Rafter unit and roof structure

Abstract

To provide a rafter unit useful for folded plate roofs and a roof structure using the same.SOLUTION: A rafter unit (9) comprises: a rafter material (7) which extends from a first apex (1c) to a second apex (1d) of a deck plate (1) provided with a folded end portion (2) having an expansion portion (2d) formed at ends of a trough portion (1a), an upright portion (1b), the first apex (1c), and the second apex (1d), and in which a first end (7c) has a flat end face (7e), and a second end (7d) has a locking claw (7f) extending in an extension direction (A) toward its lower end; and a fixing cap (8) that presses the rafter material from above and fixes it to the deck plate at the folded end portion. A roof structure (10) becomes flat on its upper surface by the rafter unit (9), reducing the number of screws to be driven in and facilitating adoption of sheet waterproofing methods, etc.SELECTED DRAWING: Figure 5

Description

[Technical field]

[0001] The present invention relates to a rafter unit consisting of a rafter and a fixing cap thereof suitable for a folded plate roof, and to a roof structure using said rafter unit. [Background technology]

[0002] Folded-plate roofs, in which corrugated metal plates (deck plates) are joined at the seams to form a roof, are well known, and a sheet waterproofing method is also known in which a heat insulating material and a waterproof sheet are laid on the deck plates of a folded-plate roof and fixed by driving screws. With such sheet waterproofing methods, when looking up at the roof from a room, the tips of the screws driven into the deck plates are clearly visible from under the deck plates, which causes a problem of poor appearance. In response to this, Patent Document 1 discloses that, as shown in FIG. 9, a fixing member 3 is placed over the seams 2 (connecting parts) of the deck plates 1,1, the fixing member 3 is elastically engaged with the seams 2, and a screw 6 is driven into the fixing member 3, so that the tips of the screws 6 do not appear on the underside of the deck plate 1, thereby solving the problem of poor appearance. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Patent No. 3646293 Summary of the Invention [Problem to be solved by the invention]

[0004] However, in Patent Document 1, as shown in Figure 9, the fixing members 3 protrude upward from the tops 1c, 1d of the deck plate 1, and the top surface of the roof is not flat, making it difficult to lay the heat insulating material 4 and waterproof sheet 5. Also, although the fixing members 3 are effective for fixing the deck plates 1,1 in the wave direction (left-right direction in Figure 9), they cannot prevent the deck plates 1,1 from shifting in the longitudinal direction (front-back direction in Figure 9), so it is necessary to increase the number of screws to be driven or to cover the fixing members 3 with a separate cover member equipped with a shift prevention device, which increases the number of work steps.

[0005] The present invention has been made in consideration of the above circumstances, and its object is to provide a rafter unit consisting of a rafter and its fixing cap, which is useful for folded plate roofs, and a roof structure which uses such a rafter unit. [Means for solving the problem]

[0006] In order to solve the above problems, the rafter unit of a first embodiment of the present invention is characterized in that it comprises a deck plate having a valley portion, rising portions on both sides of the valley portion, a first apex extending outward from the upper end of one of the rising portions, a second apex extending outward from the upper end of the other rising portion, and a seam formed at the ends of the first apex and the second apex and having an expanded portion at an upper portion, a rafter that is suspended from the first apex to the second apex, the first end being one end in the suspension direction and having a flat end surface, and the second end being the other end and having a locking claw at its lower end extending in the suspension direction, and that is locked to the seam by the end surface and the locking claw, and a fixing cap that holds the rafter from above at the seam to fix it to the deck plate.

[0007] In the second embodiment of the rafter unit, in the first embodiment, the fixing cap is a channel material that opens downward and has engagement holes for the seam portion on both side sides parallel to the hanging direction, and it is also preferable that the engagement hole has a lower entrance portion and a sliding portion cut out from the entrance portion in the hanging direction, and a fixing claw formed next to the entrance portion by cutting out the sliding portion.

[0008] In the third embodiment of the rafter unit, in the second embodiment, it is also preferable that the fixing cap is placed across the two rafters at the seam and slid in the opposite direction to the depth direction of the sliding section, so that the fixing claw is caught below the expansion section of the seam and prevented from coming off.

[0009] In the fourth aspect of the rafter unit, in the third aspect, it is also preferable that the upper surfaces of the fixing cap and the rafter are flat, and the fixing cap covers the rafter approximately flush.

[0010] In the rafter unit of the fifth aspect, in the fourth aspect, it is also preferable that the rafter is a hat steel or a C channel.

