Panel, corner member, and method for sealing panel corner

Abstract

To provide a panel and a corner member which can shorten time for production and shipping of a panel, and easily stabilizes a filling amount of a sealing material of a panel corner, and a panel corner seal method.SOLUTION: A panel 1 includes a core material 2 having a corner part 23, a metal skin 3 covering the core material 2, a corner member 5 arranged on an opening 38 formed at a part covering the corner part 23 in the metal skin 3, and a sealing material 6 that is made to fill the opening 38. The corner member 5 has a cover part 50 blocking the opening 38, a seal receiving part 51 that is positioned inside the cover part 50, and has a space S1 formed between the cover part 50 and the seal receiving part 51, and a connection part 52 connecting the cover part 50 and the seal receiving part 51. The space S1 is filled with the sealing material 6.SELECTED DRAWING: Figure 5

Description

[Technical field]

[0001] The present disclosure relates to a panel, a corner member, and a method for sealing a panel corner. [Background technology]

[0002] Patent Document 1 describes a panel that includes a core material and a metal skin that covers the core material.

[0003] The metal skin has a rectangular box shape and includes an upper piece portion covering an upper surface of the core material, a lower piece portion covering a lower surface of the core material, and a pair of side pieces covering side surfaces of the core material. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2018-87425 A Summary of the Invention [Problem to be solved by the invention]

[0005] In the panel described in the above-mentioned Patent Document 1, the adjacent ends of the upper piece, the lower piece, and the pair of side pieces are discontinuous, and openings that expose the core material are generated at the corners of the panel. Such openings are closed by filling them with a sealant, for example.

[0006] However, if the surface of the sealant filled in the corners that is exposed from the corners does not harden, it is difficult to perform finishing work on the panel or ship the panel. Moreover, since it takes time, for example about a day, for the surface of the sealant to harden, there is a problem that panels with sealant filled in the corners take a long time to manufacture.

[0007] Furthermore, in panels that have a core material and a metal skin covering it, such as the panel described in Patent Document 1, the gaps between each piece of the core material and the metal skin are prone to variation due to manufacturing errors, etc., and there is a problem that the amount of sealant filled into the corners is difficult to stabilize.

[0008] In view of the above circumstances, an object of the present disclosure is to provide a panel, a corner member, and a method for sealing the corners of a panel that can shorten the time required for producing and shipping panels and that can easily stabilize the amount of sealing material filled in the panel corners. [Means for solving the problem]

[0009] A panel according to one aspect of the present disclosure includes a core material having a corner portion, a metal skin covering the core material, a corner member disposed in an opening formed in a portion of the metal skin covering the corner portion, and a sealant filled in the opening. The corner member has a cover portion that closes the opening, a seal receiving portion that is located inside the cover portion and forms a space between the cover portion and the seal receiving portion, and a connecting portion that connects the cover portion and the seal receiving portion. The sealant is filled in the space.

[0010] A corner member according to one aspect of the present disclosure is a corner member that is disposed in an opening formed in a portion of the metal skin covering the corner portion of a panel including a core material having a corner portion and a metal skin covering the core material, and receives a sealant filled in the opening. The corner member has a cover portion that closes the opening, a seal receiving portion that is located inside the cover portion and forms a space between the cover portion and the sealant, and a connecting portion that connects the cover portion and the corner member.

[0011] A method for sealing a panel corner according to one aspect of the present disclosure is a method for sealing a panel corner, the method comprising: a core material having a corner portion and a metal skin covering the core material; filling an opening formed in a portion of the metal skin covering the corner portion with a sealant. The method comprises an arrangement step of arranging a corner member in the opening; and a filling step of filling the opening in which the corner member is arranged with the sealant. The corner member has a cover portion that closes the opening, a seal receiving portion that is located inside the cover portion and forms a space between the cover portion and the seal receiving portion, and a connecting portion that connects the cover portion and the seal receiving portion. In the filling step, the sealant is filled in the space. Effect of the Invention

[0012] According to one aspect of the present disclosure, it is possible to provide a panel, a corner member, and a method for sealing a panel corner that can shorten the time required for producing and shipping a panel and that can easily stabilize the amount of sealing material filled in the panel corner. [Brief description of the drawings]

[0013] [Figure 1] FIG. 1 is a perspective view showing a panel according to a first embodiment of the present disclosure. [Diagram 2] 2A is a cross-sectional view taken along line AA in FIG. 1, and FIG. 2B is a cross-sectional view taken along line BB in FIG. [Diagram 3] FIG. 3 is a cross-sectional view taken along line CC in FIG. [Figure 4] FIG. 4 is an enlarged perspective view showing a corner of the panel of the above, in which the sealant and the like filled in the corner are omitted. [Diagram 5] FIG. 5 is a cross-sectional view taken along line DD in FIG. 4, and also shows the sealant filled in the corners. [Figure 6] FIG. 6 is a perspective view showing a corner member provided on the panel. [Figure 7]FIG. 7A is a perspective view showing an example of the construction of the panel, and FIG. 7B is an enlarged perspective view showing part E in FIG. 7A, in which the illustration of the joint material filling the joints is omitted. [Figure 8] 8A to 8D are perspective views sequentially showing the process of sealing the corners of the panel. [Figure 9] 9A and 9B are perspective views sequentially showing the process of sealing the corners of the panel. [Figure 10] FIG. 10 is a perspective view showing a corner member included in a panel according to a second embodiment of the present disclosure. [Figure 11] 11A to 11C are perspective views sequentially showing the process of sealing the corners of the panel. [Figure 12] 12A and 12B are perspective views sequentially showing the process of sealing the corners of the panel. [Figure 13] FIG. 13 is a perspective view showing a modified example of the corner member. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0014] (Embodiment 1) 1. Overview 5, the panel 1 of the first embodiment according to the present disclosure includes a core material 2 having a corner portion 23, a metal skin 3 covering the core material 2, a corner member 5 disposed in an opening 38 formed in a portion of the metal skin 3 covering the corner portion 23, and a sealing material 6 filled in the opening 38. The corner member 5 has a cover portion 50 that closes the opening 38, a seal receiving portion 51 that is located inside the cover portion 50 and forms a space S1 between the cover portion 50 and the seal receiving portion 51, and a connecting portion 52 that connects the cover portion 50 and the seal receiving portion 51. The sealing material 6 is filled in the space S1.

[0015] Moreover, the corner member 5 of the first embodiment according to the present disclosure is a corner member 5 that is disposed in an opening 38 formed in a portion of the metal skin 3 covering the corner portion 23 of a panel 1 including a core material 2 having a corner portion 23 and a metal skin 3 covering the core material 2, and receives a sealant 6 filled in the opening 38. The corner member 5 has a cover portion 50 that closes the opening 38, a seal receiving portion 51 that is located inside the cover portion 50 and forms a space S1 between the cover portion 50 and the sealant 6, and a connecting portion 52 that connects the cover portion 50 and the seal receiving portion 51.

[0016] The method for sealing a panel corner according to the first embodiment of the present disclosure is a method for sealing a panel corner, in which a sealant 6 is filled in an opening 38 formed in a portion of the metal skin 3 covering the corner portion 23 of a panel 1 including a core material 2 having a corner portion 23 and a metal skin 3 covering the core material 2. The method for sealing a panel corner according to the first embodiment includes an arrangement step of arranging a corner member 5 in the opening 38, and a filling step of filling the opening 38 in which the corner member 5 is arranged with the sealant 6. The corner member 5 has a cover portion 50 that closes the opening 38, a seal receiving portion 51 that is located inside the cover portion 50 and forms a space S1 between the cover portion 50 and the seal receiving portion 51, and a connecting portion 52 that connects the cover portion 50 and the seal receiving portion 51. In the filling step, the sealant 6 is filled in the space S1.

