Method for manufacturing building material panel

Abstract

To facilitate construction on-site while ensuring thermal insulation efficiency and airtightness.SOLUTION: A method for manufacturing building material panels according to the present invention comprises: a step of roll forming a metal sheet to produce an outer skin material having joints provided at both ends in a width direction; a step of processing grooves into a foam block to produce an insulation material having an upper surface conforming to a shape of a bottom surface of the outer skin material and having at least one of both ends in the width direction of the outer skin material projecting outward beyond the end of the outer skin material; a step of applying an adhesive to the bottom surface of the outer skin material or the upper surface of the insulation material; and a step of heating and pressurizing the bottom surface of the outer skin material and the upper surface of the insulation material in contact with each other to bond the insulation material to the outer skin material.SELECTED DRAWING: Figure 8

Description

[Technical Field]

[0001] The present invention relates to a method for manufacturing a building panel suitable for constructing the roof or exterior wall of a building structure. [Background technology]

[0002] A building material panel comprising a metal outer skin and a heat insulating material (core material) fixed to the back surface of the outer skin has the advantages of being lightweight and strong, as well as having high heat insulating efficiency and airtightness. Therefore, building material panels are used as roofing and exterior wall materials for architectural structures such as factories, warehouses, ordinary houses, commercial facilities, and livestock barns. In a connected structure in which multiple building material panels are arranged in the girder direction and eaves-ridge direction, a cover cap extending in the eaves-ridge direction is attached across the vertical joints provided on each of two building material panels adjacent in the girder direction, covering the joint portion of the two adjacent building material panels (see, for example, Patent Document 1).

[0003] When multiple of the above-mentioned building panels are arranged in the girder direction, if a gap occurs between two adjacent building panels, the insulation efficiency, airtightness, etc. will decrease. Therefore, an airtight packing is placed between two adjacent building panels to prevent gaps from occurring between the two adjacent building panels. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] Japanese Patent Application Laid-Open No. 2024-33775 Summary of the Invention [Problem to be solved by the invention]

[0005] Incidentally, after an airtight gasket is attached to the insulating material of a previously placed building panel, when a new building panel is placed in the girder direction, it is also attached to the insulating material of that building panel. However, if the airtight gasket attached to the insulating material of the building panel is not properly attached, the airtight gasket may peel off from the insulating material of the building panel, or the peeling of the airtight gasket may damage the insulating material of the building panel. In addition, the task of placing the building panel while attaching the airtight gasket to the insulating material of the building panel is a time-consuming task, resulting in a problem of low work efficiency.

[0006] The present invention has been made in consideration of the above-mentioned problems, and aims to provide a building material panel that can be easily installed on narrow sites using short-length products while ensuring insulation efficiency, airtightness, etc., as well as a connecting structure using the building material panel and a method for manufacturing the building material panel. [Means for solving the problem]

[0007] The method for manufacturing a building panel in this invention comprises the steps of roll-forming a metal plate to produce an outer skin material with joints at both widthwise ends; groove-cutting a foam block to produce an insulating material having an upper surface that matches the shape of the bottom surface of the outer skin material and at least one of both widthwise ends of the outer skin material protruding outward beyond the end of the outer skin material; applying an adhesive to the bottom surface of the outer skin material or the top surface of the insulating material; and applying heat and pressure to the bottom surface of the outer skin material and the top surface of the insulating material while they are in contact, thereby adhering the insulating material to the outer skin material.

[0008] It is also preferable to have a step of forming a step of a lower joint located below the surface of the outer skin material at one end in the longitudinal direction of the outer skin material using a press machine.

[0009] In addition, it is preferable that the process of producing the insulation material includes a process of manufacturing a first insulation section located on the bottom surface of the outer skin material and a second insulation section located on the bottom surface of the lower joint, and a process of joining the first insulation section and the second insulation section using a hot melt adhesive to produce the insulation material. [Effects of the Invention]

[0010] According to the present disclosure, it is possible to provide a manufacturing method for building panels that can be easily installed on narrow sites using short-length products while ensuring insulation efficiency, airtightness, etc. [Brief explanation of the drawings]

