rubber seal

Abstract

To provide a packing that is easy to insert into gaps. [Solution] The system includes an installation portion 331 and a contact portion 333 that are inserted into the gap portion 32, and a sealing wall 332 that closes the opening 320 of the gap portion 32. The contact portion 333 and the sealing wall 332 are not connected.

Description

Technical Field

[0001] The present disclosure relates to packing. More specifically, the present disclosure relates to packing for closing gaps.

Background Art

[0002] Patent Document 1 describes an internal dew condensation prevention and external heat insulation device. In this device, an exterior material is installed outside the fireproof wall of a building with a space between the building, and a flame-retardant urethane foam obtained by mixing a flame-retardant material having good compatibility with urethane is filled between the fireproof wall and the exterior material. As the exterior material, a metal sandwich panel in which urethane foam or isocyanurate foam is used as a core material and sandwiched between two metal plates is used.

Prior Art Documents

Patent Documents

[0003]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0004] In the metal sandwich panel as described above, the core material and the metal plate are adhered by the adhesive force (self-adhesive force) generated when the core material cures from a liquid state to a foam. However, due to the secular change of the core material and the metal plate, the core material and the metal plate may be partially peeled off, and the metal plate bulges on the surface side of the metal sandwich panel at the portion peeled off from the core material, and the appearance of the metal sandwich panel may deteriorate. Such peeling between the core material and the metal plate is likely to occur when the core material fills an unnecessary space. Therefore, it has been considered to close the space with packing so that the core material does not fill an unnecessary space.

[0005] An object of the present disclosure is to provide packing that is easy to insert into a narrow space.

Means for Solving the Problems

[0006] A packing according to one aspect of the present disclosure comprises an installation portion and a contact portion that are inserted into a gap, and a sealing wall that closes the opening of the gap. The contact portion and the sealing wall are not connected. [Effects of the Invention]

[0007] According to this disclosure, since the sealing wall and the contact portion are not connected, the shape of the packing is more easily deformed, making it easier to insert into narrow spaces. [Brief explanation of the drawing]

[0008] [Figure 1] Figure 1 is a perspective view showing a metal sandwich panel using the packing according to this embodiment. [Figure 2] Figure 2 is a cross-sectional view showing a metal sandwich panel using the packing according to this embodiment. [Figure 3] Figure 3 is a cross-sectional view showing the connection state of a metal sandwich panel using the packing according to this embodiment. [Figure 4] Figure 4 is a cross-sectional view showing the packing according to this embodiment. [Figure 5] Figure 5 is a perspective view showing the packing according to this embodiment. [Figure 6] Figure 6 is a perspective view showing the packing according to this embodiment. [Figure 7] Figure 7A is a side view showing one embodiment of the packing according to this embodiment. Figure 7B is a side view showing another embodiment of the same. Figure 7C is a side view showing yet another embodiment of the same. [Figure 8] Figure 8 is a cross-sectional view showing a portion of a metal sandwich panel using the packing according to this embodiment. [Figure 9] Figure 9 is a schematic diagram showing a method for manufacturing a metal sandwich panel using the packing according to this embodiment. [Figure 10] Figure 10 is a schematic diagram showing the operation and effects of a metal sandwich panel using the packing according to this embodiment. [Figure 11] Figure 11 is a schematic diagram showing the operation and effects of a metal sandwich panel using the packing according to this embodiment. [Figure 12] Figure 12 is a cross-sectional view illustrating the problems with the conventional approach. [Modes for carrying out the invention]

[0009] The present disclosure will be described below based on the embodiments shown in the attached drawings, but the present disclosure is not limited to the embodiments described below, and appropriate design modifications are possible within the scope intended by the present disclosure.

[0010] (Embodiment) (1) Overview Figure 12 shows a metal sandwich panel 10x. This metal sandwich panel 10x has a resin foam 4 between two metal outer shells 1 and 2. The metal outer shells 1 and 2 are positioned opposite each other, and the resin foam 4 is provided as a core material between the metal outer shells 1 and 2. The resin foam 4 is a resin foam such as polyurethane foam or polyphenol foam, and has heat insulation and fire resistance. The resin foam 4 is formed when a resin liquid supplied to one side of one metal outer shell 1 is foamed. During the foaming of the resin liquid, the other metal outer shell 2 is positioned opposite the metal outer shell 1, and the resin liquid is further foamed between the metal outer shells 1 and 2. When the resin liquid is completely foamed, it becomes the resin foam 4. The resin foam 4 adheres to the metal outer shells 1 and 2 by its self-adhesive force.

[0011] Incidentally, the metal outer shell 1 and the metal outer shell 2 are positioned so as not to be in direct contact in order to prevent thermal bridging. For example, in Figure 12, at the bottom of the metal sandwich panel 10x, the lower part 1x of the metal outer shell 1 and the lower part 2x of the metal outer shell 2 are positioned opposite each other with a predetermined gap between them. Furthermore, resin foam 4 is filled between the lower parts 1x and 2x, so that the lower parts 1x and 2x do not come into direct contact. Here, since the gap between the lower parts 1x and 2x is formed before the resin liquid is completely foamed, a sealing material 6 is provided to close the gap between the lower parts 1x and 2x, so that the resin liquid in the process of foaming does not leak out from between the lower parts 1x and 2x.