[0017] In the panel 1, corner member 5, and panel corner sealing method of the first embodiment having the above configuration, the sealant 6 is covered with the cover portion 50 of the corner member 5, and the exposure of the sealant 6 from the opening 38 can be suppressed. Therefore, in the panel 1, corner member 5, and panel corner sealing method of the first embodiment, the finishing work on the panel 1 can be performed without waiting for the surface of the sealant 6 to harden, and the time required for production and shipping of the panel can be shortened. In addition, in the panel 1, corner member 5, and panel corner sealing method of the first embodiment, the filling range of the sealant 6 filled inside the opening 38 can be limited by the cover portion 50 and the seal receiving portion 51 of the corner member 5, and the filling amount of the sealant 6 is likely to be stable.

[0018] 2.Details Next, the panel 1 of this embodiment shown in Figures 1 to 3 will be described in more detail. The panel 1 is a construction panel, and is used, for example, as an exterior wall material. In the panel 1, the metal skin 3 forms the front surface of the panel 1 (when used as an exterior wall material, the surface facing the outdoors). Each component will be described below using the directions shown in Figure 1.

[0019] The panel 1 is a rectangular plate. The panel 1 has a longitudinal direction parallel to the up-down direction, a lateral direction parallel to the left-right direction, and a thickness direction parallel to the front-rear direction. For example, the length of the panel 1 in the up-down direction is 0.5 to 9.0 m, the length (width) in the left-right direction is 0.2 to 1.2 m, and the length (thickness) in the front-rear direction is 50 to 150 mm.

[0020] The panel 1 comprises a core material 2, a metal skin 3 covering the core material 2 from the front side, and a second metal skin 4 covering the core material 2 from the rear side.

[0021] 2-1.Core material The core material 2 has a plate-like overall shape. In this embodiment, the core material 2 has a rectangular plate-like overall shape. The plate-like overall shape is not limited to a single plate, but also includes a plurality of members arranged to form a single plate. As shown in Figs. 2A and 2B, the core material 2 includes a main body portion 20 and a fire-resistant portion 21 having a higher fire resistance than the main body portion 20.

[0022] The main body 20 has grooves 22 on the left and right side surfaces. The grooves 22 are located in the center of the left and right side surfaces of the main body 20 in the front-to-rear direction and are located over the entire length of the left and right side surfaces of the main body 20 in the up-down direction. The fire-resistant portion 21 is arranged in the grooves 22.

[0023] The main body 20 is made of a fibrous inorganic material such as rock wool or glass wool. The main body 20 is made of a plurality of block bodies arranged in the left-right direction. Each of the plurality of block bodies is made by solidifying a fibrous inorganic material into a block shape with a binder or the like. The plurality of block bodies have the same length in the up-down direction and the same length in the front-rear direction. The plurality of block bodies are in contact with each other at their adjacent sides to form the main body 20 in the shape of a single rectangular plate as a whole. Each of the plurality of block bodies may be made of, for example, a rock wool board cut into strips. In this case, the plurality of block bodies are arranged so that the fiber direction is parallel to the front-rear direction and so as to form a single rectangular plate as a whole to form the main body 20.

[0024] In this embodiment, the main body 20 has thermal insulation properties. Among the plurality of block bodies, the leftmost block body has a left side surface and the rightmost block body has a right side surface, each of which is provided with a groove portion 22. In each of the plurality of block bodies, the longitudinal direction of the fibrous inorganic material is aligned with the front-rear direction.

[0025] The main body 20 has an upper surface 200, a lower surface 201, a left side surface 202, and a right side surface 203. Any two adjacent surfaces of the upper surface 200, the lower surface 201, the left side surface 202, and the right side surface 203 form a corner.

[0026] The fire-resistant portion 21 is a member having higher fire resistance than the main body portion 20, and is, for example, a gypsum board or a calcium silicate board. The fire-resistant portion 21 has a shape corresponding to the groove portion 22 and is a single rectangular plate. The fire-resistant portion 21 fills the entire groove portion 22.

[0027] Fig. 4 shows a corner of panel 1 (the upper right corner of panel 1 in an upright position) when panel 1 is laid flat so that metal skin 3 forms the underside of panel 1. Below, each component will be explained using the directions when panel 1 is laid flat. Fireproof section 21, sealing material 6, and waterproof packing 7 are omitted from Fig. 4.

[0028] As shown in Figs. 4 and 5, the core material 2 has a first side surface 24, a second side surface 25, and an intermediate surface 26 which constitute a corner portion 23 of the core material 2. The core material 2 has an intermediate surface 26 at each of the four corners. In Figs. 4 and 5, the first side surface 24 is the upper surface 200 of the main body portion 20, and the second side surface 25 is the right side surface 203 of the main body portion 20. The intermediate surface 26 is a surface located between the first side surface 24 and the second side surface 25. In this embodiment, the intermediate surface 26 is formed by removing a part of a corner formed by two adjacent surfaces among the upper surface 200, the lower surface 201, the left side surface 202, and the right side surface 203 of the core material 2.

[0029] The intermediate surface 26 is located below the groove portion 22. In this embodiment, the intermediate surface 26 is a rectangular flat surface. The intermediate surface 26 extends from the lower end of the groove portion 22 to the lower surface of the main body portion 20 (the front surface 27 of the main body portion 20 in the upright position).

[0030] 2-2. Metal shell Each of the metal skin 3 and the second metal skin 4 shown in FIG. 1 is obtained by forming a metal plate into a desired shape by rolling, pressing, or the like. The metal plate has a thickness of, for example, 0.25 to 2.0 mm. The metal plate may be, but is not limited to, a painted steel plate, a zinc-plated steel plate, an aluminum-zinc alloy-plated steel plate, a Galvalume steel plate (registered trademark), an SGL (registered trademark) steel plate, or the like. Each configuration will be described below using the direction in which the panel 1 is in an upright position.

[0031] 1 to 3, the metal skin 3 is in the shape of a rectangular box that opens toward the rear. The metal skin 3 has a rectangular plate-shaped main body 30 that covers the front surface 27 of the main body 20 of the core material 2, an upper wall 31 that covers the upper surface 200 of the main body 20, and a lower wall 32 that covers the lower surface 201 of the main body 20. The metal skin 3 further has a left side wall 33 that covers a portion of the left side surface 202 of the main body 20 that is forward of the groove 22, and a right side wall 34 that covers a portion of the right side surface 203 of the main body 20 that is forward of the groove 22.

[0032] The upper wall 31 protrudes rearward from the upper edge of the main body 30, the lower wall 32 protrudes rearward from the lower edge of the main body 30, the left side wall 33 protrudes rearward from the left edge of the main body 30, and the right side wall 34 protrudes rearward from the right edge of the main body 30. Each of the four walls 31, 32, 33, 34 is perpendicular to the main body 30. Each of the upper and lower walls 31, 32 is rectangular plate-shaped. The left and right side walls 33, 34 have rectangular plate-shaped portions 330, 340 and rectangular plate-shaped protrusions 331, 341 protruding at right angles from the rear ends of the plate portions 330, 340 outward in the left-right direction. The upper and lower walls 31, 32 are longer in the front-rear direction than the left and right side walls 33, 34.

[0033] As shown in Figs. 1 and 4, the metal skin 3 further has an arc-shaped connecting portion 37 that connects the front ends of two circumferentially adjacent wall portions (for example, the upper wall portion 31 and the right side wall portion 34).

[0034] The metal skin 3 has a connecting portion 37 at each of the four corners. The front ends of two circumferentially adjacent wall portions of the walls 31, 32, 33, and 34 are continuous with each other via the connecting portion 37. An opening 38 is formed between two circumferentially adjacent wall portions. The opening 38 is located behind the connecting portion 37.

[0035] 1 to 3, the second metal skin 4 has a rectangular plate-shaped body 40 covering the rear surface 28 of the body 20 of the core material 2, a left side wall 41 covering a portion of the left side surface 202 of the body 20 rearward of the groove 22, and a right side wall 42 covering a portion of the right side surface 203 of the body 20 rearward of the groove 22. The left side wall 41 protrudes forward from the left edge of the body 40, and the right side wall 42 protrudes forward from the right edge of the body 40. The second metal skin 4 does not have a portion covering the upper surface 200 or the lower surface 201 of the body 20.

