Metal sandwich panel and method for producing the same

Abstract

To provide a metal sandwich panel that suppresses bulging of the metal skin to reduce the likelihood of appearance degradation.SOLUTION: A metal sandwich panel 10 includes a resin foam 4 interposed between two metal skins 1 and 2. The resin foam 4 is provided with a gas flow path 5 that allows circulation of gas generated within the resin foam 4. The gas flow path 5 is constituted by voids opening at the end face of the resin foam 4. It is preferred that the gas flow path 5 extends along the full length in the longitudinal direction of the metal sandwich panel 10 and that it opens at both end faces of the resin foam 4.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates to a metal sandwich panel and a method for manufacturing the same, and more particularly, to a metal sandwich panel having a metal skin and a core and a method for manufacturing the same. [Background technology]

[0002] Patent Document 1 describes an external insulation device that prevents internal condensation. This device is constructed by installing exterior materials on the outside of a building's fire-resistant wall with a gap between the building and the exterior materials, and filling the space between the fire-resistant wall and the exterior materials with flame-retardant urethane foam, which is made by mixing a flame-retardant material that is compatible with urethane. The exterior materials used are metal sandwich panels, which have a core of urethane foam or isocyanurate foam 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 metal sandwich panel described above, the core material and the metal plate are bonded together by the adhesive force (self-adhesion) that occurs when the core material hardens from a liquid state to a foam. However, as the core material and the metal plate change over time, the core material and the metal plate can partially separate, causing the metal plate to bulge toward the surface of the metal sandwich panel at the separated portion, which can degrade 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 outer skin, and a method for manufacturing the same. [Means for solving the problem]

[0006] A metal sandwich panel according to one aspect of the present disclosure is a metal sandwich panel having a resin foam between two metal skins. The resin foam has gas flow paths through which gas generated in the resin foam flows. The gas flow paths are formed by voids that open at the end faces of the resin foam.

[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 mixed raw material for generating the resin foam is prepared by blending a first raw material and a second raw material in a predetermined ratio. An inhibitor is prepared to inhibit the generation of the resin foam due to a reaction between the first raw material and the second raw material in the mixed raw material. The inhibitor is then supplied onto the surface of at least one of the two metal skins, and the mixed raw material is then supplied onto the surface to which the inhibitor has been supplied, thereby forming a contact area on the surface where the mixed raw material and the inhibitor come into contact. The resin foam is formed by the mixed raw material supplied onto the surface other than the contact area, and the inhibitor inhibits the generation of the resin foam at the contact area, forming voids in the resin foam. [Effects of the Invention]

[0008] According to the present disclosure, gas generated within the resin foam flows through the gas flow path and is released to the outside of the resin foam from the opening of the gas flow path at the end face of the resin foam, making it less likely for gas to accumulate within the resin foam, less likely for peeling to occur between the metal outer skin and the resin foam, and less likely for the metal outer skin to swell, resulting in less deterioration of appearance. [Brief explanation of the drawings]

[0009] [Figure 1] FIG. 1 is a partial cross-sectional view showing a metal sandwich panel according to this embodiment. [Figure 2] FIG. 2 is a perspective view showing the metal sandwich panel according to this embodiment. [Figure 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. [Figure 5] FIG. 5 is a schematic diagram showing a method for manufacturing a metal sandwich panel according to this embodiment. [Figure 6] FIG. 6 is a schematic diagram showing part of the manufacturing process of the metal sandwich panel according to this embodiment. [Figure 7] FIG. 7 is a schematic diagram showing part of the manufacturing process of the metal sandwich panel according to this embodiment. [Figure 8] FIG. 8 is a schematic diagram showing part of the manufacturing process of the metal sandwich panel according to this embodiment. [Figure 9] FIG. 9 is a schematic diagram showing part of the manufacturing process of the metal sandwich panel according to this embodiment. [Figure 10] FIG. 10 is a cross-sectional view showing the problems of the conventional technology. DETAILED DESCRIPTION OF THE INVENTION

[0010] The present disclosure will be described below based on the embodiments shown in the accompanying drawings, but 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. 10 shows a metal sandwich panel 10x having an external shape similar to that of this embodiment. This metal sandwich panel 10x includes a resin foam 4 between two metal skins 1 and 2. The metal skins 1 and 2 are arranged facing each other, and the resin foam 4 is provided between the metal skins 1 and 2 as a core material. The resin foam 4 is a resin foam such as polyurethane foam or polyphenol foam, and has insulating and fire-resistant properties. The resin foam 4 is formed by foaming a resin liquid supplied to one side of one metal skin 1. While the resin liquid is foaming, the other metal skin 2 is placed opposite the metal skin 1, and the resin liquid is further foamed between the metal skin 1 and the metal skin 2. When the resin liquid is completely foamed, the resin foam 4 is formed. The resin foam 4 adheres to the metal skins 1 and 2 by its self-adhesive strength.