[0012] Normally, the gas (such as carbon dioxide) generated during manufacturing is the vaporized foaming agent, and most of it is released from the metal sandwich panel 10x through small gaps. However, sometimes the gas is not sufficiently released and remains in the resin foam 4. Also, if unreacted components remain in the resin foam 4, these unreacted components may react after the metal sandwich panel 10x is completed, generating new gas (such as carbon dioxide). If the gas in the resin foam 4 is not released from the metal sandwich panel 10x, the gas accumulates between the resin foam 4 and the metal outer shell 1. The pressure of this gas can cause the resin foam 4 and the metal outer shell 1 to separate, resulting in a bulge 100x on a part of the metal outer shell 1, as shown in Figure 12. The area enclosed by the dashed line X in the figure is a particularly vulnerable area for bulging 100x. Therefore, the inventors have developed a metal sandwich panel 10 that is less prone to bulging 100x.

[0013] As shown in FIGS. 1, 2, and 3, the metal sandwich panel 10 includes a panel body 101 having a resin foam 4 between two metal outer skins 1 and 2, and a packing 33 according to this embodiment. The panel body 101 has a fitting protrusion 8 at one end and a fitting recess 9 at the other end. Adjacent panel bodies 101 are connected by fitting the fitting protrusion 8 and the fitting recess 9. One of the two metal outer skins 1, 2, i.e., the metal outer skin 1, has a covering portion 3 located in front of the fitting protrusion 8. The covering portion 3 is formed in a substantially U-shaped cross-section and has a void portion 32 inside. The packing 33 includes an installation portion 331 and a contact portion 333 inserted into the void portion 32, and a sealing wall 332 closing the opening 320 of the void portion 32. The contact portion 333 and the sealing wall 332 are not connected.

[0014] In the metal sandwich panel 10 using the packing 33 of this embodiment, by providing the packing 33 at the opening 320 of the void portion 32, the void portion 32 is not filled with the resin foam 4. Therefore, a portion where the adhesiveness between the metal outer skin 1 and the resin foam 4 is low (a portion where the resin foam 4 is insufficient) is unlikely to occur, and the quality is stabilized. Thus, peeling between the resin foam 4 and the metal outer skins 1, 2 is unlikely to occur, and the metal outer skins 1, 2 are unlikely to bulge, and appearance degradation is unlikely to occur.

[0015] Also, in the packing 33 of this embodiment, since the contact portion 333 inserted into the void portion 32 is not connected to the sealing wall 332, the contact portion 333 can move with respect to the sealing wall 332. Therefore, when inserting the packing 33 into the void portion 32, the contact portion 333 can be moved with respect to the sealing wall 332 to reduce the distance between the contact portion 333 and the installation portion 331, and it is easy to insert the packing 33 even in a narrow void portion 32.

[0016] The packing 33 of the present embodiment is used to prevent foreign matter from entering the gap portion 32 from the outside. Therefore, the packing 33 of the present embodiment can be applied, for example, to the manufacturing process of narrow gaps in the kitchen (such as the gap between the wall and the ceiling), doors, and refrigerator panels (such as the gap at the connection part between the panels). In addition, the packing 33 of the present embodiment can be applied as a base material (primary gasket) for liquid structure adhesives, liquid joint materials for ensuring airtightness and water tightness between exterior materials and structural members of automobiles, ships, and airplanes. Furthermore, the packing 33 of the present embodiment can be used, for example, as a base material for building joint seals, thereby reducing the usage amount of the joint seal liquid. Also, in the process of injecting a liquid sealing material into the gap portion, the packing 33 of the present embodiment is easy to manage the manifestation of the effect by quantification (easy to dry quickly and cure quickly).

[0017] (2) Details The metal sandwich panel 10 using the packing 33 of the present embodiment is an architectural panel used for the outer walls of buildings such as buildings, factories, and warehouses. As shown in FIGS. 1 to 3, the metal sandwich panel 10 has a panel body 101 and a packing 33.

[0018] The panel body 101 includes a surface plate 11 formed by a first metal outer skin 1, a back plate 21 disposed opposite to the surface plate 11 and formed by a second metal outer skin 2, and a resin foam 4 disposed between the surface plate 11 and the back plate 21. The resin foam 4 is formed as a core material of the panel body 101.

[0019] The panel body 101 is formed in a substantially rectangular shape when viewed from the front. The panel body 101 has a fitting recess 9 at one end in the width direction and a fitting projection 8 at the other end. In the metal sandwich panel 10 of the present embodiment, a plurality of them are arranged side by side on the same plane for construction. In this case, the adjacent panel bodies 101 are connected by the fitting of the fitting recess 9 and the fitting projection 8.

[0020] In the following explanation, the direction in which the fitting recess 9 and the fitting projection 8 are fitted together is defined as the width direction, the direction perpendicular to this width direction and along the in-plane direction of the metal sandwich panel 10 is defined as the length direction, and the direction perpendicular to both the width direction and the length direction is defined as the thickness direction.

[0021] The metal sandwich panel 10 is typically installed with its width in the vertical direction and its length in the horizontal direction. Therefore, the fitting recess 9 is provided at the upper end of the metal sandwich panel 10, and the fitting projection 8 is provided at the lower end of the metal sandwich panel 10. The fitting recess 9 and the fitting projection 8 are formed along the entire length of the metal sandwich panel 10. The first metal outer shell 1 and the second metal outer shell 2 face each other in the front-to-back direction, which is the same direction as the thickness direction of the metal sandwich panel 10.

