Corner panel

Abstract

To provide a corner panel allowing heat insulation at a corner panel to be obtained through auxiliary core material and heat insulation to be hardly deteriorated.SOLUTION: A corner panel 100 used for a convex corner part of a building is disclosed. The corner panel 100 is provided with two metal outer skins 1, 2, core material 4 formed of resin foam and placed between the two metal outer skins 1, 2; and a packing 90. The core material 4 is provided with a core material body 4A and auxiliary core material 4B. The auxiliary core material 4B is placed on a corner part 103 of the corner panel 100 and formed of rigid material with rigidity equal to or more than that of the core material body 4A. The packing 90 is provided above of the auxiliary core material 4B and supported on the auxiliary material 4B through contact with the auxiliary material 4B at the corner part 103.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present disclosure relates to a corner panel, and more particularly to a corner panel used in an exterior corner portion of a building. [Background technology]

[0002] Patent Document 1 describes a stepped corner panel. This stepped corner panel has a panel body with a heat insulating material laminated to the inner surface of a metal outer skin. A recessed step is recessed from the panel surface at one end of the panel body for panel fastening, and is generally parallel to the panel surface. A connecting protrusion or connecting recess is formed adjacent to the recessed step for connecting the panels. A connecting recess or connecting protrusion is formed at the other end of the panel body, and the entire panel body, including the recessed step, connecting protrusion, and connecting recess, is bent inward into a generally L-shape. The excess portion of the metal outer skin is folded inward into a generally L-shape at the recessed step and the connecting protrusion or connecting recess adjacent to the recessed step. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent No. 3954927 Summary of the Invention [Problem to be solved by the invention]

[0004] In the stepped corner panel described above, when the panel body is bent into a substantially L-shape, the insulating material is removed from the bent portion of the panel body, which can result in a decrease in insulating properties.

[0005] The present disclosure aims to provide a corner panel whose thermal insulation properties are less likely to deteriorate. [Means for solving the problem]

[0006] A corner panel according to one aspect of the present disclosure is a corner panel used in an exterior corner portion of a building, the corner panel comprising two metal exterior skins, a core material, and a gasket, the core material being formed from a resin foam and being disposed between the two metal exterior skins. The core material comprises a core material body and an auxiliary core material. The auxiliary core material is disposed in the corner portion of the corner panel. The auxiliary core material is formed from a hard material having rigidity equal to or greater than that of the core material body. The gasket is disposed above the auxiliary core material and is in contact with and supported by the auxiliary core material at the corner portion of the corner panel. [Effects of the Invention]

[0007] According to the present disclosure, the auxiliary core material can provide heat insulation in the corner portions, making it difficult for the heat insulation to decrease. [Brief explanation of the drawings]

[0008] [Figure 1] FIG. 1 is a perspective view showing a corner panel according to this embodiment. [Figure 2] FIG. 2 is a perspective view showing the connection structure of the corner panel of the same. [Figure 3] FIG. 3 is a cross-sectional view taken along line XX in FIG. [Figure 4] FIG. 4 is a cross-sectional view taken along the line YY in FIG. [Figure 5] FIG. 5 is a cross-sectional view showing an example of a connection structure of the corner panel of the same. [Figure 6] FIG. 6 is a cross-sectional view showing another example of the connecting structure of the corner panel of the same. [Figure 7] FIG. 7 is a cross-sectional view showing another example of the connecting structure of the corner panel of the same. [Figure 8] FIG. 8 is a cross-sectional view showing another example of the connecting structure of the corner panel of the same. [Figure 9] FIG. 9 is a perspective view showing a flat panel used in manufacturing the corner panel of the same. [Figure 10]FIG. 10 is a schematic diagram showing a method for manufacturing the flat panel. [Figure 11] 11A and 11B are cross-sectional views showing a simplified method for manufacturing the corner panel (when the cutting angle is 90 degrees). [Figure 12] 12A to 12C are cross-sectional views showing a simplified method for manufacturing the corner panel (when the cutting angle is 90 degrees). [Figure 13] 13A and 13B are cross-sectional views schematically showing another method for manufacturing the corner panel (when the cutting angle is 45 degrees). [Figure 14] 14A to 14C are cross-sectional views showing, in a simplified manner, another method for manufacturing the corner panel (when the cutting angle is 45 degrees). DETAILED DESCRIPTION OF THE INVENTION

[0009] 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.

[0010] (Embodiment) <Corner panel> Fig. 1 shows a corner panel 100 according to this embodiment. The corner panel 100 is a construction panel used in corners of exterior walls of buildings such as buildings, factories, warehouses, etc. In Fig. 2, two corner panels 100 are connected one above the other.

