JP7413865B2 - suspended ceiling system - Google Patents

Description

The present invention relates to a suspended ceiling system for suspending ceiling materials.

In suspended ceiling systems that suspend and support ceiling materials, plasterboard, rock wool, etc. have traditionally been used for ceiling materials, but in recent years, lightness has become important, and ceiling materials such as glass wool and glass cloth are now used. has become the mainstream.

As shown in FIG. 4, in such a conventional suspended ceiling system, a plate-shaped plate made of glass wool or the like is mounted on a flange portion 2a of a support fitting 2 such as a T-bar attached to the tip of a hanging device 1 such as a hanging bolt. The ceiling material 10 is suspended by placing the surface (lower surface in FIG. 4) of the ceiling material 10 near the periphery (see, for example, Patent Document 1 below).

Japanese Patent Application Publication No. 2018-028178

In the conventional suspended ceiling system as described above, when looking up at the ceiling, the support fittings 2 are exposed, resulting in an unsightly appearance.

In view of the above, an object of the present invention is to provide a suspended ceiling system that can suspend and support ceiling materials in an attractive manner.

In order to solve the above-mentioned problems, a suspended ceiling system according to the present invention includes a support metal fitting that is suspended by a hanging tool and is provided with a flange portion along the horizontal direction, and a lower surface of the flange portion of the support metal fitting. a fixture that is attached and has a first engagement part; a second engagement part that engages the first engagement part of the fixture, and the second engagement part is connected to the a ceiling material that is attached to the fixture so as to cover the lower surface of the flange part of the support metal fitting and the fixture by engaging with the first engaging part of the fixture; has a nonflammable base material, and a surface material having a triaxial fabric laid on the lower surface of the base material, and the surface material is hardened with a resin and has the second engagement material on the peripheral edge. It is characterized by having a joint formed therein.

According to the suspended ceiling system according to the present invention, by engaging the second engaging part of the ceiling material with the first engaging part of the fixture, the ceiling material can be connected to the lower surface of the flange part of the support fixture and the fixture. Since the support metal fittings and fixtures are not visible even when looking up at the ceiling, the ceiling material can be suspended with a good appearance.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a sectional view showing a schematic configuration of a main part of a main embodiment of a suspended ceiling system according to the present invention. FIG. 2 is a sectional view showing a schematic configuration of the ceiling material in FIG. 1. FIG. It is a sectional view showing the schematic structure of the ceiling material of other embodiments of the suspended ceiling system concerning the present invention. FIG. 1 is a cross-sectional view showing a schematic configuration of a main part of an example of a conventional suspended ceiling system.

Although embodiments of a suspended ceiling system according to the present invention will be described based on the drawings, the present invention is not limited only to the following embodiments described based on the drawings.

<Main embodiment>
A main embodiment of a suspended ceiling system according to the present invention will be described based on FIGS. 1 and 2.

As shown in FIG. 1, the suspended ceiling system 100 according to the present embodiment includes a support fitting 102 such as a T-bar, which is suspended by a hanging fitting 101 such as a hanging bolt, and is provided with a flange portion 102a along the horizontal direction. , a fitting 103 that is attached to the lower surface of the flange portion 102a of the support fitting 102 and has a first engaging portion 103a, and a second engaging portion 112a that engages with the first engaging portion 103a of the fitting 103. The second engaging part 112a engages with the first engaging part 103a of the fixture 103, so that the fixture covers the lower surface of the flange part 102a of the support fitting 102 and the fixture 103. A ceiling material 110 attached to the ceiling 103 is provided.

As shown in FIG. 2, the ceiling material 110 includes a nonflammable base material 111, a surface material 112 having a triaxial fabric laid on the lower surface of the base material 111, and a space between the base material 111 and the surface material 112. It has an adhesive layer 113 provided on.

The base material 111 has a sheet (plate) shape, and includes, for example, glass wool, glass cloth, glass nonwoven fabric, glass paper, felt material hardened with an inorganic adhesive, and the like. By containing glass wool or the like, the base material 111 becomes porous and can exhibit great lightness and sound absorption.