[0022] The metal sandwich panel 10 may be installed with its width in the left-right direction and its length in the up-down direction. In this case, the fitting recess 9 is provided at one end of the metal sandwich panel 10 in the left-right direction, and the fitting projection 8 is provided at the other end of the metal sandwich panel 10 in the left-right direction.

[0023] The first and second metal outer shells 1 and 2 are formed into predetermined shapes by processing a flat metal sheet, such as roll forming. The metal sheet can be one that has been conventionally used in forming building materials, such as SGL® steel sheet, galvalume steel sheet, galvanized steel sheet, or painted steel sheet. There are no particular limitations on the thickness of the metal sheet, and it can be, for example, 0.25 to 2.3 mm.

[0024] As shown in Figures 1 to 3, the first metal shell 1 has a first shell body 112. The first shell body 112 is formed in a flat plate shape and constitutes the main surface on the front side of the metal sandwich panel 10. The first metal shell 1 has a first transverse piece 113.

[0025] The first horizontal piece 113 protrudes rearward (towards the resin foam 4) from the upper end of the first outer shell body 112. The first metal outer shell 1 has a first vertical piece 114. The first vertical piece 114 protrudes upward from the upper end of the first horizontal piece 113. The first metal outer shell 1 has a lower grooved piece 115. The lower grooved piece 115 protrudes rearward (towards the resin foam 4) from the upper end of the first vertical piece 114. The first metal outer shell 1 has a grooved piece 116.

[0026] The grooved piece 116 protrudes upward from the upper end of the lower grooved piece 115. The first metal outer shell 1 has an upper grooved piece 117. The upper grooved piece 117 protrudes forward (away from the resin foam 4) from the upper end of the grooved piece 116. The first metal outer shell 1 has a second vertical piece 118. The second vertical piece 118 protrudes upward from the upper end of the upper grooved piece 117. The first metal outer shell 1 has a first recessed piece 119. The first recessed piece 119 protrudes downward from the upper end of the second vertical piece 118 in a way that it folds back.

[0027] The first metal outer shell 1 has a first recessed bottom piece 120. The first recessed bottom piece 120 protrudes rearward from the lower end of the first recessed piece 119. The first metal outer shell 1 has a first upper insertion piece 121. The first upper insertion piece 121 protrudes downward from the rear end of the first recessed bottom piece 120. The first upper insertion piece 121 is inserted into the resin foam 4 from the upper end face 42.

[0028] The first metal shell 1 has a cover portion 3. The cover portion 3 is provided at the lower end of the first metal shell 1. The cover portion 3 has a front cover portion 30 and a rear cover portion 31. The front cover portion 30 is formed to protrude downward from the lower end of the first shell body 112. The front cover portion 30 and the first shell body 112 are formed to be flat without any steps. The rear cover portion 31 is located behind the front cover portion 30. The rear cover portion 31 is formed to fold back upward from the lower end of the front cover portion 30. The front cover portion 30 and the rear cover portion 31 face each other with a predetermined distance between them in the thickness direction (front-to-back direction).

[0029] The cover portion 3, formed as described above, has a roughly U-shaped cross-section. The cover portion 3 also has an internal void portion 32. That is, the gap between the front cover portion 30 and the rear cover portion 31 is formed as the void portion 32. The void portion 32 is provided along the entire length of the panel body 101 in the left-right direction. The void portion 32 has an opening 320 at its upper end. The void portion 32 communicates with the internal space of the metal sandwich panel 10 (the space between the first outer shell body 112 and the second outer shell body 212 of the second metal outer shell 2) through the opening 320. The upper end of the void portion 32, the upper end of the front cover portion 30, and the upper end of the rear cover portion 31 are at approximately the same height (they are at the same vertical position). In Figures 1-4, the boundary between the resin foam 4 and the packing 33 at the opening 320 is clearly depicted as a straight line. However, the boundary between the resin foam 4 and the packing 33 may be slightly above or slightly below the opening 320, and the boundary between the resin foam 4 and the packing 33 may not be a straight line but may overlap each other.

[0030] The first metal outer shell 1 has a gap piece 122. The gap piece 122 protrudes rearward from the upper end of the rear cover portion 31. The first metal outer shell 1 has a first convex piece 123. The first convex piece 123 protrudes downward from the rear end of the gap piece 122. The first metal outer shell 1 has a first lower insertion piece 124. The first lower insertion piece 124 protrudes upward from the lower end of the first convex piece 123, folding back. The first lower insertion piece 124 is inserted into the resin foam 4 from the lower end face 40. The first lower insertion piece 124 and the first convex piece 123 face each other with a predetermined distance between them in the thickness direction (front-to-back direction). The first lower insertion piece 124 and the first convex piece 123 form a first opposing portion 111 at the lower end of the first metal outer shell 1.

[0031] A packing 33 is provided on the panel body 101. The packing 33 is provided along the entire length of the panel body 101 in the left-right direction. The packing 33 is also provided so as to substantially close the opening 320 of the void 32. Therefore, communication between the void 32 and the internal space of the panel body 101 through the opening 320 is substantially blocked by the packing 33. The packing 33 is provided at the top of the void 32. Therefore, the lower part of the void 32 remains an open space. The vertical dimension of the packing 33 can be 1 / 2 to 1 / 3 of the vertical dimension of the void 32, but is not limited to this. The packing 33 may also be provided over the entire void 32.

