Metal sandwich panel and manufacturing method thereof

Abstract

To provide a metal sandwich panel that allows an outer metal skin to hardly bulge so as to hardly cause deterioration in appearance.SOLUTION: A metal sandwich panel 10 is provided with a resin foam 4 between two outer metal skins 1, 2. The metal sandwich panel 10 has a fitting convex part 8 on one end and has a fitting concave part 9 in the other end. Adjacent metal sandwich panels 10 are connected to each other by the fitting engagement between the fitting convex part 8 and the fitting concave part 9. One outer metal skin 1 of the two outer metal skins 1, 2 has a cover part 3 positioned in front of the fitting convex part 8. The cover part 3 is formed in a generally U-shaped section, and has a cavity part 32 thereinside. An opening 320 of the cavity part 32 is closed by filling a closing member 33 in the cavity part 32.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present disclosure relates to metal sandwich panels and methods of making the same. More particularly, the present disclosure relates to metal sandwich panels having a metal skin and a core and methods of making the same. [Background technology]

[0002] Patent Document 1 describes an external insulation device for preventing internal condensation. This device is constructed by installing an exterior material on the outside of a fireproof wall of a building with a gap between it and the building, and filling the space between the fireproof wall and the exterior material with a flame-retardant urethane foam mixed with a flame-retardant material that is compatible with urethane. The exterior material is a metal sandwich panel in which a urethane foam or isocyanurate foam is used as a core material and is sandwiched between two metal plates. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Publication No. 6-264590 Summary of the Invention [Problem to be solved by the invention]

[0004] In the above-mentioned metal sandwich panel, the core material and the metal plate are bonded by an adhesive force (self-adhesive force) that occurs when the core material hardens from a liquid state to a foam. However, due to changes in the core material and the metal plate over time, the core material and the metal plate may partially peel off from each other, and the metal plate may bulge toward the surface of the metal sandwich panel at the part where it has peeled off from the core material, degrading the appearance of the metal sandwich panel.

[0005] The present disclosure aims to provide a metal sandwich panel that is less susceptible to deterioration in appearance due to bulging of the metal skin, and a manufacturing method thereof. [Means for solving the problem]

[0006] A metal sandwich panel according to one embodiment of the present disclosure is a metal sandwich panel having a resin foam between two metal skins. The metal sandwich panel has a fitting protrusion at one end and a fitting recess at the other end. Adjacent metal sandwich panels are connected by fitting the fitting protrusion and the fitting recess. One of the two metal skins has a cover portion located in front of the fitting protrusion. The cover portion is formed in a substantially U-shaped cross section and has a void portion therein. A blocking member is filled into the opening of the void portion to block the opening.

[0007] A method for manufacturing a metal sandwich panel according to one embodiment of the present disclosure is a method for manufacturing a metal sandwich panel having a resin foam between two metal skins. A cover part having a generally U-shaped cross section is provided on a metal plate to form one of the two metal skins. A blocking member is filled into an opening of the cover part to block the opening. A resin liquid is foamed between the one metal skin and the other metal skin to form the resin foam. Effect of the Invention

[0008] According to the present disclosure, by providing a blocking member at the opening of the void, the resin foam is not filled into the void, so that peeling between the resin foam and the metal skin is unlikely to occur, and the metal skin is unlikely to swell, resulting in poor appearance. [Brief description of the drawings]

[0009] [Figure 1] FIG. 1 is a partial cross-sectional view showing a metal sandwich panel according to this embodiment. [Diagram 2] FIG. 2 is a perspective view showing the metal sandwich panel according to the present embodiment. [Diagram 3] FIG. 3 is a cross-sectional view showing the metal sandwich panel according to this embodiment. [Figure 4] FIG. 4 is a cross-sectional view showing a connected state of the metal sandwich panel according to this embodiment. [Diagram 5]FIG. 5 is a schematic diagram showing a method for producing a metal sandwich panel according to this embodiment. [Figure 6] FIG. 6 is a cross-sectional view showing a problem with the conventional technology. [Figure 7] FIG. 7 is a schematic diagram showing a modified example of the metal sandwich panel according to the present embodiment. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0010] The present disclosure will be described below based on the embodiments shown in the accompanying drawings. However, the present disclosure is not limited to the following embodiments, and appropriate design changes are possible within the intended scope of the present disclosure.

