Spandrels, panels for spandrels and buildings

Abstract

To provide highly designed spandrels, panels for spandrels, and buildings. [Solution] The spandrel includes a metal substrate containing an Al-Mn alloy and a design layer laminated on the metal substrate, and the thickness of the metal substrate is 0.3 mm or more and 2.0 mm or less.

Description

[Technical Field]

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

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

[0003] [Patent Document 1] Japanese Patent Application Publication No. 2019-85789 Summary of the Invention [Problem to be solved by the invention]

[0004] The present disclosure provides a highly aesthetic spandrel, a panel for the spandrel, and a building. [Means for solving the problem]

[0005] The embodiments of the present disclosure relate to the following [1] to

[10] .

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

[0007] [2] A spandrel according to [1] or [2], having an area on the first surface located on the decorative layer side relative to the metal substrate where the flop index is 4.5 or more.

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

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

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

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

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

[0013] [8] A spandrel described in any one of [1] to [8], having a decorative portion, an engaging portion formed at one end of the decorative portion, and a receiving portion formed at the other end of the decorative portion.

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

[0015]

[10] A building equipped with the spandrel described in [1]. [Effects of the Invention]

[0016] According to the present disclosure, a highly aesthetically pleasing spandrel can be provided. [Brief explanation of the drawings]

[0017] [Figure 1] FIG. 1 is a perspective view showing a spandrel according to one embodiment. [Figure 2] Figure 2 is a vertical cross-sectional view showing multiple spandrels attached to the mounting surface of a building. [Figure 3]FIG. 3 is a perspective view showing a spandrel according to a modified example of the embodiment. [Figure 4] FIG. 4 is a schematic cross-sectional view illustrating a spandrel. [Figure 5] FIG. 5 is a schematic cross-sectional view illustrating a modified example of the spandrel. [Figure 6] 6(a)-(f) are schematic cross-sectional views illustrating a part of a method for manufacturing a spandrel. [Figure 7] FIG. 7 is a diagram illustrating a part of a method for manufacturing a spandrel. [Figure 8] FIG. 8 is a graph showing the results of Examples 1-1 to 1-4 and Comparative Examples 1-1 to 1-4. [Figure 9] FIG. 9 is a graph showing the results of Examples 2-1 to 2-4 and Comparative Examples 2-1 to 2-4. [Figure 10] FIG. 10 is a graph showing the results of Examples 3-1 to 3-4. [Figure 11] FIG. 11 is a graph showing the results of Examples 4-1 to 4-4. DETAILED DESCRIPTION OF THE INVENTION

[0018] An embodiment will be described below with reference to Figures 1 to 3. However, the present disclosure can be implemented in many different forms and should not be limited to the description of the embodiment exemplified below. Furthermore, to clarify the explanation, the drawings may show the width, thickness, and shape of each part schematically compared to the actual form, but this is merely an example and should not be interpreted as limiting. In the following drawings, the same parts are denoted by the same reference numerals, and some detailed explanations may be omitted.

[0019] In this specification, when describing a mode in which another component is disposed on a certain component, the term "above" or "below" refers to both a case in which another component is disposed directly above or below the certain component so as to be in contact with the component, and a case in which another component is disposed above or below the certain component with another component interposed therebetween, unless otherwise specified. Also, in this specification, when describing a mode in which another component is disposed on the surface of a certain component, the term "on the surface" refers to both a case in which another component is disposed directly above or below the certain component so as to be in contact with the component, and a case in which another component is disposed above or below the certain component with another component interposed therebetween, unless otherwise specified.

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

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

[0022] According to this embodiment, the spandrel 10 includes a metal substrate 55 and a design layer 56 laminated on the metal substrate 55. This enhances the design of the spandrel 10. Furthermore, the design of the spandrel 10 can be matched to the design of the building 90, allowing for a unified design between the spandrel 10 and the building 90. Furthermore, the metal substrate 55 includes an Al-Mn alloy. A metal substrate 55 containing an Al-Mn alloy is stronger than a typical aluminum plate. Therefore, the baking temperature for baking the design layer 56 onto the metal substrate 55 can be increased, improving the weather resistance of the spandrel 10. Furthermore, the metal substrate 55 includes an Al-Mn alloy, and the thickness of the metal substrate 55 is 0.3 mm or more and 2.0 mm or less. By thinning the thickness of the metal substrate 55 and hardening it in this way, the design layer 56 can be formed with a high level of design.