[0012] The metal skins 1 and 2 are arranged so as not to come into direct contact with each other in order to prevent heat bridges. For example, in FIG. 10, at the bottom of a metal sandwich panel 10x, a lower portion 1x of the metal skin 1 and a lower portion 2x of the metal skin 2 are arranged facing each other with a predetermined gap between them. A resin foam 4 is filled between the lower portions 1x and 2x, so that the lower portions 1x and 2x do not come into direct contact with each other. Here, the gap between the lower portions 1x and 2x is formed before the resin liquid is completely foamed, so a sealing material 6 is provided to close the gap between the lower portions 1x and 2x to prevent the resin liquid from leaking out between the lower portions 1x and 2x during foaming.

[0013] Usually, gases (such as carbon dioxide) generated during manufacturing are vaporized when the resin liquid foams, and most of them are discharged to the outside of the metal sandwich panel 10x through small gaps.

[0014] However, the gas may not be sufficiently released and may remain in the resin foam 4. Furthermore, if unreacted components remain in the resin foam 4, the unreacted components may react after the metal sandwich panel 10x is completed, generating new gases (such as carbon dioxide). For example, deterioration of the resin foam 4 over time (including deformation due to external forces) may cause localized poor adhesion between the resin foam 4 and the metal skins 1 and 2 on the same surface, or gas may be generated and condensed in the cracks due to a reaction between some of the raw materials of the resin foam 4 and moisture.

[0015] If the gas in the resin foam 4 is not released to the outside from the metal sandwich panel 10x, the gas accumulates between the resin foam 4 and the metal skin 1, and the pressure of this gas can cause the resin foam 4 and the metal skin 1 to separate, resulting in a bulge 100x in part of the metal skin 1, as shown in Figure 10. The area surrounded by imaginary line X in the figure is particularly prone to bulge 100x. Therefore, the present inventors have developed a metal sandwich panel 10 in which bulge 100x is less likely to occur.

[0016] As shown in Figures 1, 2, 3, and 4, a metal sandwich panel 10 according to this embodiment includes a resin foam 4 between two metal skins 1 and 2. The resin foam 4 has gas flow paths 5 through which gas generated in the resin foam 4 flows. The gas flow paths 5 are formed by voids that open at the end faces of the resin foam 4.

[0017] In the metal sandwich panel 10 of this embodiment, gas generated in the resin foam 4 flows through the gas flow path 5 and is released to the outside of the resin foam 4 from the openings of the gas flow path 5 at the end faces of the resin foam 4. Therefore, gas is less likely to accumulate in the resin foam 4, peeling between the metal skins 1 and 2 and the resin foam 4 is less likely to occur, and the metal skins 1 and 2 are less likely to swell, which makes it less likely that the appearance will deteriorate.

[0018] (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, and warehouses. As shown in Fig. 2, the metal sandwich panel 10 includes a face plate 11 made of a first metal skin 1, a back plate 21 arranged opposite the face plate 11 and made of a second metal skin 2, and a resin foam 4 disposed between the face plate 11 and the back plate 21. The resin foam 4 is formed as a core material of the metal sandwich panel 10.

[0019] 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. A plurality of 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 with the fitting protrusion 8. In the following description, for convenience, 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.

[0020] The lengthwise dimension of the metal sandwich panel 10 is greater than the widthwise and thicknesswise dimensions. The widthwise dimension of the metal sandwich panel 10 is greater than the thicknesswise dimension. The metal sandwich panel 10 is typically constructed with the width direction as the up-down direction and the lengthwise 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 outer skin 1 and the second metal outer skin 2 face each other in the thickness direction of the metal sandwich panel 10. Note that the metal sandwich panel 10 may also be constructed with the width direction as the left-right direction and the lengthwise direction as the up-down direction. In this case, the fitting recess 9 is provided at one left-right end of the metal sandwich panel 10, and the fitting protrusion 8 is provided at the other left-right end of the metal sandwich panel 10.

[0021] The first and second metal skins 1, 2 are formed into a predetermined shape by processing a flat metal plate such as by roll forming. Metal plates are those conventionally used in forming building materials, such as SGL (registered trademark) steel plate, Galvalume (registered trademark) steel plate, galvanized steel plate, and painted steel plate. The thickness of the metal plate is not particularly limited, and can be, for example, 0.25 to 2.3 mm.

[0022] 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 rearward (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 groove piece 115. The lower groove piece 115 protrudes rearward (toward the resin foam 4) from the upper end of the first vertical piece 114. The first metal skin 1 has a groove piece 116. The groove piece 116 protrudes upward from the upper end of the lower groove piece 115. The first metal skin 1 has an upper groove piece 117. The upper groove piece 117 protrudes forward (the opposite side to the resin foam 4) from the upper end of the 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 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 insert piece 121. The first upper insert 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 the upper end surface 42 thereof.

[0023] 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 to protrude downward from the lower end of the first panel main body 112. The front covering portion 30 and the first panel main body 112 are formed flat with no steps. The rear covering portion 31 is located behind the front covering portion 30. The rear covering portion 31 is formed to fold 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 in the thickness direction (front-to-back direction) with a predetermined gap between them.

