JP6901818B2

JP6901818B2 - Panel manufacturing method

Info

Publication number: JP6901818B2
Application number: JP2015120932A
Authority: JP
Inventors: 隆之生喜; 賢悟山本; 道昭大園
Original assignee: NIPPON STEEL COATED SHEET CORPORATION
Current assignee: NIPPON STEEL COATED SHEET CORPORATION
Priority date: 2015-06-16
Filing date: 2015-06-16
Publication date: 2021-07-14
Anticipated expiration: 2035-06-16
Also published as: JP2017002682A

Description

本発明は、パネルの製造方法に関するものである。より詳しくは、壁材や天井材などの建材として利用可能なパネルの製造方法に関するものである。 The present invention relates to a method for manufacturing a panel. More specifically, the present invention relates to a method for manufacturing a panel that can be used as a building material such as a wall material or a ceiling material.

従来、二枚の金属外皮の間に断熱性や耐火性を有する芯材を充填してパネルを製造することが行われている。芯材としては、一枚の板状樹脂発泡体（発泡樹脂ボード）が用いられている（例えば、特許文献１参照）。また芯材は、複数のブロック状の樹脂発泡体を組合せて板状に形成したものが用いられている（例えば、特許文献２参照）。また金属外皮と芯材とは接着されている。 Conventionally, a panel is manufactured by filling a core material having heat insulation and fire resistance between two metal outer skins. As the core material, a single plate-shaped resin foam (foamed resin board) is used (see, for example, Patent Document 1). Further, as the core material, a material formed into a plate shape by combining a plurality of block-shaped resin foams is used (see, for example, Patent Document 2). Further, the metal outer skin and the core material are adhered to each other.

特開２０１３−０７２２６６号公報Japanese Unexamined Patent Publication No. 2013-072266 特開２０１３−１４２２６８号公報Japanese Unexamined Patent Publication No. 2013-142268

上記のようなパネルにおいて、芯材の金属外皮との接着面に凹凸が生じていると、芯材と金属外皮との接着強度が低下することがあった。この場合、施工後のパネルが経時変化することにより、芯材と金属外皮が部分的に接着剥離を起こすことがあった。そして、芯材と金属外皮が接着剥離した部分では、金属外皮が膨れて建物の外観が低下するおそれがあった。また金属外皮の膨れが拡大していくと、芯材と金属外皮の接着強度が不足し、建物の耐風圧強度が低下したりパネルの耐久性が低下したりするという問題があった。 In a panel as described above, if the adhesive surface of the core material with the metal outer skin is uneven, the adhesive strength between the core material and the metal outer skin may decrease. In this case, the core material and the metal outer skin may be partially adhesively peeled off due to the change of the panel after construction with time. Then, at the portion where the core material and the metal outer skin are adhered and peeled off, the metal outer skin may swell and the appearance of the building may be deteriorated. Further, when the swelling of the metal outer skin increases, the adhesive strength between the core material and the metal outer skin becomes insufficient, and there is a problem that the wind pressure resistance strength of the building is lowered and the durability of the panel is lowered.

本発明は上記の点に鑑みてなされたものであり、金属外皮と芯材との接着剥離を生じにくくすることができるパネルの製造方法を提供することを目的とするものである。 The present invention has been made in view of the above points, and an object of the present invention is to provide a method for manufacturing a panel capable of preventing adhesive peeling between a metal outer skin and a core material.

本発明に係るパネルの製造方法は、芯材の表面に金属外皮を接着するパネルの製造方法であって、前記芯材が、複数のブロック材を長手方向及び短手方向に並べて千鳥配置に組合せて形成され、隣接する前記ブロック材の隙間に接着剤が設けられ、長手方向で隣接する前記ブロック材の対向する端面同士を接着し、前記芯材の表面の平坦の度合いが、凹の部分と凸の部分の高さの差で最大で３ｍｍ以下となるように、前記芯材の表面が切削により平坦化されることで、前記芯材の前記金属外皮との接着面が平坦化され、前記金属外皮と接着される前の前記芯材の表面が除塵され、前記芯材の表面に前記金属外皮を接着する接着剤は、発泡倍率が２倍以下で微発泡し、温度２０℃で粘度が２００ＭＰａ・ｓ以上２０００ＭＰａ・ｓ以下で、接触角が９０°以下であり、前記隣接するブロック材の前記隙間は、前記芯材の表面に前記金属外皮を接着する前記接着剤で埋められる、ことを特徴とする。 The panel manufacturing method according to the present invention is a panel manufacturing method in which a metal outer skin is adhered to the surface of a core material, and the core material is combined in a staggered arrangement by arranging a plurality of block materials in the longitudinal direction and the lateral direction. An adhesive is provided in the gap between the adjacent block materials, and the opposing end faces of the adjacent block materials are adhered to each other in the longitudinal direction, and the degree of flatness of the surface of the core material is equal to that of the concave portion. By flattening the surface of the core material by cutting so that the difference in height of the convex portion is 3 mm or less at the maximum, the adhesive surface of the core material with the metal outer skin is flattened. The surface of the core material before being adhered to the metal outer skin is dust-removed, and the adhesive that adheres the metal outer skin to the surface of the core material slightly foams at a foaming ratio of 2 times or less and has a viscosity at a temperature of 20 ° C. It is said that the contact angle is 90 ° or less at 200 MPa · s or more and 2000 MPa · s or less, and the gap between the adjacent block materials is filled with the adhesive that adheres the metal outer skin to the surface of the core material. It is a feature.

本発明にあっては、隣接する前記ブロック材は圧着されることが好ましい。 In the present invention, it is preferable that the adjacent block materials are pressure-bonded.

本発明にあっては、前記ブロック材の切断面が前記金属外皮と接着されることが好ましい。 In the present invention, it is preferable that the cut surface of the block material is adhered to the metal outer skin.

本発明に係るパネルの製造方法は、芯材の表面に金属外皮を接着するパネルの製造方法であって、前記芯材が、複数のブロック材を長手方向及び短手方向に並べて千鳥配置し、且つ前記複数のブロック材と調整部材とを組合せて形成され、隣接する前記ブロック材の隙間に接着剤が設けられ、長手方向で隣接する前記ブロック材の対向する端面同士を接着し、前記調整部材は隣接する前記ブロック材の間に設けられ、前記芯材の表面の平坦の度合いが、凹の部分と凸の部分の高さの差で最大で３ｍｍ以下となるように、前記芯材の表面が切削により平坦化されることで、前記芯材の前記金属外皮との接着面が平坦化され、前記金属外皮と接着される前の前記芯材の表面が除塵され、前記芯材の表面に前記金属外皮を接着する接着剤は、発泡倍率が２倍以下で微発泡し、温度２０℃で粘度が２００ＭＰａ・ｓ以上２０００ＭＰａ・ｓ以下で、接触角が９０°以下であり、前記隣接するブロック材の前記隙間は、前記芯材の表面に前記金属外皮を接着する前記接着剤で埋められる、ことを特徴とする。 The panel manufacturing method according to the present invention is a panel manufacturing method in which a metal outer skin is adhered to the surface of a core material, wherein a plurality of block materials are arranged in a staggered manner in the longitudinal direction and the lateral direction. Further , the adjusting member is formed by combining the plurality of block materials and the adjusting member, an adhesive is provided in the gap between the adjacent block materials, and the opposing end faces of the adjacent block materials are adhered to each other in the longitudinal direction. Is provided between the adjacent block materials, and the surface of the core material is flat so that the degree of flatness of the surface of the core material is 3 mm or less at the maximum due to the difference in height between the concave portion and the convex portion. Is flattened by cutting, so that the adhesive surface of the core material with the metal outer skin is flattened, and the surface of the core material before being adhered to the metal outer skin is dust-removed to the surface of the core material. The adhesive for adhering the metal outer skin is slightly foamed at a foaming ratio of 2 times or less, has a viscosity of 200 MPa · s or more and 2000 MPa · s or less at a temperature of 20 ° C., has a contact angle of 90 ° or less, and is an adjacent block. The gap of the material is filled with the adhesive that adheres the metal outer skin to the surface of the core material .

