JP7748236B2 - Cutting tool and cutting method - Google Patents

Description

The present disclosure relates to a cutting tool and a cutting method, and more particularly to a cutting tool used to cut a portion of insulation material and a cutting method using the cutting tool.

Patent Document 1 describes a vacuum insulation material. This vacuum insulation material comprises a core material and an outer covering material that encases the core material. The core material is formed by laminating one or more dry glass wool sheets sandwiched between wet glass wool sheets. The core material is formed by leaving the corners of one or more of the glass wool sheets untouched and cutting the corners of the remaining glass wool sheets in the thickness direction.

JP 2012-159144 A

As described in Patent Document 1, there was a need for a tool that would make it easier to perform the work when cutting off a portion of insulation.

The present disclosure aims to provide a cutting tool that makes it easy to remove a portion of insulation, and a cutting method using this cutting tool.

The excision tool according to one aspect of the present disclosure is used to excise a portion of insulating material. It includes an insertion portion that is inserted into the insulating material, and a clamping portion that clamps the portion of the insulating material between the insertion portion and the clamping portion.

A cutting method according to one aspect of the present disclosure is a method of cutting off a portion of the insulating material using the cutting tool. After inserting the insertion portion into the insulating material, the portion of the insulating material is clamped between the insertion portion and the clamping portion, and with the portion of the insulating material clamped between the insertion portion and the clamping portion, the portion of the insulating material is pulled away from the remaining portion.

This disclosure has the advantage of making it easier to remove a portion of the insulation.

1A is a plan view, a side view, and a front view of the resection tool according to the present embodiment. 2A and 2B are side views showing a method of using the excision tool according to this embodiment. FIG. 3 is a perspective view showing an example of a panel. FIG. 4 is an enlarged perspective view showing a corner of the panel, in which the sealant and other materials filled in the corner are omitted. FIG. 5 is a perspective view showing a corner member provided on the panel. 6A and 6B are perspective views sequentially showing the steps of sealing the corners of the panel. 7A to 7C are perspective views sequentially showing the process of sealing the corners of the panel. 8A and 8B are perspective views sequentially showing the steps of sealing the corners of the panel.

(Embodiment 1)
(1) Overview The excision tool 8 according to this embodiment is used to excise a portion of the thermal insulation material 2. This excision tool 8 includes an insertion portion 81 that is inserted into the thermal insulation material 2, and a clamping portion 82 that clamps a portion of the thermal insulation material 2 between the insertion portion 81 and the clamping portion 82. A method for excising a portion of the thermal insulation material 2 using this excision tool 8 involves inserting the insertion portion 81 into the thermal insulation material 2, clamping a portion of the thermal insulation material 2 between the insertion portion 81 and the clamping portion 82, and then, with the portion of the thermal insulation material 2 clamped between the insertion portion 81 and the clamping portion 82, separating the portion of the thermal insulation material 2 from the rest of the thermal insulation material 2.

The cutting tool 8 can be used to insert the insertion portion 81 into the insulation material 2 to cut a portion of the insulation material 2 from the rest of the material. With the cut portion of the insulation material 2 clamped between the insertion portion 81 and the clamping portion 82, the portion of the insulation material 2 can be pulled away from the rest of the material, making it easy to cut off a portion of the insulation material 2.

(2) Details (2.1) Configuration As shown in Figures 1A to 1C, the resection tool 8 according to this embodiment is formed to include a fixed member 91, a movable member 92, an elastic member 93, and a gripping member 94. The fixed member 91, the movable member 92, and the elastic member 93 are formed of metal members such as stainless steel, and the gripping member 94 is formed of a resin member such as plastic. Each component will be described below using the directions shown in Figures 1A to 1C.

The fixing member 91 is formed by bending a metal plate such as a stainless steel plate. The fixing member 91 includes a fixing portion 911 and an insertion portion 81. The fixing portion 911 is formed in the shape of a rectangular plate extending in the front-to-rear direction. The fixing portion 911 has a pair of slits 912. Each slit 912 extends in the front-to-rear direction and penetrates the fixing portion 911 in the up-down direction (thickness direction). The slits 912 are parallel to each other and lined up in the left-to-right direction.

The insertion portion 81 is formed to protrude downward from the front end of the fixed portion 911. The angle between the fixed portion 911 and the insertion portion 81 is approximately a right angle. The insertion portion 81 is formed in the shape of a rectangular plate extending in the vertical direction. Guide pieces 811 are provided on both the left and right ends of the insertion portion 81. The guide pieces 811 protrude diagonally forward from each of the left and right ends of the insertion portion 81. Each guide piece 811 is formed over approximately the entire length of the insertion portion 81 in the vertical direction. A blade portion 83 is provided at the tip (lower end) of the insertion portion 81. The blade portion 83 protrudes downward from the tip of the insertion portion 81. The thickness of the blade portion 83 is formed to be thinner than the thickness of the insertion portion 81. The blade portion 83 is also formed at the lower end of the guide piece 811.

