Sandwich panel and sandwich panel connection structure

Abstract

To provide a sandwich panel and a sandwich panel connection structure which excel in fire resistance performance.SOLUTION: A sandwich panel 1 of the present invention includes: a core material 5 that has at least two principal planes 5C, 5D facing each other and two side faces 5A, 5B connecting the two principal planes 5C, 5D facing each other and includes an organic core material; and a face panel 10 that covers the two principal planes 5C, 5D and two side faces 5A, 5B of the core material 5 almost entirely and has protrusions 11a-c, 13a-b and concavities 12a-b, 14a-c in a part that covers the side faces 5A, 5B.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to a sandwich panel and a sandwich panel connection structure to be installed in a partition section of a building. [Background technology]

[0002] Sandwich panels are sometimes installed in partitions in buildings to improve fire resistance. For example, one proposed sandwich panel includes a core material made of a fibrous mat formed by compression molding rock wool fibers, and metal plates bonded and integrated to both sides of the fibrous mat (see, for example, Patent Document 1).

[0003] In conventional sandwich panels made from rock wool fiber, the insulating properties of the rock wool fiber are low, so in places where insulating properties are required, it is necessary to ensure insulating properties by adding urethane foam, which has excellent insulating properties, after the sandwich panel is installed.In addition, sandwich panels made from rock wool fiber are difficult to handle during construction because the rock wool fiber is heavy. Therefore, the use of urethane foam or the like as a core material for sandwich panels has been considered in order to improve heat insulating performance and ease of handling (see, for example, Patent Document 2). [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Publication No. 6-123141 [Patent Document 2] Patent Publication No. 2021-088923 Summary of the Invention [Problem to be solved by the invention]

[0005] Partitions in buildings are sometimes constructed by joining multiple sandwich panels together at their ends. Insufficient joining of sandwich panels at their ends can lead to poor flammability due to oxygen inflow, or to gaps caused by carbonization and shrinkage of the organic material, such as urethane foam, used as the core material, resulting in thermal paths and reduced fire resistance.

[0006] Therefore, an object of the present invention is to provide a sandwich panel and a sandwich panel connection structure that have excellent fire resistance. [Means for solving the problem]

[0007] The present invention has been made to solve the above problems, and the gist of the present invention is as follows. [1] A sandwich panel comprising: a core material having at least two opposing main surfaces and two side surfaces connecting the two opposing main surfaces, the core material including an organic core material; and a surface material covering substantially the entire surfaces of the two main surfaces and the two side surfaces of the core material, the surface material having convex portions and concave portions in the portions covering the side surfaces. [2] The sandwich panel according to [1], wherein the organic core material is an organic foam. [3] A sandwich panel according to [1] or [2], wherein the surface material has a heat-sealing portion in the portion covering the side surface. [4] The sandwich panel according to [3], wherein the thermal edge separation portion is constituted by a gap. [5] A sandwich panel according to any one of [1] to [4], wherein the irregularities provided in the portion covering one of the side surfaces have an inverted shape relative to the irregularities provided in the portion covering the other side surface. [6] The sandwich panel according to any one of [1] to [5], wherein the surface material is a non-combustible surface material. [7] A sandwich panel connection structure in which the sandwich panels according to any one of [1] to [6] are arranged adjacent to each other and connected by a connecting portion where the sides of a pair of adjacent sandwich panels are butted together. [8] A sandwich panel connection structure described in [7], wherein the irregularities on the side of one sandwich panel at the connection portion have an inverted shape relative to the irregularities on the side of the other sandwich panel. [9] A sandwich panel connection structure according to [7] or [8], further comprising a partition material as a thermal edge separation portion at the connection portion.

[10] The sandwich panel connection structure according to any one of [7] to [9], further comprising a filler in the connection portion. [Effects of the Invention]

[0008] According to the present invention, it is possible to provide a sandwich panel and a sandwich panel connection structure having excellent fire resistance. [Brief explanation of the drawings]

[0009] [Figure 1] 1 is a schematic diagram of a sandwich panel connection structure according to an embodiment of the present invention. FIG. [Figure 2] 1 is a schematic cross-sectional view of a sandwich panel according to a first embodiment of the present invention. [Figure 3] FIG. 2 is a schematic cross-sectional view of a sandwich panel according to a modified example of the first embodiment of the present invention. [Figure 4] FIG. 4 is a schematic cross-sectional view of a sandwich panel according to a second embodiment of the present invention. [Figure 5] FIG. 10 is a schematic cross-sectional view of a sandwich panel according to a modified example of the second embodiment of the present invention. [Figure 6] FIG. 10 is a schematic cross-sectional view of a sandwich panel according to a third embodiment of the present invention. [Figure 7] FIG. 10 is a schematic cross-sectional view of a sandwich panel according to Modification 1 of the third embodiment of the present invention. [Figure 8] FIG. 10 is a schematic cross-sectional view of a sandwich panel according to Modification 2 of the third embodiment of the present invention. [Figure 9] FIG. 2 is a schematic cross-sectional view (part 1) of a sandwich panel according to another embodiment of the present invention. [Figure 10] FIG. 2 is a schematic cross-sectional view (part 2) of a sandwich panel according to another embodiment of the present invention. [Figure 11] FIG. 10 is a schematic cross-sectional view (part 3) of a sandwich panel according to another embodiment of the present invention. [Figure 12] FIG. 4 is a schematic cross-sectional view (part 4) of a sandwich panel according to another embodiment of the present invention. DETAILED DESCRIPTION OF THE INVENTION

[0010] The present invention will be described in more detail below using embodiments.