本発明にあっては、隣接する前記ブロック材が突き合わされていることが好ましい。 In the present invention, it is preferable that the adjacent block materials are butted against each other.

本発明にあっては、前記芯材の表面と前記金属外皮とを接着するための接着剤は、前記芯材の表面と前記金属外皮とを接着するための接着剤は、温度２０℃で粘度が２０００ＭＰａ・ｓ以下で、接触角が９０°以下であることが好ましい。 In the present invention, the adhesive for adhering the surface of the core material and the metal outer skin is the adhesive for adhering the surface of the core material and the metal outer skin, and the adhesive for adhering the surface of the core material and the metal outer skin has a viscosity at a temperature of 20 ° C. Is preferably 2000 MPa · s or less, and the contact angle is preferably 90 ° or less.

本発明にあっては、前記金属外皮の前記芯材との接着面に存在する凹部には、充填材が充填されることが好ましい。 In the present invention, it is preferable that the recesses existing on the adhesive surface of the metal outer skin with the core material are filled with a filler.

本発明にあっては、前記金属外皮と前記芯材とが押さえローラーで圧着されることが好ましい。 In the present invention, it is preferable that the metal outer skin and the core material are pressure-bonded by a pressing roller.

本発明にあっては、前記芯材の表面に前記金属外皮を接着する前記接着剤の樹脂成分は、芯材を形成する樹脂成分と同種であることが好ましい。 In the present invention, it is preferable that the resin component of the adhesive that adheres the metal outer skin to the surface of the core material is the same as the resin component that forms the core material .

本発明は、金属外皮と芯材との接着剥離を生じにくくすることができる。 INDUSTRIAL APPLICABILITY According to the present invention, it is possible to prevent adhesion peeling between the metal outer skin and the core material.

図１Ａは、本発明の一例を示す断面図であり、図１Ｂは、本発明のパネルの横張りの状態を示す正面図、図１Ｃは、本発明のパネルの縦張りの状態を示す正面図である。1A is a cross-sectional view showing an example of the present invention, FIG. 1B is a front view showing a horizontally stretched state of a panel of the present invention, and FIG. 1C is a front view showing a vertically stretched state of a panel of the present invention. Is. 図２Ａは芯材の一例を示す概略図である。図２Ｂは芯材の一例を示す一部の断面図である。FIG. 2A is a schematic view showing an example of the core material. FIG. 2B is a partial cross-sectional view showing an example of the core material. 図３Ａは芯材の一例を示す一部の断面図である。図３Ｂは芯材の他の一例を示す一部の断面図である。図３Ｃは芯材のさらに他の一例を示す一部の断面図である。FIG. 3A is a partial cross-sectional view showing an example of the core material. FIG. 3B is a partial cross-sectional view showing another example of the core material. FIG. 3C is a partial cross-sectional view showing still another example of the core material. 図４は芯材の一例を示す概略図である。FIG. 4 is a schematic view showing an example of the core material. 図５はパネルの一例を示す一部の断面図である。FIG. 5 is a partial cross-sectional view showing an example of the panel. 図６はプレス工程を示す概略図である。FIG. 6 is a schematic view showing a pressing process. 図７Ａは、本発明の一例を示す断面図であり、図７Ｂは、本発明のパネルの横張りの状態を示す正面図、図７Ｃは、本発明のパネルの縦張りの状態を示す正面図である。7A is a cross-sectional view showing an example of the present invention, FIG. 7B is a front view showing a horizontally stretched state of the panel of the present invention, and FIG. 7C is a front view showing a vertically stretched state of the panel of the present invention. Is. 図８はパネルの一例を示す一部の断面図である。FIG. 8 is a partial cross-sectional view showing an example of the panel.

以下、本発明を実施するための形態を説明する。 Hereinafter, modes for carrying out the present invention will be described.

（実施の形態１）
図１Ａは本実施形態で製造されるパネル１の一例を示している。このパネル１は、二枚の金属外皮２，３と芯材４を備えており、芯材４が二枚の金属外皮２，３の間に充填されてサンドイッチパネルとして形成されている。パネル１は正面視で略矩形板状に形成されている。パネル１の長手方向と平行な一端部には嵌合凹部５が略全長にわたって設けられている。またパネル１の上記一端部の表面には嵌合凹部５に沿って凹段部６が略全長にわたって設けられている。パネル１の長手方向と平行な他端部（上記一端部と反対側の端部）には嵌合凸部７が略全長にわたって設けられている。隣接して配設されるパネル１は嵌合凹部５と嵌合凸部７との嵌合により接続することができ、接続強度を高めることができる。またパネル１の上記他端部の表面には覆い片８が略全長にわたって設けられている。パネル１は横張りと縦張りの両方に用いることができる。横張りの場合、図１Ｂのように、水平方向（横方向）に長くなるようにパネル１が施工される。縦張りの場合、図１Ｃのように、鉛直方向（縦方向）に長くなるようにパネル１が施工される。 (Embodiment 1)
FIG. 1A shows an example of the panel 1 manufactured in this embodiment. The panel 1 includes two metal outer skins 2 and 3 and a core material 4, and the core material 4 is filled between the two metal outer skins 2 and 3 to form a sandwich panel. The panel 1 is formed in a substantially rectangular plate shape when viewed from the front. A fitting recess 5 is provided at one end parallel to the longitudinal direction of the panel 1 over substantially the entire length. Further, on the surface of the one end portion of the panel 1, a concave step portion 6 is provided along a fitting recess 5 over substantially the entire length. A fitting convex portion 7 is provided over substantially the entire length at the other end portion parallel to the longitudinal direction of the panel 1 (the end portion opposite to the one end portion). The panels 1 arranged adjacent to each other can be connected by fitting the fitting concave portion 5 and the fitting convex portion 7, and the connection strength can be increased. Further, a covering piece 8 is provided on the surface of the other end of the panel 1 over substantially the entire length. Panel 1 can be used for both horizontal and vertical installation. In the case of horizontal tension, as shown in FIG. 1B, the panel 1 is constructed so as to be elongated in the horizontal direction (horizontal direction). In the case of vertical tension, as shown in FIG. 1C, the panel 1 is constructed so as to be elongated in the vertical direction (vertical direction).

金属外皮２，３は、従来から建材を形成する際に使用される金属板を所定の形状に成形したものであり、例えば、鋼板、亜鉛めっき鋼板、ガルバリウム鋼板（登録商標）、エスジーエル鋼板（登録商標）、塗装鋼板などを挙げることができる。金属外皮２，３の板厚も特に限定は無く、例えば、０．３〜２．０ｍｍとすることができる。 The metal outer skins 2 and 3 are formed by molding a metal plate conventionally used for forming a building material into a predetermined shape. For example, a steel plate, a galvanized steel plate, a galvanized steel plate (registered trademark), and an SGL steel plate (registered). Trademark), painted steel sheet, etc. can be mentioned. The plate thickness of the metal outer skins 2 and 3 is also not particularly limited, and may be, for example, 0.3 to 2.0 mm.