The fixing member 91 is provided with a reinforcing piece 913. The reinforcing piece 913 is provided so as to protrude from the underside of the fixing portion 911. In plan view, the reinforcing piece 913 is provided between a pair of slits 912. The reinforcing piece 913 is provided from the front end to the rear end of the fixing portion 911. The front end of the reinforcing piece 913 is connected to the upper part of the rear surface of the insertion portion 81. The reinforcing piece 913 improves the rigidity of the fixing portion 911 and the insertion portion 81. The reinforcing piece 913 is provided with a partition portion 914. The partition portion 914 is formed so as to protrude downward from the reinforcing piece 913. In plan view, the front end of the partition portion 914 is located at approximately the same position as the front end of the slit 912.

The movable member 92 is formed by bending a metal plate such as a stainless steel plate. The movable member 92 has an operating portion 921, a pair of left and right slide portions 922, and a clamping portion 82. The operating portion 921 is located above the fixed portion 911, and the pair of slide portions 922 are located below the fixed portion 911. The operating portion 921 and the pair of slide portions 922 are connected via a pair of slits 912. That is, of the pair of slide portions 922, the left slide portion 922 passes through the left slit 912 and is located below the left slit 912, while the right slide 922 passes through the right slit 912 and is located below the right slit 912. A reinforcing piece 913 is disposed between the pair of slide portions 922. The operating portion 921 is provided with a connecting portion 923. The connecting portion 923 is formed to protrude rearward from the operating portion 921.

A pair of clamping portions 82 are provided on the movable member 92. Each clamping portion 82 is provided on each of the pair of sliding portions 922. That is, each clamping portion 82 is formed by protruding downward from the front end of each sliding portion 922. The pair of clamping portions 82 are arranged side by side in the left-right direction. A partition portion 914 is arranged between the pair of clamping portions 82. The pair of clamping portions 82 are arranged behind the insertion portion 81. The pair of clamping portions 82 and the insertion portion 81 are arranged facing each other in the front-to-rear direction with a predetermined gap between them.

The pair of clamping portions 82 are provided with protrusions 84. Multiple protrusions 84 are provided on each clamping portion 82. The multiple protrusions 84 are aligned vertically and protrude forward (toward the insertion portion 81) from the front end of the clamping portion 82.

The movable member 92 is formed to be slidable in the front-to-rear direction. That is, the movable member 92 is formed to be slidable along the longitudinal direction of the slit 912. The movable member 92 is slidable within the range of the length of the slit 912 in the front-to-rear direction. That is, the front end of the sliding portion 922 of the movable member 92 abuts against the front end of the slit 912, preventing it from moving further forward. On the other hand, the rear end of the sliding portion 922 of the movable member 92 abuts against the rear end of the slit 912, preventing it from moving further rearward.

The pair of clamping portions 82 are formed so that they can move toward and away from the insertion portion 81. In other words, when the movable member 92 slides forward, the pair of clamping portions 82 also move forward, bringing the pair of clamping portions 82 closer to the rear surface of the insertion portion 81. On the other hand, when the movable member 92 slides rearward from a state in which the pair of clamping portions 82 are close to the rear surface of the insertion portion 81, the pair of clamping portions 82 also move rearward, moving the pair of clamping portions 82 away from the rear surface of the insertion portion 81. In this way, the distance between the pair of clamping portions 82 and the insertion portion 81 can be changed.

The elastic member 93 biases the movable member 92 against sliding movement in the forward and backward directions. The elastic member 93 can be a coil spring made of metal or the like. The elastic member 93 is arranged so as to be freely stretchable in the forward and backward directions, and its front end is hooked and connected to the rear end of the connecting portion 923 of the movable member 92. The rear end of the elastic member 93 is hooked to a hook portion 95 provided at the rear end of the gripping member 94. The elastic member 93 biases the movable member 92 so as to constantly pull it rearward. Therefore, when the movable member 92 is not being operated to move it forward, it is always in its rearmost position. When force is applied to the operating portion 921 to operate the movable member 92 and move it forward, the elastic member 93 stretches, but the movable member 92 can be slid forward against the pulling force of the elastic member 93. Furthermore, when the force applied to the operating portion 921 is released, the elastic member 93 contracts, and the pulling force of the elastic member 93 at this time allows the movable member 92 to slide rearward. Therefore, when no force is applied to the operating portion 921, the distance between the pair of clamping portions 82 and the rear surface of the insertion portion 81 tends to be maintained at a constant (maximum) distance.

The gripping member 94 is formed long in the front-to-rear direction. The gripping member 94 has a cylindrical gripping portion 941 and an attachment portion 942 that protrudes forward from the gripping portion 941. The gripping portion 941 is the part that is gripped by a person's hand, and the operating portion 921 can be operated with the thumb or other part of the gripping hand. The elastic member 93 is disposed in the internal space of the gripping portion 941. The gripping portion 941 has an opening 943 on its front end surface, and the connecting portion 923 is inserted into the internal space of the gripping portion 941 from the opening 943.

The mounting portion 942 protrudes forward from the lower front end of the grip portion 941. The fixed portion 911 is fixed above the mounting portion 942. Below the fixed portion 911, the mounting portion 942 is provided with a storage recess 944, which houses the slide portion 922 and reinforcing piece 913. In addition, the operating portion 921 protrudes above the fixed portion 911.