[0011] In a sixth aspect, it is also preferable for the roof structure to include a deck plate having a valley portion, rising portions on both sides of the valley portion, a first apex extending outward from an upper end of one of the rising portions, a second apex extending outward from an upper end of the other of the rising portions, and a seam portion having expanded portions formed at ends of the first apex and the second apex, a rafter that is suspended from the first apex to the second apex of the deck plate, the first end being one end in the suspension direction and having a flat end surface and the second end being the other end and having a locking claw at its lower end extending in the suspension direction, and that is locked to the seam by the end surface and the locking claw, and a fixing cap that holds the rafter from above at the seam and fixes it to the deck plate. Effect of the Invention

[0012] According to the present invention, it is possible to provide a rafter unit useful for a folded plate roof and a roof structure using the same. [Brief description of the drawings]

[0013] [Figure 1] FIG. 1 is a front view of a roof structure according to an embodiment of the present invention. [Diagram 2] FIG. 2 is a front view of a deck plate according to the embodiment. [Diagram 3] FIG. 2 is a diagram of a rafter according to an embodiment of the present invention. [Figure 4] FIG. 13 is a diagram of a fixing cap according to an embodiment. [Diagram 5] FIG. 2 is a perspective view of a roof structure showing how a rafter unit is used. [Figure 6] (A) is a diagram showing the fixing cap before it is slid, (B) is a diagram showing the fixing cap after it is slid, and (C) is a diagram showing the state after the screws have been driven into the roof structure. [Figure 7] A diagram showing a rafter of a rafter unit according to a modified example. [Figure 8] FIG. 13 is a diagram showing a deck plate of a roof structure according to a modified example. [Figure 9] FIG. 1 is a diagram showing a conventional roof structure and a sheet waterproofing method. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0014] Next, preferred embodiments of the present invention will be described with reference to the drawings.

[0015] (Roof structure configuration) FIG. 1 is a front view of a roof structure 10 according to an embodiment of the present invention. The roof structure 10 is a so-called folded plate roof, in which the seams 2 at both ends of a metal plate (deck plate 1) bent into a corrugated shape are joined together to form a roof. The roof structure 10 is formed by joining a plurality of deck plates 1 in the left-right direction of FIG. 1, and FIG. 1 illustrates a part (minimum unit) of the roof structure 10. The roof structure 10 (minimum unit) includes two deck plates 1, 1 that are connected to each other, rafters 7 that are hung across each deck plate 1, and fixing caps 8 that are placed on the rafters 7, 7. In the roof structure 10, a rafter unit 9 according to this embodiment is a combination of one rafter 7 and one fixing cap 8. The roof structure 10 is also subjected to a sheet waterproofing method, and a heat insulating material 4 and a waterproof sheet 5 are laid on the roof structure 10 and fixed with screws 6. Instead of or in addition to the heat insulating material 4, a conventionally known base material (wood wool board, concrete panel, Century Board (registered trademark)) or the like may be provided.

[0016] (Deck plate configuration) 2 is a front view of a deck plate 1 according to an embodiment. The deck plate 1 is formed by bending a metal plate, and includes a valley portion 1a, rising portions 1b, 1b standing on both sides of the valley portion 1a, a first apex portion 1c extending outward from the upper end of one rising portion 1b and including an outer seam portion 2a, and a second apex portion 1d extending outward from the upper end of the other rising portion 1b and including an inner seam portion 2b. The two deck plates 1, 1 are connected by seaming the outer seam portion 2a and the inner seam portion 2b, and at the seam portion 2 (connecting portion), the upper portion having a roll-up portion is an expanded portion 2d with respect to the lower portion 2c of the seam portion 2.

[0017] (Rafter structure) FIG. 3 shows a rafter 7 according to an embodiment, including (A) a perspective view from the first end, (B) a perspective view from the second end, (C) a front view, (D) a rear view, (E) a right side view, (F) a left side view, (G) a plan view, and (H) a bottom view. The rafter 7 is a long channel material formed by roll forming or bending a metal plate, and has a so-called hat steel shape with a grooved portion 7a and outer flanges 7b at both ends. The upper surface 7g of the rafter 7 having the hat steel shape is horizontally flat. The rafter 7 is hung from the first top 1c to the second top 1d in the wave direction of the deck plate 1 with the opening of the grooved portion 7a facing downward. The direction in which the rafter 7 is hung from the first top 1c to the second top 1d is hereinafter referred to as the hanging direction A.