芯材４としては断熱性を有するものが好ましく、さらに防火性や耐火性を有するものであることが好ましい。具体的には、芯材４としてはロックウールやグラスウールなどの無機繊維体や、ウレタンフォームやフェノールフォームなどの樹脂発泡体、石膏ボード等を用いることができる。芯材４はその断熱性やパネル強度等を考慮して、厚み２０〜１５０ｍｍ、２０〜２００ｋｇ／ｍ^３にするのが好ましいが、これに限定されるものではない。芯材４は複数のブロック材４１を並設して形成されている。また、芯材４はパネル１の厚み方向（金属外皮２と３が対向する方向）に複数の層が積層されて形成されていても良い。この場合、異なる材料で形成される複数の層が積層されて芯材４が形成されていても良い。例えば、石膏ボードからなる層と樹脂発泡体からなる層とが積層されて芯材４が形成されていたり、無機繊維体からなる層と樹脂発泡体からなる層とが積層されて芯材４が形成されていても良い。また、パネル１の周端部には、上記無機繊維体や樹脂発泡体よりも耐火性の高い材料で形成された耐火芯材が設けられていることが好ましく、この場合、耐火芯材は、例えば、石膏や珪酸カルシウムなどの無機材料などで形成されていることが好ましい。尚、ブロック材４１も芯材４と同材料で形成される。 The core material 4 is preferably one having heat insulating properties, and more preferably one having fire resistance or fire resistance. Specifically, as the core material 4, inorganic fibers such as rock wool and glass wool, resin foams such as urethane foam and phenol foam, gypsum board and the like can be used. The core material 4 is preferably, but is not limited to, having a thickness of 20 to 150 mm, 20 to 200 kg / m ^{3, in consideration of its heat insulating property, panel strength, and the like.} The core material 4 is formed by arranging a plurality of block materials 41 in parallel. Further, the core material 4 may be formed by laminating a plurality of layers in the thickness direction of the panel 1 (the direction in which the metal outer skins 2 and 3 face each other). In this case, the core material 4 may be formed by laminating a plurality of layers formed of different materials. For example, a layer made of gypsum board and a layer made of a resin foam are laminated to form a core material 4, or a layer made of an inorganic fiber body and a layer made of a resin foam are laminated to form a core material 4. It may be formed. Further, it is preferable that the peripheral end portion of the panel 1 is provided with a refractory core material formed of a material having higher fire resistance than the inorganic fiber body or the resin foam, and in this case, the refractory core material is For example, it is preferably formed of an inorganic material such as gypsum or calcium silicate. The block material 41 is also made of the same material as the core material 4.

芯材４と一方の金属外皮２とは、硬化した接着剤２４を介してほとんど隙間なく密着して接着されている。また、芯材４と他方の金属外皮３とは、硬化した接着剤２５を介してほとんど隙間なく密着して接着されている。従って、芯材４と金属外皮２，３とは強固に接着されており、芯材４の表面から剥離しにくくなっている。 The core material 4 and one of the metal outer skins 2 are adhered to each other with almost no gaps via the cured adhesive 24. Further, the core material 4 and the other metal outer skin 3 are adhered to each other with almost no gap via the cured adhesive 25. Therefore, the core material 4 and the metal outer skins 2 and 3 are firmly adhered to each other, making it difficult to peel off from the surface of the core material 4.

以下に、上記のパネル１の製造方法の一例を説明する。 An example of the manufacturing method of the above panel 1 will be described below.

ロール成形等により平板状の金属板から所定の形状の金属外皮２、３が形成される。一方の金属外皮２はパネル１の表面を構成するものであり、上端部には凹部形成片９や凹段部６が形成され、下端部には覆い片８や凸部形成片１０が形成される。他方の金属外皮３はパネル１の裏面を構成するものであり、上端部には凹部形成片３０が形成され、下端部には凸部形成片２３が形成される。凹部形成片９と凹段部６と覆い片８と凸部形成片１０以外の部分において、金属外皮２の表面及び裏面は平坦な面に形成されている。また、凹部形成片３０と凸部形成片２３以外の部分において、金属外皮３の表面及び裏面は平坦な面に形成されている。 A metal outer skin 2 or 3 having a predetermined shape is formed from a flat metal plate by roll molding or the like. On the other hand, the metal outer skin 2 constitutes the surface of the panel 1, and the concave portion forming piece 9 and the concave step portion 6 are formed at the upper end portion, and the covering piece 8 and the convex portion forming piece 10 are formed at the lower end portion. To. The other metal outer skin 3 constitutes the back surface of the panel 1, and a concave portion forming piece 30 is formed at the upper end portion and a convex portion forming piece 23 is formed at the lower end portion. The front surface and the back surface of the metal outer skin 2 are formed on a flat surface in a portion other than the concave portion forming piece 9, the concave step portion 6, the covering piece 8, and the convex portion forming piece 10. Further, in the portion other than the concave portion forming piece 30 and the convex portion forming piece 23, the front surface and the back surface of the metal outer skin 3 are formed on a flat surface.

図２Ａのように、芯材４は複数のブロック材４１を組合せて板状に形成される。ブロック材４１は端面が正方形や長方形の角材のような形状に形成されている。複数のブロック材４１は平面視において縦横に並べて配置される。この場合、上端部及び下端部を除いて、各ブロック材４１は長手方向が同じ方向に向いて揃うように配置されるのが好ましい。また複数のブロック材４１は総て同じ厚さであることが好ましく、これにより、隣接する二つのブロック材４１の間に段差が生じにくく、芯材４の表面の平坦の度合いが向上しやすい。また図２Ｂのように、ブロック材４１はその周囲に隣接する他のブロック材４１と端面同士や側面同士が接着される。これにより、隣接するブロック材４１に隙間４２が生じたとしても、その隙間４２に接着剤４３が充填されやすくなり、芯材４の表面に隙間４２による凹みが生じにくく、芯材４の表面の平坦の度合いが向上しやすい。接着剤４３としては、例えば、ホットメルト接着剤が用いられるが、これに限定されるものではない。 As shown in FIG. 2A, the core material 4 is formed in a plate shape by combining a plurality of block materials 41. The end face of the block member 41 is formed in a shape like a square lumber or a rectangular lumber. The plurality of block members 41 are arranged vertically and horizontally in a plan view. In this case, except for the upper end portion and the lower end portion, it is preferable that the block members 41 are arranged so that the longitudinal directions are oriented in the same direction and aligned. Further, it is preferable that the plurality of block materials 41 all have the same thickness, so that a step is unlikely to occur between the two adjacent block materials 41, and the degree of flatness of the surface of the core material 4 is likely to be improved. Further, as shown in FIG. 2B, the block material 41 is adhered to other block materials 41 adjacent to the block material 41 so that the end faces and the side surfaces thereof are adhered to each other. As a result, even if a gap 42 is formed in the adjacent block material 41, the adhesive 43 is easily filled in the gap 42, the surface of the core material 4 is less likely to be dented by the gap 42, and the surface of the core material 4 is not easily dented. The degree of flatness tends to improve. As the adhesive 43, for example, a hot melt adhesive is used, but the adhesive is not limited to this.