[0023] 1 and 2 is a metal plate that is attached to a mounting surface 91, such as the ceiling or exterior wall of a building 90. A plurality of spandrels 10 are prepared, and the spandrels 10 are attached in order by fastening one side of each spandrel 10 with a screw and fitting the other side. In this way, the mounting surface 91 of the building 90 is covered with the plurality of spandrels 10.

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

[0025] The decorative portion 11 is the portion that is exposed to the outside when attached to the mounting surface 91 of the building 90. The decorative portion 11 constitutes the widest surface of the spandrel 10. The decorative portion 11 may be made up of a flat plate-like member. The decorative portion 11 may be arranged horizontally when the spandrel 10 is attached to the mounting surface 91. However, this is not limiting, and the decorative portion 11 may also be a surface with irregularities. The decorative portion 11 may also be made up of a curved surface.

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

[0027] A first connecting portion 14 is formed on one end side of the decorative portion 11. The first connecting portion 14 connects the decorative portion 11 and the engagement portion 12. The first connecting portion 14 may be disposed perpendicular to the decorative portion 11.

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

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

[0030] The receiving portion 13 has a storage portion 13a, an inclined portion 13b, and an attachment portion 13c. One end of the storage portion 13a is connected to the second connection portion 15. The storage portion 13a is composed of a member that is approximately C-shaped in cross section and opens toward the opposite side of the engagement portion 12. The storage portion 13a accommodates the engagement portion 12 of another spandrel 10. The inclined portion 13b extends at an angle from the other end of the storage portion 13a. The attachment portion 13c is connected to the inclined portion 13b. The attachment portion 13c is used when attaching to the attachment surface 91. The attachment portion 13c may be provided with an attachment hole (not shown). The attachment hole receives a screw or the like for fixing the spandrel 10 to the attachment surface 91. The attachment portion 13c may be arranged parallel to the decorative portion 11.

[0031] As shown in Figure 2, the engaging portion 12 and the receiving portion 13 are formed to engage with the receiving portion 13 and the engaging portion 12, respectively, of the adjacent spandrel 10. Specifically, the engaging portion 12 and the receiving portion 13 are combined by fitting the engaging portion 12 of one spandrel 10 into the receiving portion 13a of the receiving portion 13 of another spandrel 10. In this way, the adjacent spandrels 10 are joined together.

[0032] The spandrel 10 includes a metal substrate 55 and a design layer 56 laminated on the metal substrate 55. The design layer 56 may be laminated directly on the metal substrate 55, or may be laminated via another layer (such as a primer layer 57 and a base layer 58, which will be described later). The design layer 56 is weather resistant and also has design properties. Therefore, by matching the design of the design layer 56 to the exterior wall surface of the building 90, a unified appearance of the building 90 can be provided.

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

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

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

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

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

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

[0039] Figure 3 is a diagram showing a modified example of the spandrel 10 according to this embodiment. As shown in Figure 3, the engaging portion 12 may have a bent portion 12c instead of the convex portion 12b. The bent portion 12c is a portion bent into a substantially C-shape or a substantially J-shape. In this case, the bent portion 12c of the engaging portion 12 fits into the accommodation portion 13a of the receiving portion 13, thereby combining the engaging portion 12 and the receiving portion 13.

[0040] (Spandrel and method for manufacturing spandrel) The spandrels and methods of manufacturing the spandrels in the above-described embodiments will be described in detail below.

[0041] A. Spandrel 4 and 5 are schematic cross-sectional views showing the layer structure of the spandrel 10 in this embodiment. As shown in FIG. 4, the spandrel 10 has a metal base material 55 and a design layer 56 arranged in a thickness direction D TThe design layer 56 contains an organic colorant. The spandrel 10 may have a region in which the flop index is 4.5 or more on the first surface 50a located on the design layer 56 side with respect to the metal substrate 55. As shown in FIG. 5, the spandrel 10 has the metal substrate 55, the primer layer 57, the undercoat layer 58, the design layer 56, and the surface protective layer 59 arranged in the thickness direction D. T 4 and 5, the spandrel 10 may further include a protective sheet 61 that covers the decorative layer 56.