[0018] The first end 7c, which is one end of the rafter 7 in the hanging direction A, has a flat end surface 7e in the vertical direction. The second end 7d, which is the other end, has a locking claw 7f extending in the hanging direction A at its lower end. The rafter 7 is hung on the deck plate 1 so that the flat end surface 7e of the first end 7c contacts and interferes with the seam 2 of the first top 1c of the deck plate 1, and the locking claw 7f of the second end 7d contacts and interferes with the seam 2 of the second top 1d of the deck plate 1. The height H7 (FIG. 3(E)) of the rafter 7 is preferably approximately the same as the height H2 (FIG. 2) of the seam 2 (outer seam 2a). In the embodiment, the height h7 (FIG. 3(E)) of the locking claw 7f is formed to be approximately one-third of the height H7 of the rafter 7, but the height h7 of the locking claw 7f may be changed to match the height h2 (FIG. 2) of the lower part 2c of the seam 2.

[0019] (Fixed Cap Configuration) 4 shows the fixing cap 8 according to the embodiment, including (A) a front perspective view, (B) a rear perspective view, (C) a front view, (D) a rear view, (E) a right side view, (F) a left side view, (G) a plan view, and (H) a bottom view. The fixing cap 8 is a channel material formed by roll forming or bending a metal plate, and has a so-called hat bar shape with a grooved portion 8a and outer flanges 8b on both ends by forming. The upper surface 8g of the fixing cap 8 having the hat bar shape is horizontally flat. The fixing cap 8 is oriented so that the grooved portion 8a opens downward, and is placed from above over the two rafters 7, 7 related to the seam 2 to fix the rafters 7, 7. The length L8 (Fig. 4(E)) of the fixing cap 8 may be changed to match the sum of the length of the first apex 1c and the second apex 1d so that it spans from the second apex 1d of one deck plate 1 connected at the seam 2 to the first apex 1c of the other deck plate 1 in the spanning direction A. The height H8 (Fig. 4(E)) of the fixing cap 8 is preferably approximately the same as the height H7 of the rafters 7.

[0020] The fixing cap 8 has two side surfaces 8c, 8d parallel to the laying direction A, and has an engagement hole 80 for engaging with the seam 2 of the deck plate 1, 1. The engagement hole 80 is provided at approximately the center of the side surfaces 8c, 8d when viewed in the laying direction A, and has an inlet portion 81 formed at the lower end of the side surfaces 8c, 8d, a slide portion 82 cut out in the laying direction A from the end of the inlet portion 81, and a fixing claw 83 formed by the side surfaces 8c, 8d remaining beside the inlet portion 81 by cutting out the slide portion 82. A notch 84 is formed in the outer flange 8b in accordance with the inlet portion 81 of the engagement hole 80. The width B82 (FIG. 4(E)) of the slide portion 82 of the engagement hole 80 is cut out to be approximately the same width as the width B81 (FIG. 4(E)) of the inlet portion 81, and the slide portion 82 has a depth in the laying direction A.

[0021] (How to use the rafter unit) The rafter unit 9 consisting of the rafter 7 and fixing cap 8 configured as described above is used in a roof structure 10 as follows. Figure 5 is a perspective view of the roof structure 10 showing how the rafter unit 9 is used, and Figure 6 (A) shows the fixing cap 8 before it is slid, (B) shows the fixing cap 8 after it has been slid, and (C) shows the roof structure 10 after the screws 6 have been driven into it.

[0022] After the worker has fastened the deck plates 1,1 together, the worker spans the rafter 7 in the wave direction of the deck plate 1. At this time, the locking claw 7f of the second end 7d of the rafter 7 is first inserted under the seam 2 of the deck plate 1, and then the first end 7c of the rafter 7 is pressed into the first top 1c of the deck plate 1. As a result, on the second end 7d side of the rafter 7, the locking claw 7f comes into contact with and interferes with the expanding portion 2d of the seam 2 and the deck plate 1 (second top 1d), and on the first end 7c side of the rafter 7, the end face 7e comes into contact with and interferes with the expanding portion 2d of the seam 2, so that the rafter 7 is locked to the deck plate 1.

[0023] After installing the rafters 7 on the two deck plates 1, 1, the worker places the fixing cap 8 over the two rafters 7, 7 relating to the seam 2 from above. At this time, the fixing cap 8 is placed over the two rafters 7, 7 relating to the seam 2 so that the expanded portion 2d of the seam 2 passes through the inlet portion 81 of the engagement hole 80 of the fixing cap 8 (see FIG. 6(A)).