[0011] [Figure 1] 1 is a schematic perspective view showing an example of a case where a connected structure in which a plurality of building material panels shown in this embodiment are arranged is used as a roof. FIG. [Figure 2] FIG. 2 is an exploded perspective view showing the configuration of the eaves side panel. [Figure 3] FIG. 2 is an exploded perspective view showing the configuration of the ridge-side panel. [Figure 4] FIG. 2 is an explanatory diagram showing the configuration of a clip. [Figure 5] FIG. 10 is a perspective view showing the position where the clip is attached. [Figure 6] FIG. 2 is a perspective view showing the configuration of a cover cap. [Figure 7] (a) is a plan view of the connecting structure, (b) is a front view of the continuous structure, (c) is a side view showing the cover cap disassembled, and (d) is a side view showing the eaves side panel and ridge side panel disassembled. [Figure 8] 1(a) is a flowchart showing the manufacturing process of the eaves-side panel, and FIG. 1(b) is a flowchart showing the manufacturing process of the ridge-side panel. [Figure 9] This is a perspective view showing the state just before the eaves side panel and the ridge side panel are joined together. [Figure 10] This is an end view showing the state just before the eaves side panels are placed adjacent to each other in the girder direction. [Figure 11]FIG. 10 is an end view showing two adjacent eaves-side panels arranged in contact with each other. [Figure 12] This is an end view showing two adjacent eaves side panels connected together with a clip. [Figure 13] This is an end view showing one of two adjacent eave-side panels fixed to a rafter with a clip. [Figure 14] This is an end view showing the state in which a cover cap has been installed across the vertical joints of two adjacent eaves side panels. DETAILED DESCRIPTION OF THE INVENTION

[0012] The building material panel according to this embodiment and a connected structure using the building material panel will be described below with reference to the drawings. Fig. 1 is a schematic perspective view showing an example of a connected structure in which a plurality of building material panels according to this embodiment are arranged as a roof.

[0013] As shown in Fig. 1, the building material panel 10 of this embodiment is composed of two panels: an eave-side panel 20 arranged on the eave side, and a ridge-side panel 40 arranged on the ridge side. The eave-side panel 20 and the ridge-side panel 40 are arranged in this order from the eave side along the eave-ridge direction (or the beam direction). Fig. 1 illustrates an example in which a connected structure 100 in which three eave-side panels 20 and three ridge-side panels 40 are arranged in the girder direction is used as a roof.

[0014] As shown in Fig. 2, the eaves side panel 20 includes an exterior skin 21 and a heat insulating material 22. The exterior skin 21 is a metal member that forms the basic skeleton of the eaves side panel 20. The exterior skin 21 is a member that has a rectangular outline in a plan view. Hereinafter, in a plan view of the exterior skin 21, the direction along the short side is referred to as the width direction, and the direction along the long side is referred to as the longitudinal direction. Note that Fig. 2 shows a case where the width direction of the exterior skin 21 is parallel to the girder direction, and the longitudinal direction of the exterior skin 21 is parallel to the eaves-ridge direction.

[0015] The outer cover material 21 is made of a zinc-plated steel plate, an aluminum-zinc alloy-plated plate, a stainless steel plate, an aluminum plate, a copper plate, or a painted or coated metal plate thereof, each having a thickness of about 0.2 to 1.0 mm, more preferably about 0.4 mm. The outer cover material 21 is formed by subjecting a single plate material to forming processing such as roll forming.

[0016] A vertical joint 25 is provided at each end in the width direction of the outer skin material 21. The vertical joint 25 has an inclined wall portion 26, an inclined wall portion 27, a jaw portion 28, and a base portion 29.

[0017] The inclined wall portion 26 is inclined downward from one end portion in the width direction of the outer skin material 21. The inclined wall portion 27 is bent back from the lower end portion of the inclined wall portion 26 and is inclined upward. That is, the inclined wall portions 26 and 27 form a groove portion with a V-shaped cross section. This groove portion can prevent rainwater from entering the inside of the cover cap 70.

[0018] Jaw portion 28 is provided to be continuous with the upper end portion of inclined wall portion 27, and engages with a locking piece 72 of a cover cap 70, which will be described later. An upper surface 28a of jaw portion 28 is set to be slightly lower than the outer surface of outer cover material 21 so that it is flush with the outer surface of outer cover material 21 when cover cap 70, which will be described later, is attached.

[0019] The base portion 29 has a seat 29a provided at a position below the outer surface of the exterior skin material 21 and above the other end of the inclined wall portion 26, and an upright piece 29b erected from the end of the seat 29a. The seat 29a functions as a seat onto which screws 85 are screwed that secure the eaves-side panel 20 to the rafters 82 via the sheathing boards 81 (see, for example, FIG. 9). Therefore, it is preferable that the seat 29a be a horizontal surface. Although the eaves-side panel 20 is fixed to the rafters 82 via the sheathing boards 81, it is also possible to fix it to the purlin.