[0036] The left and right side wall portions 41, 42 each have a curved portion 410, 420 curved in a U-shape in a plan view, and a rectangular flat portion 411, 421 protruding forward from the front end portion of the curved portion 410, 420.

[0037] The metal skins 3, 4 have their main bodies 30, 40 bonded to the front and rear surfaces 27, 28 of the main body 20 of the core material 2, respectively, and are integrated with the core material 2. The left and right side wall portions 33, 34 of the metal skin 3 and the left and right side wall portions 41, 42 of the second metal skin 4 are connected via a metal connecting piece 11. As shown in Figures 4 and 5, the opening 38 of the metal skin 3 is located opposite the intermediate surface 26 of the core material 2. An installation space in which the corner member 5 is installed is formed between the opening 38 and the intermediate surface 26.

[0038] 2-3. Corner parts The corner members 5 are disposed one at each of the openings 38 at the four corners of the panel 1. As shown in Figures 4 to 6, the corner member 5 has a cover portion 50 that covers the opening 38, a seal receiving portion 51 that is located inside the cover portion 50 and forms a space S1 between the cover portion 50 and the sealant 6, and a connecting portion 52 that connects the cover portion 50 and the seal receiving portion 51. Below, the corner member 5 will be described using the orientation when the panel 1 is laid flat as shown in Figure 4.

[0039] In this embodiment, the corner member 5 is made of metal. The corner member 5 is formed, for example, by bending a metal plate having the same thickness as the metal skin 3.

[0040] The cover portion 50 has a shape corresponding to the opening 38. In this embodiment, the cover portion 50 has a curved shape so as to be continuous with the portion of the metal skin 3 surrounding the opening 38 (e.g., the upper wall portion 31 and the right side wall portion 34). An injection port 500 through which the sealing material 6 is injected is provided in a part of the cover portion 50.

[0041] In this embodiment, the cover part 50 has a T-shaped flat central part 501 and a pair of inclined parts 502 extending from both ends in the width direction of the central part 501 and inclined with respect to the central part 501 so as to be positioned more inward as the part is further away from the central part 501. Each of the pair of inclined parts 502 is in the shape of a rectangular plate.

[0042] Inlet 500 is provided at an end (lower end) of central portion 501 opposite to one end (upper end) to which connecting portion 52 is connected. Inlet 500 penetrates central portion 501 in the thickness direction.

[0043] A mark 503 is provided on the surface of the cover portion 50 to indicate the position where the masking tape 10, which will be described later, is applied. In this embodiment, the mark 503 is a scribed line, and is provided in a straight line on the surface of the central portion 501 and on the surface of the pair of inclined portions 502. The mark 503 is located above the injection port 500. The portion of the cover portion 50 below the mark 503 is the portion to which the masking tape 10 is applied, and the portion above the mark 503 is the portion to be covered by the waterproof packing 7.

[0044] The seal receiving portion 51 is located inside the cover portion 50, and forms a space S1 between itself and the cover portion 50. The seal receiving portion 51 has an extension piece 510 that fits into the gap between the metal skin 3 and the core material 2.

[0045] In this embodiment, the seal receiving portion 51 has a main body portion 511 parallel to the central portion 501 of the cover portion 50, and a pair of inclined portions 512 extending from both ends of the main body portion 511 in the width direction and inclined with respect to the main body portion 511 so as to be positioned more inward as the portion is further away from the main body portion 511. Each of the main body portion 511 and the pair of inclined portions 512 is a rectangular plate. In this embodiment, the pair of inclined portions 512 constitute the extension piece 510.

[0046] The main body portion 511 is a portion that follows along the middle surface 26 of the core material 2, and the pair of inclined portions 512 are portions that follow along the first side surface 24 or the second side surface 25 of the core material 2. The inclination of the pair of inclined portions 512 with respect to the main body portion 511 corresponds to the inclination of the first side surface 24 and the second side surface 25 with respect to the middle surface 26. The main body portion 511 is approximately the same size as the middle surface 26. The main body portion 511 is longer in the up-down direction than the cover portion 50. The connecting portion 52 is connected to the center in the width direction of one end (upper end) of the main body portion 511.

[0047] The connecting portion 52 is in the shape of a rectangular plate. The connecting portion 52 has a thickness in the up-down direction (thickness direction of the core material 2). The connecting portion 52 is provided with a through hole 520 that penetrates the connecting portion 52 in the thickness direction. The connecting portion 52 has the same width as the upper end portion of the center portion 501 of the cover portion 50.

[0048] The seal receiving portion 51 is longer in the vertical direction (thickness direction of the core material 2) than the cover portion 50. The lower end of the seal receiving portion 51 is located lower than the lower end of the cover portion 50. The difference in length between the seal receiving portion 51 and the cover portion 50 is approximately the same as the vertical length of the connecting portion 37 of the metal skin 3.

[0049] The corner member 5 is installed in the opening 38 so that the body portion 511 of the seal receiving portion 51 is aligned along the middle surface 26 of the core material 2 and the cover portion 50 closes the opening 38. By installing the corner member 5 in the opening 38, a filling space for the sealing material 6 is formed inside the opening 38, surrounded by the cover portion 50 of the corner member 5, the seal receiving portion 51, the connecting portion 52, the right side wall portion 34 of the metal skin 3, the upper wall portion 31, the connecting portion 37, and the body portion 30.

[0050] 2-4. Sealing materials The sealant 6 is a conventionally known sealant. For example, the sealant 6 may be a one-liquid cartridge-type polysulfide sealant. The main component of this sealant is polysulfide polymer. The polysulfide sealant cures in response to moisture in the air, and the difference in curing time throughout the year is relatively small. The polysulfide sealant has a relatively high viscosity and tends to remain in the filling space of the sealant 6. Since this sealant is one-liquid, it is not necessary to knead it as with two-liquid sealants, and workability is high. In addition, this sealant has high adhesion on the surface after curing, and has high adhesion to the metal outer skin 3 and the corner member 5. The one-liquid cartridge-type sealant is not limited to polysulfide, and may be an acrylic, polyurethane, silicone, or modified silicone sealant.

[0051] The sealing material 6 is injected into the filling space of the corner member 5 from the injection port 500 of the cover portion 50 of the corner member 5. The sealing material 6 closes the small gap between the cover portion 50 and the metal skin 3, and waterproofs the opening 38. The sealing material 6 is hardened by natural drying, heating, or humidification.

[0052] 2-5.Other As shown in Figs. 1 to 3, the panel 1 further includes a waterproof packing 7 attached to each of the wall portions 31, 32, 33, and 34. The waterproof packing 7 includes a plurality of linear packings 70 attached to the center of the upper surface of the upper wall portion 31 in the front-rear direction, the center of the lower surface of the lower wall portion 32 in the front-rear direction, and the rear end portions of the flat plate portions 330, 340 of the left and right side wall portions 33, 34, and a plurality of L-shaped corner packings 71 attached to each corner of the wall portions 31, 32, 33, and 34. Each of the plurality of packings 70 has a hollow semicircular cross section perpendicular to the longitudinal direction. Each of the plurality of corner packings 71 is an L-shaped solid block. The plurality of packings 70 and the plurality of corner packings 71 are provided in a rectangular frame shape in a front view so as to surround the entire circumference of the panel 1. The plurality of packings 70 and the plurality of corner packings 71 are joined to each other by an adhesive or the like. Each of the multiple packings 70 and the multiple corner packings 71 is made of, for example, synthetic rubber. A part of the waterproof packing 7 (more specifically, each corner packing 71) is attached to a portion above the mark 503 of the cover part 50 of the corner member 5. Each of the multiple packings 70 and the multiple corner packings 71 has an adhesive surface on the inner surface side (the side facing the wall parts 31, 32, 33, 34) and can be attached to the wall parts 31, 32, 33, 34 without using adhesive.

