Corner panel and manufacturing method thereof

Abstract

To provide a corner panel with adjustable dimensions.SOLUTION: A corner panel 100 comprises a first panel 1, a second panel 2, and a decorative member 3. The first panel 1 has a first main surface 10 and a first inclined end surface 11 continuous with the first main surface 10. The second panel 2 has a second main surface 20 and a second inclined end surface 21 continuous with the second main surface 20. The first panel 1 and the second panel 2 are each composed of metal sandwich panels having a core material 5 between two metal outer skins 41 and 42. The first panel 1 and the second panel 2 are arranged with the first inclined end face 11 and the second inclined end face 21 facing each other. The decorative member 3 is arranged on the first main surface 10 and the second main surface 20. The angle of the second main surface 20 relative to the first main surface 10 is less than 180°.SELECTED DRAWING: Figure 1

Description

Technical Field

[0001] The present disclosure relates to a corner panel and a method for manufacturing the corner panel. More specifically, the present disclosure relates to a corner panel installed at a corner portion of a building and a method for manufacturing the same.

Background Art

[0002] Patent Document 1 describes manufacturing a bent sandwich panel by V-cutting a part of a well-known flat sandwich panel and then bending it. The flat sandwich panel has an outer skin portion and an inner skin portion formed of metal plates, and a core portion disposed between the outer skin portion and the inner skin portion and adhered to the outer skin portion and the inner skin portion.

[0003] A part of the inner skin portion and a part of the core portion of the flat sandwich panel are V-cut and removed. On the other hand, the exposed surface portion of the outer skin portion is connected by a connecting portion, and when manufacturing the bent sandwich panel, the outer skin portion is not cut. Therefore, the sum of the dimension from the connecting portion to one end and the dimension from the connecting portion to the other end of the bent sandwich panel is substantially the same as the dimension from one end to the other end of the flat sandwich panel, and the dimension cannot be adjusted.

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0005] An object of the present disclosure is to provide a corner panel whose dimensions can be adjusted and a method for manufacturing the same.

Means for Solving the Problems

[0006] A corner panel according to one aspect of the present disclosure includes a first panel, a second panel, and a decorative member. The first panel has a first main surface and a first inclined end surface continuous with the first main surface. The second panel has a second main surface and a second inclined end surface continuous with the second main surface. The first panel and the second panel are each composed of a metal sandwich panel having a core material between two metal outer skins. The first panel and the second panel are arranged with the first inclined end surface and the second inclined end surface facing each other. The decorative member is arranged on the first main surface and the second main surface. The angle of the second main surface with respect to the first main surface is less than 180°.

[0007] A method for manufacturing a corner panel according to one aspect of the present disclosure is a method for manufacturing the corner panel, including a step of producing the first panel having the first inclined end surface by cutting a part of a flat base panel, a step of producing the second panel having the second inclined end surface by cutting a part of the flat base panel, a step of arranging the first panel and the second panel with the first inclined end surface and the second inclined end surface facing each other, and a step of arranging the decorative member on the first main surface and the second main surface. The flat base panel is composed of a metal sandwich panel having a core material between two metal outer skins.

Advantages of the Invention

[0008] According to the present disclosure, by adjusting the dimensions in the width direction of the first panel and the second panel, it is possible to easily adjust the dimensions in the width direction.

Brief Description of the Drawings

[0009]

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Mode for Carrying Out the Invention

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

[0011] (First Embodiment) (1) Outline The corner panel 100 of the present embodiment includes a first panel 1, a second panel 2, and a decorative member 3 (see FIG. 1). The first panel 1 has a first main surface 10 and a first inclined end surface 11 continuous with the first main surface 10. The second panel 2 has a second main surface 20 and a second inclined end surface 21 continuous with the second main surface 20. The first panel 1 and the second panel 2 are arranged in a state where the first inclined end surface 11 and the second inclined end surface 21 face each other. The decorative member 3 is arranged on the first main surface 10 and the second main surface 20. The angle of the second main surface 20 with respect to the first main surface 10 is less than 180°.

[0012] In the corner panel 100 having the above configuration, since the first panel 1 and the second panel 2 are formed separately, the gap between the first inclined end face 11 and the second inclined end face 21 can be set to a desired dimension, and the first panel 1 and the second panel 2 can be arranged. Therefore, it is easy to adjust the dimension in the width direction of the corner panel 100. In the present disclosure, the width direction includes the first direction X and the second direction Y. When the vertical direction is defined as the third direction Z substantially parallel to the vertical direction with reference to the state where the corner panel 100 is constructed, the first direction X is a direction orthogonal to the third direction Z and parallel to the first main surface 10. Further, the second direction Y is a direction orthogonal to the third direction Z and parallel to the second main surface 20. Therefore, in the corner panel 100 of the present embodiment, it is easy to adjust the dimensions (width dimensions) in the first direction X and the second direction Y.

[0013] The outer wall of a building is usually formed by arranging corner members at corner portions (outer corner portions) and arranging a plurality of rectangular plate-shaped normal panels at other portions (general portions). In this case, since the dimension in the width direction of the normal panel is constant, it is not possible to fit the normal panels precisely without gaps. Therefore, a width adjustment panel obtained by cutting the normal panel to adjust the width dimension is used.

[0014] However, when using a width adjustment panel, the normal panel has to be cut to produce the width adjustment panel at the construction site, which may be time-consuming for construction. Also, if a width adjustment panel is not used, the fire resistance and waterproofness of the outer wall may decrease.

