Spandrels, panels for spandrels, and buildings

Abstract

We provide highly aesthetically pleasing spandrels, spandrel panels, and buildings. [Solution] The spandrel comprises a metal substrate containing an Al-Mn alloy and a design layer laminated on the metal substrate, with the thickness of the metal substrate being 0.3 mm or more and 2.0 mm or less.

Description

[Technical Field]

[0001] This disclosure relates to spandrels, panels for spandrels, and buildings. [Background technology]

[0002] Conventionally, metal panels called spandrels have been installed on the ceilings, exterior walls, or interior walls of buildings such as commercial facilities or apartment complexes (see Patent Document 1). [Prior art documents] [Patent Documents]

[0003] [Patent Document 1] Japanese Patent Publication No. 2019-85789 [Overview of the Initiative] [Problems that the invention aims to solve]

[0004] This disclosure provides highly aesthetically pleasing spandrels, panels for spandrels, and buildings. [Means for solving the problem]

[0005] Embodiments of this disclosure relate to the following [1] to

[10] .

[0006] [1] A spandrel comprising a metal substrate containing an Al-Mn alloy and a design layer laminated on the metal substrate, wherein the thickness of the metal substrate is 0.3 mm or more and 2.0 mm or less.

[0007] [2] The spandrel according to [1] or [2], having a region on the first surface located on the design layer side with respect to the metal substrate in which the flop index is 4.5 or higher.

[0008] [3] A spandrel according to any one of [1] to [3], which is a roll-formed product.

[0009] [4] The spandrel according to any one of [1] to [4], wherein the design layer contains an organic colorant.

[0010] [5] The spandrel according to any one of [1] to [5], wherein the design layer is a baking layer.

[0011] [6] The spandrel according to any one of [1] to [6], wherein an accelerated weather resistance test is performed using a sunshine weather meter, and when the total ultraviolet irradiation time reaches 10,000 hours, the value of the color difference (ΔE) before and after the accelerated weather resistance test is 7 or less.

[0012] [7] The spandrel according to any one of [1] to [7], further comprising a protective sheet covering the design layer.

[0013] [8] The spandrel according to any one of [1] to [8], having a decorative part, an engaging part formed at one end of the decorative part, and a receiving part formed at the other end of the decorative part.

[0014] [9] A panel for a spandrel, comprising a metal base material containing an Al-Mn based alloy and a design layer laminated on the metal base material, wherein the thickness of the metal base material is 0.3 mm or more and 2.0 mm or less.

[0015]

[10] A building provided with the spandrel according to [1].

Advantages of the Invention

[0016] According to the present disclosure, a spandrel with high design quality can be provided.

Brief Description of the Drawings

[0017] [Figure 1] FIG. 1 is a perspective view showing a spandrel according to an embodiment. [Figure 2] FIG. 2 is a vertical cross-sectional view showing a state where a plurality of spandrels are attached to an attachment surface of a building. [Figure 3]Figure 3 is a perspective view showing a spandrel according to a modified example of one embodiment. [Figure 4] Figure 4 is a schematic cross-sectional view illustrating a spandrel. [Figure 5] Figure 5 is a schematic cross-sectional view illustrating a modified example of a spandrel. [Figure 6] Figures 6(a)-(f) are schematic cross-sectional views illustrating a part of the manufacturing method of spandrels. [Figure 7] Figure 7 illustrates a part of the manufacturing method for spandrels. [Figure 8] Figure 8 is a graph showing the results for Examples 1-1 to 1-4 and Comparative Examples 1-1 to 1-4. [Figure 9] Figure 9 is a graph showing the results for Examples 2-1 to 2-4 and Comparative Examples 2-1 to 2-4. [Figure 10] Figure 10 is a graph showing the results for Examples 3-1 to 3-4. [Figure 11] Figure 11 is a graph showing the results for Examples 4-1 to 4-4. [Modes for carrying out the invention]

[0018] Hereinafter, one embodiment will be described with reference to Figures 1 to 3. However, this disclosure can be implemented in many different ways and should not be limited to the embodiment described below. In addition, the drawings may schematically represent the width, thickness, and shape of each part compared to the actual form in order to make the explanation clearer, but this is merely an example and should not be interpreted as limiting. In the following figures, the same parts are denoted by the same reference numerals, and some detailed explanations may be omitted.

[0019] In this specification, when describing a manner in which one member is placed on another member, the term "above" or "below" includes, unless otherwise specified, both cases: when the other member is placed directly above or directly below the member so as to be in contact with it, and when the other member is placed above or below the member via yet another member. Similarly, in this specification, when describing a manner in which one member is placed on the surface of a member, the term "on the surface" includes, unless otherwise specified, both cases: when the other member is placed directly above or directly below the member so as to be in contact with it, and when the other member is placed above or below the member via yet another member.

[0020] (Spandrel configuration) The general outline of the spandrel according to this embodiment will be explained with reference to Figures 1 and 2. Figures 1 and 2 are diagrams showing the spandrel according to this embodiment.

[0021] The spandrel 10 shown in Figures 1 and 2 includes a metal substrate 55 containing an Al-Mn alloy and a design layer 56 laminated on the metal substrate 55. The thickness of the metal substrate 55 is 0.3 mm or more and 2.0 mm or less.

[0022] According to this embodiment, the spandrel 10 includes a metal substrate 55 and a design layer 56 laminated on the metal substrate 55. This enhances the aesthetic appeal of the spandrel 10. Furthermore, the design of the spandrel 10 can be matched to the design of the building 90, achieving design uniformity between the spandrel 10 and the building 90. The metal substrate 55 also contains an Al-Mn alloy. The metal substrate 55 containing an Al-Mn alloy has higher strength than a typical aluminum plate. Therefore, the baking temperature for baking the design layer 56 onto the metal substrate 55 can be increased, improving the weather resistance of the spandrel 10. The metal substrate 55 contains an Al-Mn alloy, and its thickness is between 0.3 mm and 2.0 mm. By making the metal substrate 55 thin and hard in this way, the pattern of the design layer 56 can be formed with high aesthetic appeal.

[0023] The spandrels 10 shown in Figures 1 and 2 are metal plates that are attached to mounting surfaces 91 of a building 90, such as the ceiling or exterior wall. Multiple spandrels 10 are prepared, and each spandrel 10 is attached sequentially by screwing one side of it and fitting the other side together. In this way, the mounting surface 91 of the building 90 is covered by multiple spandrels 10.

[0024] The spandrel 10 has a decorative portion 11, an engaging portion 12, and a receiving portion 13. The engaging portion 12 is formed at one end of the decorative portion 11. The receiving portion 13 is formed at the other end of the decorative portion 11. The spandrel 10 may be a roll-formed product.

[0025] The decorative part 11 is the portion that is exposed to the outside when attached to the mounting surface 91 of the building 90. The decorative part 11 constitutes the widest surface of the spandrel 10. The decorative part 11 may be made up of a flat plate-like member. The decorative part 11 may be positioned horizontally when the spandrel 10 is attached to the mounting surface 91. However, the decorative part 11 may have an uneven surface. The decorative part 11 may also be made up of a curved surface.

[0026] The decorative part 11 has an inner surface 11a and an outer surface 11b. The inner surface 11a is a surface that is not visible from the outside when the spandrel 10 is attached to the mounting surface 91. The inner surface 11a is the surface located on the opposite side of the outer surface 11b. The outer surface 11b is exposed to the outside when the spandrel 10 is attached to the mounting surface 91. The decorative layer 56 described above is arranged on the outer surface 11b side. The decorative layer 56 may be arranged on both sides of the inner surface 11a and the outer surface 11b.