[0053] The panel 1 described above is installed, for example, as shown in the construction example in FIG. 7A. The multiple panels 1 are installed so as to be lined up in the left-right and up-down directions. The multiple panels 1 are installed in a state in which the waterproof gaskets 7 are butted against each other and no gaps are formed, as shown in FIG. 7B. As shown in FIG. 7A, the joints between the metal outer skins 3 of two panels 1, 1 adjacent in the left-right or up-down direction are filled with a joint material 8, and the waterproof gaskets 7 are covered and hidden. With the joint material 8 filled, the corner members 5 and sealing materials 6 that close the openings 38 of each panel 1 are covered and hidden by the joint material 8.

[0054] 3. Sealing method Next, a description will be given of a sealing method for filling the panel corners with the sealant 6. The sealing method includes a cutting step, a positioning step, and a filling step.

[0055] 8A shows a corner of the panel 1 before sealing. The corner of the core 2 is exposed through an opening 38 between two adjacent walls of the metal skin 3 (in the figure, the top wall 31 and the right side wall 34).

[0056] In the cutting step, as shown in FIG. 8B, a part of the corner of the core material 2 is cut off to form an intermediate surface 26 in the core material 2, and a space for arranging the corner member 5 is formed between the opening 38 and the intermediate surface 26. The corner of the core material 2 can be cut off using, for example, a cutting tool 9 as shown in the figure. The cutting tool 9 has a metal cutting part 90 provided in a triangular frame shape and a grip part 91. The cutting part 90 is placed on the corner of the core material 2 from above, and the cutting tool 9 is moved downward to cut off a part of the corner of the core material 2. By forming the intermediate surface 26 in the core material 2, a corner part 23 composed of the intermediate surface 26, the first side surface 24, and the second side surface 25 is formed in the core material 2 (see FIG. 5).

[0057] In the arranging step, the corner member 5 is arranged in the opening 38 as shown in FIG. 8C. In this embodiment, in the arranging step, the corner member 5 is arranged in the opening 38 so that the main body portion 511 of the seal receiving portion 51 of the corner member 5 abuts against the intermediate surface 26 of the core material 2. At this time, as shown in FIG. 5, the cover portion 50 is positioned so as to cover the opening 38. In detail, the pair of inclined portions 502 of the cover portion 50 are positioned with a small gap between them and the upper wall portion 31 and the right side wall portion 34 of the metal skin 3, and are positioned in a manner that is close to a straight line with respect to the upper wall portion 31 and the right side wall portion 34. The lower end of the cover portion 50 abuts against the connecting portion 37 of the metal skin 3 or is positioned with a small gap between them.

[0058] At this time, the lower end of the seal receiving portion 51 abuts against the main body 30 of the metal skin 3. The extension pieces 510 (a pair of inclined portions 512) of the seal receiving portion 51 are inserted into the gap between the first side surface 24 of the core material 2 and the upper wall portion 31 of the metal skin 3, and the gap between the second side surface 25 of the core material 2 and the right side wall portion 34, respectively, and these gaps are closed or narrowed by the extension pieces 510.

[0059] By disposing the corner member 5 in the opening 38 as described above, the filling area of ​​the sealant 6 formed inside the opening 38 is limited by the cover portion 50, the seal receiving portion 51, and the connecting portion 52 of the corner member 5. The area surrounded by the cover portion 50, the seal receiving portion 51, the connecting portion 52, the right side wall portion 34 of the metal skin 3, the upper wall portion 31, the connecting portion 37, and the main body portion 30 of the corner member 5 is the filling area of ​​the sealant 6.

[0060] In the arrangement step, as shown in FIG. 8D, after the corner member 5 is arranged in the opening 38, the masking tape 10 is applied so as to cover the surrounding portion (walls 31, 34) of the opening 38 of the metal skin 3 and the cover portion 50 of the corner member 5, so as to temporarily fix the corner member 5 to the metal skin 3. At this time, the masking tape 10 is applied to the portion of the cover portion 50 of the corner member 5 that is lower than the mark 503. As a result, the masking tape 10 closes the gap between the cover portion 50 of the corner member 5 and the walls 31, 34 of the metal skin 3, and the gap between the cover portion 50 and the connecting portion 37. Next, the portion of the masking tape 10 that covers the injection port 500 of the cover portion 50 is removed using a cutting tool such as a round-blade chisel.

[0061] In the filling step, as shown in Fig. 9A, the opening 38 in which the corner member 5 is disposed is filled with the sealant 6. More specifically, the sealant 6 is injected into the injection port 500 of the cover portion 50 of the corner member 5. The sealant 6 injected into the injection port 500 spreads over the entire filling area when it hits the seal receiving portion 51. As shown in Fig. 9B, when a part of the sealant 6 protrudes from the through hole 520 of the connecting portion 52 of the corner member 5, the injection of the sealant 6 is stopped. It can be seen that the sealant 6 protrudes from the through hole 520, and thus the sealant 6 has spread over the filling area from one end (lower end) to the other end (upper end).

[0062] The through holes 520 also function as ventilation holes for discharging air within the filling area of ​​the sealing material 6. Therefore, the sealing material 6 easily spreads within the filling area.

[0063] By carrying out the above-described cutting step, arrangement step, and filling step in this order, the openings 38 in the metal skin 3 at the panel corners can be closed with the corner members 5 and sealant 6. The above-described sealing method is performed for each of the four corners of the panel 1. After the openings 38 at each of the four corners of the panel 1 have been closed with the corner members 5 and sealant 6, a waterproof gasket 7 is attached in a rectangular frame shape around the periphery of the metal skin 3 (see FIG. 1).

[0064] The masking tape 10 is removed after the sealant 6 has hardened. For example, the masking tape 10 is removed before the panel 1 is attached to the framework of a building. In other words, the panel 1 can be shipped with the masking tape 10 attached. Note that the attachment and removal of the masking tape 10 can be omitted.

[0065] According to the sealing method described above, the sealing material 6 filled in the opening 38 can be covered and hidden by the cover portion 50 of the corner member 5. Therefore, the finishing work on the panel 1 can be performed without waiting for the surface of the sealing material 6 to harden, and the time required for producing and shipping the panel can be shortened. In addition, according to this sealing method, the filling range of the sealing material 6 filled inside the opening 38 can be limited by the cover portion 50, the seal receiving portion 51, and the connecting portion 52 of the corner member 5, and the filling amount of the sealing material 6 can be stabilized.

[0066] 4. Variations Next, modifications of the above-mentioned panel 1, corner member 5, and method of sealing the corners of the panel 1 will be described.

[0067] The corner member 5 need only comprise a cover portion 50 that covers the opening 38, a seal receiving portion 51 that is located inside the cover portion 50 and forms a space S1 between it and the cover portion 50, and a connecting portion 52 that connects the cover portion 50 and the seal receiving portion 51, and is not limited to the shape shown in Figure 6, etc.

[0068] For example, the corner member 5 does not need to have the injection port 500 provided in a part of the cover portion 50. In this case, the sealing material 6 is injected, for example, from a gap between the connecting portion 52 of the corner member 5 and the upper wall portion 31 or the right side wall portion 34 of the metal skin 3.

[0069] In addition, the location where the cover part 50 and the seal receiving part 51 are connected by the connecting part 52 is not limited to one end (upper end) and may be another part. In addition, the connecting part 52 does not have to be provided with the through hole 520.

[0070] The cover portion 50 does not have to have a curved shape so as to be continuous with the surrounding portion of the opening 38 of the metal skin 3 (for example, the upper wall portion 31 and the right side wall portion 34), and may be in a flat plate shape. The cover portion 50 may be provided in an arc shape similar to the connecting portion 37 of the metal skin 3.

[0071] Furthermore, the seal receiving portion 51 does not need to have the extension piece 510 (the pair of inclined portions 512) that fits into the gap between the metal skin 3 and the core material 2, and may be composed of the main body portion 511 only.