[0024] The covering portion 3 formed as described above has a substantially U-shaped cross section. The covering portion 3 also has a gap 32 therein. That is, the gap between the front covering portion 30 and the rear covering portion 31 is formed as the gap 32. The gap 32 is provided over the entire length of the metal sandwich panel 10 in the left-right direction. The gap 32 has an opening 320 at its upper end. The gap 32 communicates with the internal space of the metal sandwich panel 10 (the space between the first panel main body 112 and the second panel main body 212 of the second metal skin 2) via the opening 320. The upper ends of the gap 32, the upper ends of the front covering portion 30, and the upper ends of the rear covering portion 31 are at substantially the same height (they are at the same vertical position).

[0025] An auxiliary member 33 is provided in the gap 32. The auxiliary member 33 is provided over the entire length of the gap 32 in the left-right direction. The auxiliary member 33 is also provided so as to close the opening 320 of the gap 32. Therefore, communication between the gap 32 and the internal space of the metal sandwich panel 10 through the opening 320 is blocked by the auxiliary member 33. The auxiliary member 33 is provided to fill the entire gap 32. The auxiliary member 33 does not have to fill the entire gap. For example, the tip of the auxiliary member 33 may be a gap (the auxiliary member 33 may be sparsely filled). The auxiliary member 33 may also protrude upward from the opening 320.

[0026] The auxiliary member 33 is a cured resin. The auxiliary member 33 may or may not be a resin foam. The auxiliary member 33 may be formed of the same resin as the resin foam 4, or may be formed of a different resin. For example, the auxiliary member 33 can be formed of unfoamed polyurethane (urethane resin). The auxiliary member 33 can also be formed of polyurethane foam (urethane foam). The auxiliary member 33 can also be formed of unfoamed polyisocyanurate (isocyanurate resin) or polyisocyanurate foam (isocyanurate foam).

[0027] The auxiliary member 33 reinforces the covering portion 3 to prevent deformation of the covering portion 3. The auxiliary member 33 is also provided to improve the heat insulating properties of the covering portion 3. If the gap portion 32 is filled with the same resin as the resin foam 4, the resin foam 4 may not be sufficiently filled to the tip of the gap portion 32, which may result in voids. In this embodiment, since the resin foam 4 may enter the narrow gap portion 32 unevenly and sparsely, causing swelling, the entire gap portion 32 is filled almost uniformly with the auxiliary liquid that forms the auxiliary member 33.

[0028] 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, folding back. The first lower insertion piece 124 is inserted into the resin foam 4 from its lower end surface 40. The first lower insertion piece 124 and the first convex piece 123 face each other across a predetermined gap 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.

[0029] 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 the upper end surface 42 thereof.

[0030] The second metal skin 2 has a lower piece 222. The lower piece 222 protrudes forward from the lower end of the second panel main 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 between them. 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 between them. 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 outer skin 2. The first opposing portion 111 and the second opposing portion 211 face each other across a predetermined distance in the thickness direction (front-rear direction). In this way, the first metal outer skin 1 and the second metal outer skin 2 are arranged so as not to come into direct contact with each other in order to prevent heat bridging.

[0031] 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 formed by 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.

[0032] As shown in FIG. 1 , a sealing material 6 is provided on the lower end surface of the metal sandwich panel 10. The sealing material 6 is provided to prevent the resin foam 4 from leaking out from between the first facing portion 111 and the second facing portion 211 during manufacturing of the metal sandwich panel 10. The sealing material 6 is provided over the entire length. The end surface 80 of the fitting protrusion 8, which is the lower end surface of the metal sandwich panel 10, is formed by the outer surface of the sealing material 6 (the surface opposite to the resin foam 4). The sealing material 6 is provided to bridge between the first protrusion piece 123 of the first facing portion 111 and the second protrusion piece 223 of the second facing portion 211. Therefore, the end surface 40 of the resin foam 4 between the first facing portion 111 and the second facing portion 211 is covered by the sealing material 6. The sealing material 6 is bonded to the outer surfaces of the first protrusion piece 123 and the second protrusion piece 223.

[0033] 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 paper is a two-layer structure of kraft paper and an adhesive laminate material. The sealing material 6 is formed into a strip extending in the length direction, and can be formed into a sheet, film, plate, or the like. The thickness (vertical dimension) of the sealing material 6 can be 0.01 mm or more and 0.5 mm or less, but is not limited to this.

[0034] The resin foam 4 is a part that constitutes the main body of the metal sandwich panel 10 and is made of a resin foam. The resin foam 4 in this embodiment can be formed from polyisocyanurate foam. The resin foam 4 may be at least one type selected from the group consisting of polyurethane foam, polystyrene foam, and polyphenol foam. The resin foam 4 may be formed from a combination of these types, or may be formed from only one of them. Furthermore, multiple types of materials may be laminated in the thickness direction. The resin foam 4 preferably has heat insulating properties and fire resistance.

[0035] In the metal sandwich panel 10 of this embodiment, the resin foam 4 has a gas flow path 5. The gas flow path 5 is a portion through which gas generated in the resin foam 4 flows. The gas flow path 5 is formed by a void (space). The end of the gas flow path 5 opens at the end face of the resin foam 4. The gas flow path 5 is formed in a substantially straight line along the longitudinal direction (left-right direction) of the metal sandwich panel 10. The right end of the gas flow path 5 opens at the right end face of the resin foam 4, and the left end of the gas flow path 5 opens at the left end face of the resin foam 4. The gas flow path 5 is formed continuously from one end to the other, with a substantially constant cross-sectional shape (opening shape).