[0027] A first connecting portion 14 is formed at one end of the decorative portion 11. The first connecting portion 14 connects the decorative portion 11 and the engaging portion 12. The first connecting portion 14 may be positioned perpendicular to the decorative portion 11.

[0028] The engaging portion 12 has a flat portion 12a and a protruding portion 12b. The flat portion 12a is made of a flat plate-like member. The flat portion 12a may be positioned perpendicular to the decorative portion 11. The flat portion 12a may be positioned parallel to the decorative portion 11. The protruding portion 12b protrudes from the flat portion 12a.

[0029] A second connecting portion 15 is formed on the other end of the decorative portion 11. The second connecting portion 15 connects the decorative portion 11 and the receiving portion 13. The second connecting portion 15 may be positioned perpendicular to the decorative portion 11.

[0030] The receiving portion 13 has a housing portion 13a, an inclined portion 13b, and a mounting portion 13c. One end of the housing portion 13a is connected to the second connecting portion 15. The housing portion 13a is composed of a member that is substantially C-shaped in cross-section and opens toward the opposite side of the engaging portion 12. The engaging portion 12 of another spandrel 10 is housed in the housing portion 13a. The inclined portion 13b extends inclined from the other end of the housing portion 13a. The mounting portion 13c is connected to the inclined portion 13b. The mounting portion 13c is used when attaching to the mounting surface 91. The mounting portion 13c may be provided with mounting holes (not shown). The mounting holes house screws or the like for fixing the spandrel 10 to the mounting surface 91. The mounting portion 13c may be arranged parallel to the decorative portion 11.

[0031] As shown in Figure 2, the engaging portion 12 and the receiving portion 13 are formed to engage with the receiving portion 13 and the engaging portion 12 of adjacent spandrels 10. Specifically, the engaging portion 12 of one spandrel 10 fits into the receiving portion 13a of the receiving portion 13 of another spandrel 10, thereby joining the engaging portion 12 and the receiving portion 13. This connects adjacent spandrels 10 to each other.

[0032] The spandrel 10 includes a metal substrate 55 and a design layer 56 laminated on the metal substrate 55. The design layer 56 may be directly laminated on the metal substrate 55, or it may be laminated via other layers (for example, a primer layer 57 and a base layer 58, which will be described later). The design layer 56 has both weather resistance and aesthetic appeal. Therefore, by matching the design of the design layer 56 to the exterior wall surface of the building 90, a unified appearance of the building 90 can be provided.

[0033] The length L1 of the spandrel 10 along the first direction D1 may be 100 mm or more and 400 mm or less, 150 mm or more and 300 mm or less, or 170 mm or more and 250 mm or less. The first direction D1 is the direction connecting the engaging portion 12 and the receiving portion 13, and is perpendicular to the outer edge 12e of the engaging portion 12 and the outer edge 13e of the receiving portion 13.

[0034] The length L2 of the spandrel 10 along the second direction D2 may be 200 mm or more and 5000 mm or less, 500 mm or more and 4000 mm or less, or 1000 mm or more and 3000 mm or less. The second direction D2 is a direction perpendicular to the first direction D1 and parallel to the outer edge 12e of the engaging portion 12 and the outer edge 13e of the receiving portion 13.

[0035] The length L3 of the spandrel 10 along the third direction D3 may be 6 mm or more and 25 mm or less, 8 mm or more and 20 mm or less, or 10 mm or more and 15 mm or less. The third direction D3 is a direction perpendicular to the first direction D1 and the second direction D2, and is perpendicular to the flat portion 12a of the engaging portion 12 and the mounting portion 13c of the receiving portion 13.

[0036] The detailed configuration of each layer of spandrel 10 will be described later.

[0037] According to this embodiment, the spandrel 10 includes a design layer 56 laminated on a metal substrate 55. By including the design layer 56 in the spandrel 10, the aesthetic appeal of the spandrel 10 can be enhanced. Furthermore, the design of the design layer 56 can be changed as appropriate. For example, by matching the design of the design layer 56 to the design of the exterior wall surface of the building 90, a unified appearance of the building 90 can be provided.

[0038] Furthermore, according to this embodiment, the spandrel 10 includes a metal substrate 55 containing an Al-Mn alloy. The metal substrate 55 containing an Al-Mn alloy has higher strength than pure aluminum. Therefore, even when the thickness of the metal substrate 55 is reduced to 0.3 mm or more and 2.0 mm or less, the design layer 56 can be baked onto the metal substrate 55 at a high temperature. This makes it possible to form a design layer 56 with high aesthetic appeal on the metal substrate 55. In addition, by baking the design layer 56 onto the metal substrate 55 at a high temperature, the weather resistance of the design layer 56 can be improved.

[0039] Figure 3 shows a modified example of the spandrel 10 according to this embodiment. As shown in Figure 3, the engaging portion 12 may have a bent portion 12c instead of a convex portion 12b. The bent portion 12c is a portion bent into a roughly C-shape or a roughly J-shape. In this case, the engaging portion 12 and the receiving portion 13 are combined by the bent portion 12c of the engaging portion 12 fitting into the housing portion 13a of the receiving portion 13.

[0040] (Spandrels and methods for manufacturing spandrels) The spandrels and methods for manufacturing the spandrels in each of the embodiments described above will be explained in detail below.

[0041] A. Spandrel Figures 4 and 5 are schematic cross-sectional views showing the layer structure of the spandrel 10 in this embodiment. As shown in Figure 4, the spandrel 10 consists of a metal base material 55 and a design layer 56, with the thickness direction D TIn this order, the design layer 56 contains an organic coloring agent. The spandrel 10 may also have a region on the first surface 50a located on the design layer 56 side with respect to the metal substrate 55 where the flop index is 4.5 or higher. Furthermore, as shown in Figure 5, the spandrel 10 has the metal substrate 55, primer layer 57, base layer 58, design layer 56, and surface protection layer 59 in the thickness direction D T In this order, they may be present. In Figures 4 and 5, the spandrel 10 may further have a protective sheet 61 covering the design layer 56.

[0042] In this embodiment, the design layer 56 may contain an organic coloring agent, and the flop index on the first surface 50a may be 4.5 or higher. In this case, a spandrel 10 is obtained that allows for a wide range of design expressions while making use of the glossiness of the metal substrate 55. In a spandrel 10 using a metal substrate 55, a unique design is created by making use of the glossiness of the metal substrate 55, and by utilizing this unique design, the range of design expression can be broadened. That is, it becomes possible to create a design expression that makes use of the base material of the metal substrate 55, or more specifically, a metallic design expression in which the brightness, saturation, and hue change significantly depending on the viewing angle.

[0043] When the design layer 56 contains an organic coloring agent, it becomes possible to achieve design expressions (diverse color expressions) with high brightness and saturation without excessively obscuring the glossiness of the metal substrate 55. Specifically, it becomes possible to reproduce design expressions such as brass, copper, corrosion patterns, and polishing patterns at a higher level than before. Furthermore, when the flop index on the first surface 50a is 4.5 or higher, the glossiness of the metal substrate 55 can be fully utilized. In conventional color difference evaluation, it is difficult to quantitatively evaluate the glossiness of the metal substrate 55 because it is greatly influenced by the glossiness of the spandrel surface 10. In contrast, in this embodiment, by focusing on the flop index, it becomes possible to quantitatively evaluate the glossiness of the metal substrate 55 without being greatly influenced by the glossiness of the spandrel surface 10.