[0011] The corner panel 100 is formed in a substantially L-shape in a plan view (viewed from above). The corner panel 100 has a corner portion 103, a first portion 101, and a second portion 102. The first portion 101 and the second portion 102 are located on either side of the corner portion 103 when viewed from the front of the corner portion 103. The first portion 101 and the second portion 102 have the same cross-sectional shape. The first portion 101 and the second portion 102 have the same cross-sectional shape as the flat panel 10 described below. The corner portion 103 is formed with a predetermined distance from the bent portion (corner) 104 of the corner panel 100 toward the first portion 101. The corner portion 103 is also formed with a predetermined distance from the bent portion (corner) 104 of the corner panel 100 toward the second portion 102. Here, the predetermined dimension is not particularly limited, but can be set to 20 mm or more and 100 mm or less, taking into consideration the thickness of the first portion 101 and the second portion 102 and the like.

[0012] As shown in Fig. 3, the corner panel 100 includes a front plate 11 made of a first metal skin 1, a back plate 21 arranged opposite the front plate 11 and made of a second metal skin 2, a core material 4 disposed between the front plate 11 and the back plate 21, and a gasket 90. The first portion 101 and the second portion 102 each have a separate second metal skin 2. The second metal skin 2 of the first portion 101 and the second metal skin 2 of the second portion 102 are connected by a connecting member 13.

[0013] The core material 4 is formed from resin foam (a foamed resin material). In this embodiment, it is preferable that the core material 4 be formed only from resin foam. This makes it easier to compensate for any damage to the core material 4 during the manufacturing of the corner panel 100. In other words, if an inorganic material such as gypsum board or calcium silicate is used as the core material 4, if damage occurs in the core material 4, using inorganic materials such as gypsum board or calcium silicate in the damaged area will result in poor insulation. Furthermore, if inorganic fibers such as glass wool are used in the damaged area, they are too soft to provide support for the gasket 90. For this reason, it is preferable that the core material 4 be formed only from resin foam, which is easy to process into the desired shape. In this embodiment, the core material 4 has a core material main body 4A and an auxiliary core material 4B.

[0014] The packing 90 has a packing body 93 and an auxiliary packing 92. The packing body 93 is disposed on the upper part of the first portion 101 and on the upper part of the second portion 102. The auxiliary packing 92 is disposed on the upper part of the corner portion 103. The packing body 93 and the auxiliary packing 92 are formed from EPDM, butyl rubber, soft urethane foam, or the like.

[0015] <<About Part 1 and Part 2>> 3 shows a cross-sectional view (cross-sectional view along line XX in FIG. 1) of the corner panel 100 in the first portion 101 and the second portion 102. The first metal skin 1 has a first panel main body 112. The first panel main body 112 is formed in a flat plate shape except for the corner portion 103, and constitutes the main surface on the obverse side of the corner panel 100.

[0016] The first metal skin 1 has a first horizontal piece 113. The first horizontal piece 113 protrudes rearward (toward the core material 4) from the upper end of the first panel main body 112. The first metal skin 1 has a first vertical piece 114. The first vertical piece 114 protrudes upward from the rear end of the first horizontal piece 113.

[0017] The first metal skin 1 has a lower groove piece 115. The lower groove piece 115 protrudes diagonally upward from the upper end of the first vertical piece 114 toward the rear (towards the core material 4). 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 diagonally upward from the upper end of the groove piece 116 toward the front (the side opposite the core material 4).

[0018] 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.

[0019] The first metal outer skin 1 has a first upper insertion piece 121. The first upper insertion piece 121 protrudes downward from the rear end of the first recess bottom piece 120. The first upper insertion piece 121 is inserted into the core body 4A from the upper end surface 42.

[0020] As shown in FIG. 3, 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.

[0021] The covering portion 3 formed as described above has a substantially U-shaped cross section. The covering portion 3 has a void portion 32 therein. That is, the gap between the front covering portion 30 and the rear covering portion 31 forms the void portion 32. The void portion 32 is provided over the entire length of the corner panel 100. The void portion 32 has an opening 320 at its upper end. The void portion 32 communicates with the internal space of the corner panel 100 (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 void portion 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 in the same position in the up-down direction).

[0022] A filling member 33 is provided in the void 32. The filling member 33 is provided over the entire length of the void 32. The filling member 33 is provided by filling the lower part of the void 32. A part of the core body 4A is filled above the filling member 33. The upper end of the filling member 33 is located slightly below the opening 320. The vertical dimension of the filling member 33 is not limited. The filling member 33 may be provided over the entire void 32.

[0023] The filling member 33 is breathable. That is, the filling member 33 has the property of allowing gas and air to pass through. This allows gases such as carbon dioxide generated from the core material body 4A to pass through the filling member 33, and the gas can be released to the outside of the corner panel 100 through the filling member 33. It is preferable that the filling member 33 has the same or higher gas permeability as the core material body 4A.

[0024] It is preferable that the filling member 33 has open cells. That is, the filling member 33 has many cells inside, and these many cells are connected to form open cells. The many connected cells (open cells) in the filling member 33 form passages through which gas and air can flow, and this makes the filling member 33 breathable.

[0025] The filling member 33 is preferably a molded product of soft urethane foam resin. This makes it possible to easily form a breathable filling member 33. Here, "soft" means that the filling member is softer than the core material 4 and is easily deformable.

