Building material panel

Abstract

To provide a building material panel capable of effectively achieving both of heat insulation and cost reduction.SOLUTION: A building material panel 10A includes a pair of face materials 21 and 22 disposed to face each other, and a core material 30 disposed to be sandwiched between the pair of face materials 21 and 22, wherein the core material 30 is formed by stacking a first core material 31 and a second core material 32, both of which are made of organic materials, and the first core material 31 is made of isocyanurate and the second core material 32 is made of an organic material other than isocyanurate.SELECTED DRAWING: Figure 2

Description

[Technical Field]

[0001] The present invention relates to a building panel. [Background technology]

[0002] Roofs and exterior walls of factories, warehouses, etc. can be easily constructed by joining multiple building material panels. For example, metal sandwich panels, which have a core material with insulating properties sandwiched between a pair of metal plate facings, have excellent airtightness and insulating properties, and are easy to install (see Patent Document 1, etc.). [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Application Laid-Open No. 2009-7874 Summary of the Invention [Problem to be solved by the invention]

[0004] In the above-mentioned metal sandwich panel, the thermal insulation properties depend largely on the function of the core material, but materials with high thermal insulation properties are costly, so there were challenges in selecting the material for the core material.

[0005] SUMMARY OF THE INVENTION It is therefore an object of the present invention to provide a building panel that effectively achieves both heat insulation and cost reduction. [Means for solving the problem]

[0006] (1) The building material panel of the present invention is a building material panel comprising a pair of face materials arranged opposite each other and a core material sandwiched between the pair of face materials, characterized in that the core material is made up of a first core material and a second core material both made of organic materials stacked together, the first core material being made of isocyanurate, and the second core material being made of an organic material other than isocyanurate.

[0007] (2) The building panel of the present invention includes an embodiment in which the second core material is at least one of phenol, urethane, and polystyrene.

[0008] (3) The building panel of the present invention includes a configuration in which the second core material is sandwiched between a pair of the first core materials. [Effects of the Invention]

[0009] According to the present invention, it is possible to provide a building panel that effectively achieves both heat insulation and cost reduction. [Brief explanation of the drawings]

[0010] [Figure 1] 1 is a perspective view schematically illustrating a portion of an exterior wall constructed by joining building material panels according to an embodiment. [Figure 2] FIG. 2 is a cross-sectional view of the building panel according to the embodiment, including a joint structure. [Figure 3] 1 is a schematic front view of a building panel according to an embodiment. FIG. [Figure 4] FIG. 10 is a cross-sectional view of a building panel according to another embodiment, including a joint structure. DETAILED DESCRIPTION OF THE INVENTION

[0011] Hereinafter, an embodiment of the present invention will be described with reference to the drawings. Fig. 1 shows a portion of an exterior wall 1 constructed by joining a plurality of building material panels (hereinafter referred to as panels) 10A of an embodiment in the horizontal direction. The panels 10A have a rectangular shape with a longitudinal direction, and are assembled into the exterior wall 1 with the longitudinal direction aligned vertically. Fig. 2 is a cross-sectional view showing the state in which joining edges 40, 50 of a pair of panels 10A joined in the horizontal direction, i.e., the width direction, are joined together.

[0012] As shown in FIG. 2, the panel 10A has a pair of metal face plates 21, 22 arranged opposite each other, and a core material 30 sandwiched between the pair of face plates 21, 22. That is, the panel 10A is a metal sandwich panel in which the core material 30 is sandwiched between the two face plates 21, 22. As shown in FIG. 3, a plurality of core materials 30 (three in this case) are arranged in the longitudinal direction of one panel 10A, with the butted end faces in contact with each other. The end faces of adjacent core materials 30 may be joined with a resin-based adhesive, such as a urethane-based or epoxy-based adhesive. Note that FIG. 3 is merely an example of the number and arrangement of core materials 30 arranged within one panel 10A and is not limited thereto. Furthermore, the core material 30 may be a single piece having the size of the panel 10A.

[0013] The metal surface materials 21 and 22 are elastic thin plate materials such as, but not limited to, color steel plate, fluorocarbon steel plate, vinyl chloride steel plate, hot-dip 55% aluminum-zinc alloy plated steel plate (Galvalume Steel Plate (registered trademark)), and stainless steel plate such as SUS. The thickness of the surface materials 21 and 22 is, for example, about 0.25 to 1.2 mm, but is not limited to this range.