The storage recess 944 has an opening 945 that spans the front end surface of the mounting portion 942 and the front underside of the mounting portion 942. The pair of clamping portions 82 and the partition portion 914 protrude downward from the storage recess 944 through the opening 945 in the front underside of the mounting portion 942. The pair of clamping portions 82 are movable through the opening 945 in the front end surface of the mounting portion 942 between a state in which they protrude forward from the storage recess 944 and a state in which they are accommodated in the storage recess 944 from the front of the storage recess 944. In other words, by operating the operating portion 921 to slide the movable member 92 forward or backward, the pair of clamping portions 82 protrude from the storage recess 944 and approach the insertion portion 81, or the pair of clamping portions 82 move away from the insertion portion 81 and are accommodated in the storage recess 944.

(2.2) Operation Figures 2A and 2B show a method of using the excision tool 8 according to this embodiment. In this case, a rock wool board having a rectangular flat plate shape in a plan view is used as the insulating material 2. The portion to be excised from the insulating material 2 is a corner 2a. That is, Figures 2A and 2B show a case where the corner 2a is excised from the insulating material 2 having a rectangular flat plate shape in a plan view using the excision tool 8.

First, as shown in Figure 2A, with the insertion portion 81 and the pair of clamping portions 82 spaced apart, the cutting tool 8 is brought close to the insulating material 2 from above, and the insertion portion 81 is inserted into the insulating material 2 from above. At this time, the blade portion 83 attached to the lower end of the insertion portion 81 cuts into the insulating material 2. When the lower end of the insertion portion 81 reaches the underside of the insulating material 2, the corner portion 2a of the insulating portion 2 is cut away from the other portion 2b. The other portion 2b corresponds to the main body portion 20, which will be described later.

Next, as shown in Figure 2B, the movable member 92 is slid forward, bringing the pair of clamping portions 82 closer to the insertion portion 81. In this case, by pressing the operating portion 921 of the movable member 92 forward, the movable member 92 slides forward, and as a result, the pair of clamping portions 82 move forward and closer to the insertion portion 81. Then, the corner 2a between the insertion portion 81 and the pair of clamping portions 82 is clamped between the insertion portion 81 and the pair of clamping portions 82. At this time, the multiple protrusions 84 provided on the clamping portions 82 bite into the corner 2a.

Then, the excision tool 8 is moved upward to separate it from the insulating material 2. At this time, by moving the excision tool 8 away from the insulating material 2 while the corner 2a is clamped (held) between the insertion portion 81 and the pair of clamping portions 82, the corner 2a separates from the other portion 2b of the insulating material 2, thereby allowing the corner 2a to be excised from the insulating material 2. Note that the elastic member 93 constantly applies a force to the movable member 92, which slides forward, tending to slide it backward. Therefore, to maintain the clamped state of the corner 2a between the insertion portion 81 and the pair of clamping portions 82, a force is continuously applied from rear to front to the operating portion 921 with the thumb or the like of the hand gripping the gripping portion 941 to prevent the movable member 92 from sliding backward. To release the excised corner 2a from the excision tool 8, the movable member 92 is slid backward to release the corner 2a from the insertion portion 81 and the pair of clamping portions 82. In this case, the finger is removed from the operating portion 921, releasing the force being applied to the operating portion 921 from rear to front. This causes the elastic member 93 to pull the movable member 92 rearward, causing it to slide and move so as to separate the insertion portion 81 and the pair of clamping portions 82.

(Regarding panel manufacturing)
The cutting tool 8 according to this embodiment can be used to manufacture building panels. The panel 1 shown in Figures 3 to 8 will be described in more detail. The panel 1 is a building panel, and is used, for example, as an exterior wall material. In the panel 1, the metal skin 3 forms the front surface of the panel 1 (the surface facing the exterior when used as an exterior wall material). Each component will be described below using the directions shown in Figure 3.

Panel 1 is a rectangular plate. It has a longitudinal direction parallel to the vertical direction, a transverse direction parallel to the left-right direction, and a thickness direction parallel to the front-to-rear direction. For example, panel 1 has a vertical length of 0.5 to 6.0 m, a left-to-right length (width) of 0.2 to 1.5 m, and a front-to-rear length (thickness) of 50 to 150 mm.

The panel 1 comprises an insulating material 2, a metal skin 3 that covers the insulating material 2 from the front side, and a second metal skin 4 that covers the insulating material 2 from the rear side.

The insulating material 2 has an overall plate-like shape. The insulating material 2 has an overall rectangular plate-like shape. An overall plate-like shape is not limited to a single plate, but also includes multiple components arranged to form a single plate.

The main body 20 has grooves 22 on its left and right side surfaces. The grooves 22 are located in the center of the left and right side surfaces of the main body 20 in the front-to-back direction and extend over the entire length of the left and right side surfaces of the main body 20 in the up-down direction. Fire-resistant sections are arranged in the grooves 22.