[0026] The filling member 33 is compressed in the void 32. When inserted into the void 32, the filling member 33 is formed in a strip shape having a certain width, but due to the expansion pressure during the formation of the core material body 4A, the filling member 33 is pressed by the core material body 4A from the upper part (opening 320 side) of the void 32 toward the lower part. As a result, the filling member 33 is compressed by the core material body 4A entering through the opening 320 and fills the void 32.

[0027] The configuration of the cover portion 3 is an example and can be modified as appropriate. For example, the cover portion 3 may or may not have a void portion 32. The filling member 33 may or may not be breathable. The filling member 33 may or may not contain a molded product of soft urethane foam resin. The core material main body 4A, which is the main body raw material, may or may not be filled. The auxiliary liquid may or may not be filled.

[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 protruding piece 123. The first protruding 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 protruding piece 123, folding back. The first lower insertion piece 124 is inserted into the core material 4 from the lower end surface 40. The first lower insertion piece 124 and the first protruding piece 123 face each other at a predetermined distance in the thickness direction (front-to-back direction). The first lower insertion piece 124 and the first protruding 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 main body 212. The second panel main body 212 is formed in a flat plate shape and constitutes the main surface on the back side of the corner panel 100. The second panel main 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 main 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 core material 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.

[0031] The second metal outer skin 2 has a second lower insertion piece 224. The second lower insertion piece 224 protrudes upward from the lower end of the second protruding piece 223 in a folded-back manner. The second lower insertion piece 224 is inserted into the core material 4 from the lower end face 40. The second lower insertion piece 224 and the second protruding piece 223 face each other in the thickness direction (front-rear direction) with a predetermined gap between them.

[0032] 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.

[0033] 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 core body 4A. A packing body 93 is provided over the entire length in the longitudinal direction (left-right direction) in 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 core body 4 located between the first opposing portion 111 and the second opposing portion 211.

[0034] As shown in FIG. 3 , a sealing material 6 is provided on the lower end surfaces of the first portion 101 and the second portion 102 of the corner panel 100. The sealing material 6 is provided to prevent the core material 4 from leaking out from between the first opposing portion 111 and the second opposing portion 211 during the manufacturing of the flat panel 10, which will be described later. The sealing material 6 is provided over the entire length. Note that the sealing material 6 is used when the first opposing portion 111 and the second opposing portion 211 of the corner panel 100 are widely separated from each other. However, when the gap between the first opposing portion 111 and the second opposing portion 211 is narrow, the sealing material 6 may not be provided because leakage of the core material 4 is unlikely to occur.

[0035] The end face 80 of the fitting protrusion 8, which is the lower end face of the corner panel 100, is formed by the outer surface of the blocking material 6 (the surface opposite the core material 4). The blocking material 6 is provided to bridge between the first protrusion piece 123 of the first opposing portion 111 and the second protrusion piece 223 of the second opposing portion 211. Therefore, the end face 40 of the core material main body 4A between the first opposing portion 111 and the second opposing portion 211 is covered by the blocking material 6. The blocking material 6 is bonded to the outer surface of the first protrusion piece 123 and the outer surface of the second protrusion piece 223. When the blocking material 6 is not used, the end face 80 of the fitting protrusion 8 in the first portion 101 and the second portion 102 is formed by the end face 40 of the core material main body 4A.

[0036] 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.

[0037] In the first portion 101 and the second portion 102, the core 4 has a core body 4A. The core body 4A is disposed between the two metal skins 1 and 2 in the portion other than the auxiliary cores 4B provided in the corner portion 103. The core body 4A is provided throughout the first portion 101 and the second portion 102 in the portion other than the auxiliary cores 4B.

[0038] The core material body 4A is a part that constitutes the main body of the corner panel 100 and is made of resin foam (a foamed resin body). The core material body 4A in this embodiment is at least one type selected from the group consisting of polyisocyanurate foam, polyurethane foam, polystyrene foam, and polyphenol foam. The core material body 4A may be formed by combining a plurality of types of these, or by using only one of them. Furthermore, a plurality of types of materials may be laminated in the thickness direction. The core material body 4A preferably has heat insulating properties and is non-flammable and flame-retardant.

[0039] <<About the corners>> FIG. 4 shows a cross-sectional view of the corner panel 100 at a corner portion 103 (a YY cross-sectional view in FIG. 1). In the corner portion 103, an auxiliary core 4B is provided as the core 4. The auxiliary core 4B may be made of the same material as the core main body 4A or a different material, but is formed of a hard material that has the same or greater rigidity as the core main body 4A. This makes it easier for the auxiliary core 4B to support the auxiliary gasket 92 than if the auxiliary core 4B were made of a soft material. For example, the auxiliary core 4B can be made of a hard polyisocyanurate foam board (Thermax (registered trademark) manufactured by Inoac Corporation).

[0040] Around the bent portion 104 located in the center of the corner portion 103 in the left-right direction, the first metal skin 1 does not have the first recess bottom piece 120, the first upper insertion piece 121, or the first recess piece 119. Similarly, around the bent portion 104, the first metal skin 1 does not have the gap piece 122, the first lower insertion piece 124, or the first protruding piece 123. In the corner portion 103, the first metal skin 1 has the first recess piece 119 in areas other than the area around the bent portion 104.