[0011] [First embodiment] As shown in FIG. 1, a sandwich panel 1 according to a first embodiment of the present invention constitutes a sandwich panel connection structure 100 for a wall surface or the like of a building, and the sandwich panel connection structure 100 serves as a partition between compartments (compartments in the Z-axis direction in FIG. 1). Examples of partitions of a building on which the sandwich panel 1 is installed include walls, partitions, floors, ceilings, and roofs, preferably walls and partitions, and more preferably exterior walls and partitions. The sandwich panels 1 are connected by connecting parts 2 that butt their side surfaces together (adjacent in the X-axis direction in FIG. 1) to form the sandwich panel connection structure 100. The sandwich panels 1 in the sandwich panel connection structure 100 are assembled by holding their upper and lower (Y-axis direction) ends between an upper frame member 3 attached to the ceiling 3A and a lower frame member 4 attached to the floor 4A.

[0012] As shown in Figure 2(a), the sandwich panel 1 comprises an organic core material 5 having two opposing main surfaces 5C, 5D and two side surfaces 5A, 5B connecting the two opposing main surfaces 5C, 5D, and a surface material 10 covering almost the entire main surfaces 5C, 5D and side surfaces 5A, 5B of the organic core material 5. In the following description, the surface material 10 will be described as main surface covering portions 1C and 1D covering the main surfaces 5C and 5D of the organic core material 5, respectively, and as side surface covering portions 1A and 1B covering the side surfaces 5A and 5B, respectively. In this embodiment, the surface material 10 covers almost the entire main surfaces 5C, 5D and side surfaces 5A, 5B of the organic core material 5, thereby preventing the organic core material 5 from burning in a fire, etc., and preventing gaps that could cause heat paths due to carbonization shrinkage caused by the burning of the organic core material 5, thereby improving fire resistance. In addition to the two side surfaces (ends in the X-axis direction in FIG. 1) that make up the connecting portion 2, the sandwich panel 1 also has two upper and lower end portions (ends in the Y-axis direction in FIG. 1) that connect the two main surfaces (the XY plane in FIG. 1), but these do not need to be covered with the surface material 10. The two upper and lower end portions are housed inside the upper frame material 3 and the lower frame material 4, and even if they are not covered with the surface material 10, the organic core material 5 can be prevented from burning through the two upper and lower end portions.

[0013] The surface material 10 covering almost the entire main surfaces 5C, 5D and side surfaces 5A, 5B of the organic core material 5 means that the surface material 10 covers almost the entire surface to an extent that it is possible to prevent the organic core material 5 from burning in the event of a fire, etc., and it is sufficient for the surface material 10 to cover, for example, 90% or more of the total area of ​​the main surfaces 5C, 5D and side surfaces 5A, 5B of the organic core material 5, preferably 95% or more, more preferably 98% or more, and even more preferably 100%. In this embodiment, the sandwich panel 1 is covered with the surface material 10 over the entire periphery without interruption, the periphery being formed by the side surface covering portions 1A, 1B and the main surface covering portions 1C, 1D.

[0014] The surface material 10 has protrusions 11a-c, 13a-b and recesses 12a-b, 14a-c provided on each of the side surface covering portions 1A and 1B. The unevenness consisting of the protrusions 11a-c and recesses 12a-b provided on one side surface covering portion 1A of the surface material 10 is the inverse of the unevenness consisting of the protrusions 13a-b and recesses 14a-c provided on the other side surface covering portion 1B, as shown in FIG. 2(b). Because the unevenness provided on one side surface covering portion 1A of the sandwich panel 1 is the inverse of the unevenness provided on the other side surface covering portion 1B, when a connecting portion 2 is formed by butting together the side surface covering portions 1A and 1B, which are the side surfaces of adjacent sandwich panels 1, as shown in FIG. 2(c), the unevenness of the side surface covering portions 1A and 1B of the adjacent sandwich panels 1 also has the inverse of the unevenness, and they can be fitted together. In this embodiment, the side covering portions 1A, 1B of adjacent sandwich panels 1 can be fitted together to form a strong connection, preventing oxygen from flowing into the connecting portion 2, suppressing deterioration of flammability, and improving fire resistance.

[0015] The protrusions 11a to c, 13a to b and recesses 12a to b, 14a to c provided on the side surface covering portions 1A and 1B will be described in detail with reference to FIG. 2(a) and 2(b), the side covering portion 1A is provided with protrusions 11a, 11b, and 11c and recesses 12a and 12b. The protrusions 11a and 11c are provided on both side surfaces of the side covering portion 1A, and the protrusion 11b is provided in the center of the side covering portion 1A. The recess 12a is provided between the protrusions 11a and 11c, and the recess 12b is provided between the protrusions 11b and 11c. As shown in Figures 2(a) and (b), the side surface covering portion 1B is provided with protrusions 13a and 13b and recesses 14a, 14b, and 14c. Recesses 14a and 14c are provided on both side surfaces of the side surface covering portion 1B, and recess 14b is provided in the center of the side surface covering portion 1B. Protrusion 13a is provided between recesses 14a and 14b, and protrusion 13b is provided between recesses 14b and 14c. In this specification, the term "recess" refers not only to recesses that are convex on both sides, but also to portions that are simply recessed from the side surface, such as recesses 14a and 14c shown in Figure 1. The convex portions 11a, 11b, and 11c provided on the side surface covering portion 1A and the concave portions 14a, 14b, and 14c provided on the side surface covering portion 1B have inverted shapes. Furthermore, the concave portions 12a and 12b provided on the side surface covering portion 1A and the convex portions 13a and 13b provided on the side surface covering portion 1B have inverted shapes. That is, when two sandwich panels 1 are prepared and the side surface covering portion 1A of one sandwich panel 1 is butted against the side surface covering portion 1B of the other sandwich panel 1 to form a connecting portion 2, the convex portions 11a, 11b, and 11c provided on the side surface covering portion 1A and the concave portions 14a, 14b, and 14c provided on the side surface covering portion 1B fit together, respectively, and the concave portions 12a and 12b provided on the side surface covering portion 1A fit together with the convex portions 13a and 13b provided on the side surface covering portion 1B, thereby enabling a strong connection between the connecting portions 2 of the adjacent sandwich panels 1.