[0032] As shown in Figures 4 to 6, the packing 33 comprises an installation portion 331, a contact portion 333, a sealing wall 332, an insertion portion 334, and a pressing portion 339.

[0033] The insertion portion 334 is provided at the lower part of the packing 33. The insertion portion 334 is formed in a wedge shape in cross-section. That is, the insertion portion 334 is tapered so that its dimensions in the front-to-back direction gradually decrease towards the lower end. A convex rib 335 is formed on the outer surface of the insertion portion 334.

[0034] The convex rib 335 is provided along the entire length of the packing 33. The convex rib 335 is formed to protrude in a stepped manner from the front and rear surfaces of the insertion portion 334. The insertion portion 334 is inserted into the gap 32 inside the cover portion 3 through the opening 320. However, if the entire front and rear surfaces of the insertion portion 334 come into contact with the inner surface of the cover portion 3, friction will be high, making insertion difficult. Therefore, the convex rib 335 is provided on the outer surface of the insertion portion 334 to cause point contact or line contact with the convex rib 335, making it difficult for the entire outer surface of the insertion portion 334 to come into contact with the inner surface of the cover portion 3 (the surface inside the gap 32), thereby making insertion of the insertion portion 334 easier.

[0035] The mounting portion 331 is located above the insertion portion 334 and in front of the contact portion 333. The lower end of the mounting portion 331 is connected to the upper end of the insertion portion 334. The front surface of the mounting portion 331 is formed to be substantially flush with the front surface of the insertion portion 334. Multiple recesses 336 are provided on the front surfaces of the mounting portion 331 and the insertion portion 334. The multiple recesses 336 are arranged in a vertical direction. Furthermore, the multiple recesses 336 are provided along the entire length of the packing 33. The multiple recesses 336 are recessed from the front surfaces of the mounting portion 331 and the insertion portion 334, forming a groove-like structure.

[0036] The contact portion 333 is located above the insertion portion 334 and behind the installation portion 331. The lower end of the contact portion 333 is connected to the upper end of the insertion portion 334. A gap is provided between the front surface of the contact portion 333 and the rear surface of the installation portion 331. The installation portion 331 and the contact portion 333 are arranged in a roughly V-shape in cross-section. That is, the contact portion 333 is inclined towards the rear from its lower end to its upper end, and the distance between the contact portion 333 and the installation portion 331 gradually increases from its lower end to its upper end.

[0037] The contact portion 333 has a convex rib 337. The convex rib 337 is provided on the upper part of the contact portion 333. The convex rib 337 is formed in a hemispherical cross-section and protrudes rearward from the upper part of the contact portion 333. The convex rib 337 is provided along the entire length of the packing 33. Because the convex rib 337 has a substantially hemispherical shape and makes point or line contact with the inner surface of the cover portion 3 (the surface inside the gap portion 32), it is less likely to get caught on the inner surface of the cover portion 3, which has a U-shaped cross-section. In addition, due to the flexibility of the packing 33 itself, when the convex rib 337 is pressed against the front surface of the rear cover portion 31 by the reaction force when the cover portion 3 opens, the contact point is always designed to maintain point or line contact with respect to the angle change of the front surface (plane) of the rear cover portion 31.

[0038] The sealing wall 332 is provided above the installation portion 331 and the contact portion 333. The front end of the sealing wall 332 is connected to the upper part of the installation portion 331. A constricted portion 338 is formed at the connection point between the sealing wall 332 and the installation portion 331. The constricted portion 338 is a part that is recessed in the vertical direction and is thinner than the thickness (vertical dimension) of the sealing wall 332. The constricted portion 338 is provided along the entire length of the packing 33.

[0039] The retaining portion 339 is provided so as to protrude above the sealing wall 332. The lower end of the retaining portion 339 is connected to the connection portion between the sealing wall 332 and the installation portion 331.

[0040] The packing 33 is flexible. That is, the packing 33 is easily bent and deformed, but it returns to its original shape (shape in Figure 4) due to restoring force. Therefore, the convex ribs 335, 337 and concave 336 formed on the packing 33 are not easily crushed. The flexible packing 33 can be made from a non-foaming material, such as a rubber molded product made of vulcanized rubber or silicone rubber.

[0041] As shown in Figures 7A to 7C, the packing 33 is foldable. Figure 7A shows the packing 33 in its normal state. From this state, by applying force to the contact portion 333 and bending the lower end of the contact portion 333, the contact portion 333 can be folded so that it is located behind the installation portion 331. Also, from the state shown in Figure 7B, by applying force to the sealing wall 332 and bending it with the constricted portion 338 as a fulcrum, the sealing wall 332 can be folded so that it is located behind the contact portion 333, as shown in Figure 7C.

[0042] Thus, in this embodiment, the packing 33 can be bent and deformed so that the installation portion 331, the contact portion 333, and the sealing wall 332 overlap, making it compact and easy to transport.

[0043] Figure 8 shows the mounting structure of the packing 33 to the first metal outer shell 1. The packing 33 has an insertion portion 334 positioned in the gap portion 32. Most of the installation portion 331 and contact portion 333 are also positioned in the gap portion 32, but the upper part of the installation portion 331 is located above the opening 320.