[0044] 1. Flop indicators In the spandrel 10 in this embodiment, as shown in FIG. 4, on the first surface 50a located on the design layer 56 side with respect to the metal substrate 55, there may be a region where the flop index is 4.5 or more. The first surface 50a is a surface located on the design layer 56 side of the spandrel 10 and is the surface that is exposed outward when the protective sheet 61 is removed.

[0045] The glossiness of the metal substrate 55 varies greatly in lightness, chroma, and hue depending on the position and angle of light reception or observation. This change characteristic is called flop, and the index for quantitatively evaluating flop is the flop index. The flop index is calculated from the following formula using each L at effective angles of 15°, 45°, and 110°. * (L * 15 、L * 45 、L * 110 ) Flop index = 2.69 × (L * 15 - L * 110 ) 1·11 / (L * 45 ) 0·85 Details of the method for measuring the flop index will be described in the examples described later.

[0046] The flop index in the above region may be 5 or more, 6 or more, 7 or more, or 8 or more. Also, when viewed from the thickness direction, the above region is usually a region containing an organic colorant.

[0047] When the spandrel 10 is viewed from the design layer 56 side, the area of the design layer 56 is defined as S A , and the area of the above region is defined as S B . The ratio of S A to S B (S B / S A ) is, for example, 1% or more, and may be 3% or more or 5% or more. On the other hand, S B / S AThis may be 100% or less than 100%, depending on the design of the design layer 56. In the latter case, the design will have areas that utilize the glossiness of the metal substrate 55 and areas that do not utilize the glossiness of the metal substrate 55. B / S A It may be 80% or less, or 60% or less.

[0048] 2. Design layer In this embodiment, the design layer 56 is a layer that imparts design to the spandrel 10 and contains an organic coloring agent. The design layer 56 may be a pattern layer having a design (pattern), and may also be called a surface pattern layer. The design layer 56 may be a solid layer (a layer with solid ink coating), or a combination of a pattern layer and a solid layer.

[0049] Examples of patterns in the pattern layer include wood grain, marble, stone, sand, tile, brick, fabric, leather, geometric shapes, letters, symbols, abstract patterns, floral patterns, wave patterns, stripe patterns, metallic patterns, and rust-effect patterns.

[0050] The design layer 56 contains an organic coloring agent (organic pigment or organic dye). Examples of organic coloring agents include perylene-based coloring agents, cyanine-based coloring agents, nickel-azo complex-based coloring agents, azomethine-based coloring agents, quinacridone-based coloring agents, and isoindolinone-based coloring agents.

[0051] The average particle size of the organic colorant is, for example, 100 μm or more and 350 μm or less, and may be 200 μm or more and 300 μm or less. In this specification, the average particle size refers to the 50% particle size (d50: median diameter) when the particle size distribution measured by the dynamic light scattering method is expressed as a volume cumulative distribution. Furthermore, the content of the organic colorant in the layer containing the organic colorant is, for example, 1 part by mass or more and 40 parts by mass or less per 100 parts by mass of the resin component.

[0052] On the other hand, the design layer 56 may contain an inorganic coloring agent (inorganic pigment or inorganic dye). Examples of inorganic coloring agents include carbon black, iron black, titanium white, antimony white, titanium yellow, pyrite, red iron oxide, cadmium red, ultramarine, and cobalt blue. The design layer 56 may also contain metallic coloring agents such as aluminum and brass; or pearlescent coloring agents such as titanium dioxide-coated mica and basic lead carbonate.

[0053] The design layer 56 contains a resin. The resin contained in the design layer 56 is preferably a cured product (crosslinked structure) of a curable resin, and more preferably a cured product of a thermosetting resin. Examples of resins contained in the design layer 56 include fluororesins, epoxy resins, phenolic resins, urea resins, polyester resins, melamine resins, alkyd resins, amide resins, polyimide resins, silicone resins, acrylic resins, urethane resins, urethane-acrylic resins, styrene resins, and cellulose resins. Among these, fluororesins are preferred as curable resins because they have good weather resistance. Examples of fluororesins include fluoroethylene-vinyl ether copolymers, fluoroethylene-vinyl ester copolymers, and fluoroethylene-acrylic copolymers.

[0054] The resin contained in the design layer 56 may be a cured product of a resin composition containing a curable resin and a curing agent. Examples of the curing agent include isocyanate compounds such as tolylene diisocyanate (TDI), diphenylmethane diisocyanate (MDI), hexamethylene diisocyanate (HDI), isophorone diisocyanate (IPID), and xylylene diisocyanate (XDI). The ratio of the curing agent to 100 parts by mass of the curable resin is not particularly limited, but may be, for example, 30 parts by mass or more and 70 parts by mass or less, or 35 parts by mass or more and 65 parts by mass or less. The design layer 56 may also contain additives such as weathering agents. Details of weathering agents will be described later.

[0055] The design layer 56 may be a single-layer structure or a laminated structure of two or more layers. Preferably, the design layer 56 has a pattern layer containing an organic colorant. The pattern layer containing the organic colorant may be one layer or two or more layers. The design layer 56 may also have a solid layer containing an organic colorant. The solid layer containing the organic colorant may be one layer or two or more layers. The design layer 56 has at least a layer containing an organic colorant, but may further have a layer containing an inorganic colorant. The layer containing the inorganic colorant may be a pattern layer containing an inorganic colorant, a solid layer containing an inorganic colorant, or both. The pattern layer containing the inorganic colorant and the solid layer containing the inorganic colorant may each be one layer or two or more layers.

[0056] The design layer 56 may have, in the thickness direction, a layer containing an inorganic colorant and a layer containing an organic colorant, in that order from the metal substrate 55 side. The layer containing the inorganic colorant and the layer containing the organic colorant may each be a solid layer or a patterned layer. For example, by providing a solid layer containing an inorganic colorant, the color of the metal substrate 55 can be adjusted. Alternatively, by layering a patterned layer containing an inorganic colorant and a patterned layer containing an organic colorant, it becomes possible to utilize the glossiness of the metal substrate 55 with the layer containing the organic colorant while partially concealing areas with the layer containing the inorganic colorant, thereby enabling complex design expression.

[0057] Similarly, the design layer 56 may have, in the thickness direction, a layer containing an organic colorant and a layer containing an inorganic colorant, in that order from the metal substrate 55 side. In this case as well, the layer containing the organic colorant and the layer containing the inorganic colorant may each be a solid layer or a pattern layer. Furthermore, the design layer 56 may have layers containing both organic and inorganic colorants. Note that the design layer 56 does not necessarily have to have a layer containing an inorganic colorant.

[0058] The design layer 56 is preferably a baked layer. A baked layer is a layer formed by heat-curing (baking) the coated composition, and is different from the design layer 56 that is attached via an adhesive layer, for example. The thickness of the design layer 56 is not particularly limited, but for example, it may be 1 μm or more and 10 μm or less, or 3 μm or more and 7 μm or less. If the design layer 56 has multiple layers, it is preferable that the total thickness of the multiple layers is within the above range.