[0011] (Embodiment) (1) Overview FIG. 6 shows a metal sandwich panel 10x similar to this embodiment. This metal sandwich panel 10x includes a resin foam 4 between two metal skins 1 and 2. The metal skin 1 and the metal skin 2 are arranged opposite to each other, and the resin foam 4 is provided between the metal skin 1 and the metal skin 2 as a core material. The resin foam 4 is a resin foam such as polyurethane foam or polyphenol foam, and has heat insulating and fire resistance. The resin foam 4 is formed by foaming a resin liquid supplied to one side of one metal skin 1. In the middle of foaming of the resin liquid, the other metal skin 2 is arranged opposite to the metal skin 1, and the resin liquid is further foamed between the metal skin 1 and the metal skin 2. Then, when the resin liquid is completely foamed, it becomes the resin foam 4. The resin foam 4 adheres to the metal skins 1 and 2 by its self-adhesive force.

[0012] Incidentally, the metal skin 1 and the metal skin 2 are arranged so as not to come into direct contact with each other in order to prevent a heat bridge. For example, in FIG. 6, at the lower part of the metal sandwich panel 10x, the lower part 1x of the metal skin 1 and the lower part 2x of the metal skin 2 are arranged facing each other with a predetermined gap therebetween. In addition, a resin foam 4 is filled between the lower part 1x and the lower part 2x, and is formed so that the lower part 1x and the lower part 2x do not come into direct contact with each other. Here, since the gap between the lower part 1x and the lower part 2x is formed before the resin liquid is completely foamed, a blocking material 6 is provided to block the gap between the lower part 1x and the lower part 2x, so that the resin liquid in the middle of foaming does not leak out from between the lower part 1x and the lower part 2x.

[0013] Usually, gas (such as carbon dioxide) generated during manufacturing is gas produced by vaporizing the foaming agent, and most of the gas is discharged to the outside of the metal sandwich panel 10x through a small gap. However, the gas may not be discharged sufficiently and may remain in the resin foam 4. If unreacted components remain in the resin foam 4, the unreacted components may react after the metal sandwich panel 10x is completed, and may generate new gas (such as carbon dioxide). If the gas in the resin foam 4 is not discharged to the outside from the metal sandwich panel 10x, the gas may accumulate between the resin foam 4 and the metal skin 1, and the resin foam 4 and the metal skin 1 may be peeled off by the pressure of this gas, and a bulge 100x may be generated in a part of the metal skin 1 as shown in FIG. 6. The area surrounded by the imaginary line X in the figure is particularly likely to cause the bulge 100x. Therefore, the present inventors have developed a metal sandwich panel 10 in which the bulge 100x is less likely to occur.

[0014] As shown in Figures 1, 3, and 4, the metal sandwich panel 10 according to this embodiment includes a resin foam 4 between two metal skins 1 and 2. The metal sandwich panel 10 has a fitting protrusion 8 at one end and a fitting recess 9 at the other end. Adjacent metal sandwich panels 10 are connected by fitting the fitting protrusion 8 with the fitting recess 9. One metal skin 1 of the two metal skins 1 and 2 has a cover portion 3 located in front of the fitting protrusion 8. The cover portion 3 is formed in a substantially U-shaped cross section and has a void portion 32 inside. An opening 320 of the void portion 32 is filled with a blocking member 33 to block the opening 320.

[0015] In the metal sandwich panel 10 of this embodiment, by providing a blocking member 33 at the opening 320 of the void 32, the resin foam 4 is not filled into the void 32. Therefore, there are less areas with low adhesion between the metal skin 1 and the resin foam 4 (areas where the resin foam 4 is insufficient), and the quality is stable. As a result, peeling between the resin foam 4 and the metal skins 1 and 2 is less likely to occur, and the metal skins 1 and 2 are less likely to swell, which makes it difficult for the appearance to deteriorate.