[0016] From the viewpoint of improving fire resistance, it is preferable to use a non-combustible surface material for the surface material 10. Examples of non-combustible surface materials include calcium silicate board, gypsum board, FRP, and metal plate, among which metal plate is preferable. The metal plate is not particularly limited, but various steel plates such as galvanized steel plate, Galvalume steel plate (registered trademark), stainless steel plate, and aluminum steel plate can be used.

[0017] The thickness of the surface material 10 is preferably 0.1 to 5 mm, more preferably 0.2 to 3 mm, and even more preferably 0.3 to 1 mm. When the thickness of the surface material 10 is equal to or greater than the above lower limit, high fire resistance can be achieved. Furthermore, when the thickness of the surface material 10 is equal to or less than the above upper limit, the weight of the sandwich panel 1 can be reduced.

[0018] The organic core material 5 is a core material of the sandwich panel 1 made of an organic material such as an organic foam. The organic foam is preferably one selected from the group consisting of urethane foam, phenol foam, styrene foam, PVC foam, and polyolefin foam such as polyethylene foam, and among these, either urethane foam or phenol foam is more preferable, with urethane foam being even more preferable.

[0019] From the viewpoint of improving fire resistance, the organic core material 5 preferably has a shape that conforms to the inner surface of the surface material 10 so as to reduce the gap formed between the organic core material 5 and the inner surface of the surface material 10. Therefore, the side surfaces 5A and 5B of the organic core material 5 may have an uneven shape. Furthermore, the uneven shapes of the side surfaces 5A and 5B may have shapes that correspond to the convex portions 11a, 11b, and 11c and concave portions 12a and 12b of the side surface covering portion 1A and the convex portions 13a, 13b and concave portions 14a, 14b, and 14c of the side surface covering portion 1B, respectively. However, if the shapes of the convex portions 11 and 13 and the concave portions 12 and 14 provided on the side surface covering portions 1A and 1B are too fine and it is difficult for the organic core material 5 to conform to them, it is preferable to exclude the fine convex portions 11 and 13 and the concave portions 12 and 14 and form a shape that conforms to the inner surface of the surface material 10.

[0020] The thickness (Z-axis direction) of the organic core material 5 is preferably 10 to 300 mm, more preferably 30 to 250 mm, and even more preferably 50 to 200 mm. When the thickness of the organic core material 5 is within the above range, it has high fire resistance and heat insulation properties and can be made lighter.

[0021] <Urethane foam> The urethane foam used as the organic core material 5 will now be described in more detail. The urethane foam used in this embodiment is formed by curing and foaming a urethane resin composition. The urethane resin contained in the urethane foam is a reaction product obtained by mixing and reacting a polyisocyanate compound and a polyol compound.

[0022] The urethane resin composition that forms the urethane foam generally contains a polyisocyanate compound and a polyol compound. The urethane resin composition preferably further contains a catalyst such as a resinification catalyst or a trimerization catalyst, and a blowing agent, and may also contain additives other than these, such as a foam stabilizer, a flame retardant, an inorganic filler, an antioxidant, a heat stabilizer, a metal damage inhibitor, an antistatic agent, a stabilizer, a crosslinking agent, a lubricant, a softener, a dye, a pigment, and a tackifying resin. The urethane resin composition can also be made flame-retardant, non-flammable, or quasi-non-flammable by incorporating a flame retardant, adjusting the amount of catalyst, or increasing the isocyanate index, as will be described later. In the case of a two-component curing type urethane resin composition, it is preferable to separate it into a polyol liquid agent (first component) containing a polyol compound and an isocyanate liquid agent (second component) containing a polyisocyanate compound. In this case, components other than the polyol compound and the polyisocyanate compound may be appropriately blended into the polyol liquid agent or the isocyanate liquid agent, but are preferably blended into the polyol liquid agent.

[0023] The organic material forming the organic core 5 may consist solely of organic substances, or may contain inorganic substances in addition to organic substances. The organic material contains, for example, an organic substance as the main component, and examples of the organic material include those in which, of the total component amount, organic substances account for, for example, 30 mass % or more, preferably 50 mass % or more, more preferably 70 mass % or more, and even more preferably 80 mass % or more.

[0024] In one embodiment of a manufacturing method for the sandwich panel 1 according to the present invention, a urethane resin composition is first foamed and cured to form a urethane foam. In this case, the urethane foam may be formed by injecting the urethane resin composition into a mold or the like, foaming and curing the composition inside the mold or the like, and then releasing the urethane foam from the mold to form the organic core material 5 having the desired shape, or the urethane foam may be processed into the desired shape by cutting or the like to form the organic core material 5. Next, a non-combustible surface material is prepared and bent to form surface material 10 having main surface covering portions 1C, 1D and side surface covering portions 1A, 1B. Surface material 10 may consist of one sheet of non-combustible surface material, or may consist of multiple sheets of non-combustible surface material. Next, the main surface covering portions 1C, 1D and side surface covering portions 1A, 1B of the surface material 10 are arranged to cover the main surfaces 5C, 5D and side surfaces 5A, 5B of the organic core material 5, and the surface material 10 is then appropriately connected to produce a sandwich panel 1 in which the surface material 10 covers at least substantially the entire main surfaces 5C, 5D and side surfaces 5A, 5B of the organic core material 5. If the surface material 10 is made of a single non-combustible surface material, the connection process is sufficient at a single location between the side surfaces. If the surface material 10 is made of multiple non-combustible surface materials, the connection process must be performed at multiple locations between the side surfaces of each surface material depending on the number of surfaces. Examples of connection processes include fusion bonding, solid-state bonding, chemical bonding, and mechanical bonding. Alternatively, the surface material 10 may be appropriately bonded to the organic core material 5 using an adhesive or the like.