[0015] On the other hand, since the corner panel 100 of the present embodiment can be manufactured at a factory by adjusting the dimension in the width direction, there is no need to create a width adjustment panel at the construction site, and the labor for construction is reduced. It is less likely that the fire resistance and waterproofness of the outer wall will decrease. Note that since the width dimension of the corner panel 100 can be known at the design stage of the building (the stage of allocating the outer wall panels), the corner panel 100 can be manufactured at a factory according to the required width dimension.

[0016] In the corner panel 100 of the present embodiment, since the first panel 1 and the second panel 2 are formed separately, the angle θ between the second main surface 20 and the first main surface 10 can be adjusted so that θ is less than 180°. Therefore, the corner panel 100 can correspond to the external corners of various angles of the building. In the corner panel 100 shown in FIG. 1, θ is 90°, but it is not limited thereto, and θ may be greater than 0 and less than 180°. For example, θ can be 30° or more and 150° or less, and preferably 45° or more and 135° or less.

[0017] In the corner panel 100 of the present embodiment, the tip F of the joint portion between the first panel 1 and the second panel 2 can be made less visible by the decorative member 3. Therefore, the boundary between the first inclined end face 11 and the second inclined end face 21 becomes less visible, and the appearance is less likely to be impaired.

[0018] (2) Details <Regarding the corner panel> The corner panel 100 of the present embodiment is a panel for an outer wall that constitutes a corner portion of a building. As shown in FIG. 1, the corner panel 100 includes a first panel 1, a second panel 2, and a decorative member 3. The corner panel 100 may also include a packing 8 and a reinforcing plate 7. The packing 8 contacts the adjacent normal panel during construction to improve waterproof performance. The reinforcing plate 7 is provided at a portion where the fixing member 6 used during construction is fixed.

[0019] The first panel 1 has a first main surface 10 and a first inclined end face 11. The first main surface 10 constitutes the outer surface of the first panel 1 (the surface facing the outdoor side when constructed). The first main surface 10 is parallel to the X direction and the Z direction, and is perpendicular to the Y direction. The first inclined end face 11 is continuously formed at one end of the first main surface 10 in the X direction. The first main surface 10 and the first inclined end face 11 are each composed of a flat surface. The angle θ1 between the first main surface 10 and the first inclined end face 11 is 45°.

[0020] The second panel 2 has a second main surface 20 and a second inclined end surface 21. The second main surface 20 constitutes the outer surface of the second panel 2 (the surface facing the outdoor side when constructed). The second main surface 20 is parallel to the Y direction and the Z direction, and is a surface perpendicular to the X direction. The second inclined end surface 21 is continuously formed at one end of the second main surface 20 in the Y direction. The second main surface 20 and the second inclined end surface 21 are each composed of a flat surface. The angle θ2 between the second main surface 20 and the second inclined end surface 21 is 45°.

[0021] The first panel 1 and the second panel 2 are each composed of a metal sandwich panel having core materials 51, 52 between two metal outer skins 41, 42. The first panel 1 includes a front outer skin 411 and a back outer skin 412 as two metal outer skins 41. The front outer skin 411 and the back outer skin 412 are arranged to face each other in the Y direction. The front outer skin 411 constitutes the first main surface 10. The second panel 2 includes a front outer skin 421 and a back outer skin 422 as two metal outer skins 42. The front outer skin 421 and the back outer skin 422 are arranged to face each other in the X direction. The front outer skin 421 constitutes the second main surface 20.

[0022] The first panel 1 and the second panel 2 are arranged in a state where the first inclined end surface 11 and the second inclined end surface 21 face each other. It is preferable that the first inclined end surface 11 and the second inclined end surface 21 are in contact over the entire surface. Thereby, the first panel 1 and the second panel 2 are formed symmetric with respect to a plane having the boundary between the first inclined end surface 11 and the second inclined end surface 21 as the plane of symmetry.

[0023] As shown in FIG. 2, the first panel 1 and the second panel 2 are connected by a back connecting member 43. The back connecting member 43 is a metal (such as a steel plate) member having an L-shaped cross section and arranged over the entire vertical length of the corner panel 100. The back connecting member 43 is arranged along the outer surfaces (the surfaces opposite to the surfaces on the core material 51, 52 side) of the back outer skin 412 and the back outer skin 422, and is fixed to the back outer skin 412 and the back outer skin 422 by a plurality of fixtures 431 such as screws.

[0024] The first panel 1 and the second panel 2 are connected by a waterproof member 44 (see Fig. 9A). The waterproof member 44 is a metal (such as a steel plate) member with an L-shaped cross-section and is arranged over the entire vertical length of the corner panel 100. The waterproof member 44 is arranged along the outer surfaces (the surfaces opposite to the surfaces of the core materials 51 and 52) of the surface outer skin 411 and the surface outer skin 421, and is fixed to the surface outer skin 411 and the surface outer skin 421 by a plurality of fixtures 441 such as screws and fixtures 442 such as double-sided tapes (butyl tapes). The waterproof member 44 is provided on the outer surfaces (the first main surface 10 and the second main surface 20) of the first panel 1 and the second panel 2 across the tip (corner) F of the joint portion of the first panel 1 and the second panel 2. Therefore, the gap between the first inclined end surface 11 and the second inclined end surface 21 can be blocked, and the waterproof property can be enhanced.