またブロック材４１は他のブロック材４１に隣接されるときに、多少、圧縮されながら配置される。これにより、圧縮されているブロック材４１は、他のブロック材４１に隣接された後、圧縮力が解除されることで圧縮前の大きさに復元することになる。従って、隣接するブロック材４１が密着しやすくなって、隣接するブロック材４１に隙間４２が生じにくくなり、芯材４の表面に隙間４２による凹みが生じにくく、芯材４の表面の平坦の度合いが向上しやすい。 Further, when the block material 41 is adjacent to another block material 41, the block material 41 is arranged while being compressed to some extent. As a result, the compressed block material 41 is restored to the size before compression by releasing the compressive force after being adjacent to the other block material 41. Therefore, the adjacent block materials 41 are easily brought into close contact with each other, gaps 42 are less likely to occur in the adjacent block materials 41, dents due to the gaps 42 are less likely to occur on the surface of the core material 4, and the degree of flatness of the surface of the core material 4 Is easy to improve.

また複数のブロック材４１は平面視において千鳥配置される。すなわち、平面視（パネル１の平面と直交する方向から見た場合）において、複数のブロック材４１が長手方向と略平行に並べられた一列のブロック材列４４と、これとは別の一列のブロック材列４５とが隣接して配置された場合に、一方のブロック材列４４におけるブロック材４１の端面同士の突き合わせ４６の位置と、他方のブロック材列４５におけるブロック材４１の端面同士の突き合わせ４７の位置とがずれているように配置される。これにより、芯材４におけるブロック材４１の端面同士の突き合わせ４６，４７の位置がばらついて、一直線上に並びにくくなり、芯材４の曲げ強度の低下が生じにくくなる。複数のブロック材４１の端面同士の突き合わせ４６，４７の位置が、一直線上に並んでいると、工事中などのパネル１の持ち運びの際、曲げ強度の低下によってパネル１に許容以上の撓みが発生し、金属外皮２，３の接着面と芯材４の接着面との剥離が生じやすく、パネル１の外観を損ねやすい。一方、複数のブロック材４１が千鳥に配置されると、芯材４の曲げ強度の低下が生じにくくなり、これに伴って、パネル１に撓みが生じにくくなり、金属外皮２，３の接着面と芯材４の接着面との剥離が生じにくくなって、パネル１の外観が損なわれにくい。尚、複数のブロック材４１を千鳥配置にするために、段付きプッシャーが好適に用いられる。段付きプッシャーは、長さの異なる複数のプッシャー部を有し、複数のブロック材４１を複数のプッシャー部で同時に押して千鳥配置にするものである。 Further, the plurality of block members 41 are staggered in a plan view. That is, in a plan view (when viewed from a direction orthogonal to the plane of the panel 1), a row of block members 44 in which a plurality of block members 41 are arranged substantially parallel to the longitudinal direction, and another row of block members 41. When the block material row 45 is arranged adjacent to each other, the position of the end faces of the block material 41 in one block material row 44 and the end faces of the block material 41 in the other block material row 45 are butted against each other. It is arranged so as to be offset from the position of 47. As a result, the positions of the abutments 46 and 47 of the end faces of the block material 41 in the core material 4 are scattered, and it becomes difficult to line up in a straight line, and the bending strength of the core material 4 is less likely to decrease. If the positions of the abutments 46 and 47 of the end faces of the plurality of block members 41 are aligned in a straight line, the panel 1 will be bent more than allowed due to a decrease in bending strength when the panel 1 is carried during construction or the like. However, the adhesive surfaces of the metal outer skins 2 and 3 and the adhesive surface of the core material 4 are likely to be peeled off, and the appearance of the panel 1 is likely to be spoiled. On the other hand, when the plurality of block materials 41 are arranged in a staggered manner, the bending strength of the core material 4 is less likely to decrease, and accordingly, the panel 1 is less likely to bend, and the adhesive surfaces of the metal outer skins 2 and 3 are less likely to occur. The peeling between the core material 4 and the adhesive surface of the core material 4 is less likely to occur, and the appearance of the panel 1 is less likely to be impaired. A stepped pusher is preferably used in order to arrange the plurality of block materials 41 in a staggered manner. The stepped pusher has a plurality of pusher portions having different lengths, and the plurality of block members 41 are simultaneously pushed by the plurality of pusher portions to form a staggered arrangement.

また、隣接する二つのブロック材４１は長手方向の端面同士が突き合わされるが、端面同士の接着面積を大きくすることで接着力を向上させるために、その端面は各種の形状に形成される。これにより、隣接する二つのブロック材４１の端面が互いにズレにくくなり、隣接する二つのブロック材４１の間に更に段差が生じにくく、芯材４の表面の平坦の度合いが向上しやすい。例えば、図３Ａのように、ブロック材４１は端部が長手方向と垂直に切断されて、端面が正方形や長方形に形成されている。また図３Ｂのように、ブロック材４１は端部が長手方向に対して斜めに切断されて、端面が菱形や平行四辺形に形成されていてもよい。また図３Ｃのように、ブロック材４１は端部に実部４８が形成されていてもよい。実部４８が形成されたブロック材４１は、相じゃくりにより、隣接する他のブロック材４１と接合可能である。 Further, the two adjacent block members 41 are abutted against each other in the longitudinal direction, and the end faces are formed into various shapes in order to improve the adhesive force by increasing the adhesive area between the end faces. As a result, the end faces of the two adjacent block members 41 are less likely to be displaced from each other, a step is less likely to occur between the two adjacent block members 41, and the degree of flatness of the surface of the core member 4 is likely to be improved. For example, as shown in FIG. 3A, the end portion of the block member 41 is cut perpendicularly to the longitudinal direction, and the end face is formed into a square or a rectangle. Further, as shown in FIG. 3B, the end portion of the block member 41 may be cut diagonally with respect to the longitudinal direction, and the end surface may be formed in a rhombus shape or a parallelogram shape. Further, as shown in FIG. 3C, the block material 41 may have a real portion 48 formed at an end portion thereof. The block material 41 on which the real portion 48 is formed can be joined to another adjacent block material 41 by interleaving.

また芯材４の接着面となる表面は、ブロック材４１を製造する際の切断面で形成されることが好ましい。例えば、原板から複数のブロック材４１を切り出した後、ブロック材４１を長手方向を軸として９０°回転させる。尚、芯材４としてロックウールやグラスウールなどの無機繊維体を用いる場合は、ブロック材４１を長手方向を軸として９０°回転させるが、芯材４として樹脂発泡体や石膏ボード等を用いる場合は、ブロック材４１を長手方向を軸として９０°回転させる必要がない。そして、この状態で複数のブロック材４１を組み合わせることにより、芯材４の接着面となる表面は、ブロック材４１の切断面で形成される。ブロック材４１の切断面は凹凸が少ないため、芯材４の接着面となる表面の凹凸が少なくなる。特に、ギャングソーと称される切断装置が用いられるのが好ましく、これにより、ブロック材４１の切断面の凹凸が非常に小さくなる。 Further, the surface to be the adhesive surface of the core material 4 is preferably formed by the cut surface when the block material 41 is manufactured. For example, after cutting out a plurality of block members 41 from the original plate, the block members 41 are rotated by 90 ° about the longitudinal direction. When an inorganic fiber such as rock wool or glass wool is used as the core material 4, the block material 41 is rotated by 90 ° about the longitudinal direction, but when a resin foam or gypsum board is used as the core material 4, the block material 41 is rotated by 90 °. , It is not necessary to rotate the block material 41 by 90 ° about the longitudinal direction. Then, by combining the plurality of block materials 41 in this state, the surface to be the adhesive surface of the core material 4 is formed by the cut surface of the block material 41. Since the cut surface of the block material 41 has few irregularities, the irregularities on the surface serving as the adhesive surface of the core material 4 are reduced. In particular, it is preferable to use a cutting device called a gang saw, which makes the unevenness of the cut surface of the block material 41 very small.