[0059] 3.Metal base material In this embodiment, the metal substrate 55 is an Al-Mn alloy. An Al-Mn alloy is an aluminum alloy in which manganese (Mn) is mainly added to increase the strength of pure aluminum. An Al-Mn alloy may also be called an aluminum-manganese alloy or a 3000 series aluminum alloy. Because the metal substrate 55 is an Al-Mn alloy, it is possible to bake the design layer 56 onto the metal substrate 55 at a high temperature, as will be described later. By baking the design layer 56 at a high temperature, the weather resistance of the spandrel 10 can be improved.

[0060] The metal substrate 55 may be bent. The thickness of the metal substrate 55 is, for example, 0.3 mm or more and 2.0 mm or less, and may be 0.5 mm or more and 1.5 mm or less, or 0.7 mm or more and 1.0 mm or less. When the thickness of the metal substrate 55 is 0.3 mm or more and 2.0 mm or less, the metal substrate 55 is thin, so a design layer 56 with high aesthetic appeal can be easily formed on the metal substrate 55.

[0061] 4. Primer layer In this embodiment, the spandrel 10 may have a primer layer 57 between the metal substrate 55 and the design layer 56. Providing the primer layer 57 improves the adhesion between the two layers adjacent to the primer layer 57.

[0062] The primer layer 57 contains a resin. The resin contained in the primer layer 57 is preferably a cured product (crosslinked structure) of a curable resin, and more preferably a thermosetting resin. Examples of resins contained in the primer layer 57 include urethane resins, acrylic polyol resins, acrylic resins, ester resins, amide resins, butyral resins, styrene resins, urethane-acrylic copolymers, polycarbonate-based urethane-acrylic copolymers (urethane-acrylic copolymers derived from polymers (polycarbonate polyols) having carbonate bonds in the polymer main chain and two or more hydroxyl groups in the terminals and side chains), vinyl chloride-vinyl acetate copolymer resins, vinyl chloride-vinyl acetate-acrylic copolymer resins, chlorinated propylene resins, nitrocellulose resins (nitrified cotton), cellulose acetate resins, and fluorine resins.

[0063] The resin contained in the primer layer 57 may be a cured product of a resin composition containing a curable resin and a curing agent. Examples of the curing agent include isocyanate compounds such as tolylene diisocyanate (TDI), diphenylmethane diisocyanate (MDI), hexamethylene diisocyanate (HDI), isophorone diisocyanate (IPID), and xylylene diisocyanate (XDI). The primer layer 57 may also contain additives such as weathering agents. Details of weathering agents will be described later.

[0064] The primer layer 57 is preferably a baked layer. The thickness of the primer layer 57 is not particularly limited, but for example, it may be 1 μm or more and 10 μm or less, or 2 μm or more and 5 μm or less.

[0065] 5. Base layer In this embodiment, the spandrel 10 may have a base layer 58 between the metal substrate 55 and the design layer 56. For example, the glossiness of the metal substrate 55 can be adjusted by providing the base layer 58. In order to take advantage of the glossiness of the metal substrate 55, the base layer 58 is usually a transparent (colored transparent or colorless transparent) layer.

[0066] The base layer 58 contains a resin. The resin contained in the base layer 58 is preferably a cured product (crosslinked structure) of a curable resin, and more preferably a cured product of a thermosetting resin. Furthermore, a fluororesin is preferred as the curable resin because it has good weather resistance. The base layer 58 may or may not contain a coloring agent. The base layer 58 may also contain an inorganic coloring agent. The curable resin and coloring agent are the same as those used in the design layer 56 described above, so their explanation is omitted here. The base layer 58 may also contain additives such as weathering agents. Details of weathering agents will be described later.

[0067] The base layer 58 is preferably a baked layer. The thickness of the base layer 58 is not particularly limited, but for example, it may be 5 μm or more and 40 μm or less, or 10 μm or more and 30 μm or less.

[0068] 6.Surface protection layer In this embodiment, the spandrel 10 may have a surface protection layer 59 on the side opposite to the metal substrate 55, relative to the design layer 56. By providing the surface protection layer 59, for example, the scratch resistance of the spandrel 10 is improved.

[0069] The surface protection layer 59 contains a resin. The resin contained in the surface protection layer 59 is preferably a cured product (crosslinked structure) of a curable resin, and more preferably a cured product of a thermosetting resin. Furthermore, a fluororesin is preferred as the curable resin because it has good weather resistance. The surface protection layer 59 may also contain a coloring agent. The curable resin and coloring agent are the same as those used in the design layer 56 described above, so their explanation is omitted here.

[0070] The surface protective layer 59 may contain one or more types of fillers. An example of a filler is an organic filler. Examples of organic fillers include resin fillers such as acrylic resins, urethane resins, nylon resins, olefin resins, and urea resins. Among these, acrylic resin fillers (acrylic beads) are preferred because they have good heat resistance and fewer manufacturing constraints. On the other hand, another example of a filler is an inorganic filler. Examples of inorganic fillers include silica, clay, heavy calcium carbonate, light calcium carbonate, precipitated barium sulfate, calcium silicate, and synthetic silicates.

[0071] The average particle size of the filler is, for example, 5 μm or more and 60 μm or less, and may be 10 μm or more and 50 μm or less, or 20 μm or more and 40 μm or less.

[0072] The surface protective layer 59 preferably contains a weather-resistant agent. Since inorganic colorants generally have low weather resistance, it is preferable that the surface protective layer 59 has sufficient weather resistance. Examples of weather-resistant agents include ultraviolet absorbers and light stabilizers.

[0073] Examples of UV absorbers include organic UV absorbers such as triazine-based UV absorbers, benzotriazole-based UV absorbers, benzophenone-based UV absorbers, oxybenzophenone-based UV absorbers, salicylate-based UV absorbers, and cyano(meth)acrylate-based UV absorbers, as well as inorganic UV absorbers such as titanium dioxide, cerium oxide, and zinc oxide. Among these, triazine-based UV absorbers are preferred.

[0074] Examples of triazine-based UV absorbers include hydroxyphenyltriazine-based UV absorbers. Examples of hydroxyphenyltriazine-based UV absorbers include 2-(2-hydroxy-4-[1-octyloxycarbonylethoxy]phenyl)-4,6-bis(4-phenylphenyl)-1,3,5-triazine, 2-[4-[(2-hydroxy-3-dodecyloxypropyl)oxy]-2-hydroxyphenyl]-4,6-bis(2,4-dimethylphenyl)-1,3,5-triazine, and 2,4-bis[2-hydroxy-4-butoxyphenyl]-6-(2,4-dibutoxyphenyl)-1,3,5-triazine. Examples include azine, 2-[4-[(2-hydroxy-3-tridecyloxypropyl)oxy]-2-hydroxyphenyl]-4,6-bis(2,4-dimethylphenyl)-1,3,5-triazine, 2-[4-[(2-hydroxy-3-(2'-ethyl)hexyl)oxy]-2-hydroxyphenyl]-4,6-bis(2,4-dimethylphenyl)-1,3,5-triazine, and 2-(4,6-diphenyl-1,3,5-triazine-2-yl)-5[2-(2-ethylhexanoyloxy)ethoxy]phenol.

[0075] The amount of UV absorber contained in the surface protective layer 59 is, for example, 0.5 parts by mass or more and 10 parts by mass or less per 100 parts by mass of resin component, and may be 0.8 parts by mass or more and 8 parts by mass or 1 part by mass or more and 5 parts by mass. If the amount of UV absorber is too high, bleed-out of the UV absorber may occur, and if the amount of UV absorber is too low, sufficient UV absorption performance may not be obtained.