[0042] In the present embodiment, the design layer 56 may contain an organic colorant, and the flop index on the first surface 50a may be 4.5 or higher. In this case, a spandrel 10 is obtained that can express a wide range of designs while taking advantage of the glossiness of the metal substrate 55. In the spandrel 10 using the metal substrate 55, a unique design is created by taking advantage of the glossiness of the metal substrate 55, and by utilizing this unique design, the range of design expression can be expanded. In other words, design expression that takes advantage of the natural characteristics of the metal substrate 55, more specifically, metallic design expression in which the lightness, saturation, and hue change significantly depending on the observation angle, is possible.

[0043] When the design layer 56 contains an organic colorant, it is possible to achieve a design expression with high brightness and saturation (diverse color expression) without excessively concealing the glossiness of the metal substrate 55. Specifically, it is possible to reproduce design expressions such as brass, copper, corrosion patterns, and polished patterns at a higher level than ever before. Furthermore, when the flop index on the first surface 50a is 4.5 or higher, the glossiness of the metal substrate 55 can be fully utilized. Conventional color difference evaluation is significantly affected by the glossiness of the surface of the spandrel 10, making it difficult to quantitatively evaluate the glossiness of the metal substrate 55. In contrast, in the present embodiment, by focusing on the flop index, it is possible to quantitatively evaluate the glossiness of the metal substrate 55 without being significantly affected by the glossiness of the surface of the spandrel 10.

[0044] 1. Flop Metrics 4, the spandrel 10 in this embodiment may have an area where the flop index is 4.5 or more on the first surface 50a located on the decorative layer 56 side with respect to the metal base material 55. The first surface 50a is the surface located on the decorative layer 56 side of the spandrel 10, and refers to the surface that is exposed to the outside when the protective sheet 61 is removed.

[0045] The glossiness of the metal substrate 55 varies greatly in brightness, saturation, and hue depending on the position and angle of light reception and observation. The characteristic of this change is called flop, and the flop index is an index that quantitatively evaluates the flop. The flop index is calculated by dividing the L at effective angles of 15°, 45°, and 110°. * (L * 15 , L * 45 , L * 110 ) is calculated using the following formula: Flop Index = 2.69 × (L * 15 -L * 110 ) 1·11 / (L * 45 ) 0·85 The method for measuring the flop index will be described in detail in the examples below.

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

[0047] When the spandrel 10 is viewed from the design layer 56 side, the area of ​​the design layer 56 is S A Let the area of ​​the above region be S B Let's say S A S against B The ratio (S B / S A ) is, for example, 1% or more, may be 3% or more, or may be 5% or more. B / S AAlthough it depends on the design of the design layer 56, it may be 100% or less. In the latter case, the design will have an area that makes the most of the glossiness of the metal base material 55 and an area that does not make the most of the glossiness of the metal base material 55. S B / S A may be 80% or less, or may be 60% or less.

[0048] 2. Design layer The design layer 56 in this embodiment is a layer that imparts design to the spandrel 10 and contains an organic colorant. The design layer 56 may be a design layer having a design (pattern) and may also be referred to as a surface design layer. The design layer 56 may be a solid layer (a layer coated with ink) or a combination of a design layer and a solid layer.

[0049] Examples of patterns in the design layer include wood grain patterns, marble patterns, stone patterns, sand patterns, tile patterns, brickwork patterns, fabric patterns, leather-striped patterns, geometric shapes, letters, symbols, abstract patterns, floral patterns, wave patterns, striped patterns, metallic patterns, and rust-like patterns.

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

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

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

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

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

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

[0056] The design layer 56 may have, in the thickness direction from the metal substrate 55 side, a layer containing an inorganic colorant and a layer containing an organic colorant, in this order. The layer containing an inorganic colorant and the layer containing an organic colorant may each independently be a solid layer or a pattern layer. For example, by providing a solid layer containing an inorganic colorant, the color of the metal substrate 55 can be adjusted. Alternatively, by overlapping a pattern layer containing an inorganic colorant with a pattern layer containing an organic colorant, the layer containing the organic colorant can maintain the glossiness of the metal substrate 55, while the layer containing the inorganic colorant can provide a partial concealing area, thereby enabling complex design expression.