[0025] The packing 8 is formed of an elastic body such as EPDM or rubber, and is a hollow member with a semi-circular arc-shaped cross-section. The packing 8 is provided over the entire circumference of the corner panel 100. On the upper surface of the corner panel 100, the packing 8 is provided on the upper surface plates 413 and 423 extending from the surface outer skins 411 and 421. In a plan view (viewed from above), the packing 8 is arranged parallel to the X direction and the Y direction. On the side surface of the corner panel 100 (the surface opposite to the first inclined end surface 11 and the second inclined end surface 21), the packing 8 is provided on the side surface plates 414 and 424 extending from the surface outer skins 411 and 421. In a side view (viewed from the side), the packing 8 is arranged parallel to the Z direction. As shown in Fig. 2, on the lower surface of the corner panel 100, the packing 8 is provided on the lower surface plates 415 and 425 extending from the surface outer skins 411 and 421. In a bottom view (viewed from below), the packing 8 is arranged parallel to the X direction and the Y direction. In Fig. 2, the decorative member 3 of the corner panel 100 is not shown.

[0026] The reinforcing plate 7 is formed of a flat plate material such as a metal plate. A plurality of reinforcing plates 7 are provided on the upper surface and the lower surface of the corner panel 100, respectively. On the upper surface of the corner panel 100, the plurality of reinforcing plates 7 are provided on the upper face plates 413 and 423 behind (indoors side) the packing 8. In plan view, the plurality of reinforcing plates 7 are arranged parallel to the X direction and the Y direction, respectively. On the lower surface of the corner panel 100, the plurality of reinforcing plates 7 are provided on the lower face plates 415 and 425. In bottom view, the plurality of reinforcing plates 7 are arranged parallel to the X direction and the Y direction, respectively. As shown in FIG. 3, a plurality of fixing members 6 for constructing the corner panel 100 are fixed to the reinforcing plate 7. In FIG. 3, the decorative member 3 of the corner panel 100 is not shown.

[0027] The corner panel 100 is fixed to the base materials 61 and 62 by a plurality of first base plates 60. As shown in FIGS. 5 and 6, the first base plate 60 is fixed to the base materials 61 and 62 by a fixture 63 such as a bolt. The first base plate 60 is also fixed to the indoor side surface of the corner panel 100 by a fixture 64 such as a screw. Further, as shown in FIG. 4, the corner panel 100 is fixed to the base materials 61 and 62 by a plurality of Z-shaped fasteners 65. The fastener 65 is fixed to the indoor side surface of the corner panel 100 by a fixture such as a screw via the second base plate 66. The fastener 65 is hooked and fixed to the base materials 61 and 62.

[0028] As shown in FIG. 6, recesses 450 are provided on both side end faces of the corner panel 100. The recesses 450 are formed over the entire vertical length of the corner panel 100. The upper end of the recess 450 opens at the upper surfaces of the core materials 51 and 52, and the lower end of the recess 450 opens at the lower surfaces of the core materials 51 and 52. A joint material 453 is provided in the recess 450. The joint material 453 is formed in a long shape so as to extend in the vertical direction. Further, as the joint material 453, a fireproof material such as a fireproof felt or a gypsum board can be used. In this case, when a fire occurs, it becomes difficult for the flame to pass through the joint, and the fire resistance is improved.

[0029] FIG. 7 is formed with both widthwise dimensions longer compared to the corner panel 100 shown in FIGS. 1 and 6. That is, the dimension of the first panel 1 in the X direction in FIG. 7 is formed longer than the dimension of the first panel 1 in the X direction in FIGS. 1 and 6. Also, the dimension of the second panel 2 in the Y direction in FIG. 7 is formed longer than the dimension of the second panel 2 in the Y direction in FIGS. 1 and 6.

[0030] FIG. 8 is formed with one widthwise dimension longer compared to the corner panel 100 shown in FIG. 7. That is, the dimension of the first panel 1 in the X direction in FIG. 8 is formed the same as the dimension of the first panel 1 in the X direction in FIG. 7. Also, the dimension of the second panel 2 in the Y direction in FIG. 8 is formed shorter than the dimension of the second panel 2 in the Y direction in FIG. 8.

[0031] Thus, in the corner panel 100 of this embodiment, the dimension of the first panel 1 in the width direction (X direction) and the dimension of the second panel 2 in the width direction (Y direction) may be the same or different. Also, the dimension of the first panel 1 in the width direction (X direction) may be longer or shorter than the dimension of the second panel 2 in the width direction (Y direction). And in this embodiment, by adjusting the dimensions of the first panel 1 and the second panel 2 in the width directions (X direction and Y direction), the adjustment of the widthwise dimension can be easily performed.

[0032] FIG. 9A shows the corner portion (outer corner) of the corner panel 100. A decorative member 3 is provided at the corner portion of the corner panel 100. The decorative member 3 is provided on the outer surfaces (the first main surface 10 and the second main surface 20) of the first panel 1 and the second panel 2 straddling the tip portion (corner portion) F of the joint portion between the first panel 1 and the second panel 2.

[0033] The decorative member 3 is formed of a metal such as aluminum and includes a first decorative member 31 and a second decorative member 32. The first decorative member 31 and the second decorative member 32 are formed as separate members (split type). As shown in FIG. 9B, the first decorative member 31 includes a first base material 310 attached to the first main surface 10, and a first surface material 311 attached to the first base material 310. The first base material 310 has a flat fixing piece 315, a mounting piece 314 protruding forward (toward the first surface material 311 side) from one end in the width direction of the fixing piece 315, a covering piece 312 protruding forward from the other end in the width direction of the fixing piece 315, and a locking piece 313 protruding from the front surface of the covering piece 312. The first surface material 311 has a flat decorative piece 316, a mounting piece 317 protruding rearward (toward the first base material 310 side) from one end in the width direction of the decorative piece 316, a corner piece 318 protruding obliquely rearward from the other end in the width direction of the decorative piece 316, and a locking piece 319 protruding from the rear surface of the decorative piece 316. The first decorative member 31 and the second decorative member 32 are members formed symmetrically with respect to a plane. The second decorative member 32 includes a second base material 320 attached to the second main surface 20, and a second surface material 321 attached to the second base material 320. The second base material 320 is formed in the same manner as the first base material 310, and the second surface material 321 is formed in the same manner as the first surface material 311.