[0036] The cross-sectional shape of the gas flow path 5 is not fixed, but can be formed, for example, as a circle, ellipse, semicircle, square, rectangle, rhombus, trapezoid, or polygon having pentagons or more. The dimensions of the gas flow path 5 are not particularly limited, but for example, the dimension of the gas flow path 5 in the front-to-rear direction is preferably smaller than the distance between the front covering part 30 and the rear covering part 31 and larger than one-third of the distance between the front covering part 30 and the rear covering part 31. The dimension of the gas flow path 5 in the up-down direction can be formed to be approximately the same as the dimension of the gas flow path 5 in the front-to-rear direction.

[0037] The gas flow channel 5 can be provided across the resin foam 4 and the auxiliary member 33. The resin foam 4 and the auxiliary member 33 are in contact with each other at and near the opening 320. The gas flow channel 5 can be formed to straddle the boundary between adjacent resin foams 4 and auxiliary members 33. In this case, the right end of the gas flow channel 5 opens at the right end surfaces of the resin foam 4 and the auxiliary member 33, and the left end of the gas flow channel 5 opens at the left end surfaces of the resin foam 4 and the auxiliary member 33. When the gas flow channel 5 is formed across the resin foam 4 and the auxiliary member 33, gas generated in the resin foam 4 as well as the auxiliary member 33 flows through the gas flow channel 5 and is released to the outside of the resin foam 4. This makes it difficult for gas to accumulate in the resin foam 4, and thus reduces the likelihood of peeling between the metal outer skin 1 and the resin foam 4. The gas flow channel 5 may be formed only in the resin foam 4, without being formed in the auxiliary member 33.

[0038] A portion of the gas flow path 5 is formed facing the surface of the metal outer skin 1 (the surface in contact with the resin foam 4, the rear surface facing the front surface of the metal outer skin 2). That is, the inner surface of the gas flow path 5 is formed by the resin foam 4, the auxiliary member 33, and the surface of the metal outer skin 1. This makes it easier to form the gas flow path 5 than when the gas flow path 5 is formed surrounded only by the resin foam 4. The inner surface of the gas flow path 5 may be formed by the resin foam 4 and the surface of the metal outer skin 1, or the inner surface of the gas flow path 5 may be formed only by the resin foam 4.

[0039] FIG. 4 shows the connection structure of two vertically adjacent metal sandwich panels 10. The two metal sandwich panels 10 are connected by fitting the mating protrusion 8 of the upper metal sandwich panel 10 into the mating recess 9 of the lower metal sandwich panel 10. Here, the end face 80 of the mating protrusion 8 is in close contact with the upper surface of the gasket 90. The cover portion 3 is located in front of the mating protrusion 8, and its lower end is located lower than the lower end of the mating protrusion 8. Therefore, the fastener 50, such as a screw, that secures the lower metal sandwich panel 10 is located behind the cover portion 3 of the upper metal sandwich panel 10, and the cover portion 3 can cover the fastener 50 so that it is not visible from the front. The fastener 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 substrate, 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 way, the metal sandwich panel 10 is fixed to the wall substrate and installed.

[0040] The metal sandwich panel 10 of this embodiment is produced as follows: Here, a case where the resin foam 4 is formed from polyisocyanurate foam will be described.

[0041] First, prepare a mixed raw material 45 for producing the resin foam 4. The mixed raw material 45 is liquid, and can be prepared by blending the first raw material and the second raw material in a predetermined ratio.

[0042] The first raw material includes a polyol. A polyol is a compound having two or more hydroxyl groups in one molecule. An example of the polyol is a polyhydric alcohol. Examples of the polyhydric alcohol include polyether-based and polyester-based (terephthalic acid-based) polyols.

[0043] The second raw material includes a polyisocyanate, such as an MDI (methylene diisocyanate)-based polyisocyanate or a TDI (tolylene diisocyanate)-based polyisocyanate.

[0044] By blending the first raw material and the second raw material in a predetermined ratio, a resin foam 4 having practically acceptable performance (such as rigidity and heat insulation) can be formed. Here, the predetermined ratio can be defined as the ratio between the number of moles of hydroxyl groups of the polyol in the first raw material and the number of moles of isocyanate groups of the polyisocyanate in the second raw material. If the number of moles of hydroxyl groups of the polyol is OH and the number of moles of isocyanate groups of the polyisocyanate is NCO, the NCO / OH ratio is preferably 0.5 / 1 or more and 3 / 1 or less, more preferably 0.8 / 1 or more and 1.2 / 1 or less, and even more preferably 0.9 / 1 or more and 1.1 / 1 or less.