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

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

[0059] 3.Metal base material The metal base material 55 in this embodiment is an Al-Mn alloy. An Al-Mn alloy is an aluminum alloy that is made by adding mainly Mn (manganese) to pure aluminum to increase its strength. The Al-Mn alloy may also be called an aluminum-manganese alloy or a 3000-series aluminum alloy. Since the metal base material 55 is an Al-Mn alloy, it becomes possible to bake the design layer 56 onto the metal base material 55 at a high temperature, as will be described later. Baking the design layer 56 at a high temperature improves the weather resistance of the spandrel 10.

[0060] The metal base material 55 may be bent. The thickness of the metal base material 55 is, for example, 0.3 mm to 2.0 mm, or 0.5 mm to 1.5 mm, or 0.7 mm to 1.0 mm. When the thickness of the metal base material 55 is 0.3 mm to 2.0 mm, the metal base material 55 is thin, so that the design layer 56 with high designability can be easily formed on the metal base material 55.

[0061] 4. Primer layer The spandrel 10 in this embodiment may have a primer layer 57 between the metal substrate 55 and the decorative layer 56. By providing the primer layer 57, the adhesion between the two layers adjacent to the primer layer 57 is improved.

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

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

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

[0065] 5. Base layer The spandrel 10 in this embodiment may have a base layer 58 between the metal substrate 55 and the design layer 56. For example, by providing the base layer 58, it is possible to adjust the glossiness of the metal substrate 55. In order to make the most of the glossiness of the metal substrate 55, the base layer 58 is usually a transparent layer (colored transparent or colorless transparent).

[0066] The base layer 58 contains a resin. The resin contained in the base layer 58 is preferably a cured product (crosslinked structure) of a curable resin, and more preferably a cured product of a thermosetting resin. The curable resin is preferably a fluorine-based resin, as this has good weather resistance. The base layer 58 may or may not contain a colorant. The base layer 58 may also contain an inorganic colorant. The curable resin and colorant are the same as the curable resin used in the design layer 56 described above, and therefore a description thereof will be omitted here. The base layer 58 may also contain an additive such as a weather resistant agent. Details of the weather resistant agent will be described later.

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

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

[0069] The surface protective layer 59 contains a resin. The resin contained in the surface protective layer 59 is preferably a cured product (crosslinked structure) of a curable resin, and more preferably a cured product of a thermosetting resin. The curable resin is preferably a fluorine-based resin, as this has good weather resistance. The surface protective layer 59 may also contain a colorant. The curable resin and colorant are the same as the curable resin used in the design layer 56 described above, and therefore a description thereof will be omitted here.

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

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

[0072] The surface protective layer 59 preferably contains a weather-resistant agent. Since the organic colorants contained in the design layer 56 generally have low weather resistance, while inorganic colorants have low weather resistance, it is preferable that the surface protective layer 59 have sufficient weather resistance. Examples of the weather-resistant agent include an ultraviolet absorber and a light stabilizer.

[0073] Examples of the ultraviolet absorber include organic ultraviolet absorbers such as triazine-based ultraviolet absorbers, benzotriazole-based ultraviolet absorbers, benzophenone-based ultraviolet absorbers, oxybenzophenone-based ultraviolet absorbers, salicylic acid ester-based ultraviolet absorbers, and cyano(meth)acrylate-based ultraviolet absorbers, and inorganic ultraviolet absorbers such as titanium dioxide, cerium oxide, and zinc oxide. Among these, triazine-based ultraviolet absorbers are preferred.

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

[0075] The content of the ultraviolet absorber in the surface protective layer 59 is, for example, 0.5 parts by mass to 10 parts by mass, alternatively 0.8 parts by mass to 8 parts by mass, or alternatively 1 part by mass to 5 parts by mass, relative to 100 parts by mass of the resin component. If the content of the ultraviolet absorber is too high, bleeding out of the ultraviolet absorber may occur, whereas if the content of the ultraviolet absorber is too low, sufficient ultraviolet absorption performance may not be obtained.