[0020] A lower joint 32 is provided at one longitudinal end of the exterior skin material 21, via a stepped-down region 31 approximately the same thickness as the exterior skin material 21. The lower joint 32 is covered by an upper joint 51 provided on the exterior skin material 41 of the ridge-side panel 40 when the upper joint 51 is placed over the lower joint 32. The lower joint 32 is provided with insertion portions 33 connected to the vertical joints 25 at both widthwise ends of the exterior skin material 21. The insertion portions 33 have a protrusion 33a connected to the jaw portion 28 and a gutter portion 33b connected to the base portion 29. When the upper joint 51 is placed over the lower joint 32, the protrusion 33a is inserted into a storage space 50 (see FIG. 3 ) formed on the back side of the jaw portion 48 provided on the vertical joint 45. When the upper joint 51 is placed over the lower joint 32, the base portion 49 provided on the vertical joint 45 fits into the gutter portion 33b.

[0021] To ensure high thermal insulation and airtightness, a foamed plastic insulating material with a thickness of, for example, about 300 mm can be used as the insulating material 22. Examples of foamed plastic insulating materials include isocyanate foam and rigid urethane foam. The thickness of the insulating material 22 is preferably in the range of 50 to 300 mm.

[0022] The heat insulating material 22 is a member fixed to the back side of the outer skin material 21. The heat insulating material 22 has a first heat insulating section 35 arranged on the back side of the outer skin material 21 and a second heat insulating section 36 arranged on the back side of the lower joint 32. The first heat insulating section 35 and the second heat insulating section 36 are each produced by performing groove processing such as wire cutting on an insulating block. The first heat insulating section 35 and the second heat insulating section 36 are bonded together using, for example, a hot melt adhesive.

[0023] For example, the width W1 of the heat insulating material 22 in the girder direction is wider than the distance (width) W2 from the standing piece 29b provided outward of the vertical joint 25 provided at one end of the exterior skin material 21 in the width direction to the standing piece 29b provided outward of the vertical joint 25 provided at the other end. Therefore, when the heat insulating material 22 is fixed to the back side of the exterior skin material 21, both ends of the heat insulating material 22 protrude outward beyond both ends of the exterior skin material 21.

[0024] Hereinafter, the length (protrusion amount) by which the left end of the heat insulating material 22 in the width direction protrudes from the left end of the outer skin material 21 is referred to as W3L, and the protrusion amount by which the right end of the heat insulating material 22 in the width direction protrudes from the right end of the outer skin material 21 is referred to as W3R. The sum of the protrusion amount W3L and the protrusion amount W3R is referred to as the total protrusion amount W3.

[0025] The protrusion amounts W3L and W3R are set to lengths that allow the insulating materials 22 of two adjacent eaves side panels 20 to abut against each other without the upstanding pieces 29b of the exterior materials 21 of two adjacent eaves side panels 20 hitting each other when multiple eaves side panels 20 are arranged in predetermined positions. In detail, the values ​​of the protrusion amounts W3L and W3R and the total protrusion amount W3 are set so that the protrusion amounts W3L and W3R are within a range of 0 to 1.5% of the width W1 of the insulating material 22, and the total protrusion amount W3 is within a range of 0 to 1.5% of the width W1 of the insulating material 22, for example.

[0026] In the eaves-ridge direction, the length L1 of the first insulating portion 35 of the insulating material 22 is shorter than the length L2 of the exterior skin material 21. Therefore, when the insulating material 22 is fixed to the back surface of the exterior skin material 21, the insulating material 22 is not present on the back surface of one end of the exterior skin material 21 in the width direction (the portion indicated by reference symbol A1 in FIG. 2) in the eaves-ridge direction. In other words, portion A1 functions as a drip edge when located at the eaves edge, for example, and as an upper joint when covering the lower joint of another building panel.

[0027] In addition, in the eaves-ridge direction, the length L3 of the second insulating portion 36 of the insulating material 22 is the same as the length L4 of the bottom joint 32 of the exterior skin material 21. Here, the above-mentioned length L1 is, for example, L1 = 1650 mm, and the length L3 is, for example, L3 = 150 mm. Furthermore, the length L2 of the exterior skin material 21 is L2 = L1 + (20 to 145) mm.

[0028] As shown in Fig. 3, the ridge-side panel 40 includes an exterior skin 41 and a heat insulating material 42. The exterior skin 41 is a metal member that forms the basic framework of the ridge-side panel 40. The material of the exterior skin 41 is the same as the material of the exterior skin 21 of the eaves-side panel 20, so details thereof will be omitted.