In particular, glass wool (approximately 2 kg/ ^m2 ) has an average sound absorption coefficient of about 0.5% to 1.0% in the reverberation room method, although it varies slightly depending on the thickness. Very preferred.

Further, when the base material 111 is glass wool (approximately 2 kg/m ² ), the thickness is preferably 8 mm or more and 24 mm or less. If the thickness is less than 8 mm, it becomes difficult to sufficiently exhibit sound absorption performance (average sound absorption coefficient of 5% or more in the reverberation room method), which is not preferable. On the other hand, if the thickness is greater than 24 mm, it is not preferable because it tends to have problems in lightness and nonflammability.

In the case of glass cloth, it is preferable that it is woven using glass fiber warp and weft so that the opening ratio is 0.5% or more and 1.0% or less and the thickness is 100 μm or more and 1 mm or less. On the other hand, in the case of a glass nonwoven fabric, the thickness is preferably 50 μm or more and 150 μm or less. Examples of the inorganic adhesive include a silica adhesive containing silica as a main component, a ceramic adhesive containing ceramic as a main component, and a cement adhesive containing cement as a main component.

In addition, the base material 111 is made using a cone calorimeter tester that complies with ISO5660-1 and complies with the fire resistance test method and performance evaluation standard based on Article 2, Item 9 of the Building Standards Act and Article 108-2 of the Building Standards Act Enforcement Order. In the exothermic test conducted, (1) the total calorific value (MJ/m ² ) for 20 minutes after the start of heating was 4 MJ/m ² or less, and (2) the maximum exothermic rate for 20 minutes after the start of heating continued for 10 seconds or more. It is preferable that the heating rate does not exceed 200 kW/m ² , and (3) it has non-combustibility that satisfies the following conditions: (3) there are no cracks or holes penetrating to the back surface that are detrimental to fire protection for 20 minutes after the start of heating.

The surface material 112 preferably has a triaxial fabric containing glass fibers, has a thickness of 100 μm or more and 1 mm or less, and has a mass of 500 g/m ² or less, since weight can be reduced. Moreover, by having the triaxial fabric, the surface material 112 becomes porous, which can reliably reduce the weight and also improve sound absorption. Moreover, the surface material 112 can have nonflammability by containing glass fiber.

The surface material 112 has four sides longer than the base material 111 and the adhesive layer 113 (for example, 20 mm or more), and is hardened and molded by impregnating resin between the glass fibers of the threads of the triaxial fabric. As a result, an L-shaped second engaging portion 112a is formed at the peripheral edge, and the rigidity is increased. Examples of the impregnating resin include thermoplastic resins, thermosetting resins, and ultraviolet curable resins.

Examples of the thermoplastic resin include polyester resins such as polyethylene terephthalate (PET) resin, polybutylene terephthalate (PBT) resin, polytrimethylene terephthalate (PTT) resin, polyethylene naphthalate (PEN) resin, and liquid crystal polyester resin, Polyolefin resins such as polyethylene (PE) resin, polypropylene (PP) resin, polybutylene resin, styrene resin, polyoxymethylene (POM) resin, polyamide (PA) resin, polycarbonate (PC) resin, polymethylene methacrylate (PMMA) ) resin, polyvinyl chloride (PVC) resin, polyphenylene sulfide (PPS) resin, polyphenylene ether (PPE) resin, modified PPE resin, thermoplastic polyimide (PI) resin, polyamideimide (PAI) resin, polyetherimide (PEI) Resin, polysulfone (PSU) resin, modified PSU resin, polyethersulfone (PES) resin, polyketone (PK) resin, polyetherketone (PEK) resin, polyetheretherketone (PEEK) resin, polyetherketoneketone (PEKK) Fluorine resins such as resins, polyarylate (PAR) resins, polyethernitrile (PEN) resins, thermoplastic phenol resins, phenoxy resins, and polytetrafluoroethylene resins, as well as polystyrene resins, polyolefin resins, and polyurethane resins. , thermoplastic elastomers such as polyester resins, polyamide resins, polybutadiene resins, polyisoprene resins, and fluorine resins, copolymers, modified products, and blends of two or more of these resins.