[0072] Furthermore, the corner members 5 are not limited to being made of metal, and may be made of other non-flammable materials. The corner members 5 do not need to be fireproof or non-flammable, and may be made of resins such as synthetic resins and plastics.

[0073] Furthermore, the intermediate surface 26 of the core material 2 is not limited to being formed by cutting off a part of the corner of the core material 2 with the cutting tool 9, but may be formed in the core material 2 in advance.

[0074] Furthermore, the intermediate surface 26 is not limited to a rectangular flat surface, and may be other shapes such as a convex surface, a concave surface, etc. In this case, the seal receiving portion 51 of the corner member 5 may be provided in a shape corresponding to the intermediate surface 26.

[0075] Furthermore, the main body 20 of the core material 2 is not limited to being formed from a fibrous inorganic material such as rock wool or glass wool, and may be a gypsum board, a calcium silicate board, etc. Furthermore, the main body 20 of the core material 2 may be formed from a foam-based organic material such as urethane foam or phenol foam, or may be a styrene board, a urethane board, etc.

[0076] In addition, the above-mentioned method of sealing the panel corners may be performed by attaching the waterproof packing 7 over the entire periphery of the metal skin 3 from above the corner member 5 in the arrangement step, and then performing the filling step.

[0077] Furthermore, in the above-described method for sealing a panel corner, in the positioning step, the extension piece 510 (the pair of inclined portions 512) of the corner member 5 may be adhered to the metal skin 3 via an adhesive, double-sided tape, or the like. In this case, it is possible to prevent a gap from being formed between the metal skin 3 and the extension piece 510, and to prevent the sealing material 6 from spreading beyond this gap. This also makes it easier to position the corner member 5. Note that the extension piece 510 (the pair of inclined portions 512) of the corner member 5 may be adhered not only to the metal skin 3 but also to the core material 2.

[0078] Moreover, the corner member 5 does not necessarily have to have the mark 503 on the surface of the cover portion 50. Moreover, the mark 503 is not limited to a scribed line, and may be a mark of another shape.

[0079] 6, the shape of the corner member 5 can be changed as appropriate. For example, the cover portion 50 of the corner member 5 may further have pieces (movement restricting portions described later) protruding from the upper and lower ends of the outer ends in the left-right direction of the pair of inclined portions 502, the lower end of the central portion 501, etc. toward the seal receiving portion 51. In this case, it is easy to prevent the cover portion 50 from deforming toward the seal receiving portion 51 when an external force is applied to the cover portion 50.

[0080] (Embodiment 2) Next, the panel 1, corner member 5, and panel corner sealing method of the second embodiment shown in Figures 10 to 12 will be described in detail with reference to the drawings. In the following, among the panel 1, corner member 5, and panel corner sealing method of the second embodiment, components common to the first embodiment will be given the same reference numerals in the drawings and detailed description will be omitted, and components different from the first embodiment will be described in detail.

[0081] In the panel 1 of this embodiment, the structure of the corner member 5 is different from that of the corner member 5 of the first embodiment.

[0082] The corner member 5 has a cover portion 50, a seal receiving portion 51, and a connecting portion 52, as well as a leakage suppression portion 53 and a movement restricting portion .

[0083] The cover part 50 has a rectangular flat central part 501 and a pair of inclined parts 502. The injection port 500 is provided across the inner ends in the width direction of the central part 501 and the pair of inclined parts 502. In other words, the central part 501 is provided to be narrower than the diameter of the injection port 500. Note that no mark 503 indicating the application position of the masking tape 10 is provided on the surface of the cover part 50.

[0084] The leakage suppression portion 53 protrudes from the cover portion 50 so as to fit along the surface of the core material 2 side of the portion (e.g., the upper wall portion 31 and the right side wall portion 34) surrounding the opening 38 of the metal outer skin 3. The leakage suppression portion 53 suppresses leakage of the sealing material 6 from the gap between the cover portion 50 and the metal outer skin 3 when the sealing material 6 is injected.

[0085] In this embodiment, the corner member 5 has a pair of leakage prevention portions 53. Each of the pair of leakage prevention portions 53 protrudes from an outer end in the width direction of each of the pair of inclined portions 502. The pair of leakage prevention portions 53 protrude from the pair of inclined portions 502 such that the outer surfaces of the pair of leakage prevention portions 53 are located more inward than the outer surfaces of the pair of inclined portions 502.

[0086] The movement restricting portion 54 is configured to restrict movement of the cover portion 50 toward the seal receiving portion 51. In this embodiment, the movement restricting portion 54 is configured with a pair of restricting pieces 540 protruding from the outer ends in the width direction of the pair of inclined portions 502 of the cover portion 50 toward the seal receiving portion 51. The pair of restricting pieces 540 protrude from the end portion of the cover portion 50 opposite to the side continuing to the connecting portion 52. The tip of each of the pair of restricting pieces 540 abuts against the main body portion 511 of the seal receiving portion 51 or forms a small gap between the main body portion 511 and the pair of restricting pieces 540.

[0087] The connecting portion 52 connects one end of the cover portion 50 and one end of the seal receiving portion 51. The connecting portion 52 has a first portion 521 protruding outward from one end of the seal receiving portion 51, and a second portion 522 protruding inward from one end of the cover portion 50 so as to form a space between the corner packing 71 and the first portion 521. The first portion 521 and the second portion 522 are provided with through holes 520, 523, respectively.

[0088] More specifically, the second portion 522 is continuous with one end of the central portion 501 of the cover portion 50. Each of the first portion 521 and the second portion 522 has a rectangular plate shape. The width of the first portion 521 and the second portion 522 is the same as the width of the central portion 501 and is narrower than the diameter of the injection port 500.

[0089] First portion 521 is perpendicular or approximately perpendicular to main body portion 511 of seal receiving portion 51. Second portion 522 is continuous with central portion 501 so as to form an obtuse angle, and is also continuous with first portion 521 so as to form an obtuse angle. The outer surface of second portion 522 is located more inward than the outer surface of central portion 501. As a result, a space is formed between second portion 522 and corner packing 71 (see FIG. 11C ).

[0090] The through holes 520 and 523 are the same size. The through holes 520 and 523 penetrate the first portion 521 and the second portion 522 in the thickness direction. The through holes 520 and 523 have a smaller diameter than the injection port 500.

[0091] In this embodiment, the sealant 6 is a quick-curing one-component modified silicone sealant.

[0092] Next, a sealing method for filling a panel corner with a sealant 6 using the above-mentioned corner member 5 will be described. The sealing method includes a cutting step, a placement step, and a filling step. Below, the sealing method of this embodiment will be described in detail with respect to the steps different from the sealing method of embodiment 1. The cutting step of this embodiment is the same as the cutting step of embodiment 1.

[0093] In the arrangement step, the corner member 5 is arranged in the opening 38, similarly to the arrangement step in embodiment 1. In this embodiment, as shown in Fig. 11A, the pair of leakage suppression portions 53 of the corner member 5 are positioned along the inner surfaces (surfaces on the core material 2 side) of the upper wall portion 31 and the right side wall portion 34 of the metal outer skin 3. As a result, the gaps between the pair of inclined portions 502 and the walls 31, 34 are blocked from the inside by the pair of leakage suppression portions 53.

[0094] 11B, after the corner member 5 is placed in the opening 38, masking tape 10 is applied below the injection port 500 to cover the area around the opening 38 of the metal skin 3 (walls 31, 34) and the cover portion 50 of the corner member 5, thereby temporarily fixing the corner member 5 to the metal skin 3. As a result, the masking tape 10 closes the gap between the lower end of the cover portion 50 and the walls 31, 34, and the gap between the cover portion 50 and the connecting portion 37. In the arrangement step of this embodiment, since the masking tape 10 does not cover the injection port 500, the task of removing a part of the masking tape 10 using a cutting tool can be omitted.