The main body 20 is made of a fibrous inorganic material such as rock wool or glass wool. The main body 20 is composed of multiple blocks lined up in the left-right direction. Each of the multiple blocks is made of fibrous inorganic material solidified into a block shape using a binder or the like. The multiple blocks have the same length in the up-down direction and the same length in the front-to-back direction. Adjacent sides of the multiple blocks abut against each other, collectively forming a single rectangular plate-shaped main body 20. Note that each of the multiple blocks may be made, for example, by cutting a rock wool board into strips. In this case, the multiple blocks are arranged so that the fiber direction is parallel to the front-to-back direction and so that collectively forming a single rectangular plate, forming the main body 20.

The main body 20 has thermal insulation properties. A groove 22 is provided on the left side of the leftmost block and on the right side of the rightmost block. The longitudinal direction of the fibrous inorganic material in each of the multiple blocks is aligned with the front-to-rear direction.

The main body 20 has an upper surface 200, a lower surface, a left side surface, and a right side surface. Two adjacent surfaces of the upper surface 200, the lower surface, the left side surface, and the right side surface 203 form a corner.

The fire-resistant portion is a member with higher fire resistance than the main body portion 20, such as gypsum board or calcium silicate board. The fire-resistant portion is a single rectangular plate shaped to fit the groove portion 22. The fire-resistant portion fills the entire groove portion 22.

Figure 4 shows a corner of panel 1 (the upper right corner of panel 1 in an upright position) when panel 1 is laid flat so that metal skin 3 forms the underside of panel 1. Below, each component will be explained using the orientation of panel 1 when laid flat. The fireproof section, sealing material 6, and waterproof gasket 7 are not shown in Figure 4.

As shown in FIG. 4, the insulating material 2 has a first side surface 24, a second side surface 25, and an intermediate surface 26 that constitute the corner portion 23 of the insulating material 2. The insulating material 2 has an intermediate surface 26 at each of its four corners. In FIGS. 4 and 5, the first side surface 24 is the top surface 200 of the main body portion 20, and the second side surface 25 is the right side surface 203 of the main body portion 20. The intermediate surface 26 is the surface located between the first side surface 24 and the second side surface 25. The intermediate surface 26 is formed by removing a portion of the corner formed by two adjacent surfaces from the top surface 200, bottom surface, left side surface, and right side surface 203 of the insulating material 2.

The intermediate surface 26 is located below the groove portion 22. The intermediate surface 26 is a rectangular flat surface. The intermediate surface 26 extends from the lower end of the groove portion 22 to the underside of the main body portion 20 (the front surface of the main body portion 20 in the upright position).

The metal skin 3 and second metal skin 4 shown in Figure 3 are each obtained by forming a metal sheet into the desired shape using rolling, pressing, or other methods. The metal sheet has a thickness of, for example, 0.25 to 2.0 mm. Examples of metal sheets include, but are not limited to, painted steel sheets, zinc-plated steel sheets, aluminum-zinc alloy-plated steel sheets, Galvalume steel sheets (registered trademark), and SGL (registered trademark) steel sheets. Below, each configuration will be explained using the direction when the panel 1 is in an upright position.

As shown in Figure 3, the metal skin 3 is shaped like a rectangular box that opens toward the rear. The metal skin 3 has a rectangular plate-shaped main body 30 that covers the front surface of the main body 20 of the thermal insulation material 2, a wall 31 that covers the upper surface 200 of the main body 20, and a lower wall that covers the lower surface of the main body 20. The metal skin 3 further has a left wall that covers the portion of the left side surface of the main body 20 that is forward of the groove 22, and a right wall 34 that covers the portion of the right side surface 203 of the main body 20 that is forward of the groove 22.

The wall 31 protrudes rearward from the upper edge of the main body 30, the lower wall protrudes rearward from the lower edge of the main body 30, the left wall protrudes rearward from the left edge of the main body 30, and the right wall 34 protrudes rearward from the right edge of the main body 30. Each of the four walls is perpendicular to the main body 30. The upper and lower wall 31 are each rectangular flat plate-shaped. The left and right wall 34 have a rectangular flat plate portion 340 and a rectangular plate-shaped protrusion that protrudes outward in the left-right direction at a right angle from the rear end of the flat plate portion 340. The upper and lower wall portions are longer in the front-to-rear direction than the left and right wall portions.

The metal outer shell 3 further has an arc-shaped connecting portion 37 that connects the front ends of two circumferentially adjacent wall portions (e.g., wall portion 31 and right wall portion 34).

The metal outer skin 3 has a connecting portion 37 at each of its four corners. The front ends of two circumferentially adjacent wall portions 31, 34 are connected via the connecting portion 37. An opening 38 is formed between the two circumferentially adjacent wall portions. The opening 38 is located behind the connecting portion 37.

As shown in Figure 4, the second metal outer skin 4 has a rectangular plate-shaped main body 40 that covers the rear surface of the main body 20 of the thermal insulation material 2, a left wall that covers the portion of the left side surface of the main body 20 behind the groove 22, and a right wall 42 that covers the portion of the right side surface 203 of the main body 20 behind the groove 22. The left wall protrudes from the left edge of the main body 40, and the right wall 42 protrudes outward from the right edge of the main body 40. Note that the second metal outer skin 4 does not have any portion that covers the top surface 200 or bottom surface of the main body 20. Note that in Figure 4, the back surface of the panel faces upward.