[0025] In another embodiment of the manufacturing method for the sandwich panel 1 according to the present embodiment, a non-combustible surface material is first prepared, and then the non-combustible surface material is bent or connected to form the surface material 10 having the main surface covering portions 1C, 1D and the side surface covering portions 1A, 1B. At this time, the surface material 10 has been connected and has a hollow flat plate shape. Next, a urethane resin composition is injected into the hollow interior of the surface material 10, and the urethane resin composition is foamed and hardened inside the surface material 10 to form an organic core material 5 of urethane foam throughout the entire interior of the surface material 10, thereby producing a sandwich panel 1 in which the surface material 10 covers at least almost the entire main surfaces 5C, 5D and side surfaces 5A, 5B of the organic core material 5.

[0026] According to the sandwich panel 1 of this embodiment described above, the surface material 10 covers almost the entire main surfaces 5C, 5D and side surfaces 5A, 5B of the organic core material 5, thereby preventing the organic core material 5 from burning in a fire, etc., and preventing gaps that could cause heat paths due to carbonization shrinkage caused by the burning of the organic core material 5, thereby improving fire resistance. Furthermore, according to the sandwich panel 1 and the connection structure 100 for sandwich panels 1 of this embodiment, when the side covering portions 1A, 1B, which are the side surfaces of adjacent sandwich panels 1, are butted together to form the connection portion 2, the convex portions 11a-c, 13a-b and the concave portions 12a-b, 14a-c provided on the side covering portions 1A, 1B are fitted together to form the connection portion 2, thereby preventing oxygen from flowing into the connection portion 2 and suppressing deterioration of flammability. Therefore, coupled with the fact that the surface material 10 covers substantially the entire main surfaces 5C, 5D and the side surfaces 5A, 5B of the organic core material 5, excellent fire resistance can be achieved.

[0027] [Modification of the first embodiment] In the first embodiment, the sandwich panel 1 is configured such that the side covering portion 1A is provided with convex portions 11a, 11b, and 11c and concave portions 12a and 12b, and the side covering portion 1B is provided with convex portions 13a and 13b and concave portions 14a, 14b, and 14c, as shown in Fig. 2. However, the sandwich panel 1 may also be configured such that the side covering portion 1A is further provided with convex portions and the side covering portion 1B is further provided with concave portions, as shown in Fig. 3.

[0028] As shown in FIG. 3(a), the sandwich panel 1 in the modified example of the first embodiment is configured such that the side surface covering portion 1A is further provided with convex portions 11d and 11e, and the side surface covering portion 1B is further provided with concave portions 14d and 14e.

[0029] The protrusions 11a to e, 13a to b and recesses 12a to b, 14a to e provided on the side surface covering portions 1A and 1B will be described in detail with reference to FIG. As shown in Figures 3(a) and (b), the side surface covering portion 1A is provided with protrusions 11a, 11b, 11c, 11d, and 11e and recesses 12a and 12b. The protrusions 11a and 11c are provided on both side surfaces of the side surface covering portion 1A, and the protrusion 11b is provided in the center of the side surface covering portion 1A. The recess 12a is provided between the protrusions 11a and 11b, and the recess 12b is provided between the protrusions 11b and 11c. The protrusion 11d is provided in the center of the recess 12a, and the protrusion 11e is provided in the center of the recess 12b. The protrusions 11d and 11e are both smaller in width (Z-axis direction) and length (X-axis direction) than the protrusion 11b. As shown in Figures 3(a) and (b), the side surface covering portion 1B is provided with protrusions 13a and 13b and recesses 14a, 14b, 14c, 14d, and 14e. Recesses 14a and 14c are provided on both side surfaces of the side surface covering portion 1B, and recess 14b is provided in the center of the side surface covering portion 1B. The protrusion 13a is provided between recesses 14a and 14b, and the protrusion 13b is provided between recesses 14b and 14c. Recess 14d is provided in the center of the protrusion 13a, and recess 14e is provided in the center of the protrusion 13b. The recesses 14d and 14e are both smaller in width (Z-axis direction) and length (X-axis direction) than recess 14b. Convex portions 11a, 11b, 11c, 11d, and 11e provided on side surface covering portion 1A and concave portions 14a, 14b, 14c, 14d, and 14e provided on side surface covering portion 1B have inverted shapes. In addition, concave portions 12a and 12b provided on side surface covering portion 1A and convex portions 13a and 13b provided on side surface covering portion 1B also have inverted shapes. In other words, when two sandwich panels 1 are prepared and a connecting portion 2 is formed by butting together the side covering portion 1A of one sandwich panel 1 and the side covering portion 1B of the other sandwich panel 1, the convex portions 11a, 11b, 11c, 11d, and 11e provided on the side covering portion 1A and the concave portions 14a, 14b, 14c, 14d, and 14e provided on the side covering portion 1B fit together, respectively, and the concave portions 12a and 12b provided on the side covering portion 1A fit together the convex portions 13a and 13b provided on the side covering portion 1B, thereby making it possible to form a stronger connection between the connecting portions 2 of adjacent sandwich panels 1.