[0095] 11C, in the arrangement step, corner packing 71 is attached to the surrounding area (walls 31, 34) of opening 38 of metal skin 3 so as to straddle opening 38 of metal skin 3. At this time, both ends of the inner surface of corner packing 71 are adhered to walls 31, 34, and the upper surface of corner packing 71 is abutted against the lower surface of protruding portion 341 of right side wall 34. At this time, the inner surface of the lower part of corner packing 71 is adhered to the upper end of center portion 501 of cover portion 50 of corner member 5 and the upper ends of the pair of inclined portions 502, respectively, and a space is formed between the inner surface of corner packing 71 and second portion 522 of connecting portion 52.

[0096] The area surrounded by the cover portion 50, the seal receiving portion 51, the connecting portion 52, the right side wall portion 34, the upper wall portion 31, the connecting portion 37 and the main body portion 30 of the metal outer skin 3 of the corner member 5, and the area between the second part 522 of the connecting portion 52 of the corner member 5 and the inner surface of the corner packing 71 are the filling areas for the sealing material 6.

[0097] In the filling step, as shown in FIG. 12A, the opening 38 in which the corner member 5 is disposed is filled with the sealing material 6. More specifically, the sealing material 6 is poured into the injection port 500 of the cover portion 50 of the corner member 5. The sealing material 6 poured into the injection port 500 spreads into the filling area when it hits the seal receiving portion 51. At this time, as shown in FIG. 12B, a part of the sealing material 6 protrudes from the through hole 523 of the second portion 522 of the connecting portion 52 and protrudes from both sides of the second portion 522 toward the corner packing 71, so that the sealing material 6 fills the space between the second portion 522 and the corner packing 71. The adhesive force of the sealing material 6 bonds the second portion 522 and the corner packing 71, and the mounting strength of the corner packing 71 to the metal skin 3 and the corner member 5 can be increased.

[0098] When a part of the sealant 6 protrudes from the through hole 520 of the first portion 521 of the connecting portion 52 of the corner member 5 or from both sides of the first portion 521, injection of the sealant 6 is stopped. The sealant 6 protruding from the through hole 520 indicates that the sealant 6 has spread from one end (lower end) to the other end (upper end) in the filling area. The sealant 6 protruding from the through hole 520 may also be used to bond the corner member 5 and the corner packing 71.

[0099] In this embodiment, since the connecting portion 52 is narrower than the diameter of the injection port 500, air in the filling area is easily discharged from both sides of the connecting portion 52 and the through holes 520, 523, and the sealing material 6 easily spreads throughout the filling area.

[0100] By carrying out the above-described cutting, arranging, and filling steps in this order, the openings 38 in the metal skin 3 at the panel corners can be closed with the corner members 5, corner packing 71, and sealing material 6. The above-described sealing method is performed for each of the four corners of the panel 1. After closing the openings 38 at each of the four corners of the panel 1 with the corner members 5, corner packing 71, and sealing material 6, multiple packings 70 are attached around the periphery of the panel 1, and the multiple packings 70 and the corner packings 71 are joined with an adhesive or the like, thereby attaching the waterproof packing 7 in a rectangular frame shape to the panel 1 (see FIG. 1).

[0101] The masking tape 10 is removed after the sealant 6 has hardened. In this embodiment, since no part of the masking tape 10 enters the injection port 500, the masking tape 10 can be easily peeled off from the metal skin 3 and the corner member 5.

[0102] According to the sealing method described above, the sealing material 6 filled in the opening 38 can be covered and hidden by the cover portion 50 of the corner member 5 and the corner packing 71. Therefore, the subsequent finishing work on the panel 1 can be performed without waiting for the surface of the sealing material 6 to harden, and the time required for producing and shipping the panel 1 can be shortened.

[0103] In addition, according to this sealing method, the pair of leakage suppression parts 53 can prevent the sealing material 6 from leaking out from the gap between the cover part 50 and the metal skin 3, so the work of removing the leaked part can be omitted, and the work time of the sealing method can be shortened. Also, according to this sealing method, the work of cutting off a part of the masking tape 10 with a cutting tool can be omitted, so the work time of the sealing method can be shortened.

[0104] Furthermore, in the panel 1 equipped with the corner member 5 of this embodiment, even if the cover portion 50 is pushed from the outside, the movement of the cover portion 50 can be restricted by the movement restricting portion 54 (the pair of restricting pieces 540).

[0105] The panel 1, corner member 5, and method for sealing the corners of the panel 1 of the embodiment 2 described above can also adopt appropriate modifications similar to those of the panel 1, corner member 5, and method for sealing the corners of the panel 1 of the embodiment 1 described above.

[0106] In addition, the second portion 522 of the connecting portion 52 of the corner member 5 of this embodiment is not limited to the shape shown in Fig. 10, etc., as long as it protrudes inward from one end of the cover portion 50 so as to form a space between it and the corner packing 71. The second portion 522 is not limited to a rectangular plate shape, and may be provided in another shape, such as an L-shaped plate shape.

[0107] Moreover, corner member 5 is not limited to the structure shown in Fig. 10. Corner member 5 may include only movement restricting portion 54 (pair of restricting pieces 540) out of a pair of leakage suppression portions 53 and movement restricting portion 54 (pair of restricting pieces 540), as in a modified example shown in Fig. 13. Also, connecting portion 52 may be formed of a rectangular plate having the same width (narrower than the diameter of injection port 500) as rectangular plate-shaped central portion 501, and may be continuous with main body portion 511 and central portion 501 of seal receiving portion 51 at right angles.

[0108] 5. Summary Like the panels 1 of the first and second embodiments and their modifications described above, the panel 1 of the first aspect has the following configuration.

[0109] That is, the panel 1 of the first embodiment comprises a core material 2 having a corner portion 23, a metal skin 3 covering the core material 2, a corner member 5 arranged in an opening 38 formed in a portion of the metal skin 3 covering the corner portion 23, and a sealing material 6 filled in the opening 38. The corner member 5 has a cover portion 50 that closes the opening 38, a seal receiving portion 51 that is located inside the cover portion 50 and forms a space S1 between it and the cover portion 50, and a connecting portion 52 that connects the cover portion 50 and the seal receiving portion 51. The sealing material 6 is filled in the space S1.

[0110] In the panel 1 of the first embodiment having the above-mentioned configuration, the sealant 6 is covered with the cover portion 50 of the corner member 5, and exposure of the sealant 6 from the opening 38 can be suppressed. Therefore, in the panel 1 of the first embodiment, finishing work on the panel 1 can be performed without waiting for the surface of the sealant 6 to harden, and the time required for production and shipping of the panel can be shortened. In addition, in the panel 1 of the first embodiment, the filling range of the sealant 6 filled inside the opening 38 can be limited by the cover portion 50 and the seal receiving portion 51 of the corner member 5, and the filling amount of the sealant 6 is likely to be stable.

[0111] Like the panels 1 of the first and second embodiments and their modifications described above, the panel 1 of the second embodiment additionally includes the following configuration in addition to the configuration of the panel 1 of the first embodiment.

[0112] That is, in the panel 1 of the second embodiment, a part of the cover part 50 is provided with an injection port 500 through which the sealing material 6 is injected.

[0113] With the above-described configuration, in the panel 1 of the second embodiment, the sealing material 6 can be injected from a position directly opposite the cover portion 50, making it easy to inject the sealing material 6 into the space S1 inside the cover portion 50.

[0114] Like the panels 1 of the first and second embodiments and their modifications described above, the panel 1 of the third embodiment additionally includes the following configuration in addition to the configuration of the panel 1 of the second embodiment.

[0115] That is, in the panel 1 of the third embodiment, the connecting portion 52 connects one end of the cover portion 50 to one end of the seal receiving portion 51. The injection port 500 is provided at the end of the cover portion 50 opposite to the one end. The connecting portion 52 is provided with a through hole 520.

