 24 may be supplied to the surface sheet 21 by using a spray, a roller, or the like in a uniform coating amount so that the fiber-reinforced resin layer 26 has the desired thickness as described above. Good. Then, as shown in FIGS. 3C and 3D, the fiber sheets 25 are laminated so that the resin composition 24 is impregnated, and the fibers are pressed by the upper and lower molding dies 2 and 3. At this time, an appropriate mold release agent may be applied to the lower surface of the upper molding die 3. Further, it may be pressed with an appropriate press pressure. Further, the resin composition 24 may be cured by heating if necessary.
Instead of such an embodiment, the fiber sheet 25 impregnated with the resin composition 24 is laminated on the surface sheet 21, or the resin composition 24 is laminated with the fiber sheet 25 on the surface sheet 21. It may be applied to the sheet 25 or the like. Further, the prepreg-like fiber sheet 25 (or the cured fiber-reinforced resin layer 26) containing the resin composition 24 and the surface sheet 21 may be laminated and integrated (including adhesion).

Further, as shown in FIG. 4, a lower molding die 4 having a convex portion 4a provided on the upper surface side as one surface side of the surfaces facing each other and a concave portion 5a provided on the lower surface side as the other surface side. The concavo-convex fiber reinforced resin layer 32 may be formed by using the upper molding die 5. The convex portion 4a of the lower molding die 4 is provided so as to have a shape and a position corresponding to the concave portion 33 of the concave-convex fiber reinforced resin layer 32. The concave portion 5a of the upper molding die 5 is provided so as to have a shape and a position corresponding to the convex portion 34 of the concave-convex fiber reinforced resin layer 32.
First, as shown in FIG. 4A, the fiber sheet 30 is placed on the upper surface side of the lower molding die 4. Then, as shown in FIG. 4B, the uncured resin composition 31 constituting the uneven fiber reinforced resin layer 32 is supplied to the fiber sheet 30, and the fiber sheet 30 is impregnated with the resin composition 31. It may be. The resin composition 31 may be applied to the fiber sheet 30 by using a spray, a roller, or the like as described above. Instead of such an embodiment, the fiber sheet 30 is immersed in a container for storing the resin composition 31, and then the excess is appropriately squeezed out to impregnate the fiber sheet 30 with the resin composition 31. May be good.

Then, as shown in FIGS. 4C and 4D, the fiber sheet 30 impregnated with the resin composition 31 is pressed by the upper and lower molding dies 4 and 5. As a result, as shown in FIG. 4 (e), the uneven fiber reinforced resin layer 32 provided with a large number of concave portions 33 and convex portions 34 is formed. Before placing the fiber sheet 30 or the fiber sheet 30 impregnated with the resin composition 31, an appropriate mold release agent is applied to the upper and lower molding dies 4 and 5 facing each other. May be good. Further, if necessary, the resin composition 31 may be cured by heating.
Further, the above-mentioned upper and lower molding dies 4 and 5 may be provided so as to be turned upside down. That is, the upper molding die 4 having the convex portion 4a provided on the lower surface side as one surface side of the surfaces facing each other, and the lower molding die 5 having the concave portion 5a provided on the upper surface side as the other surface side. It may be configured to form the uneven fiber reinforced resin layer 32 by using it.

Further, as shown in FIG. 5A, from the front surface sheet 21 and the fiber reinforced resin layer 26 placed on the lower molding die 2 with the fiber reinforced resin layer 26 side, which is the back surface side, arranged on the upper side. The uneven fiber reinforced resin layer 32 with the convex portion 34 facing downward is placed on the surface layer side sheet body. At this time, the uneven fiber reinforced resin layer 32 is formed on both or one of the front end surface (the surface facing downward) of the convex portion 34 of the uneven fiber reinforced resin layer 32 and the back surface (the surface facing upward) of the fiber reinforced resin layer 26. The adhesive 35 that joins and integrates the fiber reinforced resin layer 26 with the fiber reinforced resin layer 26 may be applied. In the illustrated example, an example in which the adhesive 35 is applied to the tip surface of the convex portion 34 of the uneven fiber reinforced resin layer 32 is shown. The adhesive 35 may be a thermosetting resin-based adhesive in which the main component of the resin is the same as the main component of the resin contained in the uneven fiber reinforced resin layer 32, and the resin composition constituting the uneven fiber reinforced resin layer 32. It may be the same as 31. Further, the fiber-reinforced resin layer 26 and the uneven fiber-reinforced resin layer 32 may be laminated and integrated by the self-adhesiveness of the resin compositions 24 and 31 contained in both or one of them.