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

[0077] The content of the light stabilizer in the surface protective layer 59 is, for example, 1 part by mass to 10 parts by mass, or alternatively 1.5 parts by mass to 8 parts by mass, or alternatively 2 parts by mass to 5 parts by mass, relative to 100 parts by mass of the resin component. If the content of the light stabilizer is too high, bleeding out of the light stabilizer may occur, and if the content of the light stabilizer is too low, sufficient light stability may not be obtained.

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

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

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

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

[0082] 8. Spandrel Layer Structure The spandrel 10 in this embodiment has a metal base material 55 and a design layer 56, in this order in the thickness direction. The spandrel 10 may further have at least one of the above-mentioned primer layer 57, undercoat layer 58, surface protective layer 59, and protective sheet 61. The layer structure of the spandrel 10 in this embodiment is not particularly limited, but examples include the following layer structures. The symbol " / " indicates the boundary between each layer. Furthermore, the two components separated by the symbol " / " may be arranged in direct contact with each other, or may be arranged with another component interposed therebetween.

[0083] (1) Metal substrate 55 / design layer 56 / protective sheet 61 (2) Metal substrate 55 / primer layer 57 / design layer 56 / protective sheet 61 (3) Metal substrate 55 / base layer 58 / design layer 56 / protective sheet 61 (4) Metal substrate 55 / primer layer 57 / undercoat layer 58 / design layer 56 / protective sheet 61 (5) Metal substrate 55 / design layer 56 / surface protective layer 59 / protective sheet 61 (6) Metal substrate 55 / primer layer 57 / design layer 56 / surface protective layer 59 / protective sheet 61 (7) Metal substrate 55 / base layer 58 / design layer 56 / surface protective layer 59 / protective sheet 61 (8) Metal substrate 55 / primer layer 57 / undercoat layer 58 / design layer 56 / surface protective layer 59 / protective sheet 61

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

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

[0086] B. Spandrel manufacturing method 6(a)-(f) and 7 are schematic cross-sectional views illustrating a method for manufacturing the spandrel 10 according to the present embodiment. First, as shown in FIG. 6(a), a metal substrate 55 is prepared (metal substrate preparation step). Next, as shown in FIG. 6(b), a primer layer 57 is formed on one side of the metal substrate 55 (primer layer formation step). Next, as shown in FIG. 6(c), a base layer 58 is formed on the side of the primer layer 57 opposite the metal substrate 55 (base layer formation step). Next, as shown in FIG. 6(d), a composition containing an organic colorant is applied to the side of the base layer 58 opposite the primer layer 57, and the applied composition is heat-cured to form a design layer 56 (design layer formation step). Next, as shown in FIG. 6(e), a surface protection layer 59 is formed on the side of the design layer 56 opposite the base layer 58 (surface protection layer formation step). Next, as shown in Figure 6(f), a protective sheet 61 is attached to the surface of the design layer 56 opposite the surface protective layer 59 (protective sheet attachment step). This results in a panel 10A for the spandrel 10. Thereafter, as shown in Figure 7, the panel 10A is molded to obtain the spandrel 10 (spandrel molding step).

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

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

[0089] The primer layer 57 can be formed, for example, by applying a composition for the primer layer 57 and then heat-curing it. Examples of methods for applying the composition include roll coating, reverse coating, air spray coating, electrostatic coating, and powder coating. When viewed in the thickness direction, the primer layer 57 is formed, for example, over the entire surface of the metal substrate 55. The heating temperature (substrate temperature) is, for example, 100°C or higher and 300°C or lower.

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

[0091] The base layer 58 can be formed, for example, by applying a composition for the base layer 58 and then heat-curing it. Examples of methods for applying the composition include flow coating, roll coating, reverse coating, air spray coating, electrostatic coating, and powder coating. When viewed in the thickness direction, the base layer 58 is formed, for example, so as to cover the entire surface of the metal substrate 55. The heating temperature (substrate temperature) is, for example, 150°C or higher and 300°C or lower, and may be 200°C or higher and 250°C or lower.