[0044] The front surface of the mounting portion 331 is in contact with the inner surface of the cover portion 3 (the surface within the gap portion 32). That is, the front surface of the mounting portion 331 is in contact with the rear surface of the front cover portion 30. At this time, in the portions of the multiple recesses 336, the front surface of the mounting portion 331 is not in contact with the rear surface of the front cover portion 30. Therefore, in the portions of the multiple recesses 336, a ventilated gap is formed.

[0045] In this embodiment, the packing 33 does not need to be adhered to the rear surface of the front cover portion 30 when inserted. Even if the packing 33 does not have a recess 336, if gas is generated, since the packing 33 and the rear surface of the front cover portion 30 are not adhered, the gas will be discharged from both ends of the metal sandwich panel 10 through the gap between the packing 33 and the rear surface of the front cover portion 30, making it less likely for blistering to occur in the first metal outer shell 1 and the second metal outer shell 2 of the metal sandwich panel 10.

[0046] The contact portion 333 has a convex rib 337 that is in contact with the inner surface of the cover portion 3. That is, the convex rib 337 of the contact portion 333 is in contact with the front surface of the rear cover portion 31. The sealing wall 332 is located above the opening 320. The lower surface of the rear end of the sealing wall 332 is positioned opposite the upper surface of the gap piece 122. The lower surface of the rear end of the sealing wall 332 can come into contact with or separate from the upper surface of the gap piece 122 due to the elastic deformation of the sealing wall 332.

[0047] Even if the thickness of each piece of the packing 33 is reduced and it is designed to have an arbitrary opening angle (slightly larger), it can be properly sealed by press-fitting it into the opening 320 of the cover portion 3 (solely by the restoring force of the packing 33 itself). The wedge-shaped packing 33 is subjected to pressure and, even when pushed deep into the gap (lower part), it rebounds appropriately, but does not generate a rebound force that would cause the exterior of the first metal outer shell 1 to bulge.

[0048] Figure 8 shows the state in which the packing 33 is attached to the first metal outer shell 1 during the manufacturing of the metal sandwich panel 10. During the manufacturing of the metal sandwich panel 10, the metal sandwich panel 10 is manufactured with its surface direction being approximately horizontal. That is, the metal sandwich panel 10 is manufactured with the vertical direction in Figure 1 being approximately horizontal (in a sideways position).

[0049] As shown in Figures 1 to 3, the second metal shell 2 has a second shell body 212. The second shell body 212 is formed in a flat plate shape and constitutes the main surface on the front side of the metal sandwich panel 10. The second shell body 212 faces the first metal shell 1 in the thickness direction. The second metal shell 2 has a second recessed piece 219. The second recessed piece 219 protrudes downward from the upper end of the second shell body 212 as if folding back. The second recessed piece 219 faces the first recessed piece 119 in the thickness direction. The second metal shell 2 has a second recessed bottom piece 220. The second recessed bottom piece 220 protrudes forward from the lower end of the second recessed piece 219. The second metal shell 2 has a second upper insertion piece 221. The second upper insertion piece 221 protrudes downward from the front end of the second recessed bottom piece 220. The second upper insertion piece 221 is inserted into the resin foam 4 from the upper end face 42.

[0050] The second metal outer shell 2 has a lower section 222. The lower section 222 protrudes forward from the lower end of the second outer shell body 212. The second metal outer shell 2 has a second convex section 223. The second convex section 223 protrudes downward from the front end of the lower section 222. The second convex section 223 faces the first convex section 123 in the thickness direction with a predetermined distance between them. The second metal outer shell 2 has a second lower insertion section 224. The second lower insertion section 224 protrudes upward from the lower end of the second convex section 223, folding back. The second lower insertion section 224 is inserted into the resin foam 4 from the lower end face 40. The second lower insertion section 224 and the second convex section 223 face each other in the thickness direction (front-back direction) with a predetermined distance between them. Furthermore, the second lower insertion piece 224 and the second protruding piece 223 form a second opposing portion 211 at the lower end of the second metal outer shell 2. The first opposing portion 111 and the second opposing portion 211 face each other with a predetermined distance between them in the thickness direction (front-to-back direction). In this way, the first metal outer shell 1 and the second metal outer shell 2 are arranged so as not to come into direct contact in order to prevent thermal bridging.

[0051] The mating recess 9 is formed by a space enclosed by a first recess piece 119, a second recess piece 219, a first recess bottom piece 120, a second recess bottom piece 220, and the upper end face 42 of the resin foam 4. A packing 90 made of EPDM, butyl rubber, and soft urethane foam is provided in the mating recess 9 along its entire length. The mating projection 8 is composed of a first opposing portion 111, a second opposing portion 211, and a part of the resin foam 4 located between the first opposing portion 111 and the second opposing portion 211.

[0052] As shown in Figures 2 and 3, a sealing material 6 is provided on the lower end face of the metal sandwich panel 10. The sealing material 6 is provided to prevent the resin foam 4 from leaking out between the first opposing portion 111 and the second opposing portion 211 during the manufacturing of the metal sandwich panel 10. The sealing material 6 is provided along the entire length. The end face 80 of the fitting projection 8, which is the lower end face of the metal sandwich panel 10, is formed by the outer surface of the sealing material 6 (the surface opposite to the resin foam 4). The sealing material 6 is provided by bridging the gap between the first projection piece 123 of the first opposing portion 111 and the second projection piece 223 of the second opposing portion 211. Therefore, the end face 40 of the resin foam 4 between the first opposing portion 111 and the second opposing portion 211 is covered by the sealing material 6. The sealing material 6 is bonded to the outer surface of the first projection piece 123 and the outer surface of the second projection piece 223.