[0034] As shown in Fig. 9A, the first decorative member 31 is attached to the first panel 1. The second decorative member 32 is attached to the second panel 2. Note that the first decorative member 31 attached to the first panel 1 and the second decorative member 32 attached to the second panel 2 are attached in a plane-symmetric manner. The first base material 310 and the second base material 320 are each fixed to the first panel 1 or the second panel 2 with a fixture 33 such as a screw, with the fixing piece 315 arranged along the outer surfaces of the surface coverings 411 and 421. At this time, the covering piece 312 is located in front of the fixture 441 and covers the fixture 441. Also, the locking piece 319 of the first surface material 311 is hooked on the locking piece 313 of the first base material 310, and the attachment piece 314 of the first base material 310 and the attachment piece 317 of the first surface material 311 are fixed with a fixture 34 such as a screw. Further, the locking piece 319 of the second surface material 321 is hooked on the locking piece 313 of the second base material 320, and the attachment piece 314 of the second base material 320 and the attachment piece 317 of the second surface material 321 are fixed with a fixture 34 such as a screw. In this way, the first base material 310 and the second base material 320 can be attached to the outer surfaces of the first panel 1 and the second panel 2 respectively. The first base material 310 and the second base material 320 are arranged with the corner pieces 318 facing each other. The decorative member 3 including the first base material 310 and the second base material 320 is provided over substantially the entire vertical length of the corner panel 100.

[0035] Fig. 10 shows a corner panel 100 in which the angle θ between the second main surface 20 and the first main surface 10 is less than 90°. The angle θ of this corner panel 100 is about 60°. In the corner panel 100 of the present embodiment, as shown in Figs. 11A and 11B, by changing the angle θ1 between the first main surface 10 and the first inclined end surface 11 and the angle θ2 between the second main surface 20 and the second inclined end surface 21 respectively, a plurality of types of corner panels 100 with different angles θ between the second main surface 20 and the first main surface 10 can be formed.

[0036] In Fig. 11A, the angle θ1 between the first main surface 10 and the first inclined end surface 11 and the angle θ2 between the second main surface 20 and the second inclined end surface 21 are each smaller than 45°. Therefore, the angle θ between the second main surface 20 and the first main surface 10 is formed to be greater than 90°. In Fig. 11B, the angle θ1 between the first main surface 10 and the first inclined end surface 11 and the angle θ2 between the second main surface 20 and the second inclined end surface 21 are each greater than 45°. Therefore, the angle θ between the second main surface 20 and the first main surface 10 is formed to be smaller than 90°.

[0037] <Regarding the manufacturing method of the corner panel> The first panel 1 and the second panel 2 of the corner panel 100 of the present embodiment can be formed from a single base panel B1. As shown in Figs. 12A and 12B, the base panel B1 is formed in a flat plate shape. The base panel B1 is formed by providing a core material 5 between two metal outer skins 4.

[0038] The two metal outer skins 4 are each obtained by shaping a metal plate into a desired shape by rolling, pressing, or the like. The metal plate has a thickness of, for example, 0.23 to 6.0 mm. The metal plate may be, but is not limited to, a painted steel plate, a galvanized steel plate, an aluminum-zinc alloy galvanized steel plate, a Galvalume (registered trademark) steel plate, an SGL (registered trademark) steel plate, or the like. Of the two metal outer skins 4, one is formed as the front metal outer skin 45 and the other is formed as the back metal outer skin 46. An upper panel 451 located above the core material 5 is provided on the upper part of the front metal outer skin 45. A lower panel 452 located below the core material 5 is provided on the lower part of the front metal outer skin 45. The size of the base panel B1 is not particularly limited, but can be, for example, 0.5 to 6.0 m in length in the vertical direction, 0.2 to 1.5 m in length (width) in the horizontal direction, and 50 to 150 mm in length (thickness) in the front-rear direction.

[0039] The core material 5 is rectangular plate-shaped when viewed from the front (seen from the front in the thickness direction). The core material 5 may be formed not only by a single board but also by combining a plurality of block-shaped members into a plate shape. In the present embodiment, the core material 5 preferably has heat insulation properties and fire resistance. The core material 5 is formed by arranging a plurality of block bodies, which are formed by solidifying fibrous inorganic materials such as rock wool or glass wool into blocks with a binder or the like, in a single rectangular plate shape. Note that the core material 5 may be formed of a foamed organic material such as urethane foam or phenolic foam, or may be a styrene board, a urethane board, or the like.

[0040] The front surface skin 411 of the first panel 1 and the front surface skin 421 of the second panel 2 are formed from the front surface metal skin 45. The back surface skin 412 of the first panel 1 and the back surface skin 422 of the second panel 2 are formed from the back surface metal skin 46. The core material 51 of the first panel 1 and the core material 52 of the second panel 2 are formed from the core material 5. Further, the recesses 450 of the first panel 1 and the second panel 2 are formed from the groove portions 47 provided at the left end portion and the right end portion of the base panel B1.