[0029] The skin material 41 is a member whose outline shape is rectangular in a plan view. As with the skin material 21 of the eaves-side panel 20, the direction along the short side of the skin material 41 in a plan view will be referred to as the width direction, and the direction along the long side will be referred to as the longitudinal direction. Figure 3 shows a case where the width direction of the skin material 41 is parallel to the girder direction, and the longitudinal direction of the skin material 41 is parallel to the eaves-ridge direction.

[0030] Vertical joints 45 are provided at both widthwise ends of the exterior skin material 41. The cross-sectional shape of the vertical joints 45 perpendicular to the eaves-ridge direction is the same as the cross-sectional shape of the vertical joints 25 provided in the exterior skin material 21. That is, the vertical joints 45 have inclined wall portions 46, 47, jaw portions 48, and base portions 49. Note that, because the shape of the vertical joints 45 and the shape of the vertical joints 25 are the same, a detailed description of the shape of the vertical joints 45 will be omitted here.

[0031] The insulating material 42 is made of a foamed plastic insulating material, for example, about 300 mm in height, similar to the insulating material 22. Examples of foamed plastic insulating materials include isocyanurate foam and rigid urethane foam, similar to the insulating material 22. The insulating material 42 is grooved by wire cutting or the like so that its top surface is shaped to fit the back surface of the outer skin material 41.

[0032] The width W4 of the insulating material 42 in the girder direction is wider than the distance (width) W5 from the standing piece 49b provided on one end side of the exterior skin material 41 in the width direction to the standing piece 49b provided on the other end side. Therefore, when the insulating material 42 is fixed to the back side of the exterior skin material 41, both ends of the insulating material 42 protrude outward beyond both ends of the exterior skin material 41 in the width direction of the exterior skin material 41.

[0033] Hereinafter, the length (protrusion amount) by which the left end of the heat insulating material 42 in the width direction protrudes from the left end of the outer skin material 41 is referred to as W6L, and the protrusion amount by which the right end of the heat insulating material 42 in the width direction protrudes from the right end of the outer skin material 41 is referred to as W6R. The sum of the protrusion amount W6L and the protrusion amount W6R is referred to as the total protrusion amount W6.

[0034] The protrusion amounts W6L and W6R are set to lengths that allow the insulating materials 42 of two adjacent ridge-side panels 40 to abut against each other without the upstanding pieces 49b of the exterior covering materials 41 of the two adjacent ridge-side panels 40 clashing when the multiple eaves-side panels 20 are respectively arranged in predetermined positions. Specifically, the protrusion amounts W6L and W6R and the total protrusion amount W6 are set so that the protrusion amounts W6L and W6R are within a range of 0 to 1.5% of the width W4 of the insulating material 42, and the total protrusion amount W6 is within a range of 0 to 1.5% of the width W4 of the insulating material 42. The protrusion amounts W6L, W6R and the total protrusion amount W6 may be the same as or different from the protrusion amounts W3L, W3R and the total protrusion amount W3.

[0035] Furthermore, in the eaves-ridge direction, the length L5 of the insulating material 42 is shorter than the length L6 of the exterior skin material 41. Therefore, when the ridge-side end of the exterior skin material 41 is aligned with the ridge-side end of the insulating material 42 in the eaves beam direction and the insulating material 42 is fixed to the exterior skin material 41, the eave-side end of the exterior skin material 41 (the portion indicated by reference numeral 51 in FIG. 3 ) is a portion to which the insulating material 42 is not fixed. This portion 51 functions as an upper joint that is overlapped above the lower joint 32 provided on the exterior skin material 21 of the eaves-side panel 20 when the ridge-side panel 40 is installed. Note that when the upper joint 51 is overlapped above the lower joint 32 provided on the exterior skin material 21 of the eaves-side panel 20, the insertion portion 33 provided on the lower joint 32 of the eaves-side panel 20 is inserted into the storage space 50 provided on the back side of the jaw portion 48 of the vertical joint 45 that extends to the upper joint 51. The length L5 of the heat insulating material 42 is, for example, L5=1655 mm, and the length L6 of the outer covering material 41 is, for example, L6=1800 mm.

[0036] Of the multiple eaves side panels 20 and ridge side panels 40 arranged as the connecting structure 100, two adjacent eaves side panels 20, 20 or two adjacent ridge side panels 40, 40 are linked by clips 60.

[0037] Fig. 4(a) is a perspective view of the clip, Fig. 4(b) is a front view of the clip, Fig. 4(c) is a top view of the clip, Fig. 4(d) is a left side view of the clip, and Fig. 4(e) is a bottom view of the clip. As shown in Fig. 4(a) to Fig. 4(e), the clip 60 is a member that has a hat-like shape when viewed from the front. Note that the left side view and right side view of the clip 60 have the same shape, so they are omitted in Fig. 4.