[0041] In the corner portion 103, the corner panel 100 does not have a second metal skin 2. In the corner portion 103, the corner panel 100 has a connecting member 13 instead of the second metal skin 2. The connecting member 13 is a substantially L-shaped member in a plan view having a pair of connecting pieces 131, and is formed from the same metal plate as the first metal skin 1 and the second metal skin 2. One connecting piece 131 is fixed to the second metal skin 2 of the first portion 101 with a rivet 132 or the like, and the other connecting piece 131 is fixed to the second metal skin 2 of the second portion 102 with a rivet 132 or the like. In this way, the second metal skin 2 of the first portion 101 and the second metal skin 2 of the second portion 102 are connected by the connecting member 13. The second metal skin 2 and the connecting pieces 131 may be fixed by adhesive other than riveting. The connecting member 13 is provided along the rear surface of the second panel main body 212 , the lower surface of the lower piece 222 and the rear surface of the second protruding piece 223 .

[0042] In the corner portion 103, the corner panel 100 does not have a core main body 4A, but instead has an auxiliary core 4B. The auxiliary core 4B is provided between the first metal skin 1 and the connecting member 13. An auxiliary gasket 92 is disposed above the auxiliary core 4B. The lower surface of the auxiliary gasket 92 is in contact with the upper surface of the auxiliary core 4B. The auxiliary gasket 92 is supported by the auxiliary core 4B to prevent it from moving downward.

[0043] The auxiliary packing 92 is formed separately from the packing body 93, but the end of the auxiliary packing 92 is connected to the end of the packing body 93. The auxiliary packing 92 and the packing body 93 have approximately the same thickness. The upper surface of the auxiliary core 4B is at the same height as the core body 4A. Therefore, the auxiliary packing 92 and the packing body 93 are continuously connected.

[0044] A sealant 95 is provided in a cross section along the bent portion 104 of the corner portion 103. The sealant 95 is provided between the auxiliary packing 92 and the second vertical piece 118. This sealant closes the gap between the auxiliary packing 92 and the second vertical piece 118, thereby improving watertightness.

[0045] A sealant 96 is provided in a cross section along the bent portion 104 of the corner portion 103. The sealant 96 is provided between the lower surface of the second metal skin 2 of the first portion 101 and the lower surface of the second metal skin 2 of the second portion 102. This sealant closes the gap between the lower surfaces of the adjacent second metal skins 2, improving watertightness.

[0046] In the corner panel 100 of this embodiment, the auxiliary gasket 92 provided in the corner portion 103 is supported by contacting it with the upper surface of the auxiliary core material 4B, so no member is required to support the auxiliary gasket 92, making it easier to manufacture the corner panel 100.

[0047] <Corner panel connection structure> 5 shows a connection structure for two vertically adjacent corner panels 100. In this case, the two corner panels 100 are connected by fitting the mating protrusion 8 of the upper second corner panel 100B into the mating recess 9 of the lower first corner panel 100A. That is, the first portions 101 of the first corner panel 100A and the second corner panel 100B are connected to each other, and the second portions 102 are connected to each other, and further the corner portions 103 are connected to each other.

[0048] Here, the end face 80 of the fitting convex portion 8 is in close contact with the upper surface of the packing 90. In the first portion 101 and the second portion 102, the end face 80 of the fitting convex portion 8 is in close contact with the upper surface of the packing body 93. In the corner portion 103, the end face 80 of the fitting convex portion 8 (including the lower surface of the sealing 96) is in close contact with the upper surface of the auxiliary packing 92.

[0049] Furthermore, the cover portion 3 is located in front of the fitting protrusion 8, and the lower end of the cover portion 3 is located lower than the lower end of the fitting protrusion 8. As a result, the fasteners 50, such as screws, that secure the lower corner panel 100 are located behind the cover portion 3 of the upper corner panel 100, and the cover portion 3 can cover the fasteners 50 so that they cannot be seen from the front. In other words, the corner panel 100 may have any cross-sectional shape that includes the cover portion 3.

[0050] The fastener 50 is driven (screwed) into the groove piece 116 from the front, penetrates the corner panel 100 in the thickness direction, and is driven (screwed) into the wall substrate such as a furring strip located behind the corner panel 100. 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 corner panel 100 is fixed to the corner portion of the wall substrate and installed.

[0051] As shown in FIGS. 1 to 5, the corner panel 100 is provided with a water-stopping material 91. Like the packing 90, the water-stopping material 91 is formed in a strip (tape) shape from EPDM, butyl rubber, soft urethane foam, or the like. The water-stopping material 91 is formed separately from the packing 90. The water-stopping material 91 is also disposed between the opposing surfaces of the first corner panel 100A and the second corner panel 100B, at least in the corner portion 103. The water-stopping material 91 is provided at the upper end of the first corner panel 100A. The outer surfaces of the first recessed piece 119 and the second vertical piece 118 of the first corner panel 100A face the outer surface of the lower end of the second corner panel 100B.