[0041] When forming the first panel 1 and the second panel 2 from the base panel B1, first, as shown in Fig. 13A, place the base panel B1 on the workbench D1. At this time, set it so that the back surface metal skin 46 faces upward. Also, a protective film may be pasted on the surface of the back surface metal skin 46. Then, set the cutting position of the base panel B1 as the cutting line L1 by marking or the like. After that, cut about half of the thickness directions of the back surface metal skin 46 and the core material 5.

[0042] Next, as shown in Fig. 13B, turn the base panel B1 upside down and set it so that the front surface metal skin 45 faces upward. Next, cut the remaining half of the thickness directions of the front surface metal skin 45 and the core material 5 along the cutting line L1. Next, as shown in Fig. 13C, among the three-divided base panel B1, remove the middle part as the removal part B10, and of the remaining two parts, make one the first panel part B11 and the other the second panel part B12.

[0043] Next, as shown in FIG. 13D, the first panel portion B11 and the second panel portion B12 are inverted vertically. Next, the first panel portion B11 and the second panel portion B12 are cut along the cutting line L2. At this time, a part of the back metal outer skin 46 in the unnecessary portion B111 of the first panel portion B11 and a part of the back metal outer skin 46 in the unnecessary portion B121 of the second panel portion B12 are peeled off from the core material 5 and then cut. Then, as shown in FIG. 14A, the unnecessary portion B111 is removed from the first panel portion B11, and the unnecessary portion B121 is removed from the second panel portion B12, whereby, as shown in FIG. 14B, the first panel 1 and the second panel 2 having equal dimensions in the width direction can be produced. The cut surface when the unnecessary portion B111 is cut off from the first panel portion B11 is formed as the first inclined end face 11 of the first panel 1. Also, the cut surface when the unnecessary portion B121 is cut off from the second panel portion B12 is formed as the second inclined end face 21 of the second panel 2. The first inclined end face 11 and the second inclined end face 21 are each composed of the cut surface of the front metal outer skin 45, the cut surface of the back metal outer skin 46, and the cut surface of the core material 5.

[0044] After the step of producing the first panel 1 and the second panel 2 as described above, a step of arranging the first panel 1 and the second panel 2 with the first inclined end face 11 and the second inclined end face 21 facing each other is performed. As shown in FIG. 14C, the first panel 1 and the second panel 2 are arranged along the right-angled assembly jig M1, the first inclined end face 11 of the first panel 1 is brought into contact with the second inclined end face 21 of the second panel 2, and the first panel 1 is arranged above the second panel 2. At this time, as shown in FIG. 14D, the seal receiving material 9 is arranged across the first panel 1 and the second panel 2, and the joint portion between the upper surfaces of the first panel 1 and the second panel 2 is sealed.

[0045] Next, as shown in Fig. 15A, attach the back connecting member 43, and attach the fixture 442 and the waterproof member 44 across the first panel 1 and the second panel 2. At this time, first, attach a part of the fixture 442 and the waterproof member 44 as shown in Fig. 9A to the longitudinal ends of the first panel 1 and the second panel 2, and then, as shown in Fig. 15B, place the first panel 1 and the second panel 2 on the assembly table D2 so that the corners of the joint portion of the first panel 1 and the second panel 2 face upward, and attach a part of the fixture 442 and the waterproof member 44 to the substantially central portion in the longitudinal direction of the first panel 1 and the second panel 2.

[0046] After that, by attaching the packing 8 and the reinforcing plate 7 to the first panel 1 and the second panel 2, and further attaching the decorative member 3, the corner panel 100 as shown in Fig. 1 can be formed.

[0047] Figs. 16A - C and Figs. 17A - D show the process of manufacturing the first panel 1 and the second panel 2 having different dimensions in the width direction. When forming the first panel 1 and the second panel 2 from the base panel B1, first, as shown in Fig. 16A, place the base panel B1 on the workbench D1. At this time, set it so that the back metal outer skin 46 faces upward. Also, a protective film may be attached on the surface of the back metal outer skin 46. Then, set the cutting position of the base panel B1 as the cutting line L1 by marking or the like. After that, cut about half of the thickness direction of the back metal outer skin 46 and the core material 5. The cutting line L1 is provided at a position shifted from the central portion in the width direction.

[0048] Next, as shown in Fig. 16B, turn the base panel B1 upside down and set it so that the front metal outer skin 45 faces upward. Next, cut the remaining half of the thickness direction of the front metal outer skin 45 and the core material 5 along the cutting line L1. Next, as shown in Fig. 16C, of the two - divided base panel B1, one is taken as the first panel portion B11 and the other is taken as the second panel portion B12.

[0049] Next, as shown in FIG. 17A, the first panel portion B11 and the second panel portion B12 are inverted vertically. Next, the first panel portion B11 and the second panel portion B12 are cut along the cutting line L2. At this time, a part of the back metal outer skin 46 in the unnecessary portion B111 of the first panel portion B11 and a part of the back metal outer skin 46 in the unnecessary portion B121 of the second panel portion B12 are peeled off from the core material 5 and then cut. Then, as shown in FIG. 17B, by removing the unnecessary portion B111 from the first panel portion B11 and the unnecessary portion B121 from the second panel portion B12, the first panel 1 having a long dimension in the width direction and the second panel 2 having a short dimension in the width direction can be produced. The cut surface when the unnecessary portion B111 is cut off from the first panel portion B11 is formed as the first inclined end face 11 of the first panel 1. Also, the cut surface when the unnecessary portion B121 is cut off from the second panel portion B12 is formed as the second inclined end face 21 of the second panel 2. The first inclined end face 11 and the second inclined end face 21 are each composed of a cut surface of the front metal outer skin 45, a cut surface of the back metal outer skin 46, and a cut surface of the core material 5.

