JP2002011737A - Method for manufacturing corner panel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method capable of simply and inexpensively manufacturing a corner panel having a shape fitted to a corner part of every kind. SOLUTION: A V-shaped notch part is formed to a laminate panel, which is formed by providing a core material between surface plates, in the cross-sectional direction thereof from either one of the surface plates to the other surface plate and the laminated panel is subsequently bent in the direction of the notch part and a foamable resin liquid is injected in the gap formed to the bent part of the laminated panel to manufacture the corner panel.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a method for manufacturing a corner panel. The method for manufacturing a corner panel according to the present invention is suitable for manufacturing a corner portion of a housing such as an outside corner, a corner inside a building, or a storage room.

[0002]

2. Description of the Related Art A laminated panel having a core material such as a heat insulating material between face plates is widely used as a building material or a material for refrigeration and heat retention. The face plate and the core material constituting such a laminated panel are:
Since the materials have different mechanical properties such as strength and elongation, it is difficult to bend the laminated panel. Therefore, laminated panels used for various corners are usually
Items corresponding to various corners were produced by press production using a fixed frame.

However, manufacturing a laminated panel (corner panel) corresponding to a corner portion by press manufacturing or the like requires a large number of man-hours, so that it takes a long time to manufacture and increases the cost. Further, the quality of the obtained corner panel tends to vary. Further, if the corner panel is manufactured by press manufacturing or the like, it is not possible to quickly respond to user needs.

In order to solve these problems, for example, Japanese Patent Application Laid-Open No. Hei 6-264555 discloses that the entire face plate or a part of the face plate is arranged in a cross-sectional direction of a composite panel in which a face plate is joined to one surface of a heat insulating material layer. A V-shaped cut portion is formed while leaving, and the composite panel is bent in the direction of the cut portion together with the remaining face plate portion, and separately formed on the heat insulating material layer located inside the bent composite panel. A method for bonding a face plate is disclosed. However, in such a method, it is necessary to separately attach a face plate inside after bending the composite panel, which is not a simple method.

[0005]

SUMMARY OF THE INVENTION An object of the present invention is to provide a method for easily and inexpensively producing a corner panel having a shape suitable for various corner portions.

[0006]

Means for Solving the Problems The inventors of the present invention have made intensive studies to solve the above problems, and have found that the above objects can be achieved by the following method, and have completed the present invention.

That is, the present invention forms a V-shaped notch extending from one of the face plates to the other in the cross-sectional direction of the laminated panel having a core material between the face plates. After bending the laminated panel in the direction of the inset portion, a method for producing a corner panel, characterized by injecting and foaming a foamable resin liquid into the gap between the bent portions of the bent laminated panel,
About.

In the method of manufacturing the corner panel, since only a simple operation is performed on the laminated panel manufactured in advance, factory assembly is possible, productivity is very good, and cost reduction is possible. Since the corner panels are manufactured in a factory, the workability at the installation site of the corner panel is also improved, and there is no individual difference among workers at the installation site, and the appearance is uniform. Further, by appropriately setting the number, position, V-shaped angle, and the like of the cut portions of the composite panel, the assembled shape of the corner panel can be freely designed. Furthermore, since the gap between the bent portions of the corner panel is formed of the same foamable resin layer as the core material, the bent portion has good jointability, and since there is no gap, the heat insulating property is also good.

In the method for manufacturing a corner panel,
After bending the laminated panel, it is preferable to fix the bent portion of the inner face plate with a stopper, and then inject foamable resin liquid into the gap between the bent portions of the bent laminated panel to cause foaming. .

[0010] By fixing the inner face plate of the bent laminated panel with a stopper, injection with a foamable resin liquid,
Foaming can be performed efficiently.

[0011]

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A method for manufacturing a corner panel according to the present invention will be described below with reference to the drawings.

First, as shown in FIG. 1, a V-shaped cut from the face plate 1 to the other face plate 1 'in the cross-sectional direction of the laminated panel A having the core material 2 between the face plates 1 and 1'. A part a is formed.

As the face plates 1 and 1 ', a thin metal plate such as iron, aluminum, copper, stainless steel, titanium, aluminum
Examples include zinc alloy plated steel sheets, enameled steel sheets, clad steel sheets, laminated steel sheets (such as vinyl chloride steel sheets), and sandwich steel sheets (such as vibration damping steel sheets). These metal thin plates may be color metal plates coated in various colors or may be formed into various shapes by roll forming, press forming, extrusion forming or the like. Furthermore, face plates 1, 1
As ´, calcium silicate plate, calcium carbonate plate,
Gypsum board, perlite cement board, rock wool board,
Inorganic materials such as a slate plate, an ALC plate and a PC plate can also be used. The face plates 1 and 1 'may be made of the same material or different materials, and can be appropriately selected according to the application.

The core material 2 includes a heat insulating material, a refractory material,
Materials that function as an adhesive, a reinforcing material, a cushioning material, a sound absorbing material, a bulking material, a lightening material, and the like can be exemplified. As such a material, for example, a foamable resin such as a phenol resin foam, a polyurethane foam, and a styrene resin foam is suitable. These foamable resins should contain inorganic fibers such as asbestos and glass wool, inorganic materials such as aluminum hydroxide, ammonium polyphosphate, graphite, calcium silicate and calcium carbonate, and inorganic fillers such as borax to make them flame-retardant. Can also.

The V-shaped cut portion a formed in the sectional direction of the laminated panel A is formed such that the tip of the cut portion a reaches the face plate 1 '. The tip of the notch a does not need to reach the inside of the face plate 1 ′, but if the face plate 1 ′ can form the outer surface of the corner panel, the tip of the notch a may It may extend to the inside. The cut portion a can be formed by processing using, for example, a circular saw, a cutter, a wave knife, or the like.