[0076] On the other hand, examples of light stabilizers include hindered amine light stabilizers. Examples of hindered amine light stabilizers include 1,2,2,6,6-pentamethyl-4-piperidinyl methacrylate, bis(1,2,2,6,6-pentamethyl-4-piperidyl) sebacate, bis(2,2,6,6-pentamethyl-4-piperidyl) sebacate, bis(1,2,2,6,6-pentamethyl-4-piperidinyl) sebacate, methyl(1,2,2,6,6-pentamethyl-4-piperidinyl) sebacate, and 2,4-bis[N-butyl-N-(1-cyclohexyloxy-2,2,6,6-tetramethylpiperidine-4-yl)amino]-6-(2-hydroxyethylamine)-1,3,5-triazine).

[0077] The amount of light stabilizer contained in the surface protective layer 59 is, for example, 1 to 10 parts by mass per 100 parts by mass of resin components, and may be 1.5 to 8 parts by mass, or 2 to 5 parts by mass. If the amount of light stabilizer is too high, bleed-out of the light stabilizer may occur, and if the amount of light stabilizer is too low, sufficient light stability may not be obtained.

[0078] The surface protective layer 59 is preferably a baked layer. The thickness of the surface protective layer 59 is not particularly limited, but for example, it may be 5 μm or more and 40 μm or less, or 10 μm or more and 30 μm or less.

[0079] 7. Protective sheet As shown in Figures 4 and 5, the protective sheet 61 is superimposed on the design layer 56 or the surface protection layer 59. The protective sheet 61 is located on the outer surface of the spandrel 10. The protective sheet 61 may be a plastic film. The protective sheet 61 is bonded to the design layer 56 or the surface protection layer 59 before use of the spandrel 10 or the panel 10A described later. The protective sheet 61 covers the design layer 56 or the surface protection layer 59 at least partially. The protective sheet 61 protects the design layer 56 or the surface protection layer 59 by preventing it from coming into direct contact with other components (e.g., the rollers 71 of the roll forming machine 70). The protective sheet 61 is peelably bonded to the design layer 56 or the surface protection layer 59.

[0080] The thickness of the protective sheet 61 may be 10 μm or more and 200 μm or less, 30 μm or more and 150 μm or less, or 50 μm or more and 100 μm or less.

[0081] The protective sheet 61 may include a substrate for the protective sheet and an adhesive layer. The adhesive layer bonds the protective sheet 61 to the design layer 56 or the surface protective layer 59. The adhesive layer may include an adhesive such as an acrylic adhesive, a rubber adhesive, a urethane adhesive, or a silicone adhesive. The substrate for the protective sheet may include one or more resins such as an acrylic resin such as polymethyl methacrylate, polyethylene terephthalate, polyethylene naphthalate, polycarbonate, polystyrene, or cyclic polyolefin.

[0082] 8. Spandrel layer structure The spandrel 10 in this embodiment has a metal substrate 55 and a design layer 56 in this order in the thickness direction. The spandrel 10 may further have at least one of the primer layer 57, base layer 58, surface protection layer 59, and protective sheet 61 described above. The layer configuration of the spandrel 10 in this embodiment is not particularly limited, but for example, the following layer configuration can be given. The symbol " / " means the boundary of each layer. Also, the two members separated by the symbol " / " may be arranged in direct contact or may be arranged via other members.

[0083] (1) Metal base material 55 / Design layer 56 / Protective sheet 61 (2) Metal substrate 55 / Primer layer 57 / Design layer 56 / Protective sheet 61 (3) Metal base material 55 / Underlayer 58 / Design layer 56 / Protective sheet 61 (4) Metal substrate 55 / Primer layer 57 / Underlayer 58 / Design layer 56 / Protective sheet 61 (5) Metal base material 55 / Design layer 56 / Surface protective layer 59 / Protective sheet 61 (6) Metal substrate 55 / Primer layer 57 / Design layer 56 / Surface protection layer 59 / Protective sheet 61 (7) Metal base material 55 / Underlayer 58 / Design layer 56 / Surface protective layer 59 / Protective sheet 61 (8) Metal substrate 55 / Primer layer 57 / Underlayer 58 / Design layer 56 / Surface protection layer 59 / Protective sheet 61

[0084] In this embodiment, the spandrel 10 may have a plurality of protrusions (raised portions) on the first surface 50a located on the design layer 56 side with respect to the metal substrate 55. Preferably, the protrusions contain at least one of a filler and a colorant, and a binder resin that aggregates at least one of the filler and the colorant. The type of colorant is not particularly limited, but pearlescent colorants are an example. The average height of the protrusions is, for example, 10 μm or more and 60 μm or less, may be 15 μm or more and 45 μm or less, or 25 μm or more and 35 μm or less. The average height of the protrusions can be determined, for example, as the arithmetic mean of the heights of 100 or more protrusions.

[0085] The weather resistance of the spandrel 10 can be measured by accelerated weathering testing using a sunshine weather meter. Specifically, the spandrel 10 is subjected to accelerated weathering testing using a sunshine weather meter. In this case, when the total UV irradiation time reaches 10,000 hours, the color difference (△E) value before and after the accelerated weathering test may be 7 or less, 5 or less, or 3 or less. Details of the accelerated weathering test will be explained in the examples described later.

[0086] B. Method for manufacturing spandrels Figures 6(a)-(f) and 7 are schematic cross-sectional views illustrating the manufacturing method of the spandrel 10 in this embodiment. First, as shown in Figure 6(a), a metal substrate 55 is prepared (metal substrate preparation step). Next, as shown in Figure 6(b), a primer layer 57 is formed on one surface of the metal substrate 55 (primer layer formation step). Next, as shown in Figure 6(c), a base layer 58 is formed on the surface of the primer layer 57 opposite to the metal substrate 55 (base layer formation step). Next, as shown in Figure 6(d), a composition containing an organic coloring agent is applied to the surface of the base layer 58 opposite to the primer layer 57 and heated and cured to form a design layer 56 (design layer formation step). Next, as shown in Figure 6(e), a surface protection layer 59 is formed on the surface of the design layer 56 opposite to the base layer 58 (surface protection layer formation step). Next, as shown in Figure 6(f), a protective sheet 61 is attached to the surface of the design layer 56 opposite to the surface protective layer 59 (protective sheet attachment step). This gives rise to a panel 10A for the spandrel 10. Subsequently, as shown in Figure 7, the spandrel 10 is obtained by molding the panel 10A (spandrel molding step).

[0087] 1.Metal base material preparation process The method for manufacturing the spandrel in this embodiment includes a metal substrate preparation step for preparing the metal substrate 55. The metal substrate 55 is the same as that described in "A. Spandrel" above.

[0088] 2.Primer layer formation process The method for manufacturing the spandrel in this embodiment may include a primer layer formation step in which a primer layer 57 is formed on one side of the metal substrate 55. In the primer layer formation step, the primer layer 57 may be formed directly on one side of the metal substrate 55, or it may be formed via another layer.

[0089] One method for forming the primer layer 57 is to apply a composition for the primer layer 57 and heat-cur it. Examples of application methods for the composition include roll coating, reverse coating, air spray coating, electrostatic coating, and powder coating. Viewed from the thickness direction, the primer layer 57 is formed over the entire surface of the metal substrate 55, for example. The heating temperature (substrate temperature) is, for example, 100°C to 300°C.