Examples of the thermosetting resin include phenolic resin (PF), epoxy resin (EP), melamine resin (MF), urea resin (UF), unsaturated polyester resin (UP), alkyd resin, polyurethane (PUR), Examples include thermosetting polyimide (PI).

Examples of the ultraviolet curable resin include acrylic and epoxy resins.

The adhesive layer 113 joins the base material 111 and the surface material 112, and is made of, for example, a 100% solids hot melt adhesive, a 100% solids moisture curing adhesive (for example, polyurethane (PUR) resin), etc. Examples include adhesives, high viscosity rubber adhesives, and high viscosity urethane resin adhesives. Examples of the hot melt adhesive include ethylene-vinyl acetate copolymer resin (EVA resin), polyamide resin, and the like.

When the adhesive described above is applied to the adhesive layer 113, the adhesive is prevented from entering the pores of the base material 111 and the surface material 112, and the adhesive strength between the base material 111 and the surface material 112 is prevented from decreasing. This is very preferable because it can be suppressed. As the high viscosity rubber adhesive or the high viscosity urethane resin adhesive, for example, it is preferable to use one having a viscosity of 40 Pa·s or more, more preferably 50 Pa·s or more.

To manufacture such a ceiling material 110, first, an impregnating liquid is created by dissolving or dispersing the above-mentioned resin (for example, a thermosetting resin) in a solvent such as water, and the surface material 112 is immersed in the impregnating liquid. As a result, resin is impregnated between the glass fibers of the threads of the fabric of the surface material 112. Examples of methods for impregnating the resin include immersing the sheet-like surface material 112 as it is in an impregnating liquid in a container, or running a web-like surface material between a pair of rolls to which the impregnating liquid has been applied. Examples include a method in which the surface material is impregnated with an impregnating liquid and then the web is cut.

Next, the surface material 112 is placed in a mold corresponding to the shape of the surface material 112 so as to form a second engaging portion 112a on the periphery of the surface material 112, and heated while being pressed (for example, at around 100° C. for 30 seconds). move back and forth. As a result, the resin can be cured without destroying the shape of the void portion of the triaxial fabric, and the second engaging portion 112a can be molded around the periphery of the surface material 112, and rigidity can be developed. .

Next, an adhesive layer (e.g., hot melt adhesive) 113 formed in a sheet or mesh shape and a base material 111 are sequentially laminated inside the surface material 112, and heated (e.g., at 100° C.) while being pressed with a mold. (before and after x 30 seconds). Thereby, the adhesive is melted, and the base material 111 and the surface material 112 are bonded by the adhesive layer 113, so that the ceiling material 110 can be obtained.

As shown in FIG. 1, the support fitting 102 has a T-shape, and is provided with a flange portion 102a at the lower end of the hanging portion 102b, and the upper end of the hanging portion 102b is connected to the hanging tool 101 to be suspended. ing.

The fixture 103 is L-shaped, has a magnetic force at least on the proximal end (upper end) side, and is configured such that the first engaging portion 103a on the distal end (lower end) side is directed toward the hanging portion 102b of the support fitting 102. , the base end (upper end) side is removably attached along the edge of the lower surface of the flange portion 102a of the support fitting 102.

In the suspended ceiling system 100 according to the present embodiment, the base end (upper end) of the fixture 103 is magnetically attached along the edge of the lower surface of the flange portion 102a of the support fixture 102 suspended from the hanging fixture 101. At the same time, the second engaging part 112a of the ceiling material 110 is hooked to the first engaging part 103a of the fixture 103 so that the ceiling material 110 covers the lower surface of the flange part 102a of the support metal fitting 102 and the fixture 103. By engaging in this manner, the ceiling material 110 can be suspended on the four sides of the periphery.

At this time, the second engaging part 112a of the ceiling material 110 has the ability to return to its original shape even if it is temporarily deformed by external stress, so the first engaging part 112a of the fixture 103 103a can be easily engaged.