[0052] The water-stopping material 91 is provided on the outer surfaces of the first recessed piece 119 and the second vertical piece 118 of the first metal skin 1. In this way, the water-stopping material 91 is provided from the front to the inner surface of the fitting recess 9 of the first corner panel 100A. The first recessed piece 119 and the second vertical piece 118 are opposed to the outer surface of the lower end of the other corner panel 100 when the upper end of the first corner panel 100A is connected to the lower end of the second corner panel 100B. Specifically, the first recessed piece 119 and the second vertical piece 118 of the lower first corner panel 100A face the outer surface (rear surface) of the rear covering portion 31, the outer surface (lower surface) of the gap piece 122, and the outer surface (front surface) of the first protruding piece 123 of the upper second corner panel 100B.

[0053] The water-stopping material 91 is provided between the second vertical piece 118 and the rear covering portion 31 and the gap piece 122, and also between the first recessed piece 119 and the first protruding piece 123 and the gap piece 122. This makes it possible to close the gap that occurs at the connection between the lower first corner panel 100A and the upper second corner panel 100B, thereby improving water-stopping properties.

[0054] The water-stopping material 91 is provided on the opposing surface (the outer surface of the second vertical piece 118) at least in the corner portion 103. This makes it possible to improve the water-stopping property even if a pinhole occurs in the corner portion 103.

[0055] The waterproof material 91 is provided in the corner portion 103, and is also provided over the entire length of the corner panel 100 in the left-right direction, extending from the corner portion 103 to the end of the first portion 101 and the end of the second portion 102.

[0056] The water-stopping material 91 can be formed in a strip shape as shown in Fig. 5, or in a rope shape as shown in Figs. 6 to 8. In this case, the water-stopping material 91 can be a round packing with an elongated circular cross section. In Fig. 6, the water-stopping material 91 is sandwiched between the first recessed piece 119 of the first corner panel 100A and the first protruding piece 123 of the second corner panel 100B. The lower end of the water-stopping material 91 is in contact with and overlaps the upper surface of the packing 90. The round packing water-stopping material 91 is pressed by the first recessed piece 119 and the first protruding piece 123, causing it to deform vertically and elongate.

[0057] In Figure 7, the water-stopping material 91 is arranged above the packing 90. In this case, the water-stopping material 91 is arranged sandwiched between the first recessed piece 119 of the first corner panel 100A and the first protruding piece 123 of the second corner panel 100B. The lower end of the water-stopping material 91 is separated from the upper surface of the packing 90 without contacting it. The water-stopping material 91 of the round packing is pressed by the first recessed piece 119 and the first protruding piece 123, and is deformed to be longer in the vertical direction.

[0058] 8, the water-stopping material 91 is sandwiched between the boundary between the first recessed piece 119 and the second vertical piece 118 of the first corner panel 100A and the gap piece 122 of the second corner panel 100B. The round packing water-stopping material 91 is pressed by the boundary between the first recessed piece 119 and the second vertical piece 118 and the gap piece 122, causing it to deform and become longer in the front-to-rear direction.

[0059] 5 to 8, a waterproof test was conducted. The waterproof test was conducted by spraying water from a sprinkler at a pressure of approximately 15 kg / cm from a point 30 cm away from the joint (joint) between the first corner panel 100A and the second corner panel 100B. 2 In another waterproofing test, water was sprayed onto the corner portion 103 from a distance of about 10 cm using a sprinkler with a discharge pressure of about 15 kg / cm. 2 I sprayed it on.

[0060] The specimens shown in Figures 5, 7, and 8 met the waterproofing test criterion of no water leakage. Furthermore, although this is not a waterproofing test criterion, the specimens shown in Figures 5 and 8 showed minimal water seepage into the sealing material 6. Furthermore, comparing the specimens shown in Figures 5 and 8, the joint spacing in Figure 8 is +0.5 to 1.0 mm from the specified joint width, whereas the joint spacing in Figure 5 is +0.5 mm or less, meaning that the specimen shown in Figure 5, with its smaller joint spacing, has a superior appearance.

[0061] Exterior wall materials such as the corner panel 100 have sufficient watertightness and wind pressure resistance against general wind and rain, but the corner portions of an exterior wall require greater wind pressure resistance than flat general portions. Therefore, it is preferable that the corner panel 100 be provided with a water-stopping material 91 at the bent portion 104 of the corner portion 103.

[0062] <Corner panel manufacturing> The corner panel 100 of this embodiment can be manufactured by cutting out a part of a flat panel 10 as shown in FIG. 9 and bending it.

[0063] As shown in Figure 3, the flat panel 10 has a cross-sectional shape similar to that of the first portion 101 and second portion 102 of the corner panel 100. The flat panel 10 is flat and not curved like the corner panel 100, and the second metal skin 2 of the flat panel 10 is one piece rather than being separated into two pieces like the corner panel 100, and the flat panel 10 does not have a connecting member 13. The core material 4 is composed only of a core material main body 4A and does not have an auxiliary core material 4B. Apart from these configurations, the flat panel 10 is similar to the corner panel 100.