[0014] The core material 30 is formed into a panel shape having predetermined length, width, and thickness dimensions. The core material 30 is configured by stacking at least one first core material 31 and at least one second core material 32. The core material 30 of this embodiment has a three-layer structure in which one second core material 32 is sandwiched between a pair of first core materials 31.

[0015] Each of the two first core materials 31 constitutes an outer portion of the core material 30 and is bonded to the face materials 21, 22 with a resin-based adhesive, such as a urethane-based or epoxy-based adhesive. The two first core materials 31 have the same thickness, which is, for example, about 10 to 30% of the entire core material 30, but is not limited to this. The thicknesses of the two first core materials 31 may be different. The first core material 31 is made of an organic material, isocyanurate, which has high thermal insulation properties. As the isocyanurate for the first core material 31, a foam such as polyisocyanurate foam is used, for example.

[0016] The second core material 32 sandwiched between the two first core materials 31 is disposed at the center of the core material 30 in the thickness direction. The thickness of the second core material 32 is, for example, approximately 40 to 60% of the entire core material 30, but is not limited to this. The second core material 32 is made of at least one resin material, such as phenol, urethane, or polystyrene, but is not limited to this as long as it is an organic material that functions as a core material. For example, a resin foam, such as urethane foam, phenol foam, or polystyrene foam, is preferably used as the second core material 32. The first core material 31 is bonded to both sides of the second core material 32 with a resin adhesive, such as a urethane or epoxy adhesive. The first core material 31 and the second core material 32 may be simply stacked on top of each other without being bonded together.

[0017] The overall dimensions of the panel 10A are arbitrary and correspond to the exterior wall 1 to be constructed, but are not limited to, for example, a longitudinal dimension (vertical direction on the exterior wall 1) of approximately 900 to 12,000 mm, a width dimension of approximately 400 to 1,200 mm, and a thickness of approximately 25 to 300 mm.

[0018] As shown in Figure 2, the panel 10A has a first joining edge 40 and a second joining edge 50 at one end (the right end in Figure 2) and the other end (the left end in Figure 2) in the width direction, respectively. The first joining edge 40 and the second joining edge 50 are shaped to fit together. The panels 10A are joined together by fitting the first joining edge 40 of one panel 10A to the second joining edge 50 of another panel 10A adjacent to that panel 10A.

[0019] The first joint edge 40 has a groove-shaped recess 41 extending along the longitudinal direction of the panel 10A (the front-to-back direction of the paper in FIG. 2 ), and an inner protrusion 42 with a trapezoidal cross section extending along the longitudinal direction is formed at the bottom of the recess 41. The recess 41 is formed by the protruding pieces 21a, 22a of the face materials 21, 22. The bottom of the recess 41 and the inner protrusion 42 are formed by processing the end face of the second core material 32 of the core material 30. The protruding pieces 21a, 22a are formed by folding back the widthwise ends of the face materials 21, 22. The inner protrusion 42 is located in the center of the thickness direction of the panel 10A. The height of the inner protrusion 42 is smaller than the protruding length of the protruding pieces 21a, 22a, and does not protrude outward in the width direction from the recess 41.

[0020] The second joint edge 50 has a protrusion 51 that extends along the longitudinal direction of the panel 10A, and the protrusion 51 has an inner recess 52 that extends along the longitudinal direction and has an inverted trapezoidal cross section. The protrusion 51 is formed by reducing the thickness of the panel 10A from both sides in the thickness direction. The inner recess 52 is located in the center of the panel 10A in the thickness direction. The inner recess 52 is formed by processing the end face of the second core material 32 of the core material 30.

[0021] The panels 10A are joined together by fitting the first joining edge 40 of one panel 10A to the second joining edge 50 of the other panel 10A adjacent to the first panel 10A. More specifically, the convex portion 51 of the second joining edge 50 is fitted into the concave portion 41 of the first joining edge 40, and the inner convex portion 42 of the first joining edge 40 is fitted into the inner concave portion 52 of the second joining edge 50. This joins the panels 10A together in the width direction. A predetermined number of panels 10A are joined together in this manner in the width direction, and the exterior wall 1 is constructed.