Each of the left and right wall sections has a curved section 420 that is curved in a U-shape when viewed from above, and a rectangular flat section 421 that protrudes from the curved section 420.

The main body portions 30, 40 of the metal skins 3, 4 are bonded to the front and rear surfaces of the main body portion 20 of the insulation material 2, respectively, and are integrated with the insulation material 2. As shown in Figure 4, the opening 38 of the metal skin 3 is located opposite the intermediate surface 26 of the insulation material 2. An installation space in which the corner member 5 is installed is formed between the opening 38 and the intermediate surface 26.

One corner member 5 is placed in each of the openings 38 at the four corners of the panel 1. As shown in Figures 4 and 5, the corner member 5 has a cover portion 50 that covers the opening 38, a seal receiving portion 51 that is located inside the cover portion 50 and forms a space S1 between the cover portion 50 and the sealant 6, and a connecting portion 52 that connects the cover portion 50 and the seal receiving portion 51. Below, the corner member 5 shown in Figure 5 will be explained using the orientation when the panel 1 is laid flat as shown in Figure 4.

The corner members 5 are made of metal. For example, the corner members 5 are formed by bending a metal plate of the same thickness as the metal outer skin 3.

The cover portion 50 has a shape that corresponds to the opening 38. The cover portion 50 has a curved shape that is continuous with the portion of the metal outer skin 3 surrounding the opening 38 (e.g., the wall portion 31 and the right wall portion 34). An injection port 500 through which the sealant 6 is injected is provided in part of the cover portion 50.

In this embodiment, the cover portion 50 has a T-shaped, flat central portion 501 and a pair of inclined portions 502 extending from both ends of the central portion 501 in the width direction and inclined relative to the central portion 501 so that the further away they are from the central portion 501, the more inward they are positioned. Each of the pair of inclined portions 502 is rectangular plate-shaped.

The injection port 500 is provided at the end (lower end) of the central portion 501 opposite the end (upper end) to which the connecting portion 52 is connected. The injection port 500 penetrates the central portion 501 in the thickness direction.

The seal receiving portion 51 is located inside the cover portion 50, forming a space S1 between it and the cover portion 50. The seal receiving portion 51 has an extension piece 510 that fits into the gap between the metal outer skin 3 and the insulation material 2.

The seal receiving portion 51 has a main body portion 511 that is parallel to the center portion 501 of the cover portion 50, and a pair of inclined portions 512 that extend from both ends of the main body portion 511 in the width direction and are inclined relative to the main body portion 511 so that the further away they are from the main body portion 511, the more inward they are positioned. The main body portion 511 and the pair of inclined portions 512 are each rectangular plate-shaped. The pair of inclined portions 512 form the extension piece 510.

The main body portion 511 is a portion that fits along the intermediate surface 26 of the insulating material 2, and the pair of inclined portions 512 are portions that fit along the first side surface 24 or the second side surface 25 of the insulating material 2. The inclination of the pair of inclined portions 512 relative to the main body portion 511 corresponds to the inclination of the first side surface 24 and the second side surface 25 relative to the intermediate surface 26. The main body portion 511 is approximately the same size as the intermediate surface 26. The main body portion 511 is longer in the vertical direction than the cover portion 50. A connecting portion 52 is connected to the center of the width of one end (upper end) of the main body portion 511.

The connecting portion 52 is rectangular plate-shaped. The connecting portion 52 has a thickness in the vertical direction (thickness direction of the insulation material 2). The connecting portion 52 has through holes 520, 523 that penetrate the connecting portion 52 in the thickness direction. The connecting portion 52 has the same width as the upper end of the central portion 501 of the cover portion 50.

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

The corner member 5 is installed in the opening 38 so that the main body 511 of the seal receiving portion 51 is aligned with the intermediate surface 26 of the insulation material 2 and the cover portion 50 closes the opening 38. By installing the corner member 5 in the opening 38, a filling space for the sealant 6 is formed inside the opening 38, surrounded by the cover portion 50 of the corner member 5, the seal receiving portion 51, the connecting portion 52, the right wall portion 34 of the metal outer skin 3, the wall portion 31, the connecting portion 37, and the main body portion 30.

The corner member 5 has a cover portion 50, a seal receiving portion 51, and a connecting portion 52, as well as a leakage prevention portion 53 and a movement restriction portion 54.

The cover portion 50 has a rectangular, flat central portion 501 and a pair of inclined portions 502. The injection port 500 is provided across the inner widthwise ends of the central portion 501 and the pair of inclined portions 502. In other words, the central portion 501 is narrower than the diameter of the injection port 500. Note that no mark 503 indicating the position where the masking tape 10 should be applied is provided on the surface of the cover portion 50.

The leakage prevention portion 53 protrudes from the cover portion 50 so as to fit along the surface of the metal outer shell 3 on the core material 2 side of the area surrounding the opening 38 (e.g., the upper wall portion 31 and the right side wall portion 34). The leakage prevention portion 53 prevents the sealing material 6 from leaking from the gap between the cover portion 50 and the metal outer shell 3 when the sealing material 6 is injected.