[0038] The clip 60 links two adjacent eave-side panels 20, 20 or two ridge-side panels 40, 40, and also functions as a retaining clip that maintains a constant installation posture of the cover cap 70. With the two adjacent panels linked together, the clip 60 is fixed to the rafters 82 via the sheathing board 81 with a screw 85, along with one of the two adjacent panels.

[0039] The clip 60 has a double-clip type clip body 61 and tongue pieces 62, 62 connected to the lower end of the clip body 61. The clip body 61, due to elastic deformation caused by springback, clamps two adjacent upright pieces 29b, 29b of the upright pieces 29b provided on two adjacent eaves-side panels 20, 20, or two adjacent upright pieces 49b, 49b of the upright pieces 49b provided on two adjacent ridge-side panels 40, 40, thereby connecting the two adjacent panels.

[0040] The tongue pieces 62, 62 come into surface contact with the seating surfaces 29a of the base portions 29 provided on two adjacent eaves side panels 20, 20 or the seating surfaces 49a of the base portions 49 provided on two adjacent ridge side panels 40, 40, thereby maintaining a constant posture of the clip 60 relative to the two adjacent eaves side panels 20, 20 or the two adjacent ridge side panels 40, 40.

[0041] Each of the tongues 62 has one or two insertion holes 63. A screw 85 is inserted through the insertion hole 63 to fix the clip 60, which connects two adjacent panels, to a rafter 82 via a sheathing board 81.

[0042] A plurality of clips 60 are arranged at predetermined intervals in the eaves-ridge direction of the connecting structure 100. As shown in Fig. 5, when three eaves-side panels 20 and three ridge-side panels 40 are arranged, two adjacent eaves-side panels 20, 20 are connected using one clip 60. Furthermore, two adjacent ridge-side panels 40, 40 are connected using two clips 60, 60. Note that the position at which the clips 60 are attached in the eaves-ridge direction is not limited to that shown in Fig. 5, but may be set as appropriate.

[0043] The cover cap 70a is attached to the vertical joints 25, 25 of two adjacent eaves side panels 20 and the vertical joints 45, 45 of two ridge side panels 40, and connects the vertical joints 25, 25 of the two adjacent eaves side panels 20 and the vertical joints 45, 45 of the two ridge side panels 40. At this time, the cover cap 70a covers the clips 60 that connect the two adjacent eaves side panels 20 and the two ridge side panels 40, and the vertical joints 25, 25, 45, 45.

[0044] As shown in Figures 6 and 7, the cover cap 70a includes a base 71 extending in the eaves-ridge direction and locking pieces 72, 72 provided at both ends of the base 71 in the girder direction. The locking piece 72 is zigzag folded downward to form a jaw portion 72a and an operating portion 72b. The jaw portion 72a elastically deforms when attached to the vertical joint 25 and the vertical joint 45, and engages with the jaw portion 28 of the vertical joint 25 and the jaw portion 48 of the vertical joint 45. The operating portion 72b is operated to release the engagement between the jaw portion 72a of the locking piece 72 and the jaw portion 28 of the vertical joint 25, and the engagement between the jaw portion 72a of the locking piece 72 and the jaw portion 48 of the vertical joint 45, respectively.

[0045] A joint 73 is provided at one end of the cover cap 70a in the longitudinal direction (ridge side). The joint 73 covers the end of the cover cap 70b on the eaves side when the cover cap 70b is attached to the vertical joints 45, 45 of the two ridge-side panels 40. This prevents rainwater and other water flowing from the ridge side of the roof toward the eaves side from getting inside.

[0046] The cover cap 70b differs from the cover cap 70a in that it does not have the joint 73, but otherwise has the same configuration as the cover cap 70a. Therefore, a description of the configuration of the cover cap 70b will be omitted. The cover cap 70b is attached to the vertical joints 45, 45 of two adjacent ridge-side panels 40.

[0047] Note that Figure 7 shows an example in which one cover cap 70a and one cover cap 70b are placed in the eaves-ridge direction, but if multiple cover caps are placed in the eaves-ridge direction, multiple cover caps 70a can be placed from the eaves side and cover cap 70b can be placed at the position closest to the ridge.

[0048] In this embodiment, an example is shown in which a cover cap 70a equipped with a joint 73 and a cover cap 70b covering the joint 73 are used, but the configuration of the cover cap is not limited to the cover cap of this embodiment.

[0049] Next, a description will be given of the process for manufacturing the building panel 10. As described above, the building panel 10 has the eaves-side panel 20 and the ridge-side panel 40. First, a description will be given of the process for manufacturing the eaves-side panel 20.