Then, as shown in FIGS. 5 (b) and 5 (c), the adhesive 35 is cured by pressing with the upper and lower molding dies 2 and 3, and the surface decorative panel 20 is formed as shown in FIG. 5 (d). It may be manufactured. The pressing by the upper and lower molding dies 2 and 3 may be a hot press or a cold press, although it depends on the type of the adhesive 35.
Further, if necessary, the bent grooves 37 and 38 as described above may be provided on the back surface side of the front surface decorative panel 20 by cutting or the like. Further, the surface decorative panel 20 may be attached to the panel core material 10 to manufacture the decorative panel 1.
According to the manufacturing method as described above, the surface decorative panel 20 can be effectively manufactured.
That is, as compared with the case where the uncured resin compositions 24 and 31 constituting the fiber reinforced resin layer 26 and the uneven fiber reinforced resin layer 32 are supplied to the back surface of the decorative sheet 22 to form the resin layer. It is possible to prevent deterioration of the appearance of the decorative sheet 22 constituting the layer. Further, since the surface sheet 21 is lined with the thermoplastic resin sheet 23, it is easy to handle and can be easily laminated and integrated.
It should be noted that the steps and order of the panel manufacturing method according to the present embodiment described above are merely examples, and may be performed in a different order, and various modifications are possible.

The surface decorative panel 20 according to the present embodiment has the above-described configuration, so that it is possible to suppress deformation such as warpage and dimensional change, and it is possible to improve the planar compression strength.
That is, the concavo-convex fiber reinforced resin layer 32 containing the fiber sheet 30 and containing the thermosetting resin as the main component of the resin is provided on the other side of the front surface sheet 21 in the thickness direction, which is the back surface side. Therefore, as compared with the conventional surface material using a wood board such as MDF (medium density fiberboard) as a base material, it is possible to suppress deformation such as warpage and dimensional change due to moisture absorption and desorption. Further, the weight can be reduced while ensuring the thickness and strength by the uneven fiber reinforced resin layer 32. Further, since the uneven fiber reinforced resin layer 32 is provided, the convex portion 34 is formed even when a load is applied in the thickness direction, as compared with a layer having the unevenness formed of the thermoplastic resin. It becomes hard to be crushed, the planar compression strength can be improved, and the heat resistance is also excellent. This makes it suitable as a surface material or the like for fittings in which a load is often applied in the thickness direction.

Further, the surface sheet 21 is configured to have a decorative layer (decorative sheet) 22 provided on one side in the thickness direction, which is the surface side of the thermoplastic resin sheet 23. Therefore, the surface smoothness of the surface decorative panel 20 is improved as compared with the case where the fiber reinforced resin layer 26 and the uneven fiber reinforced resin layer 32 are provided on the back surface side of the decorative sheet 22, and the resin layer is formed by coating or the like. Can be improved. That is, unevenness due to the fibers contained in the fiber-reinforced resin layer 26 and the uneven fiber-reinforced resin layer 32 is less likely to occur on the surface, and wrinkles and the like due to resin coating can be suppressed.

Further, in the present embodiment, the sheet-shaped fiber reinforced resin layer 26 including the fiber sheet 25 is interposed between the surface sheet 21 and the uneven fiber reinforced resin layer 32. Therefore, the dimensional stability, bending strength, and the like can be improved as compared with the case where the fiber reinforced resin layer 26 is not provided.
Further, in the present embodiment, the resin main component contained in the uneven fiber reinforced resin layer 32 and the resin main component contained in the fiber reinforced resin layer 26 are the same. Therefore, the familiarity in each layer can be improved, and boundary peeling and the like can be prevented from occurring.