[0050] After the step of producing the first panel 1 and the second panel 2 as described above, a step of arranging the first panel 1 and the second panel 2 with the first inclined end face 11 and the second inclined end face 21 facing each other is performed. As shown in FIG. 17C, the first panel 1 and the second panel 2 are arranged along the right-angled assembly jig M1, the second inclined end face 21 of the second panel 2 is brought into contact with the first inclined end face 11 of the first panel 1, and the second panel 2 is arranged above the first panel 1. At this time, similar to the case of FIG. 14D, the seal receiving material 9 is arranged across the first panel 1 and the second panel 2, and the joint portion between the upper surfaces of the first panel 1 and the second panel 2 is sealed.

[0051] Next, in the same manner as in the case of FIG. 15A, the back connecting member 43 is attached, and the fixture 442 and the waterproof member 44 are attached across the first panel 1 and the second panel 2. At this time, first, a part of the fixture 442 and the waterproof member 44 is attached to the longitudinal ends of the first panel 1 and the second panel 2, and then, as shown in FIG. 17D, with the corner of the joint portion of the first panel 1 and the second panel 2 facing upward, a part of the fixture 442 and the waterproof member 44 is attached to the substantially central portion in the longitudinal direction of the first panel 1 and the second panel 2 while placed on the assembly table D2.

[0052] Thereafter, by attaching the packing 8 and the reinforcing plate 7 to the first panel 1 and the second panel 2, and further attaching the decorative member 3, the corner panel 100 as shown in FIG. 8 can be formed.

[0053] FIGS. 18A to C show the seal receiving member 9. The seal receiving member 9 is a member made of metal such as a steel plate, and has a receiving portion 90 with a substantially V-shaped cross section and insertion portions 91 protruding from both ends along the longitudinal direction of the receiving portion 90. One end in the longitudinal direction of the seal receiving member 9 is formed with a tapered portion 92 whose dimension in the short direction gradually decreases.

[0054] As shown in FIG. 19, the seal receiving member 9 is provided at the upper and lower ends of the corner panel 100. The seal receiving member 9 is arranged across the first panel 1 and the second panel 2. The seal receiving member 9 is arranged between the upper surfaces of the core materials 51 and 52 and the upper surface plates 413 and 423. The tapered portion 92 of the seal receiving member 9 is arranged toward the outdoor side (outer corner side) of the corner panel 100. The receiving portion 90 of the seal receiving member 9 is arranged below the upper surface plates 413 and 423. The space inside the receiving portion 90 is filled with a sealing material, which closes the gap between the upper surface plate 413 of the first panel 1 and the upper surface plate 423 of the second panel 2. Thereby, the waterproof property of the corner panel 100 is improved.

[0055] As shown in FIG. 20, first, half of the seal receiver 9 in the short side direction is attached to one of the first panel 1 or the second panel 2. At this time, half of the seal receiver 9 in the short side direction is inserted between the upper surfaces of the core materials 51 and 52 and the upper face plates 413 and 423. After that, the seal material is filled in the receiving portion 90 over the entire length in the longitudinal direction. After that, the other half of the seal receiver 9 in the short side direction is arranged on the other of the first panel 1 or the second panel 2. At this time, the other half of the seal receiver 9 in the short side direction is inserted between the upper surfaces of the core materials 51 and 52 and the upper face plates 413 and 423.

[0056] As shown in FIG. 21, in the corner panel 100 of the present embodiment, it can be constructed from the outdoor side of the building. Therefore, a scaffoldless construction method is possible, eliminating the need for an external working space of the building, shortening the construction period by reducing scaffold installation and demolition work, and reducing costs. After attaching the fixing member 6 and the joint material 453 inside the building rather than the base material 61, as shown by the arrow in FIG. 21, it is carried out to the outside of the base material 61 and transported through the outside of the base material 61 to the corner portion 69 on the outside of the column 68 of the building. Then, the corner panel 100 is fixed to the base material 61 by the fixing member 6. Also, a wall panel of a general part is arranged adjacent to the corner panel 100 to form an outer wall.

[0057] As shown in FIG. 22, even for a corner panel 100 in which the width dimensions of the first panel 1 and the second panel 2 are different, after attaching the fixing member 6 and the joint material 453 in the same manner as in the case of FIG. 21, as shown by the arrow, it is carried out to the outside of the base material 61 and transported through the outside of the base material 61 to the corner portion 69 on the outside of the column 68 of the building, and then fixed to the base material 61 by the fixing member 6.

[0058] (Second Embodiment) The corner panel 100 according to this embodiment is different from the corner panel 100 according to the first embodiment in the configuration of the decorative member 3. Hereinafter, for the configurations similar to those in the first embodiment, the same reference numerals will be given and the description will be omitted as appropriate. The configurations described in the second embodiment can be applied in appropriate combination with the configurations described in the first embodiment.

[0059] The corner panel 100 includes a first panel 1, a second panel 2, and a decorative member 3. The first panel 1 and the second panel 2 are formed in the same manner as in the first embodiment. That is, as shown in FIG. 24A, a cutting line L1 is set on the base panel B1. Next, as shown in FIG. 24B, the base panel B1 is cut in half at the central portion in the width direction to form a first panel portion B11 and a second panel portion B12. Next, as shown in FIG. 25A, along the cutting line L2, the first panel portion B11 and the second panel portion B12 are each cut, and a first inclined end face 11 and a second inclined end face 21 are formed at the cut surface of the cutting line L2. Thereby, the first panel 1 and the second panel 2 are produced. Next, as shown in FIG. 25B, the first panel 1 and the second panel 2 are arranged at a right angle by opposing and contacting the first inclined end face 11 and the second inclined end face 21.