[0016] (2) Details The metal sandwich panel 10 of this embodiment is an architectural panel used for the exterior walls of buildings such as buildings, factories, warehouses, etc. As shown in Fig. 2, the metal sandwich panel 10 includes a front plate 11 made of a first metal skin 1, a back plate 21 arranged opposite the front plate 11 and made of a second metal skin 2, and a resin foam 4 disposed between the front plate 11 and the back plate 21. The resin foam 4 is formed as a core material of the metal sandwich panel 10.

[0017] The metal sandwich panel 10 of this embodiment is formed in a generally rectangular shape when viewed from the front. The metal sandwich panel 10 of this embodiment has a fitting recess 9 formed at one end in the width direction, and a fitting protrusion 8 formed at the other end. The metal sandwich panels 10 are installed side by side on the same plane. In this case, adjacent metal sandwich panels 10 are connected by fitting the fitting recess 9 and the fitting protrusion 8. In the following description, for convenience, the same direction as the direction in which the fitting recess 9 and the fitting protrusion 8 are fitted together is defined as the width direction, the direction perpendicular to the width direction and along the in-plane direction of the metal sandwich panel 10 is defined as the length direction, and the direction perpendicular to the width direction and the length direction is defined as the thickness direction.

[0018] The lengthwise dimension of the metal sandwich panel 10 is greater than the widthwise dimension and the thicknesswise dimension. The widthwise dimension of the metal sandwich panel 10 is greater than the thicknesswise dimension. The metal sandwich panel 10 is usually constructed with the width direction as the up-down direction and the length direction as the left-right direction. Therefore, the fitting recess 9 is provided at the upper end of the metal sandwich panel 10, and the fitting protrusion 8 is provided at the lower end of the metal sandwich panel 10. The fitting recess 9 and the fitting protrusion 8 are formed over the entire length of the metal sandwich panel 10 in the lengthwise direction. The first metal skin 1 and the second metal skin 2 face each other in the thickness direction of the metal sandwich panel 10. The metal sandwich panel 10 may be constructed with the width direction as the left-right direction and the length direction as the up-down direction. In that case, the fitting recess 9 is provided at one end of the metal sandwich panel 10 in the left-right direction, and the fitting protrusion 8 is provided at the other end of the metal sandwich panel 10 in the left-right direction.

[0019] The first and second metal skins 1, 2 are formed into a predetermined shape by processing a flat metal plate such as roll forming. Metal plates are those that have been used in the past to form building materials, and examples of such metal plates include SGL (registered trademark) steel plate, Galvalume steel plate (registered trademark), zinc-plated steel plate, and painted steel plate. The thickness of the metal plate is not particularly limited, and may be, for example, 0.25 to 2.3 mm.

[0020] As shown in FIG. 3, the first metal skin 1 has a first panel body 112. The first panel body 112 is formed in a flat plate shape and constitutes the main surface on the front side of the metal sandwich panel 10. The first metal skin 1 has a first horizontal piece 113. The first horizontal piece 113 protrudes backward (toward the resin foam 4) from the upper end of the first panel body 112. The first metal skin 1 has a first vertical piece 114. The first vertical piece 114 protrudes upward from the upper end of the first horizontal piece 113. The first metal skin 1 has a lower concave groove piece 115. The lower concave groove piece 115 protrudes backward (toward the resin foam 4) from the upper end of the first vertical piece 114. The first metal skin 1 has a concave groove piece 116. The concave groove piece 116 protrudes upward from the upper end of the lower concave groove piece 115. The first metal skin 1 has an upper concave groove piece 117. The upper concave groove piece 117 protrudes forward (opposite the resin foam 4) from the upper end of the concave groove piece 116. The first metal skin 1 has a second vertical piece 118. The second vertical piece 118 protrudes upward from the upper end of the upper concave groove piece 117. The first metal skin 1 has a first recessed piece 119. The first recessed piece 119 protrudes downward from the upper end of the second vertical piece 118 in a folded-back manner. The first metal skin 1 has a first recessed bottom piece 120. The first recessed bottom piece 120 protrudes rearward from the lower end of the first recessed piece 119. The first metal skin 1 has a first upper insertion piece 121. The first upper insertion piece 121 protrudes downward from the rear end of the first recessed bottom piece 120. The first upper insertion piece 121 is inserted into the resin foam 4 from its upper end face 42 .