[0050] As shown in FIG. 8(a), the process for manufacturing the eaves-side panel 20 includes an outer covering material manufacturing step S100, a heat insulating material manufacturing step S200, and a joining step S300.

[0051] The skin material manufacturing process S100 includes a roll forming process S101 and a lower joint processing process S102. The roll forming process S101 is a process in which a roll forming machine is used to roll a single plate material. By performing the roll forming process S101, the skin material 21 used for the eaves side panel 20 is produced. The lower joint processing process S102 is a process in which a press machine is used to perform step processing when adding a lower joint 32 to the eaves side panel 20.

[0052] The thermal insulation manufacturing process S200 includes a groove processing process S201 and a joining process S202. The groove processing process S201 is a process in which, for example, a method such as wire cutting is used on a thermal insulation block of a predetermined size to produce a thermal insulation material that matches the shape of the outer skin material 21. By performing the groove processing process S201, a first insulating section 35 and a second insulating section 36 of the thermal insulation material 22 are produced.

[0053] The joining step S202 is a step of joining the first heat insulating section 35 and the second heat insulating section 36 manufactured in the groove processing step S201 using, for example, a hot melt adhesive.

[0054] The joining process S300 includes an adhesive application process S301 and a heating and pressurizing process S302. The adhesive application process S301 is a process in which an automatic adhesive application device is used to apply adhesive to the bottom surface of the exterior skin material 21 or the top surface of the insulation material 22. The heating and pressurizing process S302 is a process in which a press machine is used to bond the exterior skin material 21 and the insulation material 22 together. By performing this joining process S300, the above-mentioned eaves-side panel 20 is produced.

[0055] Furthermore, the process for manufacturing the ridge-side panel 40 differs from the process for manufacturing the eave-side panel 20 in the following respects. As described above, the ridge-side panel 40 does not have a lower joint in the exterior skin 41, and the insulation 42 fixed to the exterior skin 41 does not have a stepped portion configured to match the lower joint. Therefore, as shown in FIG. 8(b), when manufacturing the ridge-side panel 40, the lower joint processing step S102 is omitted from the exterior skin manufacturing step S100. Similarly, the joining step S202 is omitted from the insulation manufacturing step S200.

[0056] Note that while Figure 8 separately describes the manufacturing of the eaves-side panel 20 and the manufacturing of the ridge-side panel 40, it is also possible to imagine a case where a mixture of eaves-side panels 20 and ridge-side panels 40 is manufactured. In such a case, for example, between the roll-forming step S101 and the lower joint processing step S102 in Figure 8(a), it is possible to add a step of determining whether the building material panel 10 to be manufactured is the eaves-side panel 20 or the ridge-side panel 40. That is, if it is determined in this determination step that the eaves-side panel 20 will be manufactured, the lower joint processing step S102 is performed. Furthermore, if it is determined in this determination step that the ridge-side panel 40 will be manufactured, the lower joint processing step S102 can be omitted.

[0057] Similarly, in the insulation material manufacturing process S200, a process of determining whether the building material panel 10 to be manufactured is an eaves side panel 20 or a ridge side panel 40 must be added between the groove processing process S201 and the joining process.

[0058] Finally, the procedure for arranging a plurality of the above-described building panels 10 to create a connected structure 100 will be described. The eaves-side panel 20 and the ridge-side panel 40 are arranged along the eaves beam direction from the eaves side of the upper surface of the sheathing board 81 on which the underlayment 83 has been placed. As shown in FIG. 9 , the ridge-side panel 40 is arranged so that the upper joint 51 of the ridge-side panel 40 overlaps the lower joint 32 of the eaves-side panel 20. At this time, the protrusion 33a of the insertion portion 33 provided on the lower joint 32 of the eaves-side panel 20 is inserted into the storage space 50 provided in the vertical joint 45 extending to the upper joint 51 provided on the ridge-side panel 40. This joins the eaves-side panel 20 and the ridge-side panel 40 together. The ridge-side panel 40 is arranged so that the upper joint 51 overlaps the lower joint 32 of the eaves-side panel 20.

[0059] As shown in Figures 10 and 11, when the eaves-side panels 20 and ridge-side panels 40 are joined together, new eaves-side panels 20 and ridge-side panels 40 are placed along the eaves beam direction at positions offset in the beam direction. The newly placed eaves-side panels 20 and ridge-side panels 40 are joined together. In this way, a predetermined number of eaves-side panels 20 and ridge-side panels 40 are placed on the sheathing board 81. The eaves-side panels 20 and ridge-side panels 40 are placed in predetermined positions on the sheathing board 81.