The corner member 5 has a pair of leakage prevention portions 53. Each of the pair of leakage prevention portions 53 protrudes from the outer widthwise ends of the pair of inclined portions 502. The pair of leakage prevention portions 53 protrude from the pair of inclined portions 502 so that their outer surfaces are positioned more inward than the outer surfaces of the pair of inclined portions 502.

The movement restricting portion 54 is configured to restrict movement of the cover portion 50 toward the seal receiving portion 51. The movement restricting portion 54 is composed of a pair of restricting pieces 540 that protrude from the outer widthwise ends of the pair of inclined portions 502 of the cover portion 50 toward the seal receiving portion 51. The pair of restricting pieces 540 protrude from the end of the cover portion 50 opposite the side that is continuous with the connecting portion 52. The tip of each of the pair of restricting pieces 540 abuts the main body portion 511 of the seal receiving portion 51, or forms a small gap between it and the main body portion 511.

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

More specifically, the second portion 522 is continuous with one end of the central portion 501 of the cover portion 50. The first portion 521 and the second portion 522 are each rectangular plate-shaped. The width of the first portion 521 and the second portion 522 is the same as the width of the central portion 501 and is narrower than the diameter of the injection port 500.

The first portion 521 is perpendicular or approximately perpendicular to the main body portion 511 of the seal receiving portion 51. The second portion 522 is continuous with the central portion 501 at an obtuse angle, and is continuous with the first portion 521 at an obtuse angle. The outer surface of the second portion 522 is located more inward than the outer surface of the central portion 501. This creates a space between the second portion 522 and the corner packing 71 (see Figure 7C).

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

A conventional sealant is used as the sealant 6. Examples of sealant 6 include one-component, cartridge-type polysulfide sealants. These sealants are primarily composed of polysulfide polymers. Polysulfide sealants cure in response to atmospheric moisture, resulting in relatively little variation in curing time throughout the year. Furthermore, polysulfide sealants have relatively high viscosity and tend to remain within the sealant 6 filling space. Because this sealant is one-component, it does not require mixing like two-component sealants, making it easy to work with. Furthermore, this sealant exhibits high surface adhesion after curing, providing excellent adhesion to the metal outer shell 3 and corner members 5. Note that one-component, cartridge-type sealants are not limited to polysulfide sealants; acrylic, polyurethane, silicone, or modified silicone sealants may also be used. The sealant 6 may also be a fast-curing, one-component modified silicone sealant.

The sealant 6 is injected into the filling space of the corner member 5 through the injection port 500 in the cover portion 50 of the corner member 5. The sealant 6 seals the small gap between the cover portion 50 and the metal outer skin 3, sealing off the opening 38. The sealant 6 hardens by natural drying, heating, or humidification.

As shown in FIG. 3 , the panel 1 further includes waterproof gaskets 7 attached to each of the wall portions 31 and 34. The waterproof gaskets 7 include multiple linear gaskets 70 attached to the front-to-rear center of the upper surface of the wall portion 31, the front-to-rear center of the lower surface of the lower wall portion, and the rear ends of the flat portions 340 of the left and right wall portions 34, as well as multiple L-shaped corner gaskets 71 attached to each corner of the wall portion 34. Each of the multiple gaskets 70 has a hollow semicircular cross section perpendicular to the longitudinal direction. Each of the multiple corner gaskets 71 is an L-shaped solid block. The multiple gaskets 70 and multiple corner gaskets 71 are arranged in a rectangular frame shape in front view, surrounding the entire periphery of the panel 1. The multiple gaskets 70 and multiple corner gaskets 71 are joined to each other with adhesive or the like. The multiple gaskets 70 and multiple corner gaskets 71 are made of, for example, synthetic rubber. Some of the waterproof gaskets 7 (specifically, each corner gasket 71) are attached to the portion of the cover portion 50 of the corner member 5 above the mark 503. Each of the multiple gaskets 70 and multiple corner gaskets 71 has an adhesive surface on the inner surface (the wall portion 31, 34 side), allowing them to be attached to the wall portions 31, 34 without the use of adhesive.

Next, we will explain the sealing method for filling the panel corners with sealant 6. The sealing method includes a cutting process, a placement process, and a filling process.

Figure 6A shows a corner of panel 1 before sealing. Corner 2a of insulation 2 is exposed through opening 38 between two adjacent walls of metal skin 3 (wall 31 and right wall 34 in the figure).

In the cutting process, as shown in FIG. 6B, the corner 2a of the insulating material 2 is cut away to form an intermediate surface 26 in the insulating material 2, thereby creating a space for arranging the corner member 5 between the opening 38 and the intermediate surface 26. The corner 2a of the insulating material 2 can be cut away using the cutting tool 8 of this embodiment. In this case, as in FIGS. 2A and 2B, the insertion portion 81 is placed against the corner 2a of the insulating material 2 from above, and the cutting tool 8 is moved downward to cut the corner 2a of the insulating material 2. The cutting tool 8 is then removed from the insulating material 2, and the corner 2a is cut away while being held by the cutting tool 8. By forming the intermediate surface 26 in the insulating material 2, a corner portion 23 consisting of the intermediate surface 26, the first side surface 24, and the second side surface 25 is formed in the insulating material 2 (see FIG. 4).