In the suspended ceiling system 100 in which the ceiling material 110 is suspended in this way, the ceiling material 110 covers the lower surface of the flange portion 102a of the support metal fitting 102 and the fixture 103, so even if you look up at the ceiling, you cannot see the support metal 102 becomes invisible.

Therefore, according to the suspended ceiling system 100 according to the present embodiment, the ceiling material 110 can be suspended with good appearance.

In addition, since the ceiling material 110 can be attached simply by hooking the second engaging portion 112a of the ceiling material 110 onto the first engaging portion 103a of the fixture 103, labor-saving installation work is achieved during construction. In addition, removal work during maintenance and inspection can be facilitated.

In addition, since the surface material 112 of the ceiling material 110 is made of a triaxial fabric (axis yarn, rightward bias yarn, leftward bias yarn), the directionality is diagonal, and the rigidity when impregnated with resin and cured is can be kept. Incidentally, if the surface material is made of biaxial (warp, weft) fabric, the directionality will be in the vertical and horizontal directions, and when it is impregnated with resin and cured, it will easily bend in the vertical or horizontal direction.

In addition, since rigidity is given to the ceiling material 110 by curing the surface material 112 with resin, the base material 111 does not need to have rigidity, so the base material 111 can be made thin (1 mm). (below) It can be made light (500 g/m ² or less).

Therefore, it is possible to construct the suspended ceiling system 100 with the ceiling material 110 in a large size (for example, 1 m x 1.5 m), so that, for example, the ceiling material 110 of the suspended ceiling system 100 will not fall off due to an earthquake or the like. Even if something happens, serious harm to people can be prevented. Furthermore, it can be different from a specific ceiling based on the ``structurally safe ceiling construction method'' stipulated by the Ministry of Land, Infrastructure, Transport and Tourism, that is, a ceiling that requires verification along multiple routes. In other words, since the ceiling can be set to a ceiling that does not require verification, complicated calculations and the like for verification can be omitted.

<Other embodiments>
In addition, in the embodiment mentioned above, the case of the suspended ceiling system 100 provided with the ceiling material 110 which consists of the base material 111, the surface material 112, and the adhesive layer 113 was demonstrated, but this invention is not limited to this. As another embodiment, for example, as shown in FIG. 3, it is also possible to apply a ceiling material 210 in which a decorative layer 214 is further provided on the lower surface of the surface material 112.

The decorative layer 214 is a layer formed by applying printing ink. Examples of the printing ink include inorganic ink and organic ink. Examples of the printing method include an inkjet printing method, a doubling method, and a silk printing method. For example, inkjet printing is suitable for expressing various gradations. Furthermore, when expressing a single color, the dobu-zuke method is suitable. Examples of the printing ink curing method include UV curing method and thermosetting method.

The ceiling material 210 provided with such a decorative layer 214 is made by, for example, pasting a back sheet on the back surface (top surface in FIG. 3) of the surface material 112 in order to prevent ink from bleeding through during printing. After applying ink to the surface (lower surface in FIG. 3) of the surface material 112 by inkjet printing or the like to form the decorative layer 214, the backsheet is peeled off from the surface material 112. Thereafter, as described above, the surface material 112 is impregnated with a resin, the resin is cured, and molded, and the base material 111 and the surface material 112 are bonded with the adhesive layer 113.

Note that the backsheet preferably has an adhesive force of 2.5 N/25 mm or more and 3.5 N/25 mm or less. If the adhesive force is less than 2.5 N/25 mm, the adhesive force is too small and the back sheet is likely to peel off, which is not preferable. On the other hand, if the adhesive force exceeds 3.5 N/25 mm, the edges of the surface material 112 may become frayed when the backsheet is peeled off after printing, which is not preferable.

Since the ceiling material 210 obtained in this way has a thin base material 111, it is possible to provide a margin for the heat generation amount of the entire ceiling material 210. The design can be improved.

Moreover, in the above-described embodiment, it is also possible to provide a ceiling material in which an uneven shape (pattern) is further provided on the surface of the surface material. Such a ceiling material can be easily manufactured and the design can be improved by further providing an uneven shape on the inner surface of the mold when molding the surface material used in the above-described embodiment. At the same time, it is also possible to develop additional sound absorption properties.