[0021] The first metal skin 1 has a covering portion 3. The covering portion 3 is provided at the lower end of the first metal skin 1. The covering portion 3 has a front covering portion 30 and a rear covering portion 31. The front covering portion 30 is formed so as to protrude downward from the lower end of the first panel body 112. The front covering portion 30 and the first panel body 112 are formed flat without any step. The rear covering portion 31 is located behind the front covering portion 30. The rear covering portion 31 is formed so as to fold back upward from the lower end of the front covering portion 30. The front covering portion 30 and the rear covering portion 31 face each other at a predetermined interval in the thickness direction (front-rear direction).

[0022] The covering portion 3 formed as described above is formed to have a substantially U-shaped cross section. The covering portion 3 has a void portion 32 inside. That is, the gap between the front covering portion 30 and the rear covering portion 31 is formed as the void portion 32. The void portion 32 is provided over the entire length of the metal sandwich panel 10 in the left-right direction. The void portion 32 has an opening 320 at its upper end. The void portion 32 communicates with the internal space of the metal sandwich panel 10 (the space between the first panel body 112 and the second panel body 212 of the second metal skin 2) through the opening 320. The upper end of the void portion 32, the upper end of the front covering portion 30, and the upper end of the rear covering portion 31 are at substantially the same height position (they are at the same position in the up-down direction). In Figures 1 to 4, the boundary between the resin foam 4 and the blocking member 33 is clearly depicted as a straight line at the position of the opening 320, but this is not limited thereto, and the boundary between the resin foam 4 and the blocking member 33 may be located slightly above or below the position of the opening 320, and the boundary between the resin foam 4 and the blocking member 33 may not be a straight line but may extend into each other.

[0023] A blocking member 33 is provided in the gap 32. The blocking member 33 is provided over the entire length of the gap 32 in the left-right direction. The blocking member 33 is provided so as to block the opening 320 of the gap 32. Therefore, the communication between the gap 32 and the internal space of the metal sandwich panel 10 through the opening 320 is blocked by the blocking member 33. The blocking member 33 is provided by filling the upper part of the gap 32. Therefore, the lower part of the gap 32 remains empty. The upper end of the blocking member 33 is at the same height as the opening 320 (the vertical positions are the same). The vertical dimension of the blocking member 33 can be 1 / 2 to 1 / 3 of the vertical dimension of the gap 32, but is not limited thereto. The blocking member 33 may be provided over the entire gap 32. The blocking member 33 may protrude upward from the opening 320.

[0024] The material of the blocking member 33 is an inorganic material or an organic material. An example of the inorganic material is AES wool. An example of the organic material is ethylene propylene rubber (EPT). EPT is used as a packing. The blocking member 33 can be any flexible solid material (including a material that solidifies from a liquid state) without any particular limitations. The blocking member 33 can be in a linear or rope shape. Specifically, a gasket or packing that matches the cross-sectional shape of the opening 320 can also be used. The "AES wool" is a fibrous inorganic material such as alkaline earth silicate wool (biosoluble fiber). In this embodiment, examples of textile products of the "AES wool" of the blocking member 33 include twisted rope, cloth, and paper.

[0025] The first metal skin 1 has a gap piece 122. The gap piece 122 protrudes rearward from the upper end of the rear cover portion 31. The first metal skin 1 has a first convex piece 123. The first convex piece 123 protrudes downward from the rear end of the gap piece 122. The first metal skin 1 has a first lower insertion piece 124. The first lower insertion piece 124 protrudes upward from the lower end of the first convex piece 123 in a folded-back manner. The first lower insertion piece 124 is inserted into the resin foam 4 from the lower end surface 40. The first lower insertion piece 124 and the first convex piece 123 face each other at a predetermined interval in the thickness direction (front-rear direction). The first lower insertion piece 124 and the first convex piece 123 form a first facing portion 111 at the lower end of the first metal skin 1.