[0090] 3. Base layer formation process The method for manufacturing the spandrel in this embodiment may include a base layer formation step in which a base layer 58 is formed on one side of the metal substrate 55. In the base layer formation step, the base layer 58 may be formed directly on one side of the metal substrate 55, or it may be formed via another layer such as the primer layer 57 described above.

[0091] One method for forming the base layer 58 is to apply a composition for the base layer 58 and heat-cur it. Examples of methods for applying the composition include flow coating, roll coating, reverse coating, air spray coating, electrostatic coating, and powder coating. When viewed from the thickness direction, the base layer 58 is formed to cover the entire surface of the metal substrate 55, for example. The heating temperature (temperature reached by the substrate) is, for example, 150°C to 300°C, and may be 200°C to 250°C.

[0092] 4. Design layer formation process The manufacturing method for the spandrel 10 in this embodiment includes a design layer formation step in which a composition containing an organic coloring agent is applied to one side of a metal substrate 55 and heated and cured to form a design layer 56. In the design layer formation step, the design layer 56 may be formed directly on one side of the metal substrate 55, or it may be formed via other layers such as the primer layer 57 and the base layer 58 described above.

[0093] One method for forming the design layer 56 is to coat it with a composition for the design layer 56 and then heat-cur it. Examples of coating methods for the composition include gravure printing, offset printing, gravure offset printing, flexographic printing, letterpress printing, screen printing, inkjet printing, and transfer printing. When viewed from the thickness direction, the design layer 56 may be formed to cover the entire surface of the metal substrate 55, or to cover a part of the metal substrate 55. The heating temperature (temperature reached by the substrate) is, for example, 150°C to 300°C, or 200°C to 250°C. Furthermore, if a process for forming other layers, such as a surface protection layer 59, described later, is performed as a subsequent process, the heat curing for forming the design layer 56 may be performed before the subsequent process, or simultaneously with the heat curing for forming other layers in the subsequent process.

[0094] As described above, the spandrel 10 in this embodiment comprises a metal substrate 55 containing an Al-Mn alloy. The metal substrate 55 containing an Al-Mn alloy has higher strength than a typical aluminum plate. Therefore, the heating temperature at which the design layer 56 is baked onto the metal substrate 55 can be increased, thereby improving the design and weather resistance of the spandrel 10.

[0095] 5.Surface protective layer formation process The spandrel manufacturing method in this embodiment may include a surface protection layer formation step in which a surface protection layer 59 is formed on the side of the design layer 56 opposite to the metal substrate 55. In the surface protection layer formation step, the surface protection layer 59 may be formed directly on the side of the design layer 56 opposite to the metal substrate 55, or it may be formed via another layer.

[0096] One method for forming the surface protective layer 59 is to apply a composition for the surface protective layer 59 and heat-cur it. Examples of methods for applying the composition include flow coating, roll coating, reverse coating, air spray coating, electrostatic coating, and powder coating. When viewed from the thickness direction, the surface protective layer 59 is formed to cover the entire surface of the metal substrate 55, for example. The heating temperature (substrate temperature) is, for example, 150°C to 300°C, and may be 200°C to 250°C.

[0097] 6. Protective sheet application process The method for manufacturing the spandrel in this embodiment may include a protective sheet application step in which a protective sheet 61 is applied to the design layer 56 side to protect the design layer 56. In the protective sheet application step, the protective sheet 61 is applied to the surface protective layer 59.

[0098] In this way, a panel 10A for the spandrel 10 is obtained through the steps described above. In this embodiment, a panel 10A for the spandrel 10 is also provided, which includes a metal substrate 55 and a design layer 56 laminated on the metal substrate.

[0099] 7. Spandrel forming process The method for manufacturing the spandrel in this embodiment may include a spandrel forming step for forming a panel 10A for the spandrel 10. By forming the panel 10A, a spandrel 10 having the shape shown in Figure 1, for example, can be obtained. The process of forming the panel 10A may include a bending process such as roll forming. Roll forming is a method of forming a panel by passing a long panel between multiple rollers of a roll forming machine. In this embodiment, as shown in Figure 7, the panel 10A is formed by passing it between multiple rollers 71 of a roll forming machine 70. As a result, the panel 10A is bent, and a spandrel 10 having a decorative part 11, an engaging part 12, and a receiving part 13 is produced. As described above, the panel 10A may have a protective sheet 61. In this case, scratches on the decorative layer 56 caused by the rollers 71 of the roll forming machine 70 can be suppressed. The protective sheet 61 may be peeled off before the spandrel 10 is attached to the mounting surface 91 of the building 90.

[0100] [Examples] Next, a specific embodiment of the panel in this embodiment will be described.

[0101] [Example 1-1] As the metal substrate, an aluminum plate (A3004PH32, dimensions: 300mm x 600mm, thickness: 1.0mm, chromate treated) was prepared. Next, as a pretreatment, the prepared aluminum plate was washed with hot water and then dried at 150°C (substrate temperature).

[0102] Next, the following base layer composition was applied to the entire surface of the aluminum plate using a curtain flow coater to a dry film thickness of 18 μm. Afterward, it was baked at 216°C (substrate temperature) to form the base layer.

[0103] (Composition for underlayment) Thermosetting fluororesin (fluoroethylene-vinyl ether copolymer) Hardening agent (isocyanate) Gray colorants (titanium dioxide, chromium oxide; 5% by mass relative to thermosetting fluororesin) Solvent (xylene:toluene = 1:1, mass ratio) Solid content concentration: 17% by mass

[0104] Next, the entire surface of the base layer was coated by gravure offset printing with the following design layer composition, such that the film thickness after drying was between 0.5 μm and 15 μm.

[0105] (Composition for design layers) Thermosetting fluororesin (fluoroethylene-vinyl ether copolymer) Hardening agent (isocyanate) Organic colorant (a blend of three colors: perylene pigment (red), cyanine pigment (blue), and nickel azo complex pigment (yellow); 15% by mass relative to the thermosetting fluororesin) Solvent (xylene:cyclohexane = 1:1, mass ratio) Solid content concentration: 19% by mass

[0106] Next, the entire surface of the design layer was coated with composition A for the surface protective layer, as described below, using a bar coater, to a dry film thickness of 19 μm. Then, it was baked at 224°C (substrate temperature) to form the surface protective layer and obtain the panel. The obtained surface protective layer is referred to as surface protective layer A.

[0107] (Composition A for surface protective layer) Thermosetting fluororesin (fluoroethylene-vinyl ether copolymer) Hardening agent (isocyanate) Solvent (xylene:toluene = 1:1, mass ratio) Solid content concentration: 30% by mass

[0108] [Examples 1-2] Other than using composition B for the surface protective layer instead of composition A for the surface protective layer. A panel was obtained in the same manner as in Example 1-1. The obtained surface protective layer will be referred to as surface protective layer B.

[0109] (Composition B for surface protective layer) Thermosetting fluororesin (fluoroethylene-vinyl ether copolymer) Hardening agent (isocyanate) Filler (silica, average particle size 1 μm; 10% by mass relative to thermosetting fluororesin) Solvent (xylene:toluene = 1:1, mass ratio) Solid content concentration: 30% by mass

[0110] [Examples 1-3] A panel was obtained in the same manner as in Example 1-1, except that composition C for the surface protective layer was used instead of composition A for the surface protective layer. The obtained surface protective layer is referred to as surface protective layer C.

