Panel manufacturing method and panel inspecting method

Abstract

To provide a manufacturing method with which it is possible to detect beforehand phenomenon such as swelling caused by residual gas, and an inspecting method that can beforehand detect this phenomenon.SOLUTION: A method for manufacturing panels 10 is a method for manufacturing panels 10 with a resin foam body 11 formed between a front material 12 and a back material 13. The method for manufacturing panels 10 includes a process in which gas is injected into the resin foam body 11 of the panels 10 and the conditions of the panels 10 are inspected.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present disclosure relates to a method for manufacturing a panel and a method for inspecting a panel. [Background technology]

[0002] Patent documents 1 and 2 disclose panels in which a core material made of synthetic resin foam is sandwiched between a front surface material and a back surface material. The panel in Patent document 1 is configured to ventilate by interposing a breathable nonwoven fabric between the front surface material and the core material. The panel in Patent document 2 interposes a sheet in which a nonwoven fabric layer and an adhesive layer are laminated between the front surface material and the core material. Holes are formed in the sheet for ventilating. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 11-117490 [Patent Document 2] Japanese Patent Application Publication No. 10-37347 Summary of the Invention [Problem to be solved by the invention]

[0004] If gas remains in the resin foam of the panel, deformation such as swelling and accompanying phenomena such as peeling of the surface material may be observed during use of the panel. Conventionally, it has not been possible to grasp in advance the phenomena that may occur during use of a panel due to the presence of residual gas during the manufacturing or inspection stage of the panel. The present disclosure has been made in consideration of the above circumstances, and aims to provide a manufacturing method that makes it possible to grasp in advance phenomena such as swelling caused by residual gas, and an inspection method that makes it possible to grasp this phenomenon in advance. The present disclosure can be realized in the following forms. [Means for solving the problem]

[0005] [1] A method for manufacturing a panel having a resin foam formed between a first panel and a second panel, comprising: A method for manufacturing a panel, comprising the step of injecting gas into the resin foam of the panel and inspecting a condition of the panel. Effect of the Invention

[0006] According to the present disclosure, it is possible to grasp in advance phenomena such as swelling caused by residual gas. [Brief description of the drawings]

[0007] [Figure 1] FIG. [Diagram 2] FIG. 2 is a schematic diagram of a gas injection unit. [Diagram 3] FIG. 2 is a side view of the tip portion of the needle. [Figure 4] FIG. 2 is a plan view of the tip portion of the needle. [Diagram 5] FIG. 11 is a plan view showing an example of the shape of a tip portion of a needle before processing. [Figure 6] 11 is a side view showing a state before a needle is inserted into a panel fixed in the inspection jig. FIG. [Figure 7] FIG. 7 is a plan view of FIG. 6. [Figure 8] 11 is a side view showing a state in which a needle is inserted into a panel fixed in the inspection jig. FIG. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0008] Here, a preferred example of the present disclosure is given. [2] The method for manufacturing a panel according to [1], wherein the panel is a building panel. [3] A method for inspecting a panel having a resin foam formed between a first surface material and a second surface material, comprising: A method for inspecting a panel, comprising the step of injecting gas into the resin foam of the panel and inspecting a condition of the panel.

[0009] The present disclosure will be described in detail below. A. Method of Manufacturing Panel 10 The manufacturing method of the panel 10 of the present disclosure is a manufacturing method of the panel 10 having the resin foam 11 formed between a first face material and a second face material. It includes a step of injecting gas into the resin foam 11 of the panel 10 and inspecting the state of the panel. Here, first, panel 10, gas injection unit 20 for injecting gas, and inspection jig 40 used in the inspection process will be described, followed by a description of the manufacturing method.