[0064] The flat panel 10 is a metal sandwich panel similar to the corner panel 100, and has a core material body 4A between two metal skins 1 and 2. The flat panel is formed in a generally rectangular shape when viewed from the front. The flat panel 10 has a fitting recess 9 formed at one end in the width direction and a fitting protrusion 8 formed at the other end.

[0065] The lengthwise (left-right) dimension of the flat panel 10 is greater than the widthwise (up-down) dimension and the thicknesswise dimension, but is not limited thereto. For example, the lengthwise dimension of the flat panel 10 can be 350 mm to 1600 mm, and the widthwise dimension can be a minimum of 600 mm and a maximum of 1000 mm. The widthwise dimension of the flat panel 10 is greater than the thicknesswise dimension. The flat panel 10 is usually constructed with the widthwise 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 flat panel 10, and the fitting protrusion 8 is provided at the lower end of the flat panel 10. The fitting recess 9 and the fitting protrusion 8 are formed over the entire lengthwise direction of the flat panel 10. The first metal outer skin 1 and the second metal outer skin 2 face each other in the thickness direction of the flat panel 10.

[0066] 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.

[0067] <<Flat Panel Manufacturing Method>> The flat panel 10 is manufactured as follows, but the manufacturing method is not limited to this. The flat panel 10 is manufactured with the surface direction being approximately horizontal. That is, the flat panel 10 is manufactured with the up-down direction in FIG. 9 being approximately horizontal (laid on its side).

[0068] First, as shown in FIG. 10 , first and second metal skins 1 and 2 are formed from metal sheets 1A and 2A. The metal sheet 1A wound in a roll shape is fed by a feeding device 55A and continuously supplied to a molding machine 56A such as a roll molding machine. The molding 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 metal sheet 2A wound in a roll shape is fed by a feeding device 55B and continuously supplied to a molding machine 56B such as a roll molding machine. The molding machine 56B then forms each portion, such as the second opposing portion 211, to form the second metal skin 2.

[0069] Next, when providing the filler 33 in the gap 32 of the covering portion 3 of the first metal skin 1, the filler 33 is inserted into the gap 32 through the opening 320. The filler 33 is inserted into the gap 32 between the molding machine 56A and the liquid supply device 58. The filler 33 may be inserted into the gap 32 manually, or a filling device 54 may be used.

[0070] 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.

[0071] Next, liquid resin 45 is supplied to one surface of the first metal skin 1 (the surface to be bonded to the core material body 4A). During the manufacture of the flat panel 10, the surface of the first metal skin 1 to be bonded to the core material body 4A faces upward. The liquid resin 45 is supplied from a liquid supply device 58 to the surface (top surface) of the first metal skin 1 facing upward. The liquid resin 45 is a liquid resin material that foams to become the core material 4. Next, while the liquid resin 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 to be bonded to the core material body 4A faces downward. The liquid resin 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 face each other vertically. At this time, a plugging material 6 is placed between the opposing portion 111 of the first metal outer skin 1 and the opposing portion 211 of the second metal outer skin 2, which are arranged opposite each other. The plugging material 6 is placed across the outer surface of the first convex piece 123 and the outer surface of the second convex piece 223. The surface of the plugging material 6 that comes into contact with the core material main body 4A is adhered by the self-adhesive force of the core material main body 4A (resin liquid 45). In addition, a packing 90 is placed in the space surrounded by the first recessed piece 119, the second recessed piece 219, the first recessed bottom piece 120, and the second recessed bottom piece 220.

[0072] To further foam the resin liquid 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 resin liquid 45 is completely foamed, it becomes the core body 4A.

[0073] The core material body 4A adheres to the first metal skin 1 and the second metal skin 2 by 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-to-back 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 core material body 4A during foaming.

[0074] In this way, the first metal skin 1 and the second metal skin 2 are integrated by the core body 4A, and the long flat panel 10A is continuously produced. The long flat panel 10A is then cut to a desired length using a cutting device 61 such as a cutter, thereby producing the flat panel 10.

[0075] <<Corner panel manufacturing method>> The manufacturing method for the corner panel 100 includes a cutting step and a folding step. In the cutting step, a portion of the second metal skin 2, a portion of the core body 4A, and a portion of the packing 90 are cut from the flat panel 10. In the folding step, the flat panel 10 after cutting is folded to form a bent corner panel 100. This manufacturing method further includes a filling step performed after the folding step and a reinforcing step performed after the filling step.

[0076] The corner panel 100 only needs to have a continuous core body 4A and auxiliary core 4B. Therefore, the auxiliary core 4B may have any shape. In the cutting process, the cutting angle with respect to the surface direction of the flat panel 10 (the direction of the surface perpendicular to the front-to-rear direction) is 90 degrees with respect to the surface direction of the flat panel 10 in FIGS. 11A-C and 12A-C, but it may be in the range of 30 to 90 degrees. The cutting angle with respect to the surface direction of the flat panel 10 is more preferably in the range of 45 to 90 degrees (see FIGS. 13A and 13B). When the cutting angle with respect to the surface direction of the flat panel 10 is 45 degrees, the auxiliary core 4B can be inserted as a single member (one piece).