[0111] (Composition C for surface protective layer) Thermosetting fluororesin (fluoroethylene-vinyl ether copolymer) Hardening agent (isocyanate) Filler (silica, average particle size 1 μm; 10% by mass relative to thermosetting fluororesin) Filler (acrylic beads, average particle size 10 μm, 4% by mass relative to thermosetting fluororesin) Filler (acrylic beads, average particle size 30 μm, 2% by mass relative to thermosetting fluororesin) Solvent (xylene:toluene = 1:1, mass ratio) Solid content concentration: 30% by mass

[0112] [Examples 1-4] A panel was obtained in the same manner as in Example 1-1, except that composition D for the surface protective layer was used instead of composition A for the surface protective layer. The obtained surface protective layer is referred to as surface protective layer D.

[0113] (Composition D for surface protective layer) Thermosetting fluororesin (fluoroethylene-vinyl ether copolymer) Hardening agent (isocyanate) Filler (silica, average particle size 1 μm; 10% by mass relative to thermosetting fluororesin) Filler (acrylic beads, average particle size 30 μm, 4% by mass relative to thermosetting fluororesin) Filler (acrylic beads, average particle size 50 μm, 2% by mass relative to thermosetting fluororesin) Solvent (xylene:toluene = 11, mass ratio) Solid content concentration: 30% by mass

[0114] [Examples 2-1 to 2-4] Panels were obtained in the same manner as in Examples 1-1 to 1-4, except that only a perylene-based pigment (red) was used as the organic coloring agent in the composition for the design layer.

[0115] [Examples 3-1 to 3-4] Panels were obtained in the same manner as in Examples 1-1 to 1-4, except that only a cyanine-based pigment (blue) was used as the organic coloring agent in the composition for the design layer.

[0116] [Examples 4-1 to 4-4] Panels were obtained in the same manner as in Examples 1-1 to 1-4, except that only a nickel azo complex pigment (yellow) was used as the organic coloring agent in the composition for the design layer.

[0117] [Comparative Examples 1-1 to 1-4] Panels were obtained in the same manner as in Examples 1-1 to 1-4, except that an inorganic colorant (a blend of three colors: iron oxide-based pigment (red), cobalt-based pigment (blue), and iron oxide-based pigment (yellow)) was used instead of the organic colorant contained in the composition for the design layer.

[0118] [Comparative Examples 2-1 to 2-4] Panels were obtained in the same manner as in Examples 1-1 to 1-4, except that an iron oxide-based pigment (red) was used instead of the organic colorant contained in the composition for the design layer.

[0119] [evaluation] The flop index was measured using the panels obtained in each example and comparative example. Specifically, the panels were placed horizontally with the surface protective layer facing upwards, and the lightness index L was measured using a three-dimensional bending angle spectrophotometer (Murakami Color Technology Laboratory, model number GCMS-4). * The following measurements were taken: Incidence angle 45°, tilt angle 0°, in-plane rotation angle 0°, light source D65, and L at reception angles of 30°, 0°, and -65°. * The following was measured. Subsequently, the flop index was calculated using the following formula. The results are shown in Tables 1 and 2. Flop index = 2.69 × (L * 15 -L * 110 ) 1·11 / (L * 45 ) 0·85 (L * 15 L at a light-receiving angle of 30° * This applies to L * 45 L at a light-receiving angle of 0° * This applies to L * 110 L at a light-receiving angle of -65° * (This applies to)

[0120] [Table 1]

[0121] [Table 2]

[0122] As shown in Table 1, in each example, the flop index was high, confirming that the glossiness of the metal substrate was well expressed. Furthermore, because organic colorants were used, vivid design expression was possible while suppressing the concealment of glossiness by the design layer. In contrast, as shown in Table 2, in each comparative example, the flop index was low, confirming that the glossiness of the metal substrate was not well expressed. This is presumed to be because the use of inorganic colorants resulted in greater concealment of glossiness by the design layer.

[0123] Figure 8 is a graph showing the results for Examples 1-1 to 1-4 and Comparative Examples 1-1 to 1-4. The triangles in Figure 8 represent the flop index of samples prepared in the same manner as Examples 1-1 to 1-4, except that no design layer was formed, and the triangles in Figures 9 to 11, which will be described later, are similar. As shown in Figure 8, Examples 1-1 to 1-4 had higher flop indices compared to Comparative Examples 1-1 to 1-4, confirming that the glossiness of the metal substrate was well represented. Furthermore, comparing Examples 1-1 to 1-4, it was confirmed that the flop index is less affected by the glossiness of the first surface (the surface of the protective layer), and that the glossiness of the metal substrate can be accurately evaluated.

[0124] Figure 9 is a graph showing the results for Examples 2-1 to 2-4 and Comparative Examples 2-1 to 2-4. As shown in Figure 9, Examples 2-1 to 2-4 had higher flop indices compared to Comparative Examples 2-1 to 2-4, confirming that the glossiness of the metal substrate was well expressed. Figure 10 is a graph showing the results for Examples 3-1 to 3-4, and Figure 11 is a graph showing the results for Examples 4-1 to 4-4. As shown in Figures 10 and 11, Examples 3-1 to 3-4 and Examples 4-1 to 4-4 had high flop indices, confirming that the glossiness of the metal substrate was well expressed.

[0125] [Example 5-1] First, a base layer was formed on the entire surface of the aluminum plate in the same manner as in Example 1-1. Next, the first composition for the design layer described below was coated onto the entire surface of the base layer by gravure offset printing so that the film thickness after drying was 0.5 μm or more and 1.5 μm or less, thereby forming an inorganic coloring layer.

[0126] (First composition for the design layer) Thermosetting fluororesin (fluoroethylene-vinyl ether copolymer) Hardening agent (isocyanate) Inorganic colorant (carbon black; 4% by mass relative to thermosetting fluororesin) Solvent (xylene:cyclohexane = 1:1, mass ratio) Solid content concentration: 15% by mass

[0127] Next, the second composition for the design layer described below was coated onto the entire surface of the inorganic colorant layer by gravure offset printing so that the film thickness after drying was between 0.5 μm and 1.5 μm, thereby forming an organic colorant layer. This resulted in obtaining a design layer having both an inorganic colorant layer and an organic colorant layer.

[0128] (Second composition for the design layer) Thermosetting fluororesin (fluoroethylene-vinyl ether copolymer) Hardening agent (isocyanate) Organic colorant (a blend of three colors: perylene pigment (red), cyanine pigment (blue), and nickel azo complex pigment (yellow); 15% by mass relative to the thermosetting fluororesin) Solvent (xylene:cyclohexane = 1:1, mass ratio) Solid content concentration: 19% by mass

[0129] Next, a surface protective layer A was formed over the entire surface of the design layer in the same manner as in Example 1-1 to obtain a panel.

[0130] [Examples 5-2 to 5-4] Panels were obtained in the same manner as in Example 5-1, except that only a perylene-based pigment (red), only a cyanine-based pigment (blue), and only a nickel azo complex-based pigment (yellow) were used as organic colorants in the second composition for the design layer.

[0131] [Comparative Example 3-1] A panel was obtained in the same manner as in Example 5-1, except that an organic colorant layer was not formed.

[0132] [Comparative Example 3-2] A panel was obtained in the same manner as in Example 5-1, except that an organic colorant layer was not formed, and composition B for the surface protective layer described above was used instead of composition A for the surface protective layer.