[0045] In addition to the first and second raw materials, the mixed raw material 45 also contains a trimerization catalyst and a blowing agent. The trimerization catalyst is a catalyst for trimerizing the polyisocyanate in the second raw material. Examples of trimerization catalysts include potassium salts such as potassium 2-ethylhexanoate and potassium acetate, and ammonium salts such as tetramethylammonium and tetraethylammonium. The trimerization catalyst produces isocyanurate from the polyisocyanate. The blowing agent is used to form numerous bubbles (cells) in the polyisocyanurate foam. Examples of blowing agents that can be used include water and hydrocarbon compounds such as pentane. Examples of pentane include n-pentane, cyclopentane, and 2-methylpentane.

[0046] In addition to the above, the mixed raw material 45 may contain solvents, foam stabilizers, flame retardants, etc.

[0047] Furthermore, an auxiliary raw material 46 for forming the auxiliary member 33 is prepared. The auxiliary member 33 can be formed from polyurethane foam. In this case, the auxiliary raw material 46 is liquid and can contain a polyol and a polyisocyanate. As the polyol, one of the examples of the first raw material of the mixed raw material 45 can be used. As the polyisocyanate, one of the examples of the second raw material of the mixed raw material 45 can be used. The polyol of the auxiliary raw material 46 and the polyol of the mixed raw material 45 can be the same or different. The polyisocyanate of the auxiliary raw material 46 and the isocyanate of the mixed raw material 45 can be the same or different.

[0048] Furthermore, the ratio between the number of moles of hydroxyl groups of the polyol in auxiliary raw material 46 and the number of moles of isocyanate groups of the polyisocyanate in auxiliary raw material 46 can be set to a predetermined ratio similar to that of mixed raw material 45. That is, if the number of moles of hydroxyl groups of the polyol in auxiliary raw material 46 is OH and the number of moles of isocyanate groups of the polyisocyanate is NCO, then NCO / OH is preferably 0.5 / 1 or more and 3 / 1 or less, more preferably 0.8 / 1 or more and 1.2 / 1 or less, and even more preferably 0.9 / 1 or more and 1.1 / 1 or less.

[0049] Furthermore, in this embodiment, an inhibitor 43 is prepared. The inhibitor 43 inhibits the generation of resin foam 4. That is, resin foam 4 is generated by the reaction between the first and second raw materials in the mixed raw material 45, but the inhibitor 43 inhibits the generation of this resin foam 4. The inhibitor 43 is liquid and changes the predetermined ratio of the first and second raw materials in the mixed raw material 45. That is, the first and second raw materials are contained in a predetermined ratio (NCO / OH) in the mixed raw material 45, but the inhibitor 43 changes this predetermined ratio. For example, if the NCO / OH ratio between the first and second raw materials in the mixed raw material 45 is 0.5 / 1 or more and 2 / 1 or less, mixing the mixed raw material 45 with the inhibitor 43 will cause the NCO / OH ratio between the first and second raw materials to fall outside the range of 0.5 / 1 or more and 2 / 1 or less. When the NCO / OH ratio between the first and second raw materials in mixed raw material 45 is 0.8 / 1 or more and 1.2 / 1 or less, the NCO / OH ratio between the first and second raw materials falls outside the range of 0.8 / 1 or more and 1.2 / 1 or less when mixed raw material 45 is mixed with inhibitor 43. Furthermore, when the NCO / OH ratio between the first and second raw materials in mixed raw material 45 is 0.9 / 1 or more and 1.1 / 1 or less when mixed raw material 45 is mixed with inhibitor 43, the NCO / OH ratio between the first and second raw materials falls outside the range of 0.9 / 1 or more and 1.1 / 1 or less.

[0050] In this way, in the portion where the mixed raw material 45 comes into contact with the inhibitor 43 and mixes, the mixing ratio of the first raw material to the second raw material deviates from the specified ratio, and the generation of polyisocyanurate foam in that portion is suppressed, and voids are generated in the resin foam 4.

[0051] Inhibitor 43 also inhibits the production of auxiliary component 33. That is, auxiliary component 33 is produced by the reaction of polyol and polyisocyanate in auxiliary raw material 46, but inhibitor 43 inhibits the production of this auxiliary component 33. Inhibitor 43 changes the predetermined ratio of polyol and polyisocyanate in auxiliary raw material 46. That is, auxiliary raw material 46 contains polyol and polyisocyanate at a predetermined ratio (NCO / OH), but inhibitor 43 changes this predetermined ratio. For example, if the NCO / OH ratio between polyol and polyisocyanate in auxiliary raw material 46 is 0.5 / 1 or more and 2 / 1 or less, mixing auxiliary raw material 46 with inhibitor 43 will cause the NCO / OH ratio between polyol and polyisocyanate to fall outside the range of 0.5 / 1 or more and 2 / 1 or less. When the NCO / OH ratio between the polyol and polyisocyanate in auxiliary raw material 46 is 0.8 / 1 or more and 1.2 / 1 or less, mixing auxiliary raw material 46 with inhibitor 43 causes the NCO / OH ratio between the polyol and polyisocyanate to fall outside the range of 0.8 / 1 or more and 1.2 / 1 or less. Furthermore, when the NCO / OH ratio between the polyol and polyisocyanate in auxiliary raw material 46 is 0.9 / 1 or more and 1.1 / 1 or less, mixing auxiliary raw material 46 with inhibitor 43 causes the NCO / OH ratio between the polyol and polyisocyanate to fall outside the range of 0.9 / 1 or more and 1.1 / 1 or less.