[0010] 1. Panel 10 A panel 10 of this embodiment is shown in FIG. 1. The panel 10 is preferably a building panel. The panel 10 is, for example, an exterior wall material, an interior wall material, a roof material, a ceiling material, a floor material, etc. of a building. As shown in FIG. 1, the panel 10 includes a resin foam 11, a surface material 12, and a back surface material 13. The surface material 12 corresponds to a "first surface material" in the present disclosure. The back surface material 13 corresponds to a "second surface material" in the present disclosure. The resin foam 11 is sandwiched between the surface material 12 and the back surface material 13.

[0011] The resin foam 11 is composed of polyisocyanurate foam, polyurethane foam, phenol foam, vinyl chloride foam, polyethylene foam, polystyrene foam, or the like. The resin foam 11 functions as a heat insulating material, a fireproofing material, a bulking material, or the like. The resin foam 11 may contain a flame retardant, or the like. The resin foam 11 is, for example, in the shape of a square plate as shown in FIG. 1. The thickness of the resin foam 11 is, for example, 20 mm or more and 80 mm or less.

[0012] For example, resin foam 11 may contain residual gases such as unreacted components of the raw materials and excess gas components (chlorine, carbon dioxide, methylene chloride, formaldehyde, water vapor, hydrogen, etc.) produced by the reaction.

[0013] The front surface material 12 and the back surface material 13 are, for example, thin metal plates. The materials of the front surface material 12 and the back surface material 13 are, for example, hot-dip 55% aluminum-zinc alloy plated steel sheet, zinc plated steel sheet, iron, aluminum, copper, stainless steel, titanium, etc., as specified in JIS G3321. The front surface material 12 and the back surface material 13 are, for example, rectangular plates as shown in FIG. 1. The thickness of the front surface material 12 and the back surface material 13 is, for example, 2 mm or more and 10 mm or less. The front surface material 12 and the back surface material 13 may be adhered to the resin foam 11 by utilizing the self-adhesiveness of the resin foam 11, or may be adhered by a separately provided adhesive. In addition, when the front surface material 12 and the back surface material 13 are adhered to the resin foam 11 by an adhesive, a primer layer may be provided between the resin foam 11 and the adhesive.

[0014] At least one of the front surface material 12 and the back surface material 13 may cover at least a part of the side surface (surface along the thickness direction) of the resin foam 11.

[0015] The front surface material 12 and the back surface material 13 may have different configurations. For example, the front surface material 12 and the back surface material 13 may be made of different materials. Also, the panel 10 may have a configuration in which the front surface material 12 and the back surface material 13 are not distinguished from each other (a configuration in which there is no distinction between whether they are disposed on the front side or the back side of a building).

[0016] 2.Gas injection unit 20 An example of the gas injection unit 20 of this embodiment is shown in Fig. 2. The gas injection unit 20 is a device that injects gas into the resin foam 11 of the panel 10.

[0017] There is no particular limitation on the configuration of gas injection unit 20. Gas injection unit 20 includes, for example, a gas cylinder 21, a regulator 22, a hose 23, a T-shaped joint 24, a pressure sensor 25, a data logger 26, a hose 27, a needle adapter 28, and a needle 30, as shown in FIG.

[0018] The gas cylinder 21 stores an inert gas such as nitrogen gas. The regulator 22 adjusts the gas pressure supplied from the gas cylinder 21 to the needle 30. One end of the hose 23 is connected to the regulator 22. The other end of the hose 23 is connected to a first socket of the T-joint 24. A flow path leading to the pressure sensor 25 is connected to the second socket of the T-joint 24. One end of a hose 27 is connected to a third socket of the T-joint 24. The other end of the hose 27 is connected to the hub of the needle 30 via a needle adapter 28.

[0019] The data logger 26 receives, for example, the detection value (pressure value) detected by the pressure sensor 25 as an electrical signal, digitally processes it, and stores it in an internal memory.