The tip angle α formed by the cut portion a in a V shape is
It can be appropriately determined according to the angle formed by the curved portion of the corner panel, and the thickness of the laminated panel, the material and thickness of the face plate,
It is determined in consideration of the type, characteristics, and other factors of the core material.
In FIG. 1, one cut portion a is provided. However, a plurality of cut portions a can be provided. When a plurality of cut portions a are provided, a corner panel having a plurality of bent portions is manufactured. can do.

The cross-sectional shape of the notch a is not particularly limited as long as the overall shape is V-shaped so that the laminated panel A can be bent. The cross-sectional shape of the distal end portion can be formed into, for example, a planar shape, an arc shape, a triangular shape, a step shape, and other various shapes. As shown in FIG. 2, the face plate 1 ′ has a planar portion b. Molding is preferred.
By providing the flat part b, the face plate 1 ′ of the laminated panel A
Is bent in the direction of the cut portion a, an appropriate gap 3 for injecting and foaming the foamable resin liquid into the bent portion of the bent laminated panel A can be provided. The width of the flat portion b is selected in consideration of the thickness of the laminated panel A, the materials of the face plates 1 and 1 ', the material of the core material 2, and the like.

Next, the laminated panel A having the cut portions a is bent in the direction of the cut portions a.

The bending is performed by bending the face plate 1 of the laminated panel A by a bender or the like. The gap 3 of the bent portion formed by bending the laminated panel A corresponds to the flat portion b in FIG. 2 and can be appropriately adjusted by the width of the flat portion b. Usually, the width of the gap 3 is preferably about 20 to 30 mm.

Next, a foamable resin liquid is injected into the gap 3 of the bent portion of the bent laminated panel A and foamed to form a foamable resin layer 4, thereby producing a corner panel as shown in FIG. .

Examples of the foamable resin liquid include the same materials as those for forming the core material 2. Among them, a hard urethane foam forming agent can be preferably used.

The rigid urethane foam-forming agent is a liquid two-component reaction-curable urethane stock solution containing a polyisocyanate component such as a prepolymer having a terminal isocyanate group, a polyol component, a blowing agent, and a catalyst. Then, it is formed by injecting into the gap 3 and foaming. Various known materials can be used as the material of these liquid urethane stock solutions without any particular limitation, and the materials can be appropriately selected. Incidentally, the two-component reaction-curable urethane stock solution,
For example, immediately after mixing with a mixing gun, gap 3
And foamed and hardened instantaneously to form a micro urethane foam urethane layer.

In forming the foamable resin layer 4,
As shown in FIG. 3, the bent inner face plate 1 can be fixed with the stopper 5.

When the reaction rate of the foamable resin liquid is high,
By injecting the foamable resin liquid into the gap 3, the foamable resin layer 4 is quickly formed, so that the stopper 5 is not particularly necessary. Note that the foaming resin that has protruded from the gap 3 is appropriately removed. On the other hand, when the reaction rate of the foamable resin liquid is low, the stopper 5 is effective, and by fixing the inner face plate 1 of the bent laminated panel A, the outflow of the foamable resin liquid can be prevented. . The stopper 5 can be used even when the reaction speed of the foamable resin liquid is high, and may be removed after the foamable resin layer 4 is formed.

The stopper 5 has a shape corresponding to the shape of the bent portion, and the same material as the face material can be appropriately selected and used. Fixing of the bent portion by the stopper 5 can be performed by screwing as shown in FIG. 3, or can be performed by bonding the stopper 5 to the face material 1.

The corner panel is manufactured as described above. When one cut portion a is provided in the laminated panel A, an L-shaped corner panel as shown in FIG. 3 is obtained. A plurality of cut portions a can be provided. For example, when two cut portions a are provided on the same face material (1, 1),
A U-shaped corner panel as shown in FIG. 4 is obtained. Furthermore, it is also possible to manufacture a corner panel by providing a plurality of cut portions a in different face materials (1, 1 ') (not shown).

[Brief description of the drawings]

FIG. 1 is a cross-sectional view showing an example of a composite panel provided with a V-shaped cut portion.

FIG. 2 is a sectional view showing an example of a V-shaped cut portion.

FIG. 3 is a sectional view showing an example of a corner panel.

FIG. 4 is a cross-sectional view showing one example of a corner panel.

[Explanation of symbols]

 A Laminated panel 1, 1 'face plate 2 Core material 3 Gap 4 Foamable resin layer 5 Stopper a Notch

 ──────────────────────────────────────────────────続 き Continued on the front page F term (reference) 2E110 AA02 GA24Z GA33W GA33X GB02W GB02X GB03W GB03X GB06W GB06X GB16W GB16X GB19W GB19X GB23W GB23X GB43Z GB49Z GB54Z 4F204 AA42 AD17 AD23 AD27 AD35 AG03 AG20 EA23 EA17A05 EB47

Claims (2)

[Claims] 1. A V-shaped cut portion extending from one of the face plates to the other face plate is formed in a cross-sectional direction of a laminated panel including a core material between face plates, and then the direction of the cut portion is defined. A method for producing a corner panel, comprising: forming a bent laminated panel, and then injecting a foamable resin liquid into a gap between bent portions of the bent laminated panel to cause foaming. 2. After bending the laminated panel, the bent portion of the inner face plate is fixed with a stopper, and then a foamable resin liquid is injected into a gap between the bent portions of the bent laminated panel. The method for producing a corner panel according to claim 1, wherein the corner panel is foamed.