[0060] As described above, the width W1 of the insulating material 22 of the eaves-side panel 20 is wider than the width W2 of the exterior skin 21, and both ends of the insulating material 22 protrude outward beyond the upright pieces 29b of the exterior skin 21. Therefore, when the eaves-side panel 20 is placed in a predetermined position on the sheathing board 81, the insulating materials 22 of two adjacent eaves-side panels 20 abut against each other. The insulating materials 42 of two adjacent ridge-side panels 40 also abut against each other. By maintaining the insulating materials of two adjacent building panels in abutting contact with each other in this way, it is possible to ensure insulation efficiency and airtightness without placing an airtight gasket (joint gasket) between the two building panels.

[0061] In addition, since there is no need to place airtight packing (joint packing), work efficiency can be improved when placing building panels and roofing. Furthermore, by having the insulating material 22 protrude outward beyond the upright pieces 29b of the exterior skin material 21, the edge distance from the abutting end face of the insulating material 22 to the position where the screws 85 are fastened can be increased, thereby preventing damage such as cracks in the insulating material 22 when the eaves side panel 20 is fixed to the rafters 82 via the sheathing boards 81.

[0062] In addition, when the building material panel 10 is the ridge-side panel 40, the same effects as those of the eaves-side panel 20 can be obtained.

[0063] As shown in Figure 11, after the eaves-side panel 20 and the ridge-side panel 40 are placed in predetermined positions on the sheathing board 81, of the upright pieces 29b provided on the two adjacent eaves-side panels 20, 20, two adjacent upright pieces 29b, 29b are clamped with clips K. Similarly, of the upright pieces 49b provided on the two adjacent ridge-side panels 40, 40, two adjacent upright pieces 49b, 49b are clamped with clips K. This connects the two adjacent eaves-side panels 20, 20 and the two adjacent ridge-side panels 40, 40.

[0064] Incidentally, the tongue 62 of the clip 60 is provided with an insertion hole 63 for inserting a screw 85. Therefore, as shown in Figures 12 and 13, when two adjacent eaves side panels 20, 20 or two adjacent ridge side panels 40, 40 are connected, the eaves side panel 20 or the ridge side panel 40 is fixed to the rafter 82 together with the clip 60 via the sheathing board 81 using the screw 85.

[0065] Finally, as shown in FIG. 14 , cover caps 70a, 70b are attached across the two vertical joints 25, 25 that are closest to the adjacent eaves-side panels 20, 20, out of the vertical joints 25 of the two adjacent eaves-side panels 20. At the same time, cover caps 70a, 70b are attached across the two vertical joints 45, 45 that are closest to the adjacent ridge-side panels 40, 40, out of the vertical joints 45 of the two adjacent ridge-side panels 40. This connects the two adjacent eaves-side panels 20, 20 and the two adjacent ridge-side panels 40, 40. At the same time, the cover caps 70a, 70b cover the clips 60 that connect the two adjacent eaves-side panels 20, 20 or the two adjacent ridge-side panels 40, 40, as well as the two adjacent vertical joints 25, 25 and vertical joints 45, 45.

[0066] In this embodiment, the eaves side panel 20 and the ridge side panel 40 are configured so that the insulating materials 22, 42 protrude outward from the upright pieces 29b, 49b of the outer skin materials 21, 41 at both ends in the girder direction, but it is not necessary to have the insulating materials protrude from the upright pieces of the outer skin material at each of both ends in the girder direction; it is sufficient to have the insulating materials protrude outward from the upright pieces of the outer skin material at at least one of both ends in the girder direction.

[0067] In this embodiment, the panels 20, 40 are arranged so that the insulating materials 22, 22 of two adjacent eaves-side panels 20, 20 or the insulating materials 42, 42 of two adjacent ridge-side panels 40, 40 abut against each other. However, depending on the abutting state of the insulating materials described above, it is possible that two adjacent upright pieces 29b, 29b or upright pieces 49b, 49b may abut against each other. Therefore, for example, when the insulating materials 22, 22 abut against each other, it is possible to place a sealant (a buffer material) between the two adjacent upright pieces 29b, 29b to prevent the two adjacent upright pieces 29b, 29b from abutting against each other. In this case, it is sufficient to place a sealant (a buffer material) between the upright pieces 49b, 49b of not only the two adjacent eaves-side panels 20, 20 but also the two adjacent ridge-side panels 40, 40.