[0020] The needle 30 is inserted into the resin foam 11 of the panel 10 to inject gas. An example of the needle 30 is shown in FIG. 3 and FIG. 4. As shown in FIG. 3 and FIG. 4, the needle 30 includes a needle tube 31 and a needle tip 32. The needle tip 32 is closed and has no opening. The needle 30 is configured such that a gas ejection hole 34, which will be described later, is not visible when viewed from the front side in the insertion direction. The needle tip 32 may be inclined with respect to the axial direction as shown in FIG. 3. The inclination of the needle tip 32 makes it easier to insert the needle 30 into the panel 10. Note that the needle tip 32 does not have to be inclined with respect to the axial direction.

[0021] A groove 33 recessed inward is provided in a portion of the needle tube 31 near the needle tip 32. A gas ejection hole 34 is provided at the rear end of the groove 33 (the end opposite the needle tip 32). The gas ejection hole 34 penetrates in a direction intersecting (for example, perpendicular to) the axial direction of the needle 30. With this configuration, when the needle 30 is inserted into the resin foam 11, the resin foam 11 is less likely to enter the gas ejection hole 34, and the gas ejection hole 34 is less likely to be blocked by the resin foam 11.

[0022] The needle 30 is formed, for example, by processing a needle of a general shape as shown in Fig. 5 using nippers or the like. The needle of the general shape shown in Fig. 5 is a shape obtained by obliquely cutting a straight tube, and an opening 134 is provided at a tip 132 that is inclined with respect to the axial direction. For example, by pushing the tip 132 of the needle in Fig. 5 with nippers, it is crushed and gas is released from the side (gas ejection hole 34 in Fig. 4). The needle 30 may be formed by cutting a needle of a different shape from that shown in Fig. 5, for example, a straight needle.

[0023] 3. Inspection fixture 40 An example of inspection jig 40 of this embodiment is shown in Figures 6 to 8. Inspection jig 40 is a jig that fixes panel 10 and a part of gas injection unit 20. As shown in Figures 6 and 7, inspection jig 40 includes a panel side fixing part 50 and a needle side fixing part 60.

[0024] 6 and 7, the panel-side fixing part 50 fixes the panel 10. The panel-side fixing part 50 has a table 51, a first side wall 52, a second side wall 53, and an adjustment part .

[0025] The table 51 has a substantially rectangular parallelepiped shape. The panel 10 can be laid flat on the upper surface of the table 51. For example, the panel 10 is placed so that the surface material 12 is on the upper side. The first side wall 52 rises from one end side of the upper surface of the table 51. The second side wall 53 rises from an end opposite the first side wall 52 on the upper surface of the table 51 so as to face the first side wall 52.

[0026] Here, as shown in Figures 6 and 7, the direction in which the first side wall 52 and the second side wall 53 face each other is defined as the X-axis direction. The direction in which the first side wall 52 is located relative to the second side wall 53 is defined as the +X direction, and the opposite direction is defined as the -X direction. As shown in Figure 7, the direction perpendicular to the X-axis direction in the horizontal plane is defined as the Y-axis direction. The upward direction in Figure 7 is defined as the +Y direction, and the downward direction is defined as the -Y direction. As shown in Figure 6, the direction perpendicular to the X-axis direction and the Y-axis direction is defined as the Z-axis direction (up-down direction). The upward direction is defined as the +Z direction, and the downward direction is defined as the -Z direction.

[0027] An opening 55 penetrating in the wall thickness direction is provided at the center of the second side wall 53 in the Y-axis direction. The adjustment unit 54 is a mechanism for moving the first side wall 52 along the X-axis direction. The adjustment unit 54 is provided with, for example, a rotary knob, and moves the first side wall 52 in response to rotation of the knob.

[0028] The panel 10, laid flat on the upper surface of the table 51, is sandwiched and fixed between the first side wall 52 and the second side wall 53. The first side wall 52 contacts one side surface of the panel 10 (the side surface on the +X side). The second side wall 53 contacts the other side surface of the panel 10 (the side surface on the -X side).

[0029] 6 and 7, the needle side fixed part 60 fixes the needle 30. The needle side fixed part 60 is adjacent to the end part on the -X side of the panel side fixed part 50. The needle side fixed part 60 has a base 61 and a fixing unit 62.