Tests conducted to confirm the effects of the suspended ceiling system according to the present invention will be described below, but the present invention is not limited to the tests described below.

<Test A>
300 mm square test specimens A1 to A3 made of the materials shown in Table 1 below were prepared. The four sides of each of these test specimens A1 to A3 were supported, and when a 1 kg weight was placed at the center (intersection of diagonals), the amount of deflection (downward amount) of the center was measured. The results are shown in Table 1 below.

<Test B>
Large-sized test specimens B1 to B3 of 1 m x 1.5 m made of the materials shown in Table 1 below were prepared. These test specimens B1 to B3 were each applied to a suspended ceiling system, and the amount of deflection (amount of descent) of the central portion (intersection of diagonals) was measured. The results are shown in Table 1 below.

As can be seen from Table 1, test specimens A1 and B1 fell without being supported and could not be measured. Although the test specimens A2 and B2 were supported because they were thick (10 mm) and had a certain degree of rigidity, the amount of deflection was large and they could not be put to practical use.

On the other hand, it was confirmed that the amount of deflection of test specimens A3 and B3 was significantly reduced compared to that of test specimens A2 and B2 (base material only), and that they were usable for practical use.

The suspended ceiling system according to the present invention can suspend and support ceiling materials in an attractive manner, so it can be extremely usefully used in the construction industry and the like.

100 Suspended ceiling system 101 Hanging tool 102 Supporting metal fitting 102a Flange part 102b Perpendicular part 103 Mounting tool 103a First engaging part 110 Ceiling material 111 Base material 112 Surface material 112a Second engaging part 113 Adhesive layer 210 Ceiling material 214 decorative layer

Claims (8)

a support metal fitting that is suspended by a hanging tool and provided with a flange portion along the horizontal direction;
a fixture that is attached to the lower surface of the flange portion of the support fixture and has a first engagement part;
It has a second engaging part that engages with the first engaging part of the fixture, and the second engaging part engages with the first engaging part of the fixture. a ceiling material attached to the fixture so as to cover the lower surface of the flange portion of the support fixture and the fixture;
Equipped with
The ceiling material is
a nonflammable base material;
a surface material laid on the lower surface of the base material and having a triaxial fabric;
has
The suspended ceiling system is characterized in that the surface material is hardened with a resin and the second engaging portion is formed at a peripheral edge. The suspended ceiling system according to claim 1, wherein the fixture is removably attached to the support fixture by magnetic force. 3. The base material includes at least one of glass wool, glass cloth, glass nonwoven fabric, glass paper, and felt material hardened with an inorganic adhesive. Suspended ceiling system. The base material is compliant with ISO 5660-1, and is tested by a cone calorimeter tester in accordance with the fire resistance test method and performance evaluation standard based on Article 2, Item 9 of the Building Standards Act and Article 108-2 of the Building Standards Act Enforcement Order. In the performance test, (1) the total calorific value (MJ/m ² ) for 20 minutes after the start of heating is 4 MJ/m ² or less, and (2) the maximum heat generation rate for 20 minutes after the start of heating is 200 kW for 10 seconds or more. / ^m2 , and (3) has non-combustibility that satisfies the condition that there are no cracks or holes penetrating to the back surface that are harmful in terms of fire protection for 20 minutes after the start of heating. A suspended ceiling system according to any one of the preceding clauses. The suspended ceiling system according to any one of claims 1 to 4, wherein the triaxial fabric contains glass fibers. The suspended ceiling system according to any one of claims 1 to 5, wherein an adhesive layer is interposed between the base material and the surface material. The adhesive layer includes at least one of a 100% solids hot melt adhesive, a 100% solids moisture curing adhesive, a high viscosity rubber adhesive, and a high viscosity urethane resin adhesive. The suspended ceiling system according to claim 6, characterized in that: The suspended ceiling system according to any one of claims 1 to 7, wherein a decorative layer is provided on the lower surface of the surface material.

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