また図４のように、隣接するブロック材４１の間には幅調整材４９を設けることが好ましい。標準的な幅寸法以外のパネル１を生産する際、余幅の箇所に幅調整材４９を挿入することにより、芯材４に空隙部分をなくすことができ、パネル１の表面の平坦度が向上しやすい。幅調整材４９は芯材４やブロック材４１と同じ材料で形成されるものであるが、幅調整材４９の幅寸法（ブロック材４１の長手方向と直交する方向の寸法）はブロック材４１の幅寸法よりも短い。また幅調整材４９はブロック材４１と同じ厚みであることが好ましい。これにより、ブロック材４１と幅調整材４９との間に段差が生じにくく、芯材４の表面の平坦の度合いが向上しやすい。尚、ブロック材４１と幅調整材４９とは隣接する端面同士が接着されるのが好ましい。 Further, as shown in FIG. 4, it is preferable to provide the width adjusting member 49 between the adjacent block members 41. When producing a panel 1 other than the standard width dimension, by inserting the width adjusting material 49 in the extra width portion, the gap portion can be eliminated in the core material 4, and the flatness of the surface of the panel 1 is improved. It's easy to do. The width adjusting material 49 is formed of the same material as the core material 4 and the block material 41, but the width dimension of the width adjusting material 49 (the dimension in the direction orthogonal to the longitudinal direction of the block material 41) is that of the block material 41. Shorter than the width dimension. Further, the width adjusting material 49 preferably has the same thickness as the block material 41. As a result, a step is less likely to occur between the block material 41 and the width adjusting material 49, and the degree of flatness of the surface of the core material 4 is likely to be improved. It is preferable that the end faces of the block material 41 and the width adjusting material 49 are adhered to each other.

また芯材４の表面は切削（サンディング）されることが好ましい。これにより、隣接する二つのブロック材４１の間に段差が生じにくく、芯材４の表面の平坦の度合いが向上しやすい。尚、芯材４が複数のブロック材４１で形成されずに、一枚物の板材である場合も、芯材４の表面は切削されることが好ましい。これにより、芯材４の表面の凸が切削されて芯材４の表面の凹凸が少なくなり、芯材４の表面の平坦の度合いが向上しやすい。芯材４の表面の平坦の度合いは、凹の部分と凸の部分の高さの差が最大で３ｍｍ以下であることが好ましく、多くの場合０．１〜０．２ｍｍ程度である。 Further, it is preferable that the surface of the core material 4 is cut (sanded). As a result, a step is unlikely to occur between the two adjacent block members 41, and the degree of flatness of the surface of the core member 4 is likely to be improved. Even when the core material 4 is not formed of the plurality of block materials 41 and is a single plate material, it is preferable that the surface of the core material 4 is cut. As a result, the convexity of the surface of the core material 4 is cut, the unevenness of the surface of the core material 4 is reduced, and the degree of flatness of the surface of the core material 4 is likely to be improved. The degree of flatness of the surface of the core material 4 is preferably such that the difference in height between the concave portion and the convex portion is 3 mm or less at the maximum, and in most cases, it is about 0.1 to 0.2 mm.

また芯材４の表面は除塵されることが好ましい。これにより、芯材４の表面に付着している切り粉（切断加工時に生じる粉塵）が除去されて、芯材４の表面の平坦の度合いが向上しやすい。また切り粉による金属外皮２，３への傷つきも少なくなる。 Further, it is preferable that the surface of the core material 4 is dust-removed. As a result, chips (dust generated during the cutting process) adhering to the surface of the core material 4 are removed, and the degree of flatness of the surface of the core material 4 is likely to be improved. In addition, the damage to the metal outer skins 2 and 3 due to chips is reduced.

また、金属外皮２，３と芯材４を挟み込む形式で押さえローラーを使用することが好ましい。これにより芯材４の表面の段差を低減するとともに、金属外皮２，３と芯材４の接着を確実なものにしやすい。 Further, it is preferable to use the pressing roller in a form of sandwiching the metal outer skins 2 and 3 and the core material 4. As a result, it is easy to reduce the step on the surface of the core material 4 and to ensure the adhesion between the metal outer skins 2 and 3 and the core material 4.

次に、金属外皮２の芯材４と接着する方の面に未硬化の接着剤２４が塗布される。また金属外皮３の芯材４と接着する方の面に未硬化の接着剤２５が塗布される。未硬化の接着剤２４、２５としてはウレタン系接着剤、フェノール系接着剤、エポキシ系接着剤などが挙げられる。接着剤２４、２５の塗布量は、例えば、５０〜４００ｇ／ｍ^２とすることができる。ここで、芯材４の表面と金属外皮２，３とを接着するための接着剤２４，２５は、粘性が低くて広がりやすく濡れ性を向上させたものであることが好ましい。これにより、芯材４の表面に多少凹凸があっても、接着剤２４，２５が広がりやすくなり、金属外皮２，３と芯材４の表面との間に接着剤２４，２５が介在しない部分が少なくなる。また図５のように、隣接する二つのブロック材４１の間に隙間４２があっても、接着剤２４、２５で隙間４２が埋められやすくなり、金属外皮２，３と芯材４の表面との間に接着剤２４，２５が介在しない部分が少なくなる。従って、金属外皮２，３と芯材４の表面とが全面にわたって接着剤２４，２５で接着されやすくなって、金属外皮２，３と芯材４との接着剥離を生じにくくなる。 Next, the uncured adhesive 24 is applied to the surface of the metal outer skin 2 that adheres to the core material 4. Further, the uncured adhesive 25 is applied to the surface of the metal outer skin 3 that adheres to the core material 4. Examples of the uncured adhesives 24 and 25 include urethane-based adhesives, phenol-based adhesives, and epoxy-based adhesives. The amount of the adhesives 24 and 25 applied can be, for example, 50 to 400 g / m ² . Here, the adhesives 24 and 25 for adhering the surface of the core material 4 and the metal outer skins 2 and 3 are preferably those having low viscosity, easy to spread, and improved wettability. As a result, even if the surface of the core material 4 is slightly uneven, the adhesives 24 and 25 can easily spread, and the adhesives 24 and 25 do not intervene between the metal outer skins 2 and 3 and the surface of the core material 4. Is reduced. Further, as shown in FIG. 5, even if there is a gap 42 between two adjacent block materials 41, the gap 42 can be easily filled with the adhesives 24 and 25, and the metal outer skins 2 and 3 and the surface of the core material 4 There are fewer parts where the adhesives 24 and 25 do not intervene between the two. Therefore, the metal outer skins 2 and 3 and the surface of the core material 4 are easily adhered with the adhesives 24 and 25 over the entire surface, and the adhesion peeling between the metal outer skins 2 and 3 and the core material 4 is less likely to occur.