[0030] The base 61 has a rectangular parallelepiped shape that is long in the X-axis direction. The base 61 is fixed to the end of the table 51 on the -X side. The fixing unit 62 is fixed to the upper surface of the base 61 so as to be slidable in the X-axis direction. The fixing unit 62 fixes the needle adapter 28 and the hose 27. The axial direction of the needle 30 is along the X-axis direction. The needle tip 32 of the needle 30 overlaps with the opening 55 of the second side wall 53 in the X-axis direction. The base 61 is provided with an adjustment mechanism (not shown) that can move the fixing unit 62 in the Z-axis direction (up and down direction). As shown in FIG. 8, the fixing unit 62 moves in the -X-axis direction, so that the needle 30 passes through the opening 55 and is inserted into the resin foam 11 of the panel 10.

[0031] 4. Manufacturing method of panel 10 A method for manufacturing the panel 10 of this embodiment will be described. The manufacturing method of the panel 10 preferably includes a formation step and an inspection step. The formation step is a step of forming the panel 10 in which the resin foam 11, the front surface material 12, and the back surface material 13 are laminated. The inspection step is a step of injecting gas into the resin foam 11 of the panel 10 and inspecting the state of the panel 10.

[0032] In the formation process, for example, a continuous production method, a batch production method, or the like is used. In the continuous production method, first, a raw material composition is supplied and spread from a mixer onto a lower surface material (a base material for the back surface material 13) that is unwound from a roll and supplied. When the resin foam 11 is a polyisocyanurate foam, the raw material composition is a mixture of polyol, polyisocyanate, foaming agent, catalyst, foam stabilizer, flame retardant, etc. Next, an upper surface material (a base material for the front surface material 12) is unwound from a roll and supplied, and the raw material composition is blended with the upper surface material and the lower surface material by a nip roll and the thickness is made uniform. Thereafter, the resin foam 11 is foamed and cured, and then cut to a predetermined size to form a panel 10 in which the resin foam 11, the front surface material 12, and the back surface material 13 are laminated. When a panel having an intermediate frame material (not shown) is to be made, the panel obtained by cutting is bonded to the intermediate frame material.

[0033] In the batch production method, a frame material of a predetermined shape is first disposed between an upper surface material (a base material for the surface material 12) and a lower surface material (a base material for the back surface material 13) to form a molding cavity. Then, a raw material composition is injected into the molding cavity by an injection molding machine from an injection port provided in the center of one of the frames (usually the center of the short side of a rectangular frame) and foamed and cured. This forms a panel 10 (a panel in which a resin foam 11, a surface material 12, and a back surface material 13 are laminated) in which the frame material is bonded to the periphery and integrated. When a panel is to be formed with an intermediate frame material (not shown), the raw material composition is injected into each of two molding spaces partitioned by the intermediate frame material.

[0034] In the inspection process, first, as shown in FIG. 6 and FIG. 7, the panel 10 and the needle 30 are fixed to the inspection jig 40. Next, as shown in FIG. 8, the fixing unit 62 is moved in the +X-axis direction to insert the needle 30 into the side surface (surface along the thickness direction) of the resin foam 11. For example, the needle 30 is inserted into a position in the vicinity of the surface material 12 in the resin foam 11. This allows gas to be injected into the surface material 12 side of the resin foam 11. The insertion position of the needle 30 is not particularly limited, and may be a position where peeling is likely to occur between the resin foam 11 and the surface material (the surface material 12 and the back surface material 13). In addition, when there is an adhesive layer or a primer layer between the resin foam 11 and the surface material, for example, the needle 30 may be inserted into the adhesive layer, the primer layer, or the interface between these layers and the resin foam 11. In the inspection process, the needle 30 may be manually inserted into the panel 10 without using the inspection jig 40 to perform inspection.