[0024] Next, the worker slides the fixing cap 8 in the direction opposite to the depth direction of the engagement hole 80. As a result, the fixing claw 83 of the fixing cap 8 is inserted between the expanding portion 2d of the seam 2 and the deck plate 1 (first top portion 1c), and the fixing claw 83 is prevented from coming off below the expanding portion 2d (see FIG. 6(B)). As a result, the rafters 7,7 are pressed down from above by the fixing cap 8 at the seam 2, and are fixed to the deck plates 1,1. The worker similarly installs rafter units 9 on multiple deck plates 1 that are connected in the wave direction.

[0025] Next, the worker installs similar rafter units 9 at a specified interval in the longitudinal direction from the row of rafter units 9 installed earlier (see Figure 5). After the worker installs the rafter units 9 over the entirety of the multiple connected deck plates 1, he lays insulation material 4 and waterproof sheet 5 on top of them, drives screws 6 into the fixing caps 8, and applies sheet waterproofing to the roof structure 10 (see Figure 6(C)).

[0026] (Action and effect) As described above, according to the rafter unit 9 of this embodiment, the rafter 7 is hung in the wave direction of the deck plate 1, and the rafter 7 is fixed to the deck plate 1 by the fixing cap 8 at the lattice point with the row of the seam 2. The upper surface 8g of the fixing cap 8 and the upper surface 7g of the rafter 7 are flat horizontal surfaces, and the height H8 of the fixing cap 8 is approximately the same as the height H7 of the rafter 7, so that the rafter unit 9 consisting of the rafter 7 and the fixing cap 8 is installed as a substantially flush frame in the roof structure 10. Therefore, in the roof structure 10 of this embodiment, the rafter unit 9 does not protrude upward only at the position of the fixing cap 8, and spreads flatly on the roof surface, making it easy to lay the heat insulating material 4 and the waterproof sheet 5. In addition, according to the rafter unit 9 of this embodiment, the installation work is very easy because it is only necessary to hang the rafter 7 on the deck plate 1, cover it with the fixing cap 8, and slide it to fix it.

[0027] In addition, according to the rafter unit 9 of this embodiment, the row of the seams 2 extends in the longitudinal direction of the connected deck plates 1, and the rafters 7 extend in the wave direction, so that a lattice-like frame is formed as a whole. Therefore, the deck plates 1, 1 can be sufficiently prevented from shifting in the longitudinal direction, and there is no need to increase the number of screws to prevent shifting in the longitudinal direction. As shown in FIG. 5, it is sufficient to drive one screw 6 into each rafter unit 9. In addition, there is no need to cover the fixing cap 8 with another cover member to prevent shifting. In particular, when covering with another cover member, it is necessary to screw the end of the cover member to the rising portion 1b of the deck plate 1, which involves the difficult task of driving the screw at an angle, but this task is not necessary when the rafter unit 9 of this embodiment is used.

[0028] Furthermore, according to the roof structure 10 using the rafter unit 9 of this embodiment, the screw 6 is driven into the fixing cap 8 and the tip of the screw 6 fits into the fixing cap 8 and the rafter 7, so that the screw 6 does not appear on the underside of the deck plate 1, thereby addressing the issue of appearance.

[0029] In addition, the rafter unit 9 according to this embodiment can be applied to any shape of deck plate known in the art, so long as it is a seam-fastened deck plate having an expansion portion at the top. Therefore, the rafter unit 9 according to this embodiment can be used not only in new construction but also in renovation work, and is particularly useful when installed together with the replacement of the insulation material 4.

[0030] (Modification) Next, preferred modifications of the above-described embodiment will be given. The same components as those in the embodiment will be given the same reference numerals and the description thereof will be omitted.

[0031] FIG. 7 shows rafters of a rafter unit 9 according to the modified examples, where (A) is a rafter 7A according to the modified example 1, (B) is a rafter 7B according to the modified example 2, and (C) is a rafter 7C according to the modified example 3. The rafter 7 may have any of the shapes of the modified examples 1 to 3, depending on the load-bearing design and manufacturing costs of the roof structure 10. In the modified examples 1 to 3, the first end 7c has a vertically flat end surface 7e, and the second end 7d has a locking claw 7f. The modified example 1 has a so-called C-channel shape with inner flanges on both ends of the grooved portion 7a. The modified example 2 has a trapezoidal grooved portion 7a that flares out toward the end. The modified example 3 has a trapezoidal grooved portion 7a that tapers downward.