[0053] The material of the sealing material 6 is not particularly limited, but it is preferably at least one selected from the group consisting of paper, resin film, nonwoven fabric, and woven fabric. As an example of paper, a two-layer structure consisting of kraft paper and an adhesive laminate can be used. The sealing material 6 is formed in a strip shape extending in the longitudinal direction and can be formed in the form of a sheet, film, or plate. The thickness (vertical dimension) of the sealing material 6 can be 0.01 mm or more and 0.5 mm or less, but is not limited thereto.

[0054] The resin foam 4 is a component that forms the main body of the metal sandwich panel 10 and is made of resin foam. In this embodiment, the resin foam 4 is at least one selected from the group consisting of polyisocyanurate foam, polyurethane foam, polystyrene foam, or polyphenol foam. Multiple types of these may be combined to form the resin foam 4, or only one of them may be used. Alternatively, multiple types of materials may be laminated in the thickness direction. Preferably, the resin foam 4 has heat insulation properties and fire resistance.

[0055] Figure 3 shows the connection structure of two adjacent metal sandwich panels 10 in the vertical direction. The two metal sandwich panels 10 are connected when the fitting projection 8 of the upper metal sandwich panel 10 is fitted into the fitting recess 9 of the lower metal sandwich panel 10. Here, the end face 80 of the fitting projection 8 is in close contact with the upper surface of the packing 90. The cover portion 3 is located in front of the fitting projection 8, and the lower end of the cover portion 3 is located below the lower end of the fitting projection 8. As a result, the fasteners 50, such as screws, that secure the lower metal sandwich panel 10 are located behind the cover portion 3 of the upper metal sandwich panel 10, and the cover portion 3 can cover the fasteners 50 so that they are not visible from the front. The fasteners 50 are driven (screwed) into the grooved piece 116 from the front, penetrate the metal sandwich panel 10 in the thickness direction, and are driven (screwed) into the wall substrate such as furring strips located behind the metal sandwich panel 10. At this time, the head 51 of the fastener 50 is positioned so as to be in close contact with the front surface of the grooved piece 116. In this way, the metal sandwich panel 10 is fixed to the wall substrate and installed.

[0056] The metal sandwich panel 10 is manufactured as follows:

[0057] First, as shown in Figure 9, the first and second metal outer shells 1 and 2 are formed from metal sheets 1A and 2A. The metal sheet 1A, wound in a roll, is fed out by a feeding device 55A and continuously supplied to a molding machine 56A, such as a roll forming machine. The molding machine 56A then forms various parts such as the covering portion 3 and the first opposing portion 111 to form the first metal outer shell 1. Similarly, the metal sheet 2A, wound in a roll, is fed out by a feeding device 55B and continuously supplied to a molding machine 56B, such as a roll forming machine. The molding machine 56B then forms various parts such as the second opposing portion 211 to form the second metal outer shell 2.

[0058] Next, a packing 33 is provided in the gap 32 of the covering portion 3 of the first metal outer shell 1. In this case, the packing 33 is inserted into the gap 32 from the opening 320. The packing 33 is inserted into the gap 32 between the molding machine 56A and the liquid supply device 58. The packing 33 may be inserted into the gap 32 manually, or a filling device 54 may be used.

[0059] In this embodiment, even if the material thickness is reduced and the opening angle between the installation portion 331 and the contact portion 333 is designed to be large, proper sealing can be achieved by press-fitting the packing into the opening 320 of the void portion 32 (solely by the restoring force of the packing 33 itself). The wedge-shaped packing 33 acts as a brake against the pressure when the resin foam 4 is foamed, and even when pushed deep into the void portion 32, it provides moderate rebound while minimizing the repulsive force that would cause the metal outer shell 1 to bulge.

[0060] Next, the first metal shell 1 is heated by a heating device 57A, such as a high-frequency heating device, while being continuously transported. Similarly, the second metal shell 2 is heated by a heating device 57B, such as a high-frequency heating device, while being continuously transported.

[0061] Next, the resin liquid 45 is supplied to one side of the first metal shell 1 (the side that will be bonded to the resin foam 4). During the manufacturing of the metal sandwich panel 10, the side of the first metal shell 1 that will be bonded to the resin foam 4 faces upward. The resin liquid 45 is supplied from the nozzle 41 of the liquid supply device 58 to the upward-facing side (top surface) of the first metal shell 1. The resin liquid 45 is a liquid resin material that foams and expands to become the resin foam 4. Here, the viscosity and other properties of the resin liquid 45 are adjusted so that it is difficult for it to penetrate into the voids 32.