[0116] In the panel 1 of the third embodiment having the above configuration, the sealant 6 can be injected from the injection port 500 of the cover portion 50, and a part of the injected sealant 6 can be made to protrude from the through hole 520 of the connecting portion 52. This makes it possible to visually confirm that the sealant 6 has been filled from one end side to the other end side in the space S1 that is covered by the cover portion 50 and not exposed. Also, in the panel 1 of the third embodiment, the through hole 520 functions as an air vent for air to escape from within the filled area of ​​the sealant 6, so that the sealant 6 can easily spread within the filled area.

[0117] Like the panel 1 of the second embodiment and its modified example described above, the panel 1 of the fourth aspect additionally includes the following configuration in addition to the configuration of the panel 1 of the second embodiment.

[0118] That is, the panel 1 of the fourth embodiment further includes a corner packing 71 attached to the metal skin 3 so as to straddle the opening 38. The connecting portion 52 connects one end of the cover portion 50 and one end of the seal receiving portion 51 to each other. The connecting portion 52 has a first portion 521 protruding outward from one end of the seal receiving portion 51, and a second portion 522 protruding inward from one end of the cover portion 50 so as to form a space between the corner packing 71 and the first portion 521. The first portion 521 and the second portion 522 are provided with through holes 520, 523, respectively.

[0119] In the panel 1 of the fourth embodiment having the above configuration, the second part 522 and the corner packing 71 can be bonded by the adhesive force of the sealing material 6 that is injected from the injection port 500 of the cover part 50 and leaks from the through hole 523 of the second part 522 of the connecting part 52. Therefore, in the panel 1 of the fourth embodiment, the mounting strength of the corner packing 71 to the metal skin 3 and the corner member 5 can be easily improved. In addition, in the panel 1 of the fourth embodiment, a part of the injected sealing material 6 can be made to protrude from the through hole 520 of the connecting part 52, and thus it can be visually confirmed that the sealing material 6 has been filled from one end side to the other end side in the space S1 that is covered by the cover part 50 and not exposed. In addition, in the panel 1 of the fourth embodiment, the through holes 520 and 523 function as vents through which air in the filling area of ​​the sealing material 6 escapes, so that the sealing material 6 is likely to spread in the filling area.

[0120] Like the panels 1 of the first and second embodiments and their modifications described above, the panel 1 of the fifth aspect additionally includes the following configuration in addition to the configuration of the panel 1 of any one of the first to fourth aspects.

[0121] That is, in the panel 1 of the fifth embodiment, the cover portion 50 has a curved shape so as to be continuous with the portion of the metal skin 3 surrounding the opening 38 .

[0122] With the above configuration, in the panel 1 of the fifth embodiment, the cover portion 50 of the corner member 5 appears continuous with the area surrounding the opening 38 of the metal skin 3, making the corner member 5 appear to be integrated with the metal skin 3.

[0123] Like the panels 1 of the first and second embodiments and their modifications described above, the panel 1 of the sixth aspect additionally has the following configuration in addition to the configuration of the panel 1 of any one of the first to fifth aspects.

[0124] That is, in the panel 1 of the sixth embodiment, the seal receiving portion 51 has an extension piece 510 that fits into the gap between the metal skin 3 and the core material 2 .

[0125] By being provided with the above-mentioned configuration, in the sixth embodiment of the panel 1, the gap between the metal skin 3 and the core material 2 can be blocked or narrowed by the extension piece 510, thereby preventing the sealing material 6 from spreading beyond the gap, and making it easier to stabilize the amount of sealing material 6 filled.

[0126] Like the panels 1 of the first and second embodiments and their modifications described above, the panel 1 of the seventh aspect additionally has the following configuration in addition to the configuration of the panel 1 of any one of the first to sixth aspects.

[0127] That is, in the panel 1 of the seventh embodiment, the corner member 5 further has a movement restricting portion 54 that restricts the movement of the cover portion 50 towards the seal receiving portion 51 side.

[0128] In the seventh embodiment of the panel 1 having the above-mentioned configuration, when an external force is applied to the cover portion 50, the movement of the cover portion 50 toward the seal receiving portion 51 can be restricted by the movement restricting portion 54, making it easier to prevent deformation of the corner member 5.

[0129] Furthermore, like the panel 1 of the above-mentioned embodiment 2 and its modified example, the panel 1 of the eighth aspect additionally has the following configuration in addition to the configuration of the panel 1 of any one of the first to seventh aspects.

[0130] That is, in the panel 1 of the eighth embodiment, the corner member 5 further has a leakage suppression portion 53 that protrudes from the cover portion 50 so as to fit along the surface of the metal skin 3 around the opening 38 on the core material 2 side.

[0131] In the panel 1 of the eighth embodiment having the above-mentioned configuration, the gap between the cover portion 50 and the metal skin 3 can be blocked from the inside by the leakage suppression portion 53, making it easy to prevent the sealing material 6 from leaking out from this gap.

[0132] Like the panels 1 of the first and second embodiments and their modifications described above, the panel 1 of the ninth aspect additionally has the following configuration in addition to the configuration of the panel 1 of any one of the first to eighth aspects.

[0133] That is, in the panel 1 of the ninth embodiment, the corner members 5 are made of metal.

[0134] By providing the above configuration, in the panel 1 of the ninth embodiment, the corner members 5 easily appear to be integrated with the metal skin 3, and fire resistance at the panel corners is easily ensured.

[0135] Like the corner members 5 of the first and second embodiments and their modifications described above, the corner member 5 of the tenth aspect has the following configuration.

[0136] That is, the corner member 5 of the tenth aspect is a corner member 5 that is disposed in an opening 38 formed in a portion of the metal skin 3 covering the corner portion 23 of a panel 1 including a core material 2 having a corner portion 23 and a metal skin 3 covering the core material 2, and receives the sealing material 6 filled in the opening 38. The corner member 5 has a cover portion 50 that closes the opening 38, a seal receiving portion 51 that is located inside the cover portion 50 and forms a space S1 between the cover portion 50 and the seal receiving portion 51 into which the sealing material 6 is filled, and a connecting portion 52 that connects the cover portion 50 and the seal receiving portion 51.

[0137] In the corner member 5 of the tenth embodiment having the above-mentioned configuration, the sealant 6 is covered with the cover portion 50, and exposure of the sealant 6 from the opening 38 can be suppressed. Therefore, in the corner member 5 of the tenth embodiment, the finishing work on the panel 1 can be performed without waiting for the surface of the sealant 6 to harden, and the time required for producing and shipping the panel can be shortened. In addition, in the corner member 5 of the tenth embodiment, the filling range of the sealant 6 filled inside the opening 38 can be limited by the cover portion 50 and the seal receiving portion 51, and the filling amount of the sealant 6 is likely to be stable.

[0138] Like the panel corner sealing methods of the above-mentioned first and second embodiments and their modified examples, the panel corner sealing method of the eleventh aspect has the following configuration.

[0139] That is, the method for sealing a panel corner of the eleventh aspect is a method for sealing a panel corner, in which a sealant 6 is filled in an opening 38 formed in a portion of the metal skin 3 covering the corner portion 23 of a panel 1 including a core material 2 having a corner portion 23 and a metal skin 3 covering the core material 2. The method for sealing a panel corner of the eleventh aspect includes an arrangement step of arranging a corner member 5 in the opening 38, and a filling step of filling the opening 38 in which the corner member 5 is arranged with the sealant 6. The corner member 5 has a cover portion 50 that closes the opening 38, a seal receiving portion 51 that is located inside the cover portion 50 and forms a space S1 between the cover portion 50 and the seal receiving portion 51, and a connecting portion 52 that connects the cover portion 50 and the seal receiving portion 51. In the filling step, the sealant 6 is filled in the space S1.

[0140] In the panel corner sealing method of the eleventh aspect having the above configuration, the sealant 6 is covered with the cover portion 50 of the corner member 5, and exposure of the sealant 6 from the opening 38 can be suppressed. Therefore, in this panel corner sealing method, the finishing work on the panel 1 can be performed without waiting for the surface of the sealant 6 to harden, and the time required for producing and shipping the panel can be shortened. In addition, in the panel corner sealing method of the eleventh aspect, the filling range of the sealant 6 filled inside the opening 38 can be limited by the cover portion 50 and the seal receiving portion 51 of the corner member 5, and the filling amount of the sealant 6 is likely to be stable.