[0060] At the joint portion between the first panel 1 and the second panel 2, a back connecting member 43 shown in FIG. 26A is provided on the inner corner side. Also, at the joint portion between the first panel 1 and the second panel 2, a decorative member 3 is provided on the outer corner side.

[0061] In the first embodiment, the decorative member 3 is of a split type, and the first decorative member 31 and the second decorative member 32 are formed as separate members. However, in the second embodiment, the decorative member 3 is of an integral type and is arranged across the first main surface 10 and the second main surface 20.

[0062] The cosmetic member 3 includes a substrate member 35 and a surface member 36 shown in Fig. 26B. The substrate member 35 is made of metal such as a steel plate or aluminum, and has a substrate body 350 with an L-shaped cross-section, and mounting portions 351 protruding forward from both ends of the substrate body 350 (outdoor direction when viewed from the substrate body 350, opposite to the direction toward the first main surface 10 and the direction opposite to the direction toward the second main surface 20). The substrate member 35 can also serve as a waterproof member 44. The surface member 36 is made of metal such as a steel plate or aluminum, and has a surface material body 360 with an L-shaped cross-section, and fixing portions 361 protruding rearward from both ends of the surface material body 360 (indoor direction when viewed from the substrate body 350, the direction toward the first main surface 10 and the direction toward the second main surface 20).

[0063] The substrate member 35 and the surface member 36 are preferably made of aluminum rather than a steel plate. When the substrate member 35 and the surface member 36 are made of aluminum, since the substrate member 35 and the surface member 36 are extrusion molded products, even if they are long (for example, 6 m in length), a right angle (pin angle) can be accurately formed, and the design property is enhanced. When the substrate member 35 and the surface member 36 are made of aluminum, compared with the case where they are made of a steel plate, there is no wrinkling buckling, less deformation, less strain on the metal surface, and good appearance. Also, when the substrate member 35 and the surface member 36 are made of aluminum, compared with the case of a steel plate, they are lightweight, so they have excellent workability and are easy to handle. Further, when the substrate member 35 and the surface member 36 are made of aluminum, compared with the case of a steel plate, the elongation due to heat at high temperatures is small. The substrate member 35 and the surface member 36 can be formed to have a plate thickness of 1.5 to 5 mm, one side in the width direction of 50 to 150 mm, and a length of 500 mm to 6 m, but are not limited thereto.

[0064] Then, the substrate member 35 is disposed across the tip portion F of the substrate body 350 over the first main surface 10 and the second main surface 20, and fixed with a fixture 37 such as a screw, whereby the substrate member 35 can be attached to the first panel 1 and the second panel 2. Further, by fixing the fixing portion 361 to the attachment portion 351 of the substrate member 35 with a fixture 38 such as a screw, the surface member 36 is disposed across the tip portion F over the first panel 1 and the second panel 2 in front of the substrate member 35. Thereby, as shown in FIG. 27A, the decorative member 3 can be attached over the entire vertical length of the corner panel 100. Then, as shown in FIG. 27B, the corner panel 100 can be formed by attaching the reinforcing plate 7 and the packing 8 to the first panel 1 and the second panel 2.

[0065] In the present embodiment, since the tip portion (corner portion) F of the joint portion between the first panel 1 and the second panel 2 is covered with the decorative member 3 which is an aluminum member, sharpness is ensured and the appearance is good. Further, in the present embodiment, since the substrate member 35 and the surface member 36 are attached over the first panel 1 and the second panel 2, fine adjustment of the position and the insertion and extraction dimensions of the decorative member 3 is easier than in the divided type of the first embodiment in which the first decorative member 31 and the second decorative member 32 are attached to the first panel 1 and the second panel 2, respectively. Further, the number of parts constituting the decorative member 3 is small, and attachment can be performed more easily than in the first embodiment.

[0066] (Summary) As described above, the corner panel (100) according to the first aspect includes a first panel (1), a second panel (2), and a decorative member (3). The first panel (1) and the second panel (2) are each composed of a metal sandwich panel having a core material (5) between two metal outer skins (4). The first panel (1) has a first main surface (10) and a first inclined end surface (11) continuous with the first main surface (10). The second panel (2) has a second main surface (20) and a second inclined end surface (21) continuous with the second main surface (20). The first panel (1) and the second panel (2) are arranged in a state where the first inclined end surface (11) and the second inclined end surface (21) face each other. The decorative member (3) is arranged on the first main surface (10) and the second main surface (20). The angle of the second main surface (20) with respect to the first main surface (10) is less than 180°.

[0067] According to this aspect, by adjusting the dimension in the width direction between the first panel (1) and the second panel (2), the dimension adjustment in the width direction can be easily performed. Further, the decorative member (3) can make the joint portion between the first panel (1) and the second panel (2) less visible, and the appearance is less likely to be damaged. Further, by adjusting the angle of the first inclined end surface (11) with respect to the first main surface (10) and the angle of the second inclined end surface (21) with respect to the second main surface (20), the angle of the second main surface (20) with respect to the first main surface (10) can be adjusted, and it is possible to cope with the external corners of various angles of the building.