[0092] 4. Design layer formation process The manufacturing method of the spandrel 10 in this embodiment includes a design layer forming step in which a composition containing an organic colorant is applied to one surface of the metal substrate 55 and then heat-cured to form the design layer 56. In the design layer forming step, the design layer 56 may be formed directly on one surface of the metal substrate 55, or may be formed via another layer such as the primer layer 57 or undercoat layer 58 described above.

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

[0094] As described above, the spandrel 10 in this embodiment includes the metal base material 55 containing an Al-Mn alloy. The metal base material 55 containing an Al-Mn alloy has a higher strength than a typical aluminum plate. This allows the heating temperature for baking the decorative layer 56 onto the metal base material 55 to be high, thereby improving the design and weather resistance of the spandrel 10.

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

[0096] The surface protective layer 59 can be formed, for example, by applying a composition for the surface protective layer 59 and then heat-curing it. Examples of methods for applying the composition include flow coating, roll coating, reverse coating, air spray coating, electrostatic coating, and powder coating. When viewed in the thickness direction, the surface protective layer 59 is formed so as to cover the entire surface of the metal substrate 55. The heating temperature (substrate temperature) may be, for example, 150°C or higher and 300°C or lower, or 200°C or higher and 250°C or lower.

[0097] 6. Protective sheet application process The method for manufacturing the spandrel in this embodiment may include a protective sheet attachment step of attaching a protective sheet 61 that protects the decorative layer 56 to the decorative layer 56 side. In the protective sheet attachment step, the protective sheet 61 is attached to the surface protective layer 59.

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

[0099] 7.Spandrel forming process The method for manufacturing a spandrel in this embodiment may include a spandrel forming step of forming a panel 10A for the spandrel 10. By forming the panel 10A, for example, a spandrel 10 having the shape shown in FIG. 1 is obtained. The step of forming the panel 10A may include a bending step such as roll forming. Roll forming refers to a technique for forming a long panel by passing it between multiple rollers of a roll forming machine. In this embodiment, as shown in FIG. 7, the panel 10A is formed by passing it between multiple rollers 71 of a roll forming machine 70. This bends the panel 10A to produce the spandrel 10 having the decorative portion 11, the engagement portion 12, and the receiving portion 13. As described above, the panel 10A may include a protective sheet 61. In this case, scratches or other damage to the design layer 56 caused by the rollers 71 of the roll forming machine 70 is prevented. The protective sheet 61 may be peeled off and removed before the spandrel 10 is attached to the attachment surface 91 of the building 90.

[0100] [Example] Next, a specific example of the panel according to this embodiment will be described.

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

[0102] Next, the following composition for the undercoat layer was applied to the entire surface of the aluminum plate using a curtain flow coater so that the film thickness after drying would be 18 μm, and then baked at 216°C (the temperature reached by the substrate) to form the undercoat layer.

[0103] (Undercoat layer composition) Thermosetting fluororesin (fluoroethylene-vinyl ether copolymer) Hardener (isocyanate) Gray colorant (titanium oxide, chromium oxide; 5% by mass based on thermosetting fluororesin) Solvent (xylene:toluene = 1:1, mass ratio) Solid content concentration: 17% by mass

[0104] Next, the composition for the design layer described below was applied to the entire surface of the undercoat layer by gravure offset printing so that the film thickness after drying would be 0.5 μm or more and 15 μm or less.

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

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

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

[0108] [Example 1-2] Except that the following composition B for the surface protective layer was used instead of composition A for the surface protective layer. A panel was obtained in the same manner as in Example 1-1. The obtained surface protective layer is referred to as surface protective layer B.