[0133] [Comparative Example 3-3] A panel was obtained in the same manner as in Example 5-1, except that an organic colorant layer was not formed, and composition C for the surface protective layer described above was used instead of composition A for the surface protective layer.

[0134] [Comparative Example 3-4] A panel was obtained in the same manner as in Example 5-1, except that an organic colorant layer was not formed, and composition D for the surface protective layer described above was used instead of composition A for the surface protective layer.

[0135] [evaluation] The flop index was measured using the panels obtained in Examples 5-1 to 5-4 and Comparative Examples 3-1 to 3-4. The measurement method was the same as described above. The results are shown in Tables 3 and 4.

[0136] [Table 3]

[0137] [Table 4]

[0138] As shown in Tables 3 and 4, it was confirmed that Examples 5-1 to 5-4, which have an organic coloring agent layer, have a flop index as high as Comparative Examples 3-1 to 3-4, which do not have an organic coloring agent layer. In other words, it was confirmed that the concealment of gloss by the organic coloring agent layer is limited, and that vivid design expression is possible with the organic coloring agent layer.

[0139] [Examples 6-1 to 6-3] Panels were obtained in the same manner as in Examples 2-1, 3-1, and 4-1, except that composition X for the underlayer was used as the underlayer composition, and composition A2 for the surface protective layer was used instead of composition A for the surface protective layer.

[0140] (Composition X for the underlayer) Thermosetting fluororesin (fluoroethylene-vinyl ether copolymer) Hardening agent (isocyanate) Gray colorants (titanium dioxide, chromium oxide; 5% by mass relative to thermosetting fluororesin) UV absorber Hindered amine light stabilizers Solid content concentration: 17% by mass

[0141] (Composition A2 for surface protective layer) Thermosetting fluororesin (fluoroethylene-vinyl ether copolymer) Hardening agent (isocyanate) UV absorber Hindered amine-based light stabilizer solvent (xylene:toluene = 1:1, mass ratio) Solid content concentration: 30% by mass

[0142] [evaluation] The weather resistance of the panels obtained in Examples 6-1 to 6-3 was evaluated. The obtained panels were subjected to accelerated weathering tests using a sunshine weather meter (SWOM). Specifically, under the following irradiation conditions, the panels were irradiated for 102 minutes, followed by 18 minutes of irradiation and spraying, with a total of 120 minutes per cycle. This cycle was repeated until the total UV irradiation time reached 10,000 hours.

[0143] <Conditions for accelerated weathering test> (Test equipment) Manufactured by Suga Test Instruments, product name "S80" (Irradiation conditions) Illuminance: 255W / m 2 Black panel temperature: 65°C, chamber humidity: 5096RH, duration: 102 minutes of irradiation followed by 18 minutes of irradiation and spraying.

[0144] The weather resistance of the panels was evaluated by color difference and gloss retention. For color difference, the value of the color difference (△E) before and after the accelerated weathering test was measured using a spectrophotometer (Konica Minolta CM-5 spectrophotometer). For gloss retention, the 60° gloss value of the surface protective layer was measured using a gloss meter in accordance with JIS K5600. The 60° gloss value was calculated as the average of 10 measurements. The results are shown in Table 5.

[0145] [Table 5]

[0146] As shown in Table 5, Examples 6-1 to 6-3 were found to have small color difference (△E) values, high gloss retention, and good weather resistance. Although organic colorants are known to have lower weather resistance than inorganic colorants, Examples 6-1 to 6-3 yielded panels that could be used for exterior components while still employing organic colorants.

[0147] [Example 7] As a metal substrate, an aluminum plate (A3004PH32, dimensions: 300mm x 600mm, thickness: 1.0mm, chromate treated) was prepared. Next, as a pretreatment, the prepared aluminum plate was washed with hot water, a polyester-based primer was applied, and then it was dried at 200°C (substrate temperature).

[0148] Next, the following base layer composition was applied to the entire surface of the aluminum plate using a curtain flow coater to a dry film thickness of 18 μm. Afterward, it was baked at 216°C (substrate temperature) to form the base layer.

[0149] (Composition for underlayment) Thermosetting polyester resin Solvent (xylene:cyclohexanone = 1:1) Solid content concentration: 40% by mass

[0150] Next, the entire surface of the base layer was coated by gravure offset printing with the following design layer composition, such that the film thickness after drying was between 0.5 μm and 15 μm.

[0151] (Composition for design layers) Thermosetting polyester resin organic colorant (a blend of three colors: perylene pigment (red), cyanine pigment (blue), and nickel azo complex pigment (yellow); 7.5% by mass relative to the thermosetting fluororesin) Solvent (xylene:cyclohexane = 1:1, mass ratio) Solid content concentration: 19% by mass

[0152] Next, the following surface protection layer composition was applied to the entire surface of the design layer using a bar coater to a dry film thickness of 22 μm. After that, it was baked at 224°C (substrate temperature) to form the surface protection layer and obtain the panel.

[0153] (Composition for surface protective layer) Thermosetting polyester resin UV absorber Hindered amine light stabilizers Filler (silica, average particle size 2 μm; 3% by mass relative to thermosetting polyester resin) Solvent (xylene:cyclohexanone = 1:1) Solid content concentration: 42% by mass

[0154] The weather resistance of the obtained panels was evaluated in the same manner as described above. As a result, the color difference (△E) and gloss retention rate were maintained to some extent up to 500 hours of UV irradiation, but when the UV irradiation time reached 1000 hours, the color difference (△E) became 4.3 and the gloss retention rate became 10%. Comparing Example 7 with Examples 6-1 to 6-3, it was confirmed that using a fluoropolymer resin as the thermosetting resin significantly improved weather resistance.

[0155] It is also possible to combine the multiple components disclosed in each of the above embodiments and modifications as needed. Alternatively, some components may be removed from all the components shown in each of the above embodiments and modifications. [Explanation of symbols]

[0156] 10 Spandrels 10A Panel 11 Makeup section 12 Engaging part 13 Receiving Department 55 Metal base material 56 Design Layer 57 Primer layer 58 Base layer 59 Surface protective layer 61 Protective Sheets 90 Buildings 91 Mounting surface

Claims

1. In spandrels, A metal substrate containing an Al-Mn alloy, The metal substrate includes a design layer laminated on the metal substrate, A spandrel having a metal substrate thickness of 0.3 mm or more and 2.0 mm or less.

2. The spandrel according to claim 1, wherein the first surface located on the design layer side with respect to the metal substrate has a region in which the flop index is 4.5 or more.

3. A spandrel according to claim 1, which is a roll-formed product.

4. The spandrel according to claim 1, wherein the design layer contains an organic coloring agent.

5. The spandrel according to claim 1, wherein the design layer is a baked layer.

6. The spandrel according to claim 1, wherein when an accelerated weathering test is performed using a sunshine weather meter and the total ultraviolet irradiation time reaches 10,000 hours, the value of the color difference (ΔE) before and after the accelerated weathering test is 7 or less.

7. The spandrel according to claim 1, further comprising a protective sheet covering the aforementioned design layer.

8. The spandrel according to claim 1, comprising a decorative portion, an engaging portion formed at one end of the decorative portion, and a receiving portion formed at the other end of the decorative portion.

9. In panels for spandrels, A metal substrate containing an Al-Mn alloy, The metal substrate includes a design layer laminated on the metal substrate, A panel in which the thickness of the metal substrate is 0.3 mm or more and 2.0 mm or less.

10. A building comprising the spandrel described in claim 1.

Images