Further, in the present embodiment, the bent grooves 37 and 38 are provided on the other side in the thickness direction, which is the back surface side of the front surface decorative panel 20, so that the groove bottom is located on the thermoplastic resin sheet 23. Therefore, even when the surface decorative panel 20 has a corner to be attached, it can be bent at the bent grooves 37 and 38 to cover it in a series. As a result, the appearance at the corners can be improved as compared with the case where a plurality of surface decorative panels 20 are butted at the corners to be attached. Further, since the bent grooves 37 and 38 are provided so that the groove bottoms are located on the thermoplastic resin sheet 23, the fibers contained in the fiber reinforced resin layer 26 and the uneven fiber reinforced resin layer 32 at the bent corners. It becomes difficult for unevenness and the like to occur due to the above, and the appearance of the corner surface can be improved.

Further, the decorative panel 1 according to the present embodiment has a configuration including a panel core material 10 and a surface decorative panel 20 attached to the panel core material 10. Therefore, as described above, the decorative surface is formed by the surface decorative panel 20 which suppresses deformation and has good planar compression strength, and is suitable as an interior panel, furniture material, or the like.
Further, in the present embodiment, the surface decorative panel 20 provided with the corner bent grooves 37 is attached to the panel core material 10 so as to be positioned according to the corners of the panel core material 10. Therefore, as described above, the appearance of the corner surface can be improved.
Further, in the present embodiment, the surface decorative panels 20 and 20 are provided on both sides of the panel core material 10 in the panel thickness direction, respectively. Therefore, both sides in the panel thickness direction can be a decorative surface having an improved appearance as described above.
Further, in the present embodiment, the panel core material 10 is configured such that the core material 16 is housed in a space surrounded by a frame body 11 including four peripheral frames 12, 13, 13, and 14. Therefore, the strength of the decorative panel 1 can be improved as compared with the case where the panel core material 10 is provided with only the core material 16 or the crosspieces on three sides or less, and is suitably used as a fitting or the like. Can be done. In addition, the weight can be reduced as compared with the solid panel core material 10.

Further, in the present embodiment, the insertion grooves 13a, 13a into which the insertion pieces 20c, 20c, 20c, 20c of the surface decorative panels 20, 20 on both sides in the panel thickness direction are inserted into the both end portions of the panel core material 10. Is provided. Therefore, the seams between the surface decorative panels 20 and 20 can be stored in a good-looking manner as compared with the case where the ends of the surface decorative panels 20 and 20 are butted together. Instead of such an aspect, the surface decorative panel 20 on one side in the panel thickness direction and the surface decorative panel 20 on the other side in the panel thickness direction are abutted or superposed on each end surface in the panel width direction. It may be a mode in which it is stored. Further, the end face in the panel width direction may be covered only by the surface decorative panel 20 on one side in the panel thickness direction. In this case, the surface decorative panel 20 on the other side in the panel thickness direction may not be provided with a bent groove.

Further, instead of providing the surface decorative panels 20 and 20 separately on both sides in the panel thickness direction, a series of surface decorative panels 20 may cover the four peripheral surfaces of the panel core material 10. Good. In this case, the insertion groove 13a may be provided only on one end of the panel core material 10. Further, instead of the mode in which the curved grooves 37 and 38 are provided on the surface decorative panels 20 and 20, the surface sheets 21 and 21 extended so as to cover both end faces in the width direction of the panel core material 10 are bent and attached. Both ends of the panel core material 10 in the width direction may be covered. In this case, the panel core material 10 may be provided with an appropriate insertion groove into which the end portions of the surface sheets 21 and 21 are inserted.
Further, instead of covering the four peripheral surfaces of the panel core material 10 with the surface decorative panel 20, only both sides in the panel thickness direction may be covered with the surface decorative panel 20. In this case, each end face in the panel width direction of the panel core material 10 may be covered with a separate edge sheet or the like, and the panel core material 10 may be covered without using each end face in the panel width direction as a decorative surface. May be an exposed mode or the like.