[0062] Next, during the foaming of the resin liquid 45, the second metal shell 2 is positioned opposite the first metal shell 1. At this time, the side of the second metal shell 2 that will be bonded to the resin foam 4 is facing downwards. Then, the resin liquid 45 is further foamed between the first shell body 112 of the first metal shell 1 and the second shell body 212 of the second metal shell 2, which are positioned opposite each other vertically. At this time, a sealing material 6 is placed between the opposing parts 111 of the first metal shell 1 and 211 of the second metal shell 2, which are positioned opposite each other. The sealing material 6 is placed across the outer surface of the first protruding piece 123 and the outer surface of the second protruding piece 223. The surface of the sealing material 6 that is in contact with the resin foam 4 is bonded by the self-adhesive force of the resin foam 4 (resin liquid 45). Furthermore, the packing 90 is positioned in the space surrounded by the first recessed piece 119, the second recessed piece 219, the first recessed bottom piece 120, and the second recessed bottom piece 220.

[0063] To further foam the resin liquid 45 between the first metal shell 1 and the second metal shell 2, the opposing first metal shell 1 and second metal shell 2 are sandwiched between a double conveyor 59 in a heating furnace 60 and heated and pressurized. When the resin liquid 45 is completely foamed, it becomes resin foam 4.

[0064] The resin foam 4 adheres to the first metal shell 1 and the second metal shell 2 by its self-adhesive force. The first metal shell 1 and the second metal shell 2 are positioned so as not to be in direct contact with each other in order to prevent thermal bridging. Therefore, the first opposing part 111 and the second opposing part 211 face each other with a predetermined distance between them in the thickness direction (front-to-back direction), but the space between the first opposing part 111 and the second opposing part 211 can be sealed with a sealing material 6 to prevent the resin foam 4 from leaking out during the foaming process.

[0065] In this way, the first metal shell 1 and the second metal shell 2 are integrated with the resin foam 4, and a long metal sandwich panel 10A is continuously manufactured. Then, by cutting the long metal sandwich panel 10A to a desired length with a cutting device 61 such as a cutter, a metal sandwich panel 10 can be manufactured.

[0066] Furthermore, in the manufacturing method of the metal sandwich panel 10 of this embodiment, before supplying the resin liquid 45 to the first metal outer shell 1, a packing 33 is provided in the void 32 and the opening 320 is closed with a sealing wall 332, making it difficult for the resin liquid 45 and resin foam 4 to penetrate into the void 32. That is, as shown in Figure 10, the resin foam 4 reaches the upper surface of the sealing wall 332 of the packing 33, but the resin foam 4 presses the sealing wall 332 toward the gap piece 122, bringing the sealing wall 332 into contact with the upper surface of the gap piece 122 and closing the gap between the sealing wall 332 and the gap piece 122, making it difficult for it to penetrate further into the void 32.

[0067] Therefore, the void 32 is not filled with resin foam 4, and the gas generated in the resin foam 4 can be discharged through the void 32 from both ends in the longitudinal direction of the metal sandwich panel 10. As a result, delamination of the resin foam 4 and the metal outer shells 1 and 2 due to gas pressure after the manufacturing of the metal sandwich panel 10 is less likely to occur, and the first metal outer shell 1 and the second metal outer shell 2 are less likely to bulge.

[0068] Furthermore, as the resin liquid 45 foams up to become the resin foam 4, the pressing portion 339 is pressed against the inner surface (the side facing the resin foam 4) of the first metal outer shell 1 by the resin foam 4. Therefore, the packing 33 is less likely to shift from its predetermined position due to the pressure of the resin liquid 45 and the resin foam 4. In other words, the pressing portion 339 not only has the effect of suppressing displacement due to the pressing force from the resin foam 4, but the pressing portion 339 also bears a reaction force F2 that counteracts the rotation of the packing 33 (a clockwise moment F1 as explained in Figure 10). That is, the downward stress that the packing 33 receives from the resin foam 4 (see Figure 10) generates a clockwise moment F1 around the axis of rotation P after the sealing wall 332 comes into contact with the gap piece 122. Then, when the convex rib 337 contacts the surface inside the gap 32, the contact portion 333 opens, creating a reaction force F2 against the stress. However, the retaining portion 339 functions to counteract the rotational stress of the packing 33, and in combination with the displacement function, the positional stability (maintaining the ideal shape) of the packing 33 is improved.

[0069] As shown in Figure 11, even if some of the resin liquid 45 enters the void 32 through the opening 320 between the sealing wall 332 and the gap piece 122, the resin liquid 45 enters the space between the installation portion 331 and the contact portion 333 of the packing 33, and foams up in this space to generate resin foam 4. The resin foam 4 between the installation portion 331 and the contact portion 333 can then press the installation portion 331 forward, causing it to adhere tightly to the rear surface of the front cover portion 30, and press the contact portion 333 backward, pressing the convex rib 337 against the front surface of the rear cover portion 31. Thus, the packing 33 can be firmly held in place. This function enhances the secondary liquid-stopping function and the positioning of the packing 33 by causing the packing 33 to expand in volume from the inside, causing the installation portion 331 and the contact portion 333 to adhere tightly to the inner surface of the void 32. The sealing wall 332 also has a primary liquid-stopping function.

[0070] In the metal sandwich panel 10 of this embodiment, even if unreacted components in the resin foam 4 react after the metal sandwich panel 10 is manufactured and generate new gas (such as carbon dioxide), this gas is introduced into the void 32 through the gap between the packing 33 and the cover 3 (the gap between the front surface of the installation part 331 and the rear surface of the front cover part 30), and then released to the outside from the left and right ends of the void 32 which are open at the left and right ends of the metal sandwich panel 10. Therefore, after the metal sandwich panel 10 is manufactured, delamination of the resin foam 4 and the metal outer shells 1 and 2 due to gas pressure is less likely to occur, and the first metal outer shell 1 and the second metal outer shell 2 are less likely to swell.