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

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

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

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

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

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

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

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

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

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

[0119] [evaluation] The flop index was measured using the panels obtained in each Example and Comparative Example. Specifically, the panel was placed horizontally with the surface protective layer facing up, and the lightness index L was measured using a three-dimensional goniospectrophotometric colorimeter (manufactured by Murakami Color Research Laboratory, model number GCMS-4). * The measurement conditions were an incident angle of 45°, tilt angle of 0°, in-plane rotation angle of 0°, light source D65, and L at receiving angles of 30°, 0°, and -65°. * The flop index was then calculated using the following formula. The results are shown in Tables 1 and 2. Flop Index = 2.69 × (L * 15 -L * 110 ) 1·11 / (L * 45 ) 0·85 (L * 15 is L at an acceptance angle of 30° * This applies to L * 45 is L at 0° acceptance angle * This applies to L * 110 is L at an acceptance angle of -65° * (corresponding to

[0120] [Table 1]

[0121] [Table 2]

[0122] As shown in Table 1, in each example, the flop index was high, and it was confirmed that the glossiness of the metal substrate was well expressed. Furthermore, because an organic colorant was used, it was possible to suppress concealment of the glossiness by the design layer while still achieving a vivid design expression. In contrast, as shown in Table 2, in each comparative example, the flop index was low, and it was confirmed that the glossiness of the metal substrate was not well expressed. This is presumably because the use of an inorganic colorant resulted in significant concealment of the glossiness by the design layer.

[0123] Fig. 8 is a graph showing the results of Examples 1-1 to 1-4 and Comparative Examples 1-1 to 1-4. The triangles in Fig. 8 represent the flop indexes of samples prepared in the same manner as Examples 1-1 to 1-4 except that no design layer was formed, and the same applies to the triangles in Figs. 9 to 11 described below. As shown in Fig. 8, Examples 1-1 to 1-4 had higher flop indexes than Comparative Examples 1-1 to 1-4, confirming that the glossiness of the metal substrate was well expressed. Furthermore, when comparing Examples 1-1 to 1-4, it was confirmed that the flop index was less affected by the glossiness of the first surface (the surface of the surface protective layer) and that the glossiness of the metal substrate could be accurately evaluated.

[0124] Fig. 9 is a graph showing the results of Examples 2-1 to 2-4 and Comparative Examples 2-1 to 2-4. As shown in Fig. 9, Examples 2-1 to 2-4 had a higher flop index than Comparative Examples 2-1 to 2-4, confirming that the glossy feel of the metal substrate was well expressed. Fig. 10 is a graph showing the results of Examples 3-1 to 3-4, and Fig. 11 is a graph showing the results of Examples 4-1 to 4-4. As shown in Figs. 10 and 11, Examples 3-1 to 3-4 and Examples 4-1 to 4-4 had a high flop index, confirming that the glossy feel of the metal substrate was well expressed.

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

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

[0127] Next, the second composition for the design layer described below was applied to the entire surface of the inorganic colorant layer by gravure offset printing so that the film thickness after drying would be 0.5 μm to 1.5 μm, thereby forming an organic colorant layer, thereby obtaining a design layer having an inorganic colorant layer and an organic colorant layer.

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

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

[0130] [Examples 5-2 to 5-4] Each panel was obtained in the same manner as in Example 5-1, except that only perylene-based pigment (red), only cyanine-based pigment (blue), or only nickel azo complex-based pigment (yellow) was used as the organic colorant contained in the second composition for the design layer.

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

[0132] [Comparative Example 3-2] A panel was obtained in the same manner as in Example 5-1, except that no organic colorant layer was formed and the above-mentioned composition B for the surface protective layer was used instead of composition A for the surface protective layer.

[0133] [Comparative Example 3-3] A panel was obtained in the same manner as in Example 5-1, except that no organic colorant layer was formed and the above-mentioned composition C for the surface protective layer was used instead of composition A for the surface protective layer.

[0134] [Comparative Example 3-4] A panel was obtained in the same manner as in Example 5-1, except that no organic colorant layer was formed and the above-mentioned composition D for the surface protective layer was used instead of composition A for the surface protective layer.

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

[0136] [Table 3]

[0137] [Table 4]

[0138] As shown in Tables 3 and 4, it was confirmed that Examples 5-1 to 5-4, which had an organic colorant layer, had a high flop index similar to Comparative Examples 3-1 to 3-4, which did not have an organic colorant layer. In other words, it was confirmed that the organic colorant layer had limited ability to conceal glossiness, and that the organic colorant layer enabled vivid design expression.