[0030] [Second embodiment] Next, a second embodiment of the present invention will be described in detail. The second embodiment differs from the first embodiment in that, as shown in FIG. 4, the side covering portions 1A, 1B constituting the connecting portion 2 where the side surfaces of the sandwich panel 1 are butted together are further provided with gaps 15, 16 as thermal edge separation portions. Below, the differences between the first embodiment and the second embodiment will be described. Furthermore, parts whose description is omitted are the same as those in the first embodiment. Furthermore, in the following description, parts having the same configuration as those in the first embodiment will be given the same reference numerals.

[0031] As shown in FIG. 4(a), gap 15 is provided in side surface covering portion 1A, and gap 16 is provided in side surface covering portion 1B. The entire periphery of sandwich panel 1, defined by side surfaces 1A, 1B and main surfaces 1C, 1D, is covered with surface material 10 except for gaps 15 and 16. As shown in FIG. 4(b), gaps 15 and 16 are provided at the positions of side surface covering portions 1A and 1B that face each other when sandwich panels 1 are abutted side-to-side. As shown in FIG. 4(c), gaps 15 and 16 combine to form gap 17 when connecting portion 2 is formed. Gap 17 (gaps 15 and 16) functions as a thermal isolation portion for heat conduction in the thickness direction (Z-axis direction) of sandwich panel 1 (heat conduction from main surface covering portion 1C to main surface covering portion 1D, or heat conduction from main surface covering portion 1D to main surface covering portion 1C).

[0032] The gaps 15, 16 may be provided over a portion of the total height (Y-axis direction) length of the side covering portions 1A, 1B, but are preferably provided over 5% to 90% of the total length, more preferably over 7% to 80% of the total length, and even more preferably over 10% to 70% of the total length. In addition, gaps 15, 16 may be provided in parts that do not constitute the connecting portion 2 of the sandwich panel 1, or may be provided on sides in the sandwich panel connecting structure 100 that are not butted against other sandwich panels 1, in which case gap 15 or gap 16 of side covering portion 1A or side covering portion 1B can function alone as a thermal edge separation portion.

[0033] The width (Z-axis direction) of the gaps 15, 16 is preferably 0.1 to 10 mm, more preferably 0.2 to 5 mm, and even more preferably 0.3 to 3 mm. By keeping the width of the gaps 15, 16 within the above range, the surface material 10 can maintain coverage of substantially the entire main surfaces 5C, 5D and side surfaces 5A, 5B of the organic core material 5, thereby providing high fire resistance and improving the thermal insulation between the compartments.

[0034] The method of forming the gaps 15, 16 is, for example, when forming the surface material 10 by bending a non-combustible surface material, by making the areas corresponding to the gaps 15, 16 the ends of the non-combustible surface material and not joining the ends together to form the gaps 15, 16. Another method of forming the gaps 15, 16 is to form the gaps 15, 16 by making the areas corresponding to the gaps 15, 16 areas where the non-combustible surface materials are not connected to each other when the surface material 10 is made up of multiple non-combustible surface materials.

[0035] According to the sandwich panel 1 and sandwich panel connection structure 100 relating to the second embodiment of the present invention, it is possible to obtain the same effects as those of the sandwich panel 1 and sandwich panel connection structure 100 relating to the first embodiment. Furthermore, in the second embodiment, gaps 15 and 16 are further provided in side covering portions 1A and 1B that constitute connecting portion 2 where the side surfaces of sandwich panel 1 are butted together, so that when connecting portion 2 is formed, gap 17 is formed by combining gaps 15 and 16, and gap 17 functions as a thermal isolation portion for heat conduction in the thickness direction of sandwich panel 1. This suppresses heat transfer in the thickness direction, and also tends to improve fire resistance.

[0036] [Modification of the second embodiment] In the second embodiment, the sandwich panel 1 is configured such that the side covering portion 1A is provided with convex portions 11a, 11b, and 11c and concave portions 12a and 12b, and the side covering portion 1B is provided with convex portions 13a and 13b and concave portions 14a, 14b, and 14c, as shown in Fig. 4. However, the sandwich panel 1 may also be configured such that the side covering portion 1A is further provided with convex portions and the side covering portion 1B is further provided with concave portions, as shown in Fig. 5.

[0037] As shown in FIG. 5(a), the sandwich panel 1 in the modified example of the second embodiment is configured such that the side surface covering portion 1A is further provided with convex portions 11d and 11e, and the side surface covering portion 1B is further provided with concave portions 14d and 14e.

[0038] The protrusions 11a to e, 13a to b and recesses 12a to b, 14a to e provided on the side surface covering portions 1A and 1B will be described in detail with reference to FIG. As shown in Figures 5(a) and (b), the side surface covering portion 1A is provided with protrusions 11a, 11b, 11c, 11d, and 11e and recesses 12a and 12b. The protrusions 11a and 11c are provided on both side surfaces of the side surface covering portion 1A, and the protrusion 11b is provided in the center of the side surface covering portion 1A. The recess 12a is provided between the protrusions 11a and 11b, and the recess 12b is provided between the protrusions 11b and 11c. The protrusion 11d is provided in the center of the recess 12a, and the protrusion 11e is provided in the center of the recess 12b. The protrusions 11d and 11e are both smaller in width (Z-axis direction) and length (X-axis direction) than the protrusion 11b. As shown in Figures 5(a) and (b), the side surface covering portion 1B is provided with protrusions 13a and 13b and recesses 14a, 14b, 14c, 14d, and 14e. Recesses 14a and 14c are provided on both side surfaces of the side surface covering portion 1B, and recess 14b is provided in the center of the side surface covering portion 1B. The protrusion 13a is provided between recesses 14a and 14b, and the protrusion 13b is provided between recesses 14b and 14c. Recess 14d is provided in the center of the protrusion 13a, and recess 14e is provided in the center of the protrusion 13b. The recesses 14d and 14e are smaller in both width (Z-axis direction) and length (X-axis direction) than recess 14b. Convex portions 11a, 11b, 11c, 11d, and 11e provided on side surface covering portion 1A and concave portions 14a, 14b, 14c, 14d, and 14e provided on side surface covering portion 1B have inverted shapes. In addition, concave portions 12a and 12b provided on side surface covering portion 1A and convex portions 13a and 13b provided on side surface covering portion 1B also have inverted shapes. In other words, when two sandwich panels 1 are prepared and a connecting portion 2 is formed by butting together the side covering portion 1A of one sandwich panel 1 and the side covering portion 1B of the other sandwich panel 1, the convex portions 11a, 11b, 11c, 11d, and 11e provided on the side covering portion 1A and the concave portions 14a, 14b, 14c, 14d, and 14e provided on the side covering portion 1B fit together, respectively, and the concave portions 12a and 12b provided on the side covering portion 1A fit together the convex portions 13a and 13b provided on the side covering portion 1B, thereby making it possible to form a stronger connection between the connecting portions 2 of adjacent sandwich panels 1.