[0071] The packing 33 may also fill the entire gap 32. That is, the packing 33 can be provided in contact with the front cover portion 30 and the rear cover portion 31 facing each other in the front-rear direction, extending from the lower end of the gap 32 to the opening 320.

[0072] (summary) As described above, the packing (33) according to the first embodiment comprises an installation portion (331) and a contact portion (333) inserted into the gap portion (32), and a sealing wall (332) that closes the opening (320) of the gap portion (32). The contact portion (333) and the sealing wall (332) are not connected.

[0073] According to this embodiment, by sealing the opening (320) of the void (32) with the packing (33), it is difficult for unwanted materials to enter the void (32) from the outside. Also, since the sealing wall (332) and the contact portion (333) are not connected, the shape of the packing (33) can be easily deformed, and it can be inserted into the void (32) with appropriate pressure.

[0074] The second embodiment is a packing (33) according to the first embodiment, wherein the sealing wall (332) is provided projecting rearward from the upper end of the installation portion (331) and is formed with a gap between it and the upper end of the contact portion (333).

[0075] According to this embodiment, there is a gap between the sealing wall (332) and the contact portion (333), and the sealing wall (332) and the contact portion (333) are not connected, so the shape of the packing (33) is easily deformed, and it can be inserted into the gap portion (32) with appropriate pressure.

[0076] A third embodiment is a packing (33) according to the first embodiment, having a constricted portion (338) at the connection between the sealing wall (332) and the installation portion (331).

[0077] According to this embodiment, the sealing wall (332) can move closer to and further away from the installation portion (331) with the constricted portion (338) as a fulcrum, making it easier for the sealing wall (332) to close the opening (320) of the void portion (32).

[0078] A fourth embodiment is a packing (33) according to the first embodiment, wherein the contact portion (333) has a hemispherical convex rib (337) that contacts the surface inside the gap portion (32).

[0079] According to this embodiment, the hemispherical convex rib (337) is in contact with the surface inside the void (32), making it easier to insert the contact portion (333) into the void (32).

[0080] A fifth aspect is a packing (33) according to the first aspect, further comprising an insertion portion (334) to which the lower end of the installation portion (331) and the lower end of the contact portion (333) are connected. The insertion portion (334) has a wedge-shaped cross-section and has a convex rib (335) on its outer surface. The installation portion (331) and the contact portion (333) are arranged in a substantially V-shape in cross-section.

[0081] According to this embodiment, the installation portion (331) and the contact portion (333) are easily inserted into the gap portion (32).

[0082] A sixth aspect is a packing (33) according to the first aspect, further comprising a retaining portion (339) that protrudes above the sealing wall (332).

[0083] According to this embodiment, by pressing down on the retaining portion (339), the displacement of the packing (33) can be reduced.

[0084] A seventh embodiment is a packing (33) according to the first embodiment, having a recess (336) on the outer surface of an installation portion (331) facing the surface inside the gap portion (32).

[0085] In this embodiment, the recess (336) can serve as a ventilation layer or drainage channel for discharging water that has entered from outside the void (32) or gas accumulated inside the void (32) to the outside. In the case of a metal sandwich panel (10) using a packing (33), gas generated from the resin foam (4) can be discharged to the outside of the panel body (101) through the recess (336), preventing the metal outer shell (1, 2) from bulging due to gas generated from the resin foam (4). Even if the recess (336) is not designed to be present in the packing (33), a gap exists at the boundary between the packing (33) and the metal outer shell (1, 2), and since this gap is the part where the resin foam (4) and the metal outer shell (1, 2) are not bonded, this gap acts as a ventilation layer, ensuring breathability.

[0086] The eighth aspect is a packing (33) relating to any one of the first to seventh aspects, wherein the packing (33) is flexible.

[0087] According to this embodiment, the packing (33) becomes more easily deformable and easier to insert into the gap (32). [Explanation of Symbols]

[0088] 32 Cavity 33 Packing 320 aperture 331 Installation section 332 Sealing Wall 333 Contact area 334 Insertion part 335 Convex Rib 336 recess 337 Convex Rib 338 Waist area 339 Pressing part

Claims

1. It comprises an installation portion and a contact portion that are inserted into the gap, and a sealing wall that closes the opening of the gap, The contact portion and the sealing wall are not connected. rubber seal.

2. The sealing wall is provided projecting rearward from the upper end of the installation portion and is formed with a gap between it and the upper end of the contact portion. The packing according to claim 1.

3. The connection portion between the sealing wall and the installation portion has a constricted portion. The packing according to claim 1.

4. The contact portion has a hemispherical convex rib that contacts the surface inside the gap. The packing according to claim 1.

5. The device further has an insertion portion to which the lower end of the installation portion and the lower end of the contact portion are connected. The insertion portion has a wedge-shaped cross-section and has a convex rib on its outer surface. The installation portion and the contact portion are arranged in a substantially V-shape in cross-section. The packing according to claim 1.

6. It further comprises a pressing portion that protrudes above the sealing wall. The packing according to claim 1.

7. The outer surface of the installation portion facing the surface inside the gap has a recess, The packing according to claim 1.

8. Having flexibility, A packing according to any one of claims 1 to 7.

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