[0026] As shown in FIG. 3, the second metal skin 2 has a second panel body 212. The second panel body 212 is formed in a flat plate shape and constitutes the main surface on the front side of the metal sandwich panel 10. The second panel body 212 faces the first metal skin 1 in the thickness direction. The second metal skin 2 has a second recessed piece 219. The second recessed piece 219 protrudes downward from the upper end of the second panel body 212 in a folded-back manner. The second recessed piece 219 faces the first recessed piece 119 in the thickness direction. The second metal skin 2 has a second recessed bottom piece 220. The second recessed bottom piece 220 protrudes forward from the lower end of the second recessed piece 219. The second metal skin 2 has a second upper insertion piece 221. The second upper insertion piece 221 protrudes downward from the front end of the second recessed bottom piece 220. The second upper insertion piece 221 is inserted into the resin foam 4 from its upper end face 42 .

[0027] The second metal skin 2 has a lower piece 222. The lower piece 222 protrudes forward from the lower end of the second panel body 212. The second metal skin 2 has a second convex piece 223. The second convex piece 223 protrudes downward from the front end of the lower piece 222. The second convex piece 223 faces the first convex piece 123 in the thickness direction with a predetermined gap therebetween. The second metal skin 2 has a second lower insertion piece 224. The second lower insertion piece 224 protrudes upward from the lower end of the second convex piece 223 in a folded-back manner. The second lower insertion piece 224 is inserted into the resin foam 4 from the lower end surface 40. The second lower insertion piece 224 and the second convex piece 223 face each other in the thickness direction (front-rear direction) with a predetermined gap therebetween. The second lower insertion piece 224 and the second protruding piece 223 form a second opposing portion 211 at the lower end of the second metal skin 2. The first opposing portion 111 and the second opposing portion 211 face each other at a predetermined distance in the thickness direction (front-rear direction). In this way, the first metal skin 1 and the second metal skin 2 are arranged not to come into direct contact with each other in order to prevent a heat bridge.

[0028] The fitting recess 9 is formed by a space surrounded by the first recess piece 119, the second recess piece 219, the first recess bottom piece 120, the second recess bottom piece 220, and the upper end surface 42 of the resin foam 4. A packing 90 made of EPDM, butyl rubber, soft urethane foam, or the like is provided over the entire length of the fitting recess 9. The fitting protrusion 8 is composed of the first opposing portion 111, the second opposing portion 211, and a part of the resin foam 4 located between the first opposing portion 111 and the second opposing portion 211.

[0029] As shown in FIG. 1, a blocking material 6 is provided on the lower end surface of the metal sandwich panel 10. The blocking material 6 is provided to suppress leakage of the resin foam 4 from between the first opposing portion 111 and the second opposing portion 211 during the manufacture of the metal sandwich panel 10. The blocking material 6 is provided over the entire length in the longitudinal direction. The end surface 80 of the fitting convex portion 8, which is the lower end surface of the metal sandwich panel 10, is formed by the outer surface of the blocking material 6 (the surface opposite to the resin foam 4). The blocking material 6 is provided to bridge between the first convex piece 123 of the first opposing portion 111 and the second convex piece 223 of the second opposing portion 211. Therefore, the end surface 40 of the resin foam 4 between the first opposing portion 111 and the second opposing portion 211 is covered by the blocking material 6. The blocking material 6 is bonded to the outer surface of the first convex piece 123 and the outer surface of the second convex piece 223.

[0030] The material of the sealing material 6 is not particularly limited, but is preferably at least one selected from the group consisting of paper, resin film, nonwoven fabric, and woven fabric. An example of the paper is a two-layer structure of craft paper and adhesive laminate material. The sealing material 6 is formed in a belt shape extending in the length direction, and can be formed into a sheet, film, plate, or the like. The thickness of the sealing material 6 (dimension in the vertical direction) can be 0.01 mm or more and 0.5 mm or less, but is not limited thereto.

[0031] The resin foam 4 is a part constituting the main body of the metal sandwich panel 10, and is made of a resin foam. The resin foam 4 in this embodiment is at least one type selected from the group consisting of polyisocyanurate foam, polyurethane foam, polystyrene foam, and polyphenol foam. The resin foam 4 may be formed by combining a plurality of types of these foams, or may be formed by using only one of them. Also, a plurality of types of materials may be laminated in the thickness direction. The resin foam 4 is preferably heat-insulating and fire-resistant.