[0141] Furthermore, like the panel corner sealing methods of the above-mentioned embodiment 1 and its modified examples, the panel corner sealing method of the twelfth aspect additionally has the following configuration in addition to the configuration of the panel corner sealing method of the eleventh aspect.

[0142] That is, in the panel corner sealing method of the twelfth embodiment, the connecting portion 52 connects one end of the cover portion 50 and one end of the seal receiving portion 51 to each other, and an injection port 500 is provided at the end of the cover portion 50 opposite to the one end, and the connecting portion 52 is provided with a through hole 520. In the filling step, the sealant 6 is injected into the injection port 500, and the sealant 6 is filled into the space S1 such that the sealant 6 protrudes from the through hole 520.

[0143] In the panel corner sealing method of the twelfth embodiment having the above configuration, the sealant 6 is injected from the injection port 500 of the cover portion 50, and a part of the injected sealant 6 is allowed to protrude from the through hole 520 of the connecting portion 52, so that it is possible to visually confirm that the sealant 6 has been filled from one end side to the other end side of the space S1 that is covered and not exposed by the cover portion 50. Also, in the panel corner sealing method of the twelfth embodiment, the through hole 520 functions as an air hole through which air within the filled area of ​​the sealant 6 can escape, so that the sealant 6 easily spreads within the filled area.

[0144] Furthermore, like the panel corner sealing methods of the above-mentioned embodiment 2 and its modified examples, the panel corner sealing method of the thirteenth aspect additionally has the following configuration in addition to the configuration of the panel corner sealing method of the eleventh aspect.

[0145] That is, in the panel corner sealing method of the thirteenth aspect, the panel 1 further includes a corner packing 71 attached to the metal skin 3 so as to straddle the opening 38. The connecting portion 52 connects one end of the cover portion 50 and one end of the seal receiving portion 51 to each other. The connecting portion 52 has a first portion 521 protruding outward from one end of the seal receiving portion 51, and a second portion 522 protruding inward from one end of the cover portion 50 so as to form a space between the corner packing 71 and the first portion 521. The first portion 521 and the second portion 522 are provided with through holes 520, 523, respectively. The cover portion 50 is provided with an injection port 500. In the filling process, the sealing material 6 is injected into the injection port 500 and allowed to protrude from the through hole 523 of the second part 522, thereby bonding the corner member 5 and the corner gasket 71 with the sealing material 6, and the sealing material 6 is filled in the space so that the sealing material 6 protrudes from the through hole 520 of the first part 521.

[0146] In the panel corner sealing method of the thirteenth aspect having the above configuration, the corner member 5 and the corner packing 71 can be bonded by the sealing material 6 protruding from the through hole 523 of the second portion 522, which makes it easy to improve the attachment strength of the corner packing 71 to the metal skin 3 and the corner member 5. In addition, in the panel corner sealing method of the thirteenth aspect, by making a part of the injected sealing material 6 protrude from the through hole 520 of the connecting portion 52, it is possible to visually confirm that the sealing material 6 has been filled from one end side to the other end side of the space S1 that is covered by the cover portion 50 and not exposed. In addition, in the panel corner sealing method of the thirteenth aspect, the through holes 520 and 523 function as vents through which air in the filling area of ​​the sealing material 6 can escape, so that the sealing material 6 is likely to spread in the filling area.

[0147] The present disclosure has been described above based on the form shown in the attached drawings, but the present disclosure is not limited to the above form, and appropriate design changes are possible within the intended scope of the present disclosure. [Explanation of symbols]

[0148] 1 Panel 2 Core material 23 Corner section 3 Metal shell 38 Aperture 5 Corner parts 50 Cover part 500 inlet 51 Seal receiving part 510 Extension piece 52 Connecting part 520 Through hole 521 First part 522 Second part 523 Through hole 53 Leak suppression section 54 Movement Control Department 6 Sealing materials 71 Corner packing S1 Space

Claims

1. A core material having a corner portion; A metal skin covering the core material; a corner member disposed in an opening formed in a portion of the metal skin that covers the corner portion; A sealant is filled in the opening. The corner member is A cover portion that covers the opening; a seal receiving portion located inside the cover portion and forming a space between the cover portion and the seal receiving portion; A connecting portion connecting the cover portion and the seal receiving portion, The space is filled with the sealing material. panel.

2. A part of the cover portion is provided with an injection port through which the sealing material is injected. The panel of claim 1.

3. The connecting portion connects one end of the cover portion and one end of the seal receiving portion to each other, The injection port is provided at an end portion of the cover portion opposite to the one end portion, The connecting portion is provided with a through hole. The panel of claim 2.

4. Further, a corner packing is attached to the metal skin so as to span the opening, The connecting portion connects one end of the cover portion and one end of the seal receiving portion to each other, the connecting portion has a first portion protruding outward from the one end of the seal receiving portion and a second portion protruding inward from the one end of the cover portion so as to form a space between the corner packing and the first portion, Each of the first portion and the second portion is provided with a through hole. The panel of claim 2.

5. The cover portion has a curved shape so as to be continuous with a portion of the metal outer skin surrounding the opening. A panel according to any one of claims 1 to 4.

6. The seal receiving portion has an extension piece that fits into a gap between the metal outer shell and the core material. A panel according to any one of claims 1 to 5.

7. The corner member further includes a movement restricting portion that restricts movement of the cover portion toward the seal receiving portion. A panel according to any one of claims 1 to 6.

8. The corner member further includes a leakage suppression portion protruding from the cover portion so as to follow a surface of the metal outer skin surrounding the opening on the side of the core material. A panel according to any one of claims 1 to 7.

9. The corner member is made of metal. A panel according to any one of claims 1 to 8.

10. A corner member is provided in an opening formed in a portion of a panel including a core having a corner portion and a metal skin covering the core, the corner member receiving a sealant filled in the opening, the corner member comprising: The seal receiving portion includes a cover portion that closes the opening, a seal receiving portion that is located inside the cover portion and forms a space between the cover portion and the seal receiving portion into which the sealing material is filled, and a connecting portion that connects the cover portion and the seal receiving portion. Corner parts.

11. A method for sealing a panel corner, comprising filling a sealant into an opening formed in a portion of the metal skin covering the corner of a panel having a core material with a corner portion, the method comprising the steps of: a placement step of placing a corner member in the opening; and a filling step of filling the opening in which the corner member is disposed with the sealant, The corner member is a cover portion that closes the opening, a seal receiving portion that is located inside the cover portion and forms a space between the cover portion and the seal receiving portion, and a connecting portion that connects the cover portion and the seal receiving portion, In the filling step, the space is filled with the sealing material. How to seal panel corners.

12. The connecting portion connects one end of the cover portion and one end of the seal receiving portion to each other, An injection port is provided at an end of the cover portion opposite to the one end, The connecting portion is provided with a through hole, In the filling step, the sealant is injected into the injection port, and the sealant is filled into the space so that the sealant protrudes from the through hole. The method for sealing a panel corner according to claim 11.

13. The panel further includes a corner packing attached to the metal skin so as to span the opening, The connecting portion connects one end of the cover portion and one end of the seal receiving portion to each other, the connecting portion has a first portion protruding outward from the one end of the seal receiving portion and a second portion protruding inward from the one end of the cover portion so as to form a space between the corner packing and the first portion, Each of the first portion and the second portion is provided with a through hole, The cover portion is provided with an injection port, In the filling step, the sealant is injected into the injection port and protrudes from the through hole of the second portion, thereby bonding the corner member and the corner packing with the sealant, filling the space with the sealant so that the sealant protrudes from the through hole of the first portion; The method for sealing a panel corner according to claim 11.

Images