[0039] [Third embodiment] Next, a third embodiment of the present invention will be described in detail. The third embodiment differs from the first embodiment in that, as shown in FIG. 6, a partition material 6 serving as a thermal edge separation portion is further provided at the connecting portion 2 where the side surfaces of the sandwich panels 1 are butted together. Hereinafter, the differences between the first embodiment and the third embodiment will be described. Furthermore, parts whose description is omitted are the same as those in the first embodiment. Furthermore, in the following description, parts having the same configuration as those in the first embodiment will be given the same reference numerals.

[0040] 6(a), in the sandwich panel 1 according to this embodiment, in order to configure the connecting portion 2 to further include a partition material 6 when adjacent sandwich panels 1 are butted side by side, an opening 18 having a shape that allows the partition material 6 to be inserted is provided in the side covering portion 1A, and a gap 51 having approximately the same shape as the opening 18 and a depth that allows the partition material 6 to be inserted is provided in the side surface 5A of the organic core material 5. In addition, an opening 19 having a shape that allows the partition material 6 to be inserted is provided in the side covering portion 1B, and a gap 50 having approximately the same shape as the opening 19 and a depth that allows the partition material 6 to be inserted is provided in the side surface 5B of the organic core material 5. As shown in Figure 6(b), the openings 18, 19 and voids 50, 51 are provided at the positions of the opposing side covering portions 1A, 1B and side surfaces 5A, 5B of the organic core material 5 when the sandwich panels 1 are adjacent and butted together, and as shown in Figure 6(c), when the connecting portion 2 is constructed, the partition material 6 is inserted into the space created by the openings 18, 19 and voids 50, 51.

[0041] The partition material 6 functions as a thermal separator for heat conduction in the thickness direction (Z-axis direction) of the sandwich panel 1 (heat conduction from the main surface covering portion 1C to the main surface covering portion 1D, or heat conduction from the main surface covering portion 1D to the main surface covering portion 1C). The partition material 6 is a plate-like member and is not particularly limited as long as it functions as a heat insulating portion, and examples thereof include inorganic materials such as calcium silicate board, concrete, and gypsum board.

[0042] The gaps 50, 51 and the partition material 6 may be provided over the entire height (Y-axis direction) of the side covering portions 1A, 1B, or may be provided over part of the entire height (Y-axis direction) of the side covering portions 1A, 1B.

[0043] The width (Z-axis direction) of the partition material 6 is preferably 1 to 30 mm, more preferably 2 to 25 mm, and even more preferably 3 to 20 mm. When the width of the partition material 6 is within the above range, the heat insulation between the compartments can be improved. Furthermore, the length (X-axis direction) of the partition material 6 is preferably 20 to 100 mm, more preferably 35 to 85 mm, and even more preferably 50 to 70 mm. By keeping the length of the partition material 6 within the above range, the heat insulation between the compartments can be improved.

[0044] According to the sandwich panel 1 and sandwich panel connection structure 100 relating to the third embodiment of the present invention, it is possible to obtain the same effects as those of the sandwich panel 1 and sandwich panel connection structure 100 relating to the first embodiment. In addition, in the third embodiment, a partition material 6 is further provided at the connecting portion 2 where the side surfaces of the sandwich panel 1 are butted together, so that when the connecting portion 2 is configured, the partition material 6 can function as a thermal edge separator for heat conduction in the thickness direction of the sandwich panel 1.

[0045] [Modification 1 of the third embodiment] In the third embodiment, the sandwich panel 1 is configured such that the side covering portion 1A is provided with convex portions 11a, 11b, and 11c and concave portions 12a and 12b, and the side covering portion 1B is provided with convex portions 13a and 13b and concave portions 14a, 14b, and 14c, as shown in Fig. 6. However, the sandwich panel 1 may also be configured such that the side covering portion 1A is further provided with convex portions and the side covering portion 1B is further provided with concave portions, as shown in Fig. 7.

[0046] As shown in FIG. 7(a), the sandwich panel 1 in the modified example of the third embodiment is configured such that the side surface covering portion 1A is further provided with convex portions 11d and 11e, and the side surface covering portion 1B is further provided with concave portions 14d and 14e.