[0032] FIG. 4 shows a connection structure of two metal sandwich panels 10 adjacent in the vertical direction. The fitting protrusion 8 of the upper metal sandwich panel 10 is fitted into the fitting recess 9 of the lower metal sandwich panel 10 to connect the two metal sandwich panels 10. Here, the end face 80 of the fitting protrusion 8 is in close contact with the upper surface of the packing 90. In addition, the cover portion 3 is located in front of the fitting protrusion 8, and the lower end of the cover portion 3 is located lower than the lower end of the fitting protrusion 8. Therefore, the fixing device 50 such as a screw that fixes the lower metal sandwich panel 10 is located behind the covering portion 3 of the upper metal sandwich panel 10, and the fixing device 50 can be covered by the covering portion 3 so that it cannot be seen from the front. The fixing device 50 is driven (screwed) into the recessed groove piece 116 from the front, penetrates the metal sandwich panel 10 in the thickness direction, and is driven (screwed) into a wall base such as a furring strip located behind the metal sandwich panel 10. At this time, the head 51 of the fastener 50 is positioned so as to be in close contact with the front surface of the groove piece 116. In this manner, the metal sandwich panel 10 is fixed to the wall substrate and installed.

[0033] The metal sandwich panel 10 of the present embodiment is manufactured as follows.

[0034] First, as shown in FIG. 5, the first and second metal skins 1, 2 are formed from metal sheets 1A, 2A. The metal sheet 1A wound in a roll shape is fed by a feeding device 55A and continuously supplied to a roll forming machine 56A. Then, the roll forming machine 56A forms each part, such as the cover part 3 and the first opposing part 111, to form the first metal skin 1. Similarly, the metal sheet 2A wound in a roll shape is fed by a feeding device 55B and continuously supplied to the roll forming machine 56B. Then, the roll forming machine 56B forms each part, such as the second opposing part 211, to form the second metal skin 2.

[0035] Next, the blocking member 33 is provided in the gap 32 of the covering portion 3 of the first metal skin 1. In this case, the blocking member 33 is filled into the gap 32 from the opening 320. The blocking member 33 is filled into the gap 32 between the roll forming machine 56A and the liquid supplying device 58. The blocking member 33 may be filled into the gap 32 manually or by using an appropriate filling device.

[0036] Next, the first metal skin 1 is continuously transported and heated by a heating device 57A such as a high-frequency heating device. Similarly, the second metal skin 2 is continuously transported and heated by a heating device 57B such as a high-frequency heating device.

[0037] Next, the resin liquid 41 is supplied to one side (the side to be bonded to the resin foam 4) of the first metal skin 1. When the metal sandwich panel 10 is manufactured, the side of the first metal skin 1 to be bonded to the resin foam 4 faces upward. The resin liquid 41 is supplied from a liquid supply device 58 to the upward facing surface of the first metal skin 1. The resin liquid 41 is a liquid resin material that foams to become the resin foam 4. Next, in the middle of foaming of the resin liquid 41, the second metal skin 2 is placed opposite to the first metal skin 1. At this time, the side of the second metal skin 2 to be bonded to the resin foam 4 faces downward. Then, the resin liquid 41 is further foamed between the first panel body 112 of the first metal skin 1 and the second panel body 212 of the second metal skin 2, which face each other vertically. At this time, a plugging material 6 is placed between the opposing portion 111 of the first metal skin 1 and the opposing portion 211 of the second metal skin 2, which are arranged opposite to each other. The plugging material 6 is placed across the outer surface of the first convex piece 123 and the outer surface of the second convex piece 223. The surface of the plugging material 6 that comes into contact with the resin foam 4 is adhered by the self-adhesive force of the resin foam 4 (resin liquid 41). In addition, a packing 90 is placed in the space surrounded by the first recessed piece 119, the second recessed piece 219, the first recessed bottom piece 120, and the second recessed bottom piece 220.

[0038] In order to further foam the resin liquid 41 between the first metal skin 1 and the second metal skin 2, the opposing first metal skin 1 and second metal skin 2 are sandwiched between a double conveyor 59 in a heating furnace 60 while being heated and pressurized. When the resin liquid 41 is completely foamed, it becomes a resin foam 4.