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

[0140] (Composition X for base layer) Thermosetting fluororesin (fluoroethylene-vinyl ether copolymer) Hardener (isocyanate) Gray colorant (titanium oxide, chromium oxide; 5% by mass based on thermosetting fluororesin) UV absorbers Hindered amine light stabilizers Solid content concentration: 17% by mass

[0141] (Surface protective layer composition A2) Thermosetting fluororesin (fluoroethylene-vinyl ether copolymer) Hardener (isocyanate) UV absorbers Hindered amine light stabilizer solvent (xylene:toluene = 1:1, mass ratio) Solid content concentration: 30% by mass

[0142] [evaluation] The weather resistance of the panels obtained in Examples 6-1 to 6-3 was evaluated. The obtained panels were subjected to an accelerated weather resistance test using a Sunshine Weather Meter (SWOM). Specifically, under the following irradiation conditions, the panels were irradiated for 102 minutes, followed by irradiating and spraying for 18 minutes, totaling 120 minutes, and this cycle was repeated until the total ultraviolet irradiation time was 10,000 hours.

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

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

[0145] [Table 5]

[0146] As shown in Table 5, Examples 6-1 to 6-3 were confirmed to have small color difference (ΔE), high gloss retention, and good weather resistance. Organic colorants are known to have lower weather resistance than inorganic colorants, but Examples 6-1 to 6-3 used organic colorants to obtain panels that can also be used as exterior components.

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

[0148] Next, the following composition for the undercoat layer was applied to the entire surface of the aluminum plate using a curtain flow coater so that the film thickness after drying would be 18 μm, and then baked at 216°C (the temperature reached by the substrate) to form the undercoat layer.

[0149] (Undercoat layer composition) Thermosetting polyester resin Solvent (xylene:cyclohexanone = 1:1) Solid content concentration: 40% by mass

[0150] Next, the composition for the design layer described below was applied to the entire surface of the undercoat layer by gravure offset printing so that the film thickness after drying would be 0.5 μm or more and 15 μm or less.

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

[0152] Next, the composition for the surface protection layer described below was applied to the entire surface of the design layer using a bar coater so that the film thickness after drying would be 22 μm, and then baked at 224 ° C (the temperature reached by the substrate) to form a surface protection layer, thereby obtaining a panel.

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

[0154] The weather resistance of the obtained panel was evaluated in the same manner as above. As a result, the color difference (ΔE) and gloss retention were maintained to a certain extent until the ultraviolet irradiation time reached 500 hours, but when the ultraviolet irradiation time reached 1000 hours, the color difference (ΔE) became 4.3 and the gloss retention became 10%. Comparing Example 7 with Examples 6-1 to 6-3, it was confirmed that the weather resistance was significantly improved by using a fluorine-based resin as the thermosetting resin.

[0155] It is also possible to combine the multiple components disclosed in the above embodiments and modifications as needed, or to delete some of the components disclosed in the above embodiments and modifications. [Explanation of symbols]

[0156] 10 Spandrel 10A Panel 11 Cosmetic Department 12 Engagement portion 13 Receiving Department 55 Metal base material 56 Design Layer 57 Primer layer 58 Base layer 59 Surface protective layer 61 Protective Sheet 90 Buildings 91 Mounting surface

Claims

1. In the spandrel, a metal substrate containing an Al—Mn-based alloy; A design layer laminated on the metal substrate, The thickness of the metal substrate is 0.3 mm or more and 2.0 mm or less, The design layer is a baked layer, The thickness of the design layer is 1 μm or more and 10 μm or less, The design layer comprises a fluorine-based resin.

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

3. The spandrel of claim 1 , which is a roll-formed product.

4. The spandrel of claim 1 , wherein the design layer contains an organic colorant.

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

6. The spandrel of claim 1 , further comprising a protective sheet covering the decorative layer.

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

8. In the spandrel panels, a metal substrate containing an Al—Mn-based alloy; A design layer laminated on the metal substrate, The thickness of the metal substrate is 0.3 mm or more and 2.0 mm or less, The design layer is a baked layer, The thickness of the design layer is 1 μm or more and 10 μm or less, The panel, wherein the design layer contains a fluorine-based resin.

9. A building comprising the spandrel according to claim 1.

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