[0077] The case where the cutting angle is 90 degrees will be explained below.

[0078] As shown in FIG. 11A, in the cutting process, a blade is cut into the second metal skin 2 and the core material main body 4A in the thickness direction of the flat panel 10 to cut out a portion of the second metal skin 2, a portion of the core material main body 4A, and a portion of the gasket 90.

[0079] More specifically, as shown in Fig. 11A, a power tool such as a circular saw is used to cut a portion of the second metal skin 2 and a portion of the core body 4A. In this case, the entire length of the second metal skin 2 and the core body 4A in the vertical direction is cut. The second metal skin 2 and the core body 4A are cut at two locations spaced apart in the horizontal direction. Two cut marks 26 that are approximately parallel to each other are formed in the second metal skin 2 and the core body 4A.

[0080] After forming two cut marks 26 in the second metal skin 2 and the core material body 4A, the portion of the second metal skin 2 between the two cut marks 26 is removed. By removing a portion of the second metal skin 2, a portion of the core material body 4A and a portion of the gasket 90 bonded to a portion of the second metal skin 2 between the two cut marks 26 are removed. In this manner, a space 47 is formed in the flat panel 10 (see FIG. 11B ). A portion of the first metal skin 1 (a portion of the first recess bottom piece 120 and a portion of the first upper insertion piece 121) is also removed. A corner portion 103 is formed where a portion of the second metal skin 2, a portion of the core material body 4A, and a portion of the gasket 90 are removed, and a bent portion 104 is formed where a portion of the first metal skin 1 is removed.

[0081] After the cutting process is completed, the bending process is performed. In the bending process, as shown in Fig. 12A, the first metal skin 1 is bent around the midpoint of the bottom surface of the space 47 in the panel width direction. In this embodiment, a movable bending mold is pressed from directly above against the midpoint of the bottom surface of the space 47, bending the first metal skin 1 at approximately 90 degrees.

[0082] After the folding process is completed, the filling process is carried out. In the filling process, as shown in FIG. 12B, multiple (two components) auxiliary core materials 4B are inserted into the space 47 of the core material main body 4A, and the space 47 is filled with the auxiliary core materials 4B. The auxiliary core materials 4B may or may not be glued. The auxiliary core materials 4B are held down by the core material main body 4A, the connecting members 13, and the metal skin 1, so they will not come off even if they are not glued. When the auxiliary core materials 4B are glued, they are adhered to the core material main body 4A via a sealant, for example.

[0083] After the filling process is completed, the reinforcing process is performed. In the reinforcing process, as shown in FIG. 12C, a connecting member 13 is attached to the surface (rear surface) of the second metal skin 2 so as to cover the auxiliary core material 4B. In this embodiment, the connecting member 13 is made by bending a steel plate into an L-shape. The connecting member 13 has the same length as the length of the bent flat panel 10 in the front-to-rear direction. The connecting member 13 is fixed to the second metal skin 2 of the bent flat panel 10, for example, by riveting using rivets 132. The connecting member 13 can be adhered to the second metal skin 2 by means other than riveting.

[0084] Auxiliary packing 92 is newly installed in the location removed in Figure 11B. Then, waterproof material 91 is installed (see Figures 1 and 2).

[0085] The bent corner panel 100 shown in FIG. 1 is formed by carrying out the cutting step, folding step, filling step, and reinforcing step described above in this order on the flat panel 10.

[0086] The following describes the case where the cutting angle is 45 degrees.

[0087] As shown in Figure 13A, in the cutting process, a blade is inserted into the second metal skin 2 and the core material main body 4A at an angle of 45 degrees relative to the thickness direction of the flat panel 10, and a portion of the second metal skin 2, a portion of the core material main body 4A, and a portion of the gasket 90 are cut away.

[0088] 13A, a power tool such as a circular saw is used to cut a portion of the second metal skin 2 and a portion of the core body 4A. In this case, the entire length of the second metal skin 2 and the core body 4A in the vertical direction is cut. The second metal skin 2 and the core body 4A are cut at two locations spaced apart in the horizontal direction.

[0089] After forming two cut marks 26 in the second metal skin 2 and the core material body 4A, the portion of the second metal skin 2 between the two cut marks 26 is removed. By removing a portion of the second metal skin 2, a portion of the core material body 4A and a portion of the gasket 90 bonded to a portion of the second metal skin 2 between the two cut marks 26 are removed. In this manner, a space 47 is formed in the flat panel 10 (see FIG. 13B). A portion of the first metal skin 1 (a portion of the first recess bottom piece 120 and a portion of the first upper insertion piece 121) is also removed. A corner portion 103 is formed where a portion of the second metal skin 2, a portion of the core material body 4A, and a portion of the gasket 90 are removed, and a bent portion 104 is formed where a portion of the first metal skin 1 is removed.