[0039] The resin foam 4 adheres to the first metal skin 1 and the second metal skin 2 by its own adhesive force. The first metal skin 1 and the second metal skin 2 are arranged so as not to come into direct contact with each other in order to prevent a heat bridge. Therefore, the first opposing portion 111 and the second opposing portion 211 face each other in the thickness direction (front-rear direction) with a predetermined gap therebetween, and the gap between the first opposing portion 111 and the second opposing portion 211 can be blocked with a blocking material 6 to prevent the resin foam 4 from leaking out during foaming.

[0040] In this manner, the first metal skin 1 and the second metal skin 2 are integrated with the resin foam 4, and a long metal sandwich panel 10A is continuously manufactured. Then, the long metal sandwich panel 10A is cut to a desired length with a cutting device 61 such as a cutter, whereby the metal sandwich panel 10 can be manufactured.

[0041] In the manufacturing method of the metal sandwich panel 10 of this embodiment, the void 32 is filled with the blocking member 33 to block the opening 320 before the resin liquid 41 is supplied to the first metal skin 1, so that the resin liquid 41 and the resin foam 4 are unlikely to enter the void 32. That is, the resin foam 4 reaches the upper surface of the blocking member 33, but is unlikely to enter the void 32 any further. Therefore, after manufacturing the metal sandwich panel 10, peeling between the resin foam 4 and the metal skins 1 and 2 due to gas pressure is unlikely to occur, and the first metal skin 1 and the second metal skin 2 are unlikely to swell.

[0042] Moreover, it is preferable that the blocking member 33 has air permeability and does not fill the entire gap 32. For example, the blocking member 33 is in close contact with the inner surface of the covering part 3 in the front-rear direction (the surfaces facing each other in the front-rear direction of the front covering part 30 and the rear covering part 31), but the blocking member 33 can be prevented from filling the gap 32 in the lower half of the covering part 3. That is, the blocking member 33 fills the gap 32 in approximately the upper half of the covering part 3.

[0043] In such a case, even if unreacted components react in the resin foam 4 after the production of the metal sandwich panel 10 to generate new gas (such as carbon dioxide), the gas is introduced into the gap 32 through the blocking member 33 and then released to the outside from the left and right ends of the gap 32 that open to the left and right ends of the metal sandwich panel 10. Therefore, after the production of the metal sandwich panel 10, peeling between the resin foam 4 and the metal skins 1 and 2 due to gas pressure is unlikely to occur, and the first metal skin 1 and the second metal skin 2 are unlikely to swell.

[0044] The blocking member 33 may fill the entire gap 32. That is, the blocking member 33 can be provided in contact with the surfaces of the front covering part 30 and the rear covering part 31 facing each other in the front-rear direction, from the lower end of the gap 32 to the opening 320. In this case, it is preferable that the blocking member 33 has air permeability, so that gas newly generated in the resin foam 4 can pass through the blocking member 33 and be discharged from the left and right ends of the metal sandwich panel 10.

[0045] The breathable blocking member 33 can be formed of a resin sheet material having open or semi-closed bubbles. For example, "Color Foam (registered trademark)" by Inoac Corporation can be used as the breathable blocking member 33. If the breathable blocking member 33 has a low density, it has good breathability, but may be too soft and difficult to insert into the gap 32. If the breathable blocking member 33 has a high density, it has low breathability, but is hard and easy to insert into the gap 32.

[0046] (Modification) Various materials can be used as the blocking member 33. The blocking member 33 shown in Fig. 7 is a resin molded product, and can be formed long over the entire length of the metal sandwich panel 10 in the left-right direction. Fig. 7 shows the state when the blocking member 33 is attached to the first metal skin 1 during the production of the metal sandwich panel 10 shown in Fig. 5.

[0047] The blocking member 33 includes a flat front insertion piece 331, a flat rear insertion piece 333, and a flat lid piece 332. The front insertion piece 331 and the rear insertion piece 333 are connected at their lower ends. The angle between the front insertion piece 331 and the rear insertion piece 333 is an acute angle, and the front insertion piece 331 and the rear insertion piece 333 form a substantially V-shape. The lid piece 332 protrudes rearward from an upper portion of the front insertion piece 331. The rear end of the lid piece 332 is located rearward of the rear insertion piece 333.