[0052] In this way, in the area where the auxiliary raw material 46 comes into contact with and mixes with the inhibitor 43, the mixing ratio of the polyol and polyisocyanate deviates from the specified ratio, and the production of polyurethane in that area is suppressed, resulting in the formation of voids in the auxiliary member 33.

[0053] The inhibitor 43 can be used without any particular limitation as long as it can change the predetermined ratio of the first raw material to the second raw material in the mixed raw material 45 and the predetermined ratio of the polyol to the polyisocyanate in the auxiliary raw material 46. For example, the inhibitor 43 can contain the same polyol as the first raw material. The inhibitor 43 can also contain the same polyisocyanate as the second raw material. The inhibitor 43 can also contain both the same polyol as the first raw material and the same polyisocyanate as the second raw material. When the inhibitor 43 contains a polyol, it is preferably the same polyol as the first raw material. When the inhibitor 43 contains a polyisocyanate, it is preferably the same polyisocyanate as the second raw material. The inhibitor 43 preferably contains the same polyol as the first raw material because this facilitates the formation of voids that become gas flow paths 5.

[0054] Next, as shown in FIG. 5 , first and second metal skins 1 and 2 are formed from metal sheets 1A and 2A. The rolled metal sheet 1A is unwound by a unwinding device 55A and continuously supplied to a roll forming machine 56A. The roll forming machine 56A then forms each portion, such as the cover portion 3 and the first opposing portion 111, to form the first metal skin 1. Similarly, the rolled metal sheet 2A is unwound by a unwinding device 55B and continuously supplied to a roll forming machine 56B. The roll forming machine 56B then forms each portion, such as the second opposing portion 211, to form the second metal skin 2.

[0055] Next, the first metal skin 1 is continuously conveyed and heated by a heating device 57A such as a high-frequency heating device. Similarly, the second metal skin 2 is continuously conveyed and heated by a heating device 57B such as a high-frequency heating device.

[0056] Next, as shown in FIG. 6, a liquid retarder 43 is applied onto one side of the first metal skin 1 (the surface to be bonded to the resin foam 4). During the production of the metal sandwich panel 10, the side of the first metal skin 1 to be bonded to the resin foam 4 faces upward. The retarder 43 is continuously applied from one end to the other in the left-right direction of the first metal skin 1. The retarder 43 is also applied so as to be positioned at the opening 320 of the gap 32 and its surroundings. The amount of the retarder 43 to be applied varies depending on the components in the retarder 43, the components of the mixed raw material 45, and the components of the auxiliary raw material 46, but is 3 g / m to 10 g / m. The retarder 43 can be applied using an application device 62 equipped with a nozzle or the like.

[0057] Next, as shown in Fig. 7, a liquid auxiliary material 46 is supplied to the first metal skin 1. The auxiliary material 46 is sprayed from a nozzle 44 and supplied into the gap 32 through the opening 320. The auxiliary material 46 fills the entire gap 32 and comes into contact with the inhibitor 43 around the opening 320, as shown in Fig. 8. In this way, a first contact portion 521 is formed on the surface of the first metal skin 1, where the inhibitor 43 and the auxiliary material 46 come into contact and mix.

[0058] Next, as shown in FIG. 8, the mixed raw material 45 is supplied onto one side of the first metal skin 1 (the surface to be bonded to the resin foam 4). The mixed raw material 45 is sprayed from the nozzle 41 of the liquid supply device 58 and supplied onto the surface of the first metal skin 1 to which the inhibitor 43 has been supplied (the surface of the first panel body 112). Then, as shown in FIG. 8, the mixed raw material 45 comes into contact with the inhibitor 43 around the opening 320. In this way, a second contact portion 522 is formed on the surface of the first metal skin 1, where the inhibitor 43 and the mixed raw material 45 come into contact and mix.

[0059] Next, as shown in FIG. 9 , the resin foam 4 is formed by foaming the mixed raw material 45. At the same time that the resin foam 4 is being produced by foaming the mixed raw material 45, the auxiliary member 33 is produced from the auxiliary raw material 46. While the mixed raw material 45 is foaming, the second metal skin 2 is placed opposite the first metal skin 1. At this time, the surface of the second metal skin 2 that is to be bonded to the resin foam 4 faces downward. The mixed raw material 45 is then 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 are opposed to each other. At this time, a blocking material 6 is placed between the opposing portions 111 of the first metal skin 1 and 211 of the second metal skin 2. The blocking material 6 is placed across the outer surfaces of the first protruding piece 123 and the second protruding piece 223. The surface of the sealing material 6 that comes into contact with the resin foam 4 is adhered by the self-adhesive force of the resin foam 4 (mixed raw material 45). In addition, the packing 90 is disposed in the space surrounded by the first recess piece 119, the second recess piece 219, the first recess bottom piece 120, and the second recess bottom piece 220.

[0060] To further foam the mixed raw material 45 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 mixed raw material 45 is completely foamed, it becomes a resin foam 4.