[0090] After the cutting process is completed, the folding process is performed. In the folding process, as shown in FIG. 14A , the first metal skin 1 is folded around the midpoint of the bottom of the space 47 in the panel width direction. In this embodiment, a movable folding mold is pressed from directly above against the midpoint of the bottom of the space 47, folding the first metal skin 1 at approximately 90 degrees (approximately an L-shape). At this time, excess portions are generated in the first horizontal piece 113, the first vertical piece 114, the lower groove piece 115, the groove piece 116, the upper groove piece 117, and the second vertical piece 118 in relation to the panel main body 112. However, these excess portions are not cut off but are folded inside the corner panel 100 (toward the rear surface of the first metal skin 1). Therefore, no cuts are formed in the first horizontal piece 113, the first vertical piece 114, the lower groove piece 115, the groove piece 116, the upper groove piece 117 and the second vertical piece 118, and waterproofing is less likely to be impaired.

[0091] After the folding process is completed, the filling process is carried out. In the filling process, as shown in FIG. 14B, an auxiliary core 4B is inserted into the space 47 of the core body 4A, filling the space 47 with the auxiliary core 4B. The auxiliary core 4B may or may not be glued. The auxiliary core 4B is held in place by the core body 4A, the connecting member 13, and the metal skin 1, so it will not come off even if it is not glued. When the auxiliary core 4B is glued, it is adhered to the core body 4A via a sealant, for example.

[0092] Once the filling process is complete, the reinforcing process is carried out in the same manner as above, as shown in Figure 14C. Also, a new auxiliary packing 92 is installed in the place removed in Figure 13B. Then, the water-stopping material 91 is installed (see Figures 1 and 2).

[0093] The bent corner panel 100 shown in FIG. 1 is formed by carrying out the cutting step, folding step, filling step, and reinforcing step described above in this order on the flat panel 10.

[0094] (summary) As described above, the first aspect is a corner panel (100) used in an exterior corner portion of a building. The corner panel (100) comprises two metal outer skins (1, 2), a core (4) formed from resin foam and disposed between the two metal outer skins (1, 2), and a gasket (90). The core (4) comprises a core body (4A) and an auxiliary core (4B). The auxiliary core (4B) is disposed in a corner portion (103) of the corner panel (100) and is formed from a hard material having rigidity equal to or greater than that of the core body (4A). The gasket (90) is disposed above the auxiliary core (4B) and is in contact with and supported by the auxiliary core (4B) at the corner portion (103).

[0095] According to this embodiment, the auxiliary core material (4B) can provide heat insulation to the corner portion (103), so that the heat insulation is unlikely to be reduced. Also, the auxiliary core material (4B) can support the packing (90) in the corner portion (103), so that the watertightness is unlikely to be reduced.

[0096] The second aspect is the corner panel (100) according to the first aspect, wherein the packing (90) has an auxiliary packing (92). The auxiliary packing (92) is disposed above the auxiliary core (4B) and is in contact with and supported by the auxiliary core (4B) at the corner portion (103).

[0097] According to this embodiment, the auxiliary packing (92) can be supported by the auxiliary core material (4B) at the corner portion (103), and the watertightness is less likely to be impaired.

[0098] The third aspect is the corner panel (100) according to the first aspect, in which the auxiliary core (4B) is made up of two or more members.

[0099] According to this embodiment, the shapes of the auxiliary cores (4B) are less likely to be complicated, and the auxiliary cores (4B) are easier to manufacture.

[0100] The fourth aspect is the corner panel (100) according to the first aspect, in which the auxiliary core (4B) is made up of a single member.

[0101] According to this embodiment, it is not necessary to form a plurality of auxiliary core members (4B), and an increase in the number of parts can be suppressed, making it easier to manufacture the corner panel.

[0102] In a fourth aspect, in the corner panel (100) according to any one of the first to fourth aspects, the resin foam is a polyisocyanurate foam.

[0103] According to this embodiment, the core body (4A) and the auxiliary core (4B) can be formed from the same type of resin foam, making it easy to obtain uniform heat insulating performance. [Explanation of symbols]

[0104] 1 Metal shell 2 Metal shell 4 Core material 4A Core body 4B auxiliary core material 90 Gasket 92 Auxiliary packing 100 Corner Panel 103 Corner part

Claims

1. A corner panel used at the corner of a building, The corner panel includes two metal skins, a core material formed from a resin foam and disposed between the two metal skins, and a packing. The core material includes a core material main body and an auxiliary core material, The auxiliary core is disposed at the corner of the corner panel and is made of a hard material having rigidity equal to or greater than that of the core body. the packing is disposed above the auxiliary core material, and is in contact with and supported by the auxiliary core material at the corner portions; Corner panel.

2. The packing includes an auxiliary packing, the auxiliary packing is disposed above the auxiliary core material, and is in contact with and supported by the auxiliary core material at the corner portion; The corner panel according to claim 1 .

3. The auxiliary core material is composed of two or more members. The corner panel according to claim 1 .

4. The auxiliary core material is composed of one member. The corner panel according to claim 1 .

5. The resin foam is a polyisocyanurate foam. The corner panel according to any one of claims 1 to 4.

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