[0048] Such a blocking member 33 is attached to the first metal skin 1 before the resin liquid 41 is supplied to the first metal skin 1. The blocking member 33 is configured so that the front insertion piece 331 and the rear insertion piece 333 are inserted into the gap portion 32 from the opening 320. The lid piece 332 is disposed in contact with the upper surface of the gap piece 122. The lid piece 332 blocks the opening 320 over its entire length in the left-right direction.

[0049] (summary) As described above, the metal sandwich panel (10) according to the first embodiment includes a resin foam (4) between two metal skins (1, 2). The metal sandwich panel (10) has a fitting protrusion (8) at one end and a fitting recess (9) at the other end. Adjacent metal sandwich panels (10) are connected by fitting the fitting protrusion (8) with the fitting recess (9). One metal skin (1) of the two metal skins (1, 2) has a cover portion (3) located in front of the fitting protrusion (8). The cover portion (3) is formed with a substantially U-shaped cross section and has a void portion (32) therein. The void portion (32) is filled with a blocking member (33) to block an opening (320) of the void portion (32).

[0050] According to this embodiment, by providing the blocking member 33 at the opening 320 of the cavity 32, the resin foam 4 is not filled into the cavity 32. This makes it difficult for the resin foam 4 to peel off from the metal skins 1, 2, and makes it difficult for the metal skins 1, 2 to swell, resulting in poor appearance.

[0051] A second aspect is the metal sandwich panel (10) according to the first aspect, in which the material of the blocking member (33) is an inorganic material or an organic material.

[0052] According to this embodiment, the voids (32) are less likely to be filled with the resin foam (4).

[0053] A third aspect is the metal sandwich panel (10) according to the first aspect, in which the closing member (33) has air permeability.

[0054] According to this embodiment, the gas generated in the resin foam (4) can be discharged to the outside of the metal sandwich panel (10) through the blocking member (33), so that the metal outer skins (1, 2) are less likely to bulge due to gas, and the appearance is less likely to deteriorate.

[0055] The fourth aspect is a manufacturing method for a metal sandwich panel (10) having a resin foam (4) between two metal skins (1, 2). A cover portion (3) having a generally U-shaped cross section is provided on a metal plate to form one metal skin (1) of the two metal skins (1, 2). A blocking member (33) is filled into a gap portion (32) of the cover portion (3) to block an opening (320) of the gap portion (32). A resin liquid (41) is foamed between one metal skin (1) and the other metal skin (2) to form a resin foam (4).

[0056] According to this embodiment, by providing the blocking member (33) at the opening (320) of the gap (32), the resin liquid (41) is less likely to enter the gap (32), and the resin foam (4) is less likely to fill the gap (32). Therefore, the resin foam (4) is less likely to peel off from the metal skins (1, 2), and the metal skins (1, 2) are less likely to swell, which makes it difficult for the appearance to deteriorate. [Explanation of symbols]

[0057] 10 Metal sandwich panels 1 Metal shell 2 Metal shell 3 Cover 32 Cavity 320 aperture 33 Closure member 4. Resin foam 41 Resin Liquid 8 Fitting protrusion 9 Fitting recess

Claims

1. A metal sandwich panel having a resin foam between two metal skins, The metal sandwich panel has a fitting protrusion at one end and a fitting recess at the other end, Adjacent metal sandwich panels are connected by fitting the fitting convex portion and the fitting concave portion, One of the two metal shells has a cover portion located in front of the fitting protrusion, The cover portion is formed in a substantially U-shaped cross section and has a gap therein, A blocking member is filled into the gap to block the opening of the gap. Metal sandwich panel.

2. The material of the blocking member is an inorganic material or an organic material. The metal sandwich panel according to claim 1.

3. The blocking member has air permeability. The metal sandwich panel according to claim 1.

4. A method for manufacturing a metal sandwich panel having a resin foam between two metal skins, comprising the steps of: a cover portion having a substantially U-shaped cross section is provided on a metal plate to form one of the two metal outer shells; A blocking member is filled in the gap of the cover portion to block the opening of the gap, forming the resin foam by foaming a resin liquid between the one metal skin and the other metal skin; A method for manufacturing metal sandwich panels.

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