[0035] Next, a foam-forming liquid is applied to the side surfaces of the panel 10. Specifically, the foam-forming liquid is applied to a pair of side surfaces (a pair of side surfaces back-to-back in the Y-axis direction) of the panel 10 (more specifically, the resin foam 11) that are not in contact with the first side wall 52 and the second side wall 53 of the table 51. The foam-forming liquid is, for example, an aqueous solution of a surfactant such as soapy water or an aqueous solution of a detergent. The foam-forming liquid is a liquid having a surface tension sufficient to cause bubbles to form when gas leaks from the side surfaces of the panel 10 and expands.

[0036] Next, gas is supplied from the gas cylinder 21 to the needle 30 to inject the gas into the panel 10. For example, the regulator 22 is operated to increase the gas injection pressure over time. For example, a process of increasing the gas pressure by a certain amount and maintaining the gas pressure at that amount for a certain period of time is repeated.

[0037] During the process of increasing the gas pressure, for example, intermittently, the occurrence of gas leakage from panel 10 (the occurrence of bubbles in the aqueous surfactant solution) and the occurrence of peeling sounds or breaking sounds are checked. Then, the gas pressure when these phenomena occur and whether the gas pressure is increasing or being maintained are checked. The gas pressure and whether the gas pressure is increasing or being maintained may be recorded by data logger 26.

[0038] After the gas pressure reaches a certain value, the gas pressure is maintained for a certain period of time. Thereafter, the regulator 22 is closed, and after the gas pressure on the needle 30 side has dropped sufficiently, the needle 30 is removed from the panel 10. Then, the front surface material 12 and the back surface material 13 are peeled off from the resin foam 11, and the internal state of the panel 10 is confirmed.

[0039] For example, when gas leaks from panel 10 at a relatively low gas pressure, it can be assumed that even if gas is present inside panel 10, there is a flow path for the gas to escape to the outside, and that defects such as bulging of panel 10 are unlikely to occur. Also, when gas pressure is relatively high and defects such as bulging of panel 10 do not occur, or when destruction does not occur, it can be assumed that sufficient adhesion is obtained between resin foam 11 and first side wall 52 and second side wall 53. Also, when interfacial peeling occurs in panel 10 at a relatively low gas pressure, it can be assumed that peeling is likely to occur from voids or the like.

[0040] 5. Effect of manufacturing method of panel 10 The manufacturing method for panel 10 of the present disclosure is a method for manufacturing panel 10 having resin foam 11 formed between a front surface material 12 (first surface material) and a back surface material 13 (second surface material). This manufacturing method includes a step of injecting gas into resin foam 11 of panel 10 and inspecting the condition of panel 10. This configuration makes it possible to observe the state of panel 10 caused by the gas injected into resin foam 11. In this way, it is possible to observe phenomena caused by the injected gas, which is regarded as residual gas originally stored in resin foam 11, and therefore it is possible to grasp in advance phenomena caused by the residual gas in panel 10. In particular, it is possible to grasp the tendency of panel 10 to bulge due to peeling between resin foam 11 and the face materials (front surface material 12 and back surface material 13). Moreover, by using such a manufacturing method, it is possible to provide a panel 10 that is less susceptible to deformation such as swelling.

[0041] In the above inspection process, there is little influence of temperature-dependent gas expansion effects, distortion of the surface material, adhesive strength, etc., which are concerns in conventional humidification and heat accelerated testing, and there is no need to consider these concerns.

[0042] As a countermeasure against the bulging of the panel 10, it is possible to form a gas flow path that can be visually confirmed. In this case, it is necessary to enlarge the gas flow path to a size that can be visually confirmed. In contrast, in the inspection process of the present disclosure, the presence or absence of a gas flow path is confirmed by gas diffusion, so even if the gas flow path is very small, it can be confirmed sufficiently.