粘性が低い（低粘度）接着剤２４，２５は、温度２０℃（液温２０℃）で２０００ＭＰａ・ｓ以下であることが好ましい。接着剤２４、２５の粘度の測定は、ＪＩＳＺ８８１３（単一円筒形回転粘度計による粘度測定方法）を用いることができる。接着剤２４，２５は、温度２０℃（液温２０℃）で２００ＭＰａ・ｓ以上の粘度を有することが好ましい。これよりも粘度が低すぎると低粘度過ぎて塗布しにくくなるなどの取り扱い性が低下しやすくなる。 The low-viscosity (low-viscosity) adhesives 24 and 25 are preferably 2000 MPa · s or less at a temperature of 20 ° C. (liquid temperature 20 ° C.). JIS Z 8813 (a method for measuring the viscosity with a single cylindrical rotational viscometer) can be used for measuring the viscosities of the adhesives 24 and 25. The adhesives 24 and 25 preferably have a viscosity of 200 MPa · s or more at a temperature of 20 ° C. (liquid temperature 20 ° C.). If the viscosity is too low, the viscosity is too low and it becomes difficult to apply, and the handleability tends to decrease.

濡れ性を向上させた（高濡れ性）接着剤２４，２５は、接触角が９０°以下の親水性域であることが好ましい。接着剤２４、２５の接触角の測定はθ／２法に準じて行うことができる。具体的には、２５℃の空気雰囲気下で、基板（日鉄住金鋼板株式会社製の品番「ニスクカラー（登録商標）ＧＬ」）の表面に、接着剤２４，２５を１５ミリリットル滴下し、これを試料として接触角計で接触角を測定することができる。接着剤２４，２５の接触角は５０°以上であることが好ましい。これよりも接触角が小さいと濡れ性が低すぎて塗布しにくくなるなどの取り扱い性が低下しやすくなる。 The adhesives 24 and 25 having improved wettability (high wettability) preferably have a contact angle of 90 ° or less in a hydrophilic region. The contact angles of the adhesives 24 and 25 can be measured according to the θ / 2 method. Specifically, in an air atmosphere of 25 ° C., 15 ml of adhesives 24 and 25 was dropped on the surface of the substrate (part number "Niskukara (registered trademark) GL" manufactured by Nittetsu Sumikin Steel Co., Ltd.), and this was applied. The contact angle can be measured with a contact angle meter as a sample. The contact angles of the adhesives 24 and 25 are preferably 50 ° or more. If the contact angle is smaller than this, the wettability is too low and it becomes difficult to apply, and the handleability tends to decrease.

また接着剤２４，２５は硬化前に微発泡するものであることが好ましい。このように硬化前に微発泡する樹脂剤２４、２５を用いることにより、硬化後の接着剤２４，２５に空気等の気泡が含まれ、無発泡の接着剤に比べて、体積を増加させることができる。よって、無発泡の接着剤に比べて、隣接する二つのブロック材４１の間に隙間４２があっても、微発泡の接着剤２４、２５で隙間４２が埋められやすくなり、金属外皮２，３と芯材４の表面との間に接着剤２４，２５が介在しない部分が少なくなる。従って、金属外皮２，３と芯材４の表面とが全面にわたって接着剤２４，２５で接着されやすくなって、金属外皮２，３と芯材４との接着剥離を生じにくくなる。ここで、微発泡の接着剤２４，２５は無発泡の接着剤に比べて、発泡倍率が２倍以下のものをいう。微発泡の接着剤２４，２５は無発泡の接着剤２４，２５に発泡剤を配合して調製することができる。微発泡の接着剤２４，２５は、例えば、粗トリレンジイソシアネートなどのポリイソシアネートと、エチレングリコールなどのポリオールと、２−エチルヘキサン酸カリウムなどの三量化触媒と、シクロペンタンやｎ−ペンタンや水などの発泡剤とを混合して調製される。 Further, it is preferable that the adhesives 24 and 25 are slightly foamed before curing. By using the resin agents 24 and 25 that slightly foam before curing in this way, the adhesives 24 and 25 after curing contain air bubbles and the like, and the volume is increased as compared with the non-foaming adhesive. Can be done. Therefore, as compared with the non-foaming adhesive, even if there is a gap 42 between two adjacent block materials 41, the gap 42 is easily filled with the slightly foamed adhesives 24 and 25, and the metal outer skins 2 and 3 are easily filled. There are fewer portions where the adhesives 24 and 25 do not intervene between the core material 4 and the surface of the core material 4. Therefore, the metal outer skins 2 and 3 and the surface of the core material 4 are easily adhered with the adhesives 24 and 25 over the entire surface, and the adhesion peeling between the metal outer skins 2 and 3 and the core material 4 is less likely to occur. Here, the slightly foamed adhesives 24 and 25 have a foaming ratio of 2 times or less as compared with the non-foamed adhesive. The slightly foamed adhesives 24 and 25 can be prepared by blending a foaming agent with the non-foaming adhesives 24 and 25. The slightly foaming adhesives 24 and 25 include, for example, a polyisocyanate such as crude tolylene diisocyanate, a polyol such as ethylene glycol, a trimerization catalyst such as potassium 2-ethylhexanoate, cyclopentane, n-pentane, and water. It is prepared by mixing with a foaming agent such as.

また、接着剤２４、２５の樹脂成分は芯材４を形成する樹脂成分と同種であることが好ましい。例えば、芯材４がポリイソシアヌレートフォームである場合は、接着剤２４、２５の樹脂成分もポリイソシアヌレートであることが好ましい。また、芯材４をフェノールフォームやポリウレタンフォームで形成する場合も、接着剤２４、２５の樹脂成分もフェノールやポリウレタンを用いることが好ましい。このように接着剤２４、２５の樹脂成分と芯材４を形成する樹脂成分とが同種であると、芯材４と接着剤２４，２５とを異種の樹脂成分で形成する場合に比べて、芯材４と接着剤２４，２５との接着性を高くすることができ、金属外皮２，３と芯材４との界面での剥離が生じにくくなる。 Further, the resin components of the adhesives 24 and 25 are preferably the same as the resin components forming the core material 4. For example, when the core material 4 is a polyisocyanurate foam, it is preferable that the resin components of the adhesives 24 and 25 are also polyisocyanurates. Further, when the core material 4 is formed of phenol foam or polyurethane foam, it is preferable to use phenol or polyurethane as the resin component of the adhesives 24 and 25. When the resin components of the adhesives 24 and 25 and the resin components forming the core material 4 are of the same type as described above, the case where the core material 4 and the adhesives 24 and 25 are formed of different resin components is compared with the case where the core material 4 and the adhesives 24 and 25 are formed of different resin components. The adhesiveness between the core material 4 and the adhesives 24 and 25 can be increased, and peeling at the interface between the metal outer skins 2 and 3 and the core material 4 is less likely to occur.