In addition, when the insertion portion 81 is placed against the corner 2a of the thermal insulation material 2 from above and the cutting tool 8 is moved downward, the insertion portion 81 is inserted into the thermal insulation material 2 while each guide piece 811 is placed against the inner surface of the wall portions 31, 34 (see Figure 1A). This allows the insertion portion 81 to be moved while being guided by the wall portions 31, 34, making it less likely for the insertion portion 81 to shift out of position and making it easier to insert it straight into the desired position.

In the placement process, the corner member 5 is placed in the opening 38. As shown in Figure 7A, the pair of leakage prevention portions 53 of the corner member 5 are positioned along the inner surfaces (the surfaces facing the core material 2) of the upper wall portion 31 and right side wall portion 34 of the metal outer skin 3. As a result, the gap between the pair of inclined portions 502 and the wall portions 31, 34 is blocked from the inside by the pair of leakage prevention portions 53.

In the placement process, as shown in FIG. 7B , after the corner member 5 is placed in the opening 38, masking tape 10 is applied below the injection port 500 to the metal outer skin 3, covering the area surrounding the opening 38 (walls 31, 34) and the cover portion 50 of the corner member 5, temporarily fixing the corner member 5 to the metal outer skin 3. As a result, the masking tape 10 seals the gap between the lower end of the cover portion 50 and the walls 31, 34, and the gap between the cover portion 50 and the connecting portion 37. In the placement process of this embodiment, because the masking tape 10 does not cover the injection port 500, the process of removing part of the masking tape 10 using a cutting tool can be omitted.

In the placement process, as shown in Figure 7C, corner packing 71 is attached to the area (walls 31, 34) surrounding opening 38 in metal outer skin 3 so as to straddle opening 38 in metal outer skin 3. At this time, both ends of the inner surface of corner packing 71 are adhered to walls 31, 34, and the upper surface of corner packing 71 is abutted against the lower surface of protrusion 341 of right side wall 34. At this time, the inner surface of the lower part of corner packing 71 is adhered to the upper end of center portion 501 of cover portion 50 of corner member 5 and the upper end of the pair of inclined portions 502, respectively, and a space is formed between the inner surface of corner packing 71 and second portion 522 of connecting portion 52.

The area surrounded by the cover portion 50, seal receiving portion 51, connecting portion 52, right side wall portion 34, upper wall portion 31, connecting portion 37, and main body portion 30 of the corner member 5, and the area between the second portion 522 of the connecting portion 52 of the corner member 5 and the inner surface of the corner packing 71 are the areas filled with sealing material 6.

In the filling process, as shown in FIG. 8A, the opening 38 in which the corner member 5 is positioned is filled with sealant 6. Specifically, the sealant 6 is injected into the injection port 500 of the cover portion 50 of the corner member 5. The sealant 6 injected into the injection port 500 contacts the seal receiving portion 51 and spreads into the filling area. At this time, as shown in FIG. 8B, some of the sealant 6 protrudes from the through hole 523 of the second portion 522 of the connecting portion 52 and protrudes from both sides of the second portion 522 toward the corner packing 71, filling the space between the second portion 522 and the corner packing 71 with sealant 6. The adhesive strength of the sealant 6 bonds the second portion 522 to the corner packing 71, thereby increasing the attachment strength of the corner packing 71 to the metal outer skin 3 and corner member 5.

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

Because the connecting portion 52 is narrower than the diameter of the injection port 500, air within the filling area is easily expelled from both sides of the connecting portion 52 and the through-holes 520 and 523, making it easier for the sealing material 6 to spread throughout the entire filling area.

By performing the cutting, placement, and filling processes described above in this order, the openings 38 in the metal skin 3 at the panel corners can be sealed with the corner members 5, corner gaskets 71, and sealant 6. The sealing method described above is performed on each of the four corners of the panel 1. After sealing the openings 38 at each of the four corners of the panel 1 with the corner members 5, corner gaskets 71, and sealant 6, multiple gaskets 70 are attached around the periphery of the panel 1, and the multiple gaskets 70 are joined to the corner gaskets 71 with adhesive or the like, thereby attaching the waterproof gasket 7 to the panel 1 in a rectangular frame shape (see Figure 3).

The masking tape 10 is removed after the sealant 6 has hardened. In this embodiment, no part of the masking tape 10 enters the injection port 500, making it easy to peel the masking tape 10 from the metal outer skin 3 and corner member 5.

(3) Modifications The first embodiment is merely one of various embodiments of the present disclosure. The first embodiment can be modified in various ways depending on the design and the like as long as the object of the present disclosure can be achieved.

In the first embodiment, the insulating material 2 is described as a rock wool board, but this is not limited to this. For example, the cutting tool 8 can also be used with organic resin-based insulating material 2 such as glass wool board, phenol foam board, urethane foam board, or polystyrene foam board. In other words, the cutting tool 8 can be used with any insulating material 2 that is hard enough to insert the insertion portion 81.

In the first embodiment, the corner 2a was described as the portion to be cut from the insulating material 2, but this is not limited to this. The cutting tool 8 can be used to cut off a portion of any location on the insulating material 2.