Further, instead of the configuration in which the surface decorative panels 20 and 20 are provided on both sides of the panel core material 10 in the panel thickness direction as described above, the surface decorative panels 20 may be provided on only one side in the panel thickness direction. .. In this case, a fiber reinforced resin layer 26 or an uneven fiber reinforced resin layer 32 that does not include the surface sheet 21 may be provided on the other side in the panel thickness direction, or another surface material may be provided, and further, the panel. The core material 10 may be exposed. Further, in the present embodiment, an example is shown in which the panel core material 10 has the core material 16 housed in the space surrounded by the frame body 11, but the panel core material 10 is composed of only the frame body 11 or only the core material 16. It may be made of a solid plate-like body or the like. As a specific configuration of the decorative panel 1 described above, various other modifications are possible.

Next, an example of a surface decorative panel and a method for manufacturing a surface decorative panel according to another embodiment of the present invention will be described with reference to the drawings.
FIG. 7 is a diagram schematically showing an example of a surface decorative panel and a surface decorative panel manufacturing method according to the second embodiment.
The differences from the first embodiment will be mainly described, and the same configurations will be designated by the same reference numerals, and the description thereof will be omitted or briefly described.

As shown in FIG. 7C, the surface decorative panel 20A according to the present embodiment is mainly different from the first embodiment in that the fiber reinforced resin layer 26 is not provided.
That is, in the present embodiment, the uneven fiber reinforced resin layer 32 is provided on the back surface side of the front surface sheet 21 without interposing the fiber reinforced resin layer 26.
In this case, in order to make the thickness dimension of the surface decorative panel 20A itself as the above dimension, the thickness dimension of both or one of the thermoplastic resin sheet 23 of the surface sheet 21 and the uneven fiber reinforced resin layer 32. May be larger than that of the first embodiment.

Further, the surface decorative panel 20A may be manufactured as follows.
First, as shown in FIG. 7A, the surface sheet 21 is placed on the upper surface of the lower molding die 2 so that the decorative surface faces the upper surface in the same manner as described above. Then, the uneven fiber reinforced resin layer 32 is laminated on the back surface of the front surface sheet 21 via the adhesive 35 in substantially the same manner as described above. Then, as shown in FIG. 7B, the surface decorative panel 20A may be manufactured by pressing and integrating with the upper and lower molding dies 2 and 3.
Further, when the front surface decorative panel 20A is used as the surface material of the decorative panel 1, the same as above, the front surface side may be provided with the corner bent groove 37 and the end bent groove 38 as described above. Good. Further, the surface decorative panel 20A may be attached to the panel core material 10 to manufacture the decorative panel 1.
The surface decorative panel 20A and the surface decorative panel manufacturing method according to the present embodiment also have substantially the same effects as those of the first embodiment described above.

Next, an example of the surface decorative panel according to still another embodiment of the present invention will be described with reference to the drawings.
FIG. 8 is a diagram schematically showing an example of a surface decorative panel according to the third embodiment.
The differences from the first embodiment will be mainly described, and the same configurations will be designated by the same reference numerals, and the description thereof will be omitted or briefly described.

Similar to the first embodiment, the surface decorative panel 20B according to the present embodiment has a structure in which a fiber reinforced resin layer 26 is provided between the surface sheet 21 constituting the decorative surface and the uneven fiber reinforced resin layer 32. There is. Further, the surface decorative panel 20B is configured to be used as a cover for covering the existing interior building material. In the present embodiment, as shown in FIG. 8B, the surface decorative panel 20B is a baseboard covering a strip-shaped baseboard 8 arranged along the inside corner between the wall surface 6 and the floor surface 7. It is configured to be used as a cover. Further, as shown in FIGS. 8A and 8B, a bent groove 39 corresponding to the upper end corner of the baseboard 8 on the front surface side is provided on the back surface side of the front surface decorative panel 20B. The bent groove 39 is formed along the surface side piece 20Ba of the surface decorative panel 20B along one side (surface) in the thickness direction of the baseboard 8 and one end surface (upper end surface) in the width direction of the baseboard 8. It is provided so as to be located at the boundary between the end face piece portion 20Bb and the end face portion 20Bb.