次に、未硬化の接着剤２４を介して一方の金属外皮２と平板状の芯材４の片面とを重ね合わせると共に未硬化の接着剤２５を介して他方の金属外皮３と平板状の芯材４の他の片面とを重ね合わせることによって、金属外皮２，３と芯材４とが積層された積層体２２が形成される。ここで、芯材４の金属外皮２，３と接着される面は、ほとんど凹凸のない平坦面に形成されている。積層体２２では芯材４の片面と金属外皮２とが未硬化の接着剤２４を介して重ねられている。芯材４が、石膏ボードからなる層と、樹脂発泡体や無機繊維体からなる層とが積層されて形成されている場合、樹脂発泡体や無機繊維体からなる層の表面と金属外皮２とが未硬化の接着剤２４を介して重ねられる。 Next, one metal outer skin 2 and one side of the flat plate-shaped core material 4 are overlapped with each other via the uncured adhesive 24, and the other metal outer skin 3 and the flat plate-shaped core are overlapped with each other via the uncured adhesive 25. By superimposing the other one side of the material 4, the laminated body 22 in which the metal outer skins 2 and 3 and the core material 4 are laminated is formed. Here, the surface of the core material 4 to be adhered to the metal outer skins 2 and 3 is formed as a flat surface having almost no unevenness. In the laminated body 22, one side of the core material 4 and the metal outer skin 2 are overlapped with each other via an uncured adhesive 24. When the core material 4 is formed by laminating a layer made of gypsum board and a layer made of a resin foam or an inorganic fiber body, the surface of the layer made of the resin foam or the inorganic fiber body and the metal outer skin 2 are formed. Is layered via the uncured adhesive 24.

次に、積層体２２はプレス機によりプレス（加圧）される。図６に示すように、プレス機１３としては一対の加圧コンベア１４，１５を備えたものを例示することができる。加圧コンベア１４は一対の回転軸１６，１７に無端ループ状にベルト１８を掛け渡すことにより形成されている。ベルト１８は回転軸１６，１７の回転駆動により前進後退自在に形成されている。加圧コンベア１５も一対の回転軸１９，２０に無端ループ状にベルト２１を掛け渡すことにより形成されている。ベルト２１は回転軸１９，２０の回転駆動により前進後退自在に形成されている。加圧コンベア１４と加圧コンベア１５は上下に対向して配置されている。ベルト１８の回転軸１６，１７よりも下側に位置する時の進行方向と、ベルト２１の回転軸１９，２０よりも上側に位置する時の進行方向とが一致している。 Next, the laminate 22 is pressed (pressurized) by a press machine. As shown in FIG. 6, as the press machine 13, a press machine 13 including a pair of pressure conveyors 14 and 15 can be exemplified. The pressure conveyor 14 is formed by hanging a belt 18 on a pair of rotating shafts 16 and 17 in an endless loop shape. The belt 18 is formed so as to be able to move forward and backward by rotationally driving the rotating shafts 16 and 17. The pressure conveyor 15 is also formed by hanging a belt 21 on a pair of rotating shafts 19 and 20 in an endless loop shape. The belt 21 is formed so as to be able to move forward and backward by rotationally driving the rotating shafts 19 and 20. The pressure conveyor 14 and the pressure conveyor 15 are arranged so as to face each other vertically. The traveling direction when the belt 18 is located below the rotating shafts 16 and 17 and the traveling direction when the belt 21 is located above the rotating shafts 19 and 20 coincide with each other.

そして、積層体２２は、加圧コンベア１４のベルト１８と加圧コンベア１５のベルト２１とで上下に挟まれることによりプレスされる。また、プレス時にはベルト１８とベルト２１が進行しており、これにより、積層体２２はベルト１８、２１で略水平に搬送されながらプレスされる。このプレスにより、一方の金属外皮２が未硬化の接着剤２４を介して芯材４の片面に押し付けられ、他方の金属外皮３が未硬化の接着剤２５を介して芯材４の他の片面に密着される。この後、未硬化の接着剤２４，２５が硬化することにより、金属外皮２と芯材４とが硬化した接着剤２４で接着されて一体化されると共に金属外皮３と芯材４とが硬化した接着剤２５で接着されて一体化され、パネル１が形成される。またプレス時及びそれ以降において積層体２２を加温して接着剤２４，２５の硬化を促進してもよい。この場合、発泡剤を含有する接着剤２４，２５であれば、加温により未硬化の接着剤２４，２５が発泡剤で微発泡し、その後、微発泡した接着剤２４，２５が硬化する。また、凹部形成片９と凹部形成片３０とが対向してその間がパネル１の嵌合凹部５として形成される。また、凸部形成片１０と凸部形成片２３との間に芯材４の端部が挟まれてパネル１の嵌合凸部７が形成される。 Then, the laminated body 22 is pressed by being vertically sandwiched between the belt 18 of the pressure conveyor 14 and the belt 21 of the pressure conveyor 15. Further, at the time of pressing, the belt 18 and the belt 21 are in progress, so that the laminated body 22 is pressed while being conveyed substantially horizontally by the belts 18 and 21. By this press, one metal outer skin 2 is pressed against one side of the core material 4 via the uncured adhesive 24, and the other metal outer skin 3 is pressed against one side of the core material 4 via the uncured adhesive 25. Is in close contact with. After that, the uncured adhesives 24 and 25 are cured, so that the metal outer skin 2 and the core material 4 are adhered and integrated with the cured adhesive 24, and the metal outer skin 3 and the core material 4 are cured. The panel 1 is formed by being adhered and integrated with the adhesive 25. Further, the laminate 22 may be heated at the time of pressing and thereafter to accelerate the curing of the adhesives 24 and 25. In this case, if the adhesives 24 and 25 contain a foaming agent, the uncured adhesives 24 and 25 are slightly foamed by the foaming agent by heating, and then the slightly foamed adhesives 24 and 25 are cured. Further, the recess forming piece 9 and the recess forming piece 30 face each other, and a space between them is formed as a fitting recess 5 of the panel 1. Further, the end portion of the core member 4 is sandwiched between the convex portion forming piece 10 and the convex portion forming piece 23, and the fitting convex portion 7 of the panel 1 is formed.

（実施の形態２）
図７Ａのように、実施の形態２は、実施の形態１と対比して、金属外皮２が波板に形成されている点が異なる。すなわち、パネル１の表面には長手方向の略全長にわたって筋状の模様が形成されている。この筋状の模様は、パネル１の表面を構成する一方の金属外皮２が波板で形成されることにより発現されている。パネル１は横張りと縦張りの両方に用いることができる。横張りの場合、図７Ｂのように、上記筋状の模様が水平方向（横方向）に長くなるようにパネル１が施工される。縦張りの場合、図７Ｃのように、上記筋状の模様が鉛直方向（縦方向）に長くなるようにパネル１が施工される。パネル１は、筋状の模様が形成された金属外皮２を屋外側に向けて施工されることが多いが、これに限らず、筋状の模様が形成された金属外皮２を屋内側に向けて施工されることもある。 (Embodiment 2)
As shown in FIG. 7A, the second embodiment is different from the first embodiment in that the metal outer skin 2 is formed on the corrugated iron plate. That is, a streak pattern is formed on the surface of the panel 1 over substantially the entire length in the longitudinal direction. This streaky pattern is expressed by the fact that one of the metal outer skins 2 constituting the surface of the panel 1 is formed of corrugated iron. Panel 1 can be used for both horizontal and vertical installation. In the case of horizontal tension, as shown in FIG. 7B, the panel 1 is constructed so that the streaky pattern becomes longer in the horizontal direction (horizontal direction). In the case of vertical tension, as shown in FIG. 7C, the panel 1 is constructed so that the streak pattern becomes longer in the vertical direction (vertical direction). The panel 1 is often constructed with the metal outer skin 2 having the streak pattern formed facing the outdoor side, but the present invention is not limited to this, and the metal outer skin 2 having the streak pattern formed is directed toward the indoor side. It may be constructed.