[0043] The panel 10 of the present disclosure is preferably a building panel. In the manufacturing method of the panel 10 of the present disclosure, inspection is performed using an injected gas that can flow within the resin foam 11, making it possible to utilize the diffusive nature of the gas and therefore to observe the condition of the panel 10 over a relatively wide range. Therefore, this manufacturing method of the panel 10 can be effectively applied to architectural panels that are expected to be relatively large in size. Each architectural panel is relatively large, so when performing reproduction tests using accelerated heat and humidity tests as in the past, the equipment required is large-scale and reproducibility is easily questioned. In addition, when using the ease of peeling as an index in peel tests, the adhesive strength between the resin foam and the surface material at the defect location changes due to various factors such as the environmental temperature and the load applied. In addition, because the peel strength is not uniform across the wide surface of the architectural panel, it was necessary to measure all the locations where defects were likely to occur. In the manufacturing method of panel 10 of the present disclosure, by utilizing the gas flow within resin foam 11, it is possible to grasp phenomena caused by residual gas over a relatively wide range, and it is also possible to easily grasp the likelihood of defects and the like occurring in architectural panels.

[0044] B. Panel 10 Testing Method The method for inspecting a panel 10 according to the present disclosure is a method for inspecting a panel 10 having a resin foam 11 formed between a first face material and a second face material. The method includes a step of injecting gas into the resin foam 11 of the panel 10 and inspecting the state of the panel 10. In this inspection method, the descriptions in the section "A. Manufacturing method of panel 10" regarding "panel 10," "gas injection unit 20 for injecting gas," "inspection jig 40 used in the inspection process," and "process of inspecting the condition of the panel" are applied as is, and the descriptions thereof are omitted. EXAMPLES

[0045] Next, the above embodiment will be described more specifically with reference to examples. Experimental Examples 1 to 3 are all examples. 1. Panel manufacturing Using the manufacturing method of the above embodiment, each panel of Experimental Examples 1-3 was manufactured. The panel size of each of the panels of Experimental Examples 1-3 was 600 mm x 1200 mm. The panels of Experimental Examples 1-3 were the same product (panel) but from different lots.

[0046] The configuration of the panel in Experimental Example 1-3 is shown below. Resin foam: Polyisocyanurate foam Surface material: Hot-dip 55% aluminum-zinc alloy plated steel sheet as specified in JIS G3321, thickness 0.5mm Backside material: Hot-dip 55% aluminum-zinc alloy plated steel sheet specified in JIS G3321, thickness 0.5mm

[0047] The inspection process was the same as that of the above embodiment. Specifically, the panel was fixed to the inspection jig so that the surface material was on the upper side. The needle was inserted along the surface material so as to be located in the vicinity of the surface material in the resin foam (see FIG. 8). In all of Experimental Examples 1-3, the needle was inserted into the resin foam to a length of 20 cm. Then, gas was injected into the panel from the needle. The regulator was operated to increase the gas pressure from 0 MPa. Specifically, the process of increasing the gas pressure by 0.05 MPa and maintaining it for 10 seconds was repeated. After the gas pressure reached 0.7 MPa, the gas pressure was maintained for 30 seconds. Then, the regulator was closed, and after the gas pressure on the needle side was sufficiently reduced, the needle was removed from the panel. Then, the surface material and the back material were peeled off from the resin foam to confirm the internal state of the panel.

[0048] The results of the inspection process for each of Experimental Examples 1-3 are shown in Table 1. In Table 1, in the column for "Gas pressure at time of discovery" under "Gas leak discovery," if a change in value is recorded, this indicates that a gas leak was discovered during pressure increase, and represents the change from the maintained pressure just before pressure increase to the next target maintained pressure. The same is true for the column for "Gas pressure at time of occurrence" under "Peeling sounds, breaking sounds." If only one value is recorded, this represents the maintained pressure at the time the gas leak was discovered.