[0061] The resin foam 4 adheres to the first metal skin 1 and the second metal skin 2 by its self-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 to prevent heat bridging. Therefore, 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), and the gap between the first opposing portion 111 and the second opposing portion 211 can be sealed with a sealing material 6 to prevent leakage of the resin foam 4 during foaming.

[0062] In this way, 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 produced. Then, the long metal sandwich panel 10A is cut to a desired length with a cutting device 61 such as a cutter, thereby producing the metal sandwich panel 10.

[0063] In this embodiment, the first raw material and the second raw material in the mixed raw material 45 react to form the resin foam 4, but the predetermined balance between the first raw material and the second raw material is lost in the second contact area 522, and the resin foam 4 is not formed locally (locally). Therefore, unreacted first raw material, second raw material, and inhibitor 43 remain in the second contact area 522. Furthermore, the polyol and polyisocyanate in the auxiliary raw material 46 react to form the auxiliary member 33, but the predetermined balance between the polyol and polyisocyanate is lost in the first contact area 521, and the auxiliary member 33 is not formed locally (locally). Therefore, unreacted polyol, polyisocyanate, and inhibitor 43 remain in the first contact area 521.

[0064] Then, the unreacted first raw material, second raw material, polyol, polyisocyanate, and inhibitor 43 are evaporated or otherwise discharged to the outside of the metal sandwich panel 10 through openings in the left and right end faces of the resin foam 4 and the auxiliary member 33. As a result, a contact portion 52 consisting of the first contact portion 521 and the second contact portion 522 becomes a void, and this void forms the gas flow path 5. In other words, the resin foam 4 and the auxiliary member 33 are formed in areas other than the contact portion 52, and a void is formed in the contact portion 52.

[0065] In this embodiment, even if unreacted components react in the resin foam 4 or the auxiliary member 33 after the metal sandwich panel 10 is manufactured and new gas (such as carbon dioxide) is generated, the gas flows through the gas flow path 5 and is then released to the outside from the openings at the left and right ends of the gas flow path 5, which are open at the left and right ends of the resin foam 4 and the auxiliary member 33. Therefore, after the metal sandwich panel 10 is manufactured, peeling between the resin foam 4 and the auxiliary member 33 and the metal skins 1 and 2 due to gas pressure is less likely to occur, and the first metal skin 1 and the second metal skin 2 are less likely to swell.

[0066] (Variation) The embodiment is merely one of various embodiments of the present disclosure, and various modifications can be made to the embodiment depending on the design and the like as long as the object of the present disclosure can be achieved.

[0067] In the embodiment, the resin foam 4 is a foam of a urethane-based resin, but the present invention is not limited to this. For example, the resin foam 4 may be a foam of a phenol-based resin. In this case, the first raw material contains a curing agent, and the second raw material contains a phenolic foam concentrate. The curing agent may be an organic phosphoric acid-based agent or a mixture of a phosphoric acid-based agent and a PSA-based agent. The phenolic foam concentrate contains a resol-type or novolac-type phenolic resin prepolymer.

[0068] In the embodiment, a case has been described in which the gas flow path 5 opens to both end faces of the resin foam 4 in the longitudinal direction of the metal sandwich panel 10, but this is not limited to this, and the gas flow path 5 may open to only one end face of the resin foam 4.

[0069] In the embodiment, the case where one gas flow path 5 is formed has been described, but the present invention is not limited to this, and the resin foam 4 may have a plurality of gas flow paths 5.

[0070] In the embodiment, the gas flow passage 5 is formed in a substantially straight linear shape, but the gas flow passage 5 is not limited to this, and may be formed in a meandering shape.

[0071] In the embodiment, the gas flow path 5 is formed near the cover 3, but the gas flow path 5 is not limited to this and can be formed at any location in the resin foam 4. The gas flow path 5 can also be formed at any location in the auxiliary member 33.

[0072] (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 resin foam 4 has a gas flow path 5 through which gas generated in the resin foam 4 flows. The gas flow path 5 is formed by a gap that opens at the end face of the resin foam 4.

[0073] According to this embodiment, the gas generated in the resin foam 4 flows through the gas flow path 5 and is released to the outside of the resin foam 4 from the opening of the gas flow path 5 at the end face of the resin foam 4. Therefore, gas is less likely to accumulate in the resin foam 4, peeling between the metal outer skins 1, 2 and the resin foam 4 is less likely to occur, and the metal outer skins 1, 2 are less likely to swell, which makes it less likely to cause a deterioration in appearance.

[0074] The second aspect is the metal sandwich panel 10 according to the first aspect, in which the gas flow path 5 is formed over the entire longitudinal length of the metal sandwich panel 10. The gas flow path 5 opens at both end faces of the resin foam 4.

[0075] According to this embodiment, gas is less likely to accumulate in the resin foam (4) over the entire longitudinal length of the metal sandwich panel (10), and peeling between the metal skins (1, 2) and the resin foam (4) is less likely to occur.

[0076] A third aspect is a metal sandwich panel (10) according to the first aspect, in which one metal skin (1) of the two metal skins (1, 2) has a cover part (3) formed with a generally U-shaped cross section and having a gap (32) therein. An auxiliary member (33) filling the gap (32) is provided adjacent to the resin foam (4). A gas flow path (5) is formed across the resin foam (4) and the auxiliary member (33).