[0022] 2, the joints between joined panels 10A may be filled with a sealant 60 to improve waterproofing. The sealant 60 prevents the passage of water, other liquids, or moisture, including steam, thereby ensuring the water resistance and steam resistance of the exterior wall 1.

[0023] The panel 10A of the embodiment includes a pair of facing panels 21, 22 and a core material 30 sandwiched between the pair of facing panels 21, 22. The core material 30 is made up of a first core material 31 and a second core material 32, both of which are made of organic materials, stacked together. The first core material 31 is made of isocyanurate, and the second core material 32 is made of an organic material other than isocyanurate. Examples of the second core material 32 include resin foams such as urethane foam, phenol foam, and polystyrene foam.

[0024] The panel 10A of the embodiment can exhibit heat insulating properties over a wide temperature range, for example, from the deep freezing range (about -55°C) to a constant temperature (about 15°C) and even temperatures above constant temperature, due to the first core material 31 and the second core material 32. This makes the panel 10A suitable for use as an excellent heat insulating panel.

[0025] In the panel 10A of the embodiment, the isocyanurate constituting the first core 31 has better thermal insulation and flame retardancy than the second core 32 made of, for example, ordinary urethane foam. However, considering cost, isocyanurate is relatively expensive, so constructing the entire core 30 with a first core 31 made of isocyanurate would be cost-inefficient. On the other hand, the second core 32 made of urethane foam or the like is less expensive than the first core 31. Therefore, the panel 10A of the embodiment has high thermal insulation properties due to the first core 31 made of isocyanurate, which is relatively expensive but has high thermal insulation properties, and costs can be reduced by using a portion of the second core 32 made of urethane foam or the like. In other words, the panel 10A effectively achieves both thermal insulation and cost control.

[0026] Furthermore, by placing the first core material 31, made of highly flame-retardant isocyanurate, on the side of the facing materials 21, 22, which are likely to be directly exposed to fire and heat up to high temperatures during a fire, so that it is in direct contact with these facing materials 21, 22, fire resistance is significantly improved. This increases the likelihood of the panel being certified as non-combustible. In contrast, if the second core material 32, made of urethane foam or the like, is placed on the side of the facing materials 21, 22, the second core material 32 will melt easily, resulting in poor fire resistance and making it difficult to obtain non-combustible certification.

[0027] FIG. 4 shows a building panel 10B according to another embodiment of the present invention. This panel 10B has a two-layer structure consisting of one first core material 31 and one second core material 32 stacked on top of each other. The core materials 31, 32 are approximately the same thickness, but may have different thicknesses. The panel 10B has the same first joint edge 40 and second joint edge 50 as the above panel 10A, and the joint structure between the panels 10B is the same.

[0028] The panel 10B of this embodiment also includes the first core material 31 and the second core material 32, and can therefore be used as a panel that combines heat insulation properties with cost reduction.

[0029] The building material panel of the present invention is not limited to the configuration of the panels 10A and 10B described above, as long as it has the configuration of the present invention. For example, the building material panel of the present invention also includes a configuration in which a first core material 31 is sandwiched between a pair of second core materials 32, which is the opposite stacking pattern to the panel 10A. Furthermore, the number and stacking pattern of the first core materials 31 and second core materials 32 are arbitrary, and may be, for example, a layer configuration in which two of each core material 31 and 32 are alternately stacked, or three of one and two of the other are alternately stacked.

[0030] The building material panel of the present invention is not limited to being used to construct exterior walls as in the above embodiment, but can also be used as a panel to construct various types of walls such as interior walls and partition walls, as well as roofs and ceilings. [Explanation of symbols]

[0031] 10A, 10B...building material panels, 21, 22...face materials, 30...core material, 31...first core material, 32...second core material.

Claims

1. A building panel comprising a pair of face materials arranged opposite each other and a core material arranged sandwiched between the pair of face materials, the core material is a stack of a first core material and a second core material, both of which are made of an organic material; the first core material is made of isocyanurate, A building panel characterized in that the second core material is made of an organic material other than isocyanurate.

2. 2. The building panel according to claim 1, wherein the second core material is at least one of phenol, urethane, and polystyrene.

3. 3. The building panel according to claim 1, wherein the second core material is sandwiched between a pair of the first core materials.

Images