[0047] The protrusions 11a to e, 13a to b and recesses 12a to b, 14a to e provided on the side surface covering portions 1A and 1B will be described in detail with reference to FIG. As shown in Figures 7(a) and (b), the side surface covering portion 1A is provided with convex portions 11a, 11b, 11c, 11d, and 11e and concave portions 12a and 12b. The convex portions 11a and 11c are provided on both side surfaces of the side surface covering portion 1A, and the convex portion 11b is provided in the center of the side surface covering portion 1A. The concave portion 12a is provided between the convex portions 11a and 11b, and the concave portion 12b is provided between the convex portions 11b and 11c. The convex portion 11d is provided in the center of the concave portion 12a, and the convex portion 11e is provided in the center of the concave portion 12b. As shown in Figures 7(a) and (b), the side surface covering portion 1B is provided with protrusions 13a and 13b and recesses 14a, 14b, 14c, 14d, and 14e. Recesses 14a and 14c are provided on both side surfaces of the side surface covering portion 1B, and recess 14b is provided in the center of the side surface covering portion 1B. The protrusion 13a is provided between recesses 14a and 14b, and the protrusion 13b is provided between recesses 14b and 14c. Recess 14d is provided in the center of the protrusion 13a, and recess 14e is provided in the center of the protrusion 13b. Convex portions 11a, 11b, 11c, 11d, and 11e provided on side surface covering portion 1A and concave portions 14a, 14b, 14c, 14d, and 14e provided on side surface covering portion 1B have inverted shapes. In addition, concave portions 12a and 12b provided on side surface covering portion 1A and convex portions 13a and 13b provided on side surface covering portion 1B also have inverted shapes. In other words, when two sandwich panels 1 are prepared and the side covering portion 1A of one sandwich panel 1 is butted against the side covering portion 1B of the other sandwich panel 1 to form the connecting portion 2, the convex portions 11a, 11b, 11c, 11d, and 11e provided on the side covering portion 1A fit together with the concave portions 14a, 14b, 14c, 14d, and 14e provided on the side covering portion 1B, respectively, and the concave portions 12a and 12b provided on the side covering portion 1A fit together with the convex portions 13a and 13b provided on the side covering portion 1B, thereby making it possible to form a stronger connection between adjacent sandwich panels 1.

[0048] [Modification 2 of the third embodiment] In the third embodiment, the sandwich panel 1 is configured such that the side covering portion 1A is provided with convex portions 11a, 11b, and 11c and concave portions 12a and 12b, and the side covering portion 1B is provided with convex portions 13a and 13b and concave portions 14a, 14b, and 14c, as shown in Fig. 6. However, the sandwich panel 1 may be configured such that the convex portion 11b is not provided in the center of the side covering portion 1A, and the concave portion 14b is not provided in the center of the side covering portion 1B, as shown in Fig. 8.

[0049] As shown in Figure 8(a), the sandwich panel 1 in a modified example of the third embodiment is configured such that the side covering portion 1A is provided with convex portions 11a, 11c, 11d, and 11e, and the side covering portion 1B is provided with concave portions 14a, 14c, 14d, and 14e.

[0050] The protrusions 11a, 11c, 11d, and 11e and the recesses 14a, 14c, 14d, and 14e provided on the side surface covering portions 1A and 1B will be described in detail with reference to FIG. 8(a) and 8(b), the side surface covering portion 1A is provided with protrusions 11a, 11c, 11d, and 11e. The protrusions 11a and 11c are provided on both side surfaces of the side surface covering portion 1A. The protrusion 11d is provided near the protrusion 11a, and the protrusion 11e is provided near the protrusion 11c. 8(a) and 8(b), recesses 14a, 14c, 14d, and 14e are provided in the side surface covering portion 1B. The recesses 14a and 14c are provided on both side surfaces of the side surface covering portion 1B. The recess 14d is provided near the recess 14a, and the recess 14e is provided near the recess 14c. The convex portions 11a, 11c, 11d, and 11e provided on the side surface covering portion 1A and the concave portions 14a, 14c, 14d, and 14e provided on the side surface covering portion 1B have an inverted shape. In other words, when two sandwich panels 1 are prepared and the side surface covering portion 1A of one sandwich panel 1 is butted against the side surface covering portion 1B of the other sandwich panel 1 to form the connecting portion 2, the convex portions 11a, 11c, 11d, and 11e provided on the side surface covering portion 1A and the concave portions 14a, 14c, 14d, and 14e provided on the side surface covering portion 1B fit together, respectively, thereby enabling the connection between the adjacent sandwich panels 1 to be more firmly configured.

[0051] [Other embodiments] The present invention is not limited to the configurations of the first to third embodiments described above, and any improvements and modifications may be made without departing from the technical spirit of the present invention. For example, the convex portions provided on side surface covering portion 1A in the first to third embodiments may be changed to concave portions, and the concave portions provided on side surface covering portion 1B may be changed to convex portions. Specifically, in the modified example of the first embodiment, convex portion 11d is provided at the center of concave portion 12a, convex portion 11e is provided at the center of concave portion 12b, concave portion 14d is provided at the center of convex portion 13a, and concave portion 14e is provided at the center of convex portion 13b. However, as shown in Figures 9(a) and (b), convex portions 11d and 11e may be changed to concave portions 12c and 12d, and concave portions 14d and 14e may be changed to convex portions 13c and 13d. Furthermore, in the first to third embodiments, the unevenness consisting of convex and concave portions of the side covering portion 1A of the sandwich panel 1 was the inverse of the unevenness consisting of concave and convex portions of the side covering portion 1B, but when forming the sandwich panel connecting structure 100, as long as the unevenness consisting of convex and concave portions of the side covering portions of adjacent sandwich panels 1 that are butted together have inverse shapes, the two side covering portions of the same sandwich panel 1 do not have to have inverse shapes.