[0068] The second aspect is the corner panel (100) according to the first aspect, wherein the decorative member (3) includes a first decorative member (31) provided on the first panel (1) and a second decorative member (32) provided on the second panel (2). The first decorative member (31) includes a first base material (310) attached to the first main surface (10) and a first surface material (311) attached to the first base material (310). The second decorative member (32) includes a second base material (320) attached to the second main surface (20) and a second surface material (321) attached to the second base material (320).

[0069] According to this aspect, the decorative member (3) includes a separate first decorative member (31) and a second decorative member (32). By providing the first decorative member (31) on the first panel (1) and the second decorative member (32) on the second panel (2), when adjusting the angle of the first inclined end face (11) with respect to the first main surface (10) and the angle of the second inclined end face (21) with respect to the second main surface (20), the decorative member (3) is less likely to be an obstacle, and the angle adjustment can be easily performed.

[0070] The third aspect is the corner panel (100) according to the first aspect, wherein the decorative member (3) includes a substrate member (35) and a surface member (36). The substrate member (35) includes a substrate body (350) disposed across the first main surface (10) and the second main surface (20), and a mounting portion (351) protruding forward from the substrate body (350). The surface member (36) includes a surface material body (360) disposed across the first main surface (10) and the second main surface (20) in front of the substrate body (350), and a fixing portion (361) protruding rearward from the surface material body (360). The surface member (36) is attached to the substrate member (35) by fixing the mounting portion (351) and the fixing portion (361).

[0071] According to this aspect, the surface member (36) can cover the joint portion between the first panel (1) and the second panel (2) to make it less visible, and the appearance is less likely to be damaged.

[0072] The fourth aspect is the corner panel (100) according to the first aspect, further including a waterproof member (44) disposed across the first main surface (10) and the second main surface (20) so as to cover the gap between the first inclined end face (11) and the second inclined end face (21).

[0073] According to this aspect, the waterproof member (44) can reduce the intrusion of water such as rainwater from the gap between the first inclined end face (11) and the second inclined end face (21), and width adjustment and angle adjustment can be performed without impairing the waterproof property.

[0074] The manufacturing method of the corner panel (100) according to the fifth aspect is a method for manufacturing the corner panel (100) of any one of the first to fourth aspects. This method includes a step of producing a first panel (1) having a first inclined end face (11) by cutting a part of a flat base panel (B1), a step of producing a second panel (2) having a second inclined end face (21) by cutting a part of the flat base panel (B1), a step of arranging the first panel (1) and the second panel (2) with the first inclined end face (11) and the second inclined end face (21) facing each other, and a step of arranging a decorative member (3) on the first main face (10) and the second main face (20). The flat base panel (B1) is composed of a metal sandwich panel having a core material (5) between two metal outer skins (4).

[0075] According to this aspect, by adjusting the dimensions in the width direction of the first panel (1) and the second panel (2), it is easy to manufacture a corner panel (100) capable of adjusting the dimensions in the width direction. Also, the decorative member (3) can make the joint portion between the first panel (1) and the second panel (2) less visible, and it is easy to manufacture a corner panel (100) whose appearance is less damaged. Further, by adjusting the angle of the first inclined end face (11) with respect to the first main face (10) and the angle of the second inclined end face (21) with respect to the second main face (20), the angle of the second main face (20) with respect to the first main face (10) can be adjusted, and it is easy to manufacture a corner panel (100) that can correspond to the outer corners of various angles of a building.

Explanation of Signs

[0076] 100 Corner panel 1 First panel 2 Second panel 3 Decorative member 4 Metal outer skin 5 Core material 10 First main face 11 First inclined end face 20 Second main face 21 Second inclined end face 31 First decorative member 32 Second decorative member 310 First underlying material 311 First surface material 320 Second underlying material 321 Second surface material 41, 42 Metal outer skin 44 Waterproof member 51, 52 Core material B1 Base panel

Claims

1. a first panel having a first main surface and a first inclined end surface continuous with the first main surface; a second panel having a second main surface and a second inclined end surface continuous with the second main surface; A decorative member, The first panel and the second panel are each composed of a metal sandwich panel having a core material between two metal skins, The first panel and the second panel are arranged with the first inclined end surface and the second inclined end surface facing each other, The decorative member is disposed on the first main surface and the second main surface, The angle of the second main surface relative to the first main surface is less than 180°; Corner panel.

2. The decorative member includes a first decorative member provided on the first panel and a second decorative member provided on the second panel, The first decorative member includes a first base material attached to the first main surface, and a first surface material attached to the first base material, The second decorative member includes a second base material attached to the second main surface, and a second surface material attached to the second base material. The corner panel according to claim 1 .

3. The decorative member includes a substrate member and a surface member, The substrate member is A substrate body disposed across the first main surface and the second main surface; A mounting portion protruding forward from the substrate body, The surface member is A surface material body disposed in front of the substrate body across the first main surface and the second main surface; A fixing portion protruding rearward from the surface material body, The surface member is attached to the base member by fixing the mounting portion and the fixing portion. The corner panel according to claim 1 .

4. The insulating member further includes a waterproof member disposed across the first main surface and the second main surface so as to cover a gap between the first inclined end surface and the second inclined end surface. The corner panel according to claim 1 .

5. A method for manufacturing the corner panel according to any one of claims 1 to 4, comprising the steps of: A step of producing the first panel having the first inclined end surface by removing a portion of a flat base panel; a step of producing the second panel having the second inclined end surface by removing a portion of a flat base panel; placing the first panel and the second panel with the first inclined end surface and the second inclined end surface facing each other; placing the decorative member on the first main surface and the second main surface; Equipped with The flat base panel is composed of a metal sandwich panel having a core material between two metal skins. A method for manufacturing corner panels.

Images