(summary)
As described above, the excision tool (8) according to the first aspect is used to excise a portion of the insulating material (2). This excision tool (8) includes an insertion portion (81) that is inserted into the insulating material (2) and a clamping portion (82) that clamps the portion of the insulating material (2) between the insertion portion (81) and the clamping portion (82).

According to the first aspect, after inserting the insertion portion (81) into the insulating material (2), a portion of the insulating material (2) is sandwiched between the insertion portion (81) and the clamping portion (82), and while this portion of the insulating material (2) is sandwiched between the insertion portion (81) and the clamping portion (82), this portion of the insulating material (2) can be separated from the rest of the insulating material (2), making it easy to remove a portion of the insulating material (2).

The second aspect is the excision tool (8) according to the first aspect, in which the insertion portion (81) and the clamping portion (82) are arranged opposite each other and are formed so as to be able to move toward and away from each other.

According to the second aspect, when a portion of the insulating material (2) is clamped between the insertion portion (81) and the clamping portion (82), the insertion portion (81) and the clamping portion (82) can be brought close to each other, making it easier to remove a portion of the insulating material (2).

The third aspect is the excision tool (8) according to the first or second aspect, in which the insertion portion (81) has a blade portion (83) that cuts into the insulating material (2).

According to the third aspect, the blade portion (83) allows the insertion portion (81) to be easily inserted into the insulating material (2), facilitating the process of cutting away a portion of the insulating material (2).

The fourth aspect is the excision tool (8) according to any one of the first to third aspects, in which the clamping portion (82) has a protrusion (84) that bites into the portion of the insulating material (2).

According to the fourth aspect, when a portion of the insulating material (2) is clamped between the insertion portion (81) and the clamping portion (82), the protrusion portion (84) can be inserted into the portion of the insulating material (2), making it easier to remove the portion of the insulating material (2).

The fifth aspect is an excision tool (8) according to any one of the first to fourth aspects, comprising a fixed member (91) having an insertion portion (81) and a movable member (92) having a clamping portion (82). The movable member (92) is arranged to be slidable relative to the fixed member (91).

According to the fifth aspect, when a portion of the insulating material (2) is clamped between the insertion portion (81) and the clamping portion (82), the protrusion portion (84) can be caused to bite into the portion of the insulating material (2), making it easier to remove the portion of the insulating material (2).

The sixth aspect is the excision tool (8) according to the fifth aspect, which includes an elastic member (93) that biases the sliding movement of the movable member (92).

According to the sixth aspect, when the movable member (92) is slid relative to the fixed member (91), the movable member (92) is biased by the elastic member (93), which facilitates sliding movement and makes it easier to remove a portion of the insulating material (2).

The cutting method according to the seventh aspect is a method for cutting off a portion of the insulating material (2) using any one of the cutting tools described in the first to sixth aspects. In this cutting method, after inserting the insertion portion (81) into the insulating material (2), a portion of the insulating material (2) is clamped between the insertion portion (81) and the clamping portion (82), and with the portion of the insulating material (2) clamped between the insertion portion (81) and the clamping portion (82), the portion of the insulating material (2) is separated from the rest of the insulating material (2).

According to the seventh aspect, it is easy to remove a portion of the insulating material (2).

The eighth aspect is a cutting method according to the seventh aspect, in which the portion of the insulating material (2) is a corner (2a) of the insulating material (2).

According to the eighth aspect, it is easy to cut off the corners (2a) of the insulating material (2).

2 Heat insulating material 2a Corner portion 8 Cutting tool 81 Insertion portion 82 Clamping portion 83 Blade portion 84 Protrusion portion 91 Fixed member 92 Movable member 93 Elastic member

Claims (7)

A cutting tool used to cut away a portion of insulation,
an insertion portion to be inserted into the thermal insulation material;
a clamping portion that clamps a portion of the heat insulating material between the clamping portion and the insertion portion ,
The clamping portion has a protrusion that bites into the portion of the thermal insulating material,
The protruding portion protrudes toward the insertion portion so as to bite into the portion of the thermal insulating material sandwiched between the clamping portion and the insertion portion.
Excision tool. The insertion portion and the clamping portion are disposed opposite to each other and are formed so as to be movable toward and away from each other.
The excision tool of claim 1 . The insertion portion has a blade portion that cuts into the thermal insulation material.
3. The excision tool of claim 1 or 2. a fixing member having the insertion portion;
a movable member having the clamping portion,
The movable member is slidably disposed relative to the fixed member.
The excision tool according to any one of claims 1 to 3 . an elastic member that biases the movable member to slide in a direction in which the clamping portion moves away from the insertion portion;
The excision tool of claim 4. A method for removing a portion of the insulating material using the removal tool according to any one of claims 1 to 5, comprising the steps of:
After inserting the insertion portion into the heat insulating material, a portion of the heat insulating material is sandwiched between the insertion portion and the sandwiching portion;
With the portion of the thermal insulating material sandwiched between the insertion portion and the sandwiching portion, the portion of the thermal insulating material is separated from the other portion.
Excision method. The portion of the insulating material is a corner of the insulating material.
The ablation method according to claim 6 .