In the illustrated example, the bent groove 39 is formed into a substantially V-shaped groove shape when viewed in the groove longitudinal direction so that the corners formed by bending the bent groove 39 are substantially right-angled in the same manner as described above. An example is shown in which the groove is composed of one groove, but the present invention is not limited to such an embodiment. The bent groove 39 may be composed of a plurality of grooves so that the corner portion formed by bending in the bent groove 39 has an R chamfer shape or a C chamfer shape.
Further, the surface decorative panel 20B may be attached to the skirting board 8 with an appropriate adhesive, adhesive material or the like.

The surface decorative panel 20B according to the present embodiment having such a configuration also exhibits substantially the same effect as described above. Further, the surface decorative panel 20B according to the present embodiment can also be manufactured in substantially the same manner as the above-described surface decorative panel manufacturing method.
In the present embodiment, an example in which the surface decorative panel 20B is used as a skirting board cover for covering the existing skirting board 8 is shown, but the present invention is not limited to such a mode, and the existing opening frame, window frame, and peripheral edge are not limited to this. It may be used as a cover or the like for covering other existing interior building materials such as.
In addition, different configurations described in each of the above embodiments may be appropriately rearranged or combined to be applied.
Further, in each of the above embodiments, the decorative layer is an example of the decorative sheet 22, but the present invention is not limited to such an embodiment and may be a coating layer or the like.
Further, the back surface side fiber reinforced resin layer including the fiber sheet and other back surface sheets may be provided on the back surface side of the uneven fiber reinforced resin layers 32, 32A and 32B. The surface decorative panels 20, 20A, and 20B according to each of the above embodiments can be modified in various ways.

1 Decorative panel 10 Panel core material 20, 20A, 20B Surface decorative panel 21 Surface sheet 22 Decorative sheet (decorative layer)
23 Thermoplastic resin sheet 25 Fiber sheet 26 Fiber reinforced resin layer 30 Fiber sheet 32, 32A, 32B Concavo-convex fiber reinforced resin layer 33 Concave part 34, 34A, 34B Convex part 37 Corner bent groove (folded groove)
38 End bent groove (bent groove)
39 Folded groove

Claims (7)

A surface sheet provided with a decorative single plate, decorative printing paper or resin film constituting a decorative layer on one side in the thickness direction of the thermoplastic resin sheet, and a surface sheet provided on the other side in the thickness direction of the surface sheet in the thickness direction. Concavo-convex fiber reinforced resin having a large number of convex portions protruding toward one side in the thickness direction so as to form a concave portion opening on the other side, and containing a fiber sheet, and containing a thermosetting resin as a resin main component. A surface decorative panel characterized by having layers. In claim 1,
A surface decorative panel characterized in that a sheet-shaped fiber reinforced resin layer containing a fiber sheet is interposed between the surface sheet and the uneven fiber reinforced resin layer. In claim 2,
A surface decorative panel characterized in that the resin main component contained in the uneven fiber reinforced resin layer and the resin main component contained in the fiber reinforced resin layer are the same. In any one of claims 1 to 3,
The surface decorative panel is characterized in that a bent groove is provided on the other side of the surface decorative panel in the thickness direction so that the groove bottom is located on the thermoplastic resin sheet. A decorative panel comprising a panel core material and a surface decorative panel according to any one of claims 1 to 4, which is attached to the panel core material. On one side of the thermoplastic resin sheet in the thickness direction, there is a recess that opens on the other side in the thickness direction of the surface sheet provided with the decorative single plate, decorative printing paper, or resin film that constitutes the decorative layer. The surface is made by laminating and integrating an uneven fiber reinforced resin layer containing a fiber sheet and having a thermosetting resin as a resin main component, having a large number of convex portions protruding toward one side in the thickness direction so as to be formed. A method for manufacturing a surface decorative panel, which comprises manufacturing a decorative panel. A sheet-like fiber-reinforced resin containing a fiber sheet on one side of the thermoplastic resin sheet in the thickness direction of a surface sheet provided with a decorative single plate, a decorative printing paper, or a resin film forming a decorative layer. It has a layer and a large number of protrusions that project toward one side in the thickness direction so that a recess that opens on the other side in the thickness direction is formed, and also contains a fiber sheet, and contains a thermosetting resin as a resin main component. A method for manufacturing a surface decorative panel, which comprises laminating and integrating the uneven fiber reinforced resin layer to be used to produce a surface decorative panel.

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