金属外皮２はエンボス加工やリブ加工等により波板に形成される。波板の金属外皮２の断面形状は、図８に示すように、複数の山部１１と複数の谷部１２とが上下方向に交互に並ぶように形成されている。隣り合う山部１１、１１の間隔（ピッチ）Ｐと隣り合う谷部１２、１２の間隔（ピッチ）Ｐは、例えば、６〜６０ｍｍに形成されている。また山部１１の高さ（谷部１２の深さ）Ｈは、例えば、０．５〜３ｍｍに形成されている。好ましくは、間隔Ｐは１５〜４０ｍｍ、高さＨは０．６〜１．５ｍｍに形成され、最も好ましくは、間隔Ｐは２３〜２５ｍｍ、高さＨは０．７〜０．９ｍｍに形成される。山部１１の頂部や谷部１２の底部は鈍角に形成されるが、鋭角に形成されていてもよく、また曲面に形成されていても良い。このような金属外皮２は芯材４と接着される面が凹凸面２６に形成されている。尚、嵌合凹部５及び凹段部６はパネル１の一方の側端部に形成され、嵌合凸部７及び覆い片８がパネルの他方の側端部に形成されていても良い。また、この場合、筋状の模様は縦方向に長く形成されている。他の金属外皮３、芯材４、接着剤２４，２５は実施の形態１と同様に形成されている。 The metal outer skin 2 is formed on a corrugated plate by embossing, rib processing, or the like. As shown in FIG. 8, the cross-sectional shape of the metal outer skin 2 of the corrugated sheet is formed so that a plurality of peaks 11 and a plurality of valleys 12 are alternately arranged in the vertical direction. The distance (pitch) P between the adjacent peaks 11 and 11 and the distance (pitch) P between the adjacent valleys 12 and 12 are formed to be, for example, 6 to 60 mm. Further, the height H of the mountain portion 11 (depth of the valley portion 12) H is formed to be, for example, 0.5 to 3 mm. Preferably, the spacing P is formed at 15-40 mm and the height H is formed at 0.6-1.5 mm, and most preferably the spacing P is formed at 23-25 mm and the height H is formed at 0.7-0.9 mm. To. The top of the mountain portion 11 and the bottom of the valley portion 12 are formed at an obtuse angle, but may be formed at an acute angle or may be formed on a curved surface. In such a metal outer skin 2, the surface to be adhered to the core material 4 is formed on the uneven surface 26. The fitting concave portion 5 and the concave step portion 6 may be formed on one side end portion of the panel 1, and the fitting convex portion 7 and the covering piece 8 may be formed on the other side end portion of the panel. Further, in this case, the streak pattern is formed long in the vertical direction. The other metal outer skin 3, the core material 4, and the adhesives 24 and 25 are formed in the same manner as in the first embodiment.

金属外皮２には、凹凸面２６の凹部２７に充填材２８が充填されている。これにより、金属外皮２の芯材４と接着される側の面を平坦化することができる。充填材２８は微発泡の接着剤２４，２５と同様なものであって、例えば、発泡倍率２倍以下の微発泡ウレタン系接着剤などを硬化させて形成される。金属外皮２は充填材２８が充填された後、実施の形態１と同様にして芯材４と接着される。そして、充填材２８を用いることにより、接着剤２４が凹部２７に入りにくくなり、接着剤２４が金属外皮２と芯材４の表面との間に略均一に介在されることになり、接着２４が不足する箇所が少なくなり、金属外皮２，３と芯材４との接着剥離を生じにくくなる。 The metal outer skin 2 is filled with a filler 28 in the recesses 27 of the uneven surface 26. As a result, the surface of the metal outer skin 2 on the side to be adhered to the core material 4 can be flattened. The filler 28 is similar to the slightly foamed adhesives 24 and 25, and is formed by curing, for example, a slightly foamed urethane-based adhesive having a foaming ratio of 2 times or less. After the filler 28 is filled, the metal outer skin 2 is adhered to the core material 4 in the same manner as in the first embodiment. Then, by using the filler 28, the adhesive 24 is less likely to enter the recess 27, and the adhesive 24 is interposed between the metal outer skin 2 and the surface of the core material 4 substantially uniformly, so that the adhesive 24 is bonded. There are few places where there is a shortage, and it becomes difficult for the metal outer skins 2 and 3 to peel off from the core material 4.

１パネル
２金属外皮
３金属外皮
４芯材
２４接着剤
２５接着剤
２７凹部
２８充填材
４１ブロック材
４３接着剤 1 Panel 2 Metal husk 3 Metal husk 4 Core material 24 Adhesive 25 Adhesive 27 Recess 28 Filler 41 Block material 43 Adhesive

Claims

It is a method of manufacturing a panel that adheres a metal outer skin to the surface of the core material.
The core material is formed by arranging a plurality of block materials in the longitudinal direction and the lateral direction and combining them in a staggered arrangement.
An adhesive is provided in the gap between the adjacent block materials, and the opposing end faces of the adjacent block materials are adhered to each other in the longitudinal direction.
The core is flattened by cutting so that the degree of flatness of the surface of the core material is 3 mm or less at the maximum due to the difference in height between the concave portion and the convex portion. The adhesive surface of the material with the metal outer skin is flattened,
The surface of the core material before being adhered to the metal outer skin is dust-removed.
The adhesive that adheres the metal outer skin to the surface of the core material slightly foams at a foaming ratio of 2 times or less, has a viscosity of 200 MPa · s or more and 2000 MPa · s or less at a temperature of 20 ° C., and has a contact angle of 90 ° or less. Yes,
The gap between the adjacent block materials is filled with the adhesive that adheres the metal outer skin to the surface of the core material.
A method of manufacturing a panel, which is characterized in that.

The method for manufacturing a panel according to claim 1, wherein the adjacent block material is crimped.

The method for manufacturing a panel according to claim 1 or 2, wherein the cut surface of the block material is adhered to the metal outer skin.

The method for manufacturing a panel according to any one of claims 1 to 3, wherein the adjacent block materials are butted against each other.

The method for manufacturing a panel according to any one of claims 1 to 4, wherein the recesses existing in the adhesive surface of the metal outer skin with the core material are filled with a filler . Production method.

The method for manufacturing a panel according to any one of claims 1 to 5, wherein the metal outer skin and the core material are crimped with a pressing roller .

It is a method of manufacturing a panel that adheres a metal outer skin to the surface of the core material.
The core material is formed by arranging a plurality of block materials in the longitudinal direction and the lateral direction in a staggered manner and combining the plurality of block materials and an adjusting member.
An adhesive is provided in the gap between the adjacent block materials, and the opposing end faces of the adjacent block materials are adhered to each other in the longitudinal direction.
The adjusting member is provided between the adjacent block members and is provided.
The core is flattened by cutting so that the degree of flatness of the surface of the core material is 3 mm or less at the maximum due to the difference in height between the concave portion and the convex portion. The adhesive surface of the material with the metal outer skin is flattened,
The surface of the core material before being adhered to the metal outer skin is dust-removed.
The adhesive that adheres the metal outer skin to the surface of the core material slightly foams at a foaming ratio of 2 times or less, has a viscosity of 200 MPa · s or more and 2000 MPa · s or less at a temperature of 20 ° C., and has a contact angle of 90 ° or less. Yes,
The gap between the adjacent block materials is filled with the adhesive that adheres the metal outer skin to the surface of the core material.
A method of manufacturing a panel, which is characterized in that.

In the method for manufacturing a panel according to any one of claims 1 to 7, the resin component of the adhesive that adheres the metal outer skin to the surface of the core material is the same as the resin component that forms the core material. A method of manufacturing a panel, which is characterized in that.