[0052] In the above explanation, when the side covering portion 1A and the side covering portion 1B of the other sandwich panel 1 are butted together, adjacent sandwich panels 1 are connected by fitting the unevenness of the side covering portion 1A with the unevenness of the side covering portion 1B. However, as shown in Figures 10(a) and (b), a configuration in which a filler 7 is placed in the fitting portion 70 may also be used. In other words, the unevenness of the side covering portion 1A may have a structure in which it fits into the unevenness of the side covering portion 1B via the filler 7. 10(a) and (b) show a configuration in which the filler 7 is placed over the entire fitting portion 70 that constitutes the connecting portion 2, but a configuration in which the filler 7 is placed over only a portion of the fitting portion 70 that constitutes the connecting portion 2 may also be used. For example, in FIG. 10(b), a configuration may be used in which the filler 7 is placed in the fitting portion between the large recess and protrusion in the center of the connecting portion 2, and the filler 7 is not placed in the small recess and protrusion at both ends. By configuring the fitting portion 70 to have filler material 7 placed therein, even if gaps occur due to precision errors in the convex and concave portions provided in the side covering portions 1A and 1B, the gaps can be filled with filler material 7, thereby enabling the connection between adjacent sandwich panels 1 to be firmly constructed. As the filler 7, a material having fire resistance and heat insulation properties, such as rock wool, ceramic wool, or glass wool, and having the ability to conform to the fitting portion 70 can be used.

[0053] 10(a) and 10(b), when the filler 7 is arranged in the fitting portion 70, the location where the filler 7 is arranged also functions as a thermal edge separator for heat conduction in the X-axis direction of the sandwich panel 1. In this modified example, gaps 15, 16 can be provided as shown in the second embodiment, but in this case, the presence of the filler 7 as a thermal edge separator means that it is not necessary to align the positions of the gaps 15, 16, and they may be provided at different positions (Z-axis direction) of the side covering portions 1A, 1B.

[0054] In the above description, the core material of the sandwich panel 1 is an organic core material, but a portion of the core material may be an inorganic core material. Specifically, as shown in FIGS. 11(a) and 11(b), the core material on the side surfaces 5A and 5B side may be an inorganic core material 8, and the core material between them may be an organic core material 5. By using an inorganic core material 8 as the core material on the side surfaces 5A and 5B of the surface material 10, the mechanical strength of the surface material 10 on the side surfaces 1A and 1B covering portions 1A and 1B side can be improved. When the side surface covering portions 1A and 1B are butted together to form a connecting portion 2, the shapes of the side surface covering portions 1A and 1B can be maintained, making it possible to form the connecting portion 2 stably. As the inorganic core material 8, rock wool, ceramic wool, gypsum, calcium silicate, glass wool, etc. can be used. In this modification, the organic core material may occupy, for example, 50% by volume or more of the core material 5, preferably 65% ​​by volume or more, and more preferably 80% by volume or more.

[0055] The core material 5 may be divided into multiple pieces, for example, in the X-axis direction. In this case, the sandwich panel 1 can be obtained by inserting multiple core materials 5 into a surface material 10 that has been pre-processed into a rectangular frame shape. Furthermore, by dividing the core material 5, depending on the application and mode of use, the entire core material 5 can be made of organic core material, or as shown in Figure 11, part of the core material 5 can be made of inorganic core material and the rest can be made of organic core material.

[0056] In the above description, the side covering portions 1A, 1B of the surface material 10 are not limited to the configurations of the above embodiments as long as the concave and convex shapes fit together, and may have other configurations, for example, the structure shown in Fig. 12. In this configuration, the side covering portion 1A of one sandwich panel 1 may be concave and convex with a pair of convex portions at both ends in the Z-axis direction and a concave portion 12a between them, and the side covering portion 1B of the other sandwich panel 1 may be concave and convex with a pair of concave portions at both ends in the Z-axis direction and a convex portion 13a between them. [Explanation of symbols]

[0057] 1. Sandwich panel 10 Surface material 1A, 1B Side covering part 1C,1D Main surface coating part 11 Convex part 12 recess 13 Convex part 14 Recess 15,16,17 Gap 18,19 Opening 2 Connecting part 3 Upper frame material 3A Ceiling 4 Lower frame material 4A floor 5 Core material 5A,5B side 5C,5D main surface 6 Partition material 7 Filling material 8. Inorganic core material 50,51 void

Claims

1. a core material having at least two opposing main surfaces and two side surfaces connecting the two opposing main surfaces, the core material including an organic core material; A sandwich panel comprising: a surface material that covers substantially the entire surfaces of the two main surfaces and the two side surfaces of the core material and has convex portions and concave portions provided in the portions covering the side surfaces.

2. The sandwich panel according to claim 1 , wherein the organic core material is an organic foam.

3. The sandwich panel according to claim 1 , wherein the surface material has a thermal edge separation portion in a portion covering the side surface.

4. The sandwich panel according to claim 3, wherein the thermal break is formed by a gap.

5. The sandwich panel according to claim 1 , wherein the irregularities provided in the portion covering one of the side surfaces have an inverted shape relative to the irregularities provided in the portion covering the other side surface.

6. The sandwich panel according to claim 1, wherein the surface material is a non-combustible surface material.

7. A sandwich panel connection structure in which the sandwich panels according to any one of claims 1 to 6 are arranged adjacent to each other and connected by connecting portions where the sides of a pair of adjacent sandwich panels are butted together.

8. The sandwich panel connection structure according to claim 7, wherein the irregularities on the side surface of one sandwich panel at the connection portion have an inverted shape relative to the irregularities on the side surface of the other sandwich panel.

9. The sandwich panel connection structure according to claim 7, further comprising a partition material as a thermal edge separation portion at the connection portion.

10. The sandwich panel connection structure according to claim 7 , further comprising a filler material in the connection portion.

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