[0077] According to this embodiment, in addition to the gas generated in the resin foam 4, the gas generated in the auxiliary member 33 also flows through the gas flow path 5 and is released to the outside of the resin foam 4. Therefore, gas is less likely to accumulate in the resin foam 4, and separation between the metal outer skins 1, 2 and the resin foam 4 is less likely to occur.

[0078] A fourth aspect is the metal sandwich panel (10) according to any one of the first to third aspects, wherein the resin foam (4) includes a polyisocyanurate foam.

[0079] According to this embodiment, gas generated from the polyisocyanurate foam in the resin foam 4 flows through the gas flow path 5 and is released to the outside of the resin foam 4. Therefore, gas is less likely to accumulate in the resin foam 4, and separation between the metal skins 1, 2 and the resin foam 4 is less likely to occur.

[0080] The fifth aspect is a method for manufacturing a metal sandwich panel (10) having a resin foam (4) between two metal skins (1, 2). A mixed raw material (45) for producing the resin foam (4) is prepared by blending a first raw material and a second raw material in a predetermined ratio. An inhibitor (43) is prepared to inhibit the production of the resin foam (4) due to a reaction between the first raw material and the second raw material in the mixed raw material (45). The inhibitor (43) is supplied onto the surface of at least one metal skin (1) of the two metal skins (1, 2), and then the mixed raw material (45) is supplied onto the surface to which the inhibitor (43) has been supplied, thereby forming a contact portion (52) on the surface where the mixed raw material (45) and the inhibitor (43) come into contact. A resin foam (4) is formed by the mixed raw material (45) supplied onto the surface other than the contact portion (52), and at the contact portion (52), the generation of the resin foam (4) is suppressed by the inhibitor (43), and voids are formed in the resin foam (4).

[0081] According to this embodiment, the gas flow path (5) can be easily formed by the gap.

[0082] A sixth aspect is a method for manufacturing a metal sandwich panel (10) according to the fifth aspect, wherein the inhibitor (43) contains at least one of the first raw material and the second raw material, and the ratio of the first raw material to the second raw material in the contact portion (52) is outside the predetermined ratio range.

[0083] According to this embodiment, the ratio between the first raw material and the second raw material is outside the predetermined range, so that the resin foam (4) is not easily generated and voids are easily formed.

[0084] A seventh aspect is a method for producing a metal sandwich panel (10) according to the fifth or sixth aspect, wherein the first raw material contains a polyol, the second raw material contains a polyisocyanate, and the inhibitor (43) contains at least one of a polyol and a polyisocyanate.

[0085] According to this embodiment, the ratio of the polyol in the first raw material to the polyisocyanate in the second raw material is outside the predetermined ratio range, so that the resin foam (4) is not easily generated and voids are easily formed. [Explanation of symbols]

[0086] 10 Metal sandwich panels 1 Metal shell 2 Metal shell 3 Cover 32 Gap 33 Auxiliary parts 4 Resin foam 43 Inhibitor 45 Mixed raw materials 5 Gas flow path 52 Contact part

Claims

1. A metal sandwich panel having a resin foam between two metal skins, the resin foam has a gas flow path through which gas generated in the resin foam flows, the gas flow path is formed by a void that opens at an end surface of the resin foam. Metal sandwich panel.

2. The gas flow path is formed over the entire length of the metal sandwich panel in the longitudinal direction and opens at both end faces of the resin foam. The metal sandwich panel according to claim 1.

3. One of the two metal outer shells includes a cover portion having a substantially U-shaped cross section and a gap therein, an auxiliary member to be filled in the gap is provided adjacent to the resin foam, The gas flow path is formed across the resin foam and the auxiliary member. The metal sandwich panel according to claim 1.

4. The resin foam includes a polyisocyanurate foam. The metal sandwich panel according to any one of claims 1 to 3.

5. A method for manufacturing a metal sandwich panel having a resin foam between two metal skins, comprising: preparing a mixed raw material for producing the resin foam by blending a first raw material and a second raw material in a predetermined ratio; preparing an inhibitor for inhibiting the generation of the resin foam due to a reaction between the first raw material and the second raw material in the mixed raw material; After providing the inhibitor on the surface of at least one of the two metal shells, supplying the mixed raw material onto the surface to which the inhibitor has been supplied, thereby forming a contact portion on the surface where the mixed raw material and the inhibitor come into contact with each other; The resin foam is formed from the mixed raw material supplied onto the surface other than the contact portion, and At the contact portion, the inhibitor inhibits the generation of the resin foam, thereby forming voids in the resin foam. Manufacturing method of metal sandwich panels.

6. the inhibitor includes at least one of the first raw material and the second raw material, a ratio of the first raw material to the second raw material at the contact portion is outside the predetermined ratio range; A method for producing the metal sandwich panel according to claim 5.

7. the first raw material includes a polyol; the second raw material includes a polyisocyanate; The inhibitor includes at least one of a polyol and a polyisocyanate. The method for producing a metal sandwich panel according to claim 5 or 6.

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