[0032] FIG. 8 is a diagram showing a deck plate of a roof structure 10 according to a modification, in which (A) is a deck plate 1A according to modification 4, (B) is a deck plate 1B according to modification 5, (C) is a deck plate 1C according to modification 6, (D) is a deck plate 1D according to modification 7, and (E) is a deck plate 1E according to modification 8. As described above, the rafter unit 9 according to this embodiment can be applied to a seam-fastened deck plate having an expanded portion at the upper part, and modifications 4 to 8 are examples thereof. Modification 4 is a deck plate 1A in which the first apex 1c and the second apex 1d have an inclination. Modification 5 is a deck plate 1B in which the valley portion 1a is arc-shaped. Modification 6 is a deck plate 1C in which the valley portion 1a is stepped. Modification 7 is a deck plate 1D in which the valley portion 1a is longer than that of the embodiment. Modification 8 is a deck plate 1E in which a plurality of corrugations are formed in the valley portion 1a of one deck plate. Even in these modified examples 4 to 8, the rafter unit 9 can be used by modifying the length L7 (Figure 3 (E)) of the rafter 7 and bringing the locking claws 7f and end faces 7e at both ends of the rafter 7 into contact with the seam 2 of the deck plate 1.

[0033] In the embodiment and modified examples, the shape of the seam 2 of the deck plate 1 is one example, and the seam 2 of the deck plate 1 may have a seam shape having an expanded portion at the upper portion. The outer seam 2a and the inner seam 2b may be reversed, and the inner seam 2b may be formed at the first apex 1c of the deck plate 1, and the outer seam 2a at the second apex 1d. The roof structure 10 including the rafters 7, fixing caps 8, and deck plate 1 is not limited to the example in which the sheet waterproofing method shown in the embodiment is applied, but may be applied to any long roof in general.

[0034] Although the preferred embodiment and modifications of the present invention have been described above, these can be modified and combined based on the knowledge of those skilled in the art, and such modifications are also included within the scope of the present invention. [Explanation of symbols]

[0035] 1...deck plate, 1a...valley portion, 1b...rising portion, 1c...first apex portion, 1d...second apex portion, 2...seam portion, 2a...outer seam portion, 2b...inner seam portion, 2c...lower portion, 2d...expansion portion, 4...insulation material, 5...waterproof sheet, 6...screw, 7...rafter, 7a...channel portion, 7b...outer flange, 7c...first end portion, 7d...second end portion, 7e...flat end surface, 7f...retaining claw, 7g...top surface, 8...fixing cap, 8a...channel portion, 8b...outer flange, 8c,8d...side surface, 8g...top surface, 80...engagement hole, 81...entrance portion, 82...sliding portion, 83...fixing claw, 84...notch, 9...rafter unit, 10...roof structure

Claims

1. a deck plate having a valley portion, rising portions on both sides of the valley portion, a first apex extending outward from an upper end of one of the rising portions, a second apex extending outward from an upper end of the other of the rising portions, and a seam portion having an expanded portion at an upper portion formed at ends of the first apex and the second apex, a rafter that is suspended from the first apex to the second apex, the first end being one end in the suspension direction with a flat end surface, and the second end being the other end with a locking claw at its lower end that extends in the suspension direction, and that is locked to the seam by the end surface and the locking claw; A fixing cap that holds the rafter from above at the seam and fixes it to the deck plate; A rafter unit comprising:

2. The rafter unit described in claim 1, characterized in that the fixing cap is a channel material that opens downward and has engagement holes for the seam portion on both side sides parallel to the hanging direction, the engagement holes having a lower entrance portion, a sliding portion cut out from the entrance portion in the hanging direction, and a fixing claw formed next to the entrance portion by cutting out the sliding portion.

3. The rafter unit described in claim 2, characterized in that the fixing cap is placed across the two rafters at the seam portion and slides in the opposite direction to the depth direction of the sliding portion, so that the fixing claws get caught below the expanded portion of the seam and are prevented from coming off.

4. 4. The rafter unit according to claim 3, wherein the upper surfaces of the fixing cap and the rafter are flat, and the fixing cap fits over the rafter approximately flush.

5. The rafter unit according to claim 4, wherein the rafters are hat steel or C-channel.

6. a deck plate including a valley portion, rising portions on both sides of the valley portion, a first apex portion extending outward from an upper end portion of one of the rising portions, a second apex portion extending outward from an upper end portion of the other of the rising portions, and a seam portion having an expanded portion formed at ends of the first apex portion and the second apex portion; a rafter that is hung from the first apex to the second apex of the deck plate, the first end being one end in the hanging direction and having a flat end surface, and the second end being the other end and having a locking claw at its lower end that extends in the hanging direction, and is locked to the seam by the end surface and the locking claw; A fixing cap that holds the rafter from above at the seam and fixes it to the deck plate; A roof structure comprising:

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