[0049] [Table 1]

[0050] Risk of blistering The risk of blistering was evaluated based on the results of the inspection process for each of Experimental Examples 1-3. The evaluation criteria were as follows, and the results are shown in Table 1. The following evaluations were made in order of the best results: "C", "B", and "A". "A": High risk of blistering "B": Medium risk of blistering "C": Low risk of blistering

[0051] -Prediction of the size of the bulge when it occurs Based on the results of the inspection process for each of Experimental Examples 1-3, the size of the blister when it occurred was predicted. The prediction criteria were as follows, and the results are shown in Table 1. The following evaluations are given in order of the best results: "C", "B", and "A". "A": Large swelling when it occurs "B": Medium swelling when swelling occurs "C": The swelling is small when it occurs.

[0052] 2. Results of the inspection process In Experimental Example 1, a gas leak was found when the gas pressure was increased from 0.00 MPa to 0.05 MPa. Since the gas leak occurs when the gas pressure is relatively low, it can be assumed that even if residual gas is already present inside the resin foam, there is a flow path for the gas to escape to the outside, and defects such as bulging of the panel are unlikely to occur. Therefore, peeling or destruction of the panel does not occur during the inspection process, and it can be understood that the risk of bulging of the panel is low.

[0053] In Experimental Example 2, no gas leakage was found until the gas pressure was increased to 0.2 MPa. Furthermore, when the gas pressure was increased from 0.20 MPa to 0.25 MPa, a peeling sound was heard, and interfacial peeling (peel between the resin foam and the surface material) was observed during internal observation. Therefore, it is presumed that interfacial peeling occurred when the gas pressure was increased from 0.20 MPa to 0.25 MPa. As interfacial peeling occurs at such a relatively low gas pressure, it can be understood that there is a high risk of panel blistering.

[0054] In Experimental Example 3, no gas leakage was found even when the gas pressure was increased. In addition, when the gas pressure was increased from 0.45 MPa to 0.50 MPa, the panel was heard to break, and material destruction (destruction of the resin foam, etc.) of the panel was observed during internal observation. Therefore, it is presumed that material destruction occurred when the gas pressure was increased from 0.45 MPa to 0.50 MPa. Since material destruction occurred at such a relatively high gas pressure, it can be understood that the risk of blistering of the panel is lower than in Experimental Example 2 due to factors such as the strong adhesive strength between the resin foam and the surface material. Furthermore, compared to Experimental Example 2, it is presumed that the blistering will be larger when it occurs because there is no escape route for the gas in the resin foam.

[0055] 3. Effects of the embodiment According to the above examples, it was possible to observe the state of the panel caused by the gas injected into the resin foam. It was possible to grasp the tendency of the panel to bulge due to peeling between the resin foam and the surface materials (front surface material and back surface material). By using the inspection process of the present disclosure in the panel manufacturing method, it is possible to prevent panels that may suffer from phenomena such as bulging from being supplied to the market.

[0056] The present disclosure is not limited to the above-described embodiments, and various modifications and variations are possible within the scope of the claims of the present disclosure. [Explanation of symbols]

[0057] 10: Panel 11: Resin foam 12: Surface material (first surface material) 13: Backing material (second surface material) 20: Gas injection unit 21: Gas Cylinder 22: Regulator 23: Hose 24: T-joint 25: Pressure sensor 26: Data logger 27: Hose 28: Needle adapter 30: Needle 31: Needle tube 32: Needle tip 33: Groove 34: Gas Vent 40: Inspection fixture 50: Panel side fixing part 51: Table 52: First side wall 53: Second side wall 54: Adjustment section 55: Aperture 60: Needle side fixing part 61: Pedestal 62: Fixed Unit 132: Tip 134: Aperture

Claims

1. A method for manufacturing a panel having a resin foam formed between a first panel and a second panel, comprising: A method for manufacturing a panel, comprising the step of injecting gas into the resin foam of the panel and inspecting a condition of the panel.

2. The method of claim 1 , wherein the panel is a building panel.

3. A method for inspecting a panel having a resin foam formed between a first surface material and a second surface material, comprising: A method for inspecting a panel, comprising the step of injecting gas into the resin foam of the panel and inspecting a condition of the panel.

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