[0068] In this embodiment, the building panel 10 is described as being composed of two panels, the eave-side panel 20 and the ridge-side panel 40. However, there are also cases where three or more building panels are arranged in the eaves-ridge direction. In such a case, it is possible to compose the building panel from three types of panels: a panel arranged at the eave-side end in the eaves-ridge direction, a panel arranged at the ridge-side end, and one or more panels arranged between these two panels. In this case, the panel arranged at the eave-side end is a building panel with an exterior skin material having a lower joint at one longitudinal end. Similarly, the panel arranged at the ridge-side end is a building panel with an exterior skin material having an upper joint at one longitudinal end, as in this embodiment. Furthermore, the panel arranged between the panel arranged at the eave-side end and the panel arranged at the ridge-side end is a building panel with an exterior skin material having a lower joint at one longitudinal end and an upper joint at the other longitudinal end. <Summary of effects>

[0069] The building material panel 10 (20, 40) shown in this embodiment comprises a metal skin material 21 (41) with vertical joints 25 (45) provided at both widthwise ends, and a heat insulating material 22 (42) fixed to the back surface of the skin material 21 (41). After another building material panel is placed adjacent to one of the widthwise end portions of the skin material 21 (41), a cover cap 70 is engaged across the vertical joint 25 (45) and the adjacent joint of the other building material panel to connect it to the other building material panel, thereby constructing a roof or wall of an architectural structure. The building material panel 10 (20, 40) is characterized in that at least one end of both widthwise ends of the heat insulating material 22 (42) of the skin material 21 (41) protrudes outward beyond the upright piece 29 b (49 b) erected on the outer edge of the vertical joint 25 (45).

[0070] With this, when the building panels are placed in a predetermined position on the sheathing board 81, the insulating materials of two building panels adjacent in the beam direction are held in contact with each other. Therefore, it is possible to ensure insulation efficiency and airtightness without using airtight packing (joint packing) between the two building panels adjacent in the beam direction.

[0071] In addition, the core material is at least one insulating material 22 (42) formed by groove-processing an insulating block to match the shape of the bottom surface of the outer skin material 21 (41), and it is preferable that the at least one insulating material 22 (42) is fixed to the bottom surface of the outer skin material 21 (41) or the top surface of the insulating material 22 (42) using an adhesive.

[0072] Conventional building panels have a structure in which insulation is placed between the outer and inner skin materials. Building panels with this structure are manufactured by heating and pressurizing the space between the outer and inner skin materials while injecting a foaming agent, which is the raw material for the insulation. However, building panels manufactured by injecting a foaming agent can cause voids (air bubbles) to form in the insulation, which can deform the outer skin material. Furthermore, conventional building panels are manufactured using a multi-stage press to inject the foaming agent, but this has problems such as being unable to manufacture building panels thicker than a specified thickness and requiring a long hardening time for the injected foaming agent.

[0073] However, in this embodiment, by using an adhesive to bond pre-made insulation blocks with grooves to the outer skin, there is no need to consider the occurrence of voids and the resulting deformation of the outer skin. Furthermore, the curing time of the adhesive used to bond the insulation to the outer skin is shorter than the curing time of the foaming agent, improving manufacturing efficiency. Furthermore, by using a process to bond the insulation to the outer skin, it is possible to manufacture building panels of the desired thickness.

[0074] In addition, the connecting structure 100 of this embodiment arranges the eaves side panels 20 or ridge side panels 40 that constitute the building material panel 10 adjacent to each other at least in the width direction of the exterior skin material 21 (41), and with the insulating materials 22, 22 (42, 42) of two adjacent eaves side panels 20, 20 (or ridge side panels 40, 40) in the width direction of the exterior skin material 21 (41) abutting each other, and engages a cover cap 70 across the two vertical joints 25, 25 (45, 45) that are closest to the adjacent eaves side panels 20 (or ridge side panels 40) of the vertical joints 25 (45) provided at both ends of the eaves side panel 20 (or ridge side panel 40) in the width direction of the exterior skin material 21 (41).

[0075] With this, when the building material panel is placed in a predetermined position on the sheathing board 81, the insulating materials 22, 22 (42, 42) of two adjacent eaves side panels 20, 20 (or ridge side panels 40, 40) are in contact with each other, and these two eaves side panels 20, 20 (or ridge side panels 40, 40) are linked together. Therefore, gaps are prevented from occurring between the two adjacent eaves side panels 20, 20 (or ridge side panels 40, 40). As a result, insulation efficiency and airtightness are ensured.

[0076] In addition, of the upright pieces 29b (49b) provided at the vertical joints 25, 25 (45, 45) of two adjacent eaves side panels 20, 20 (or ridge side panels 40, 40), the two adjacent upright pieces 29b, 29b (49b, 49b) are held by clips 60, and the clips 60 holding the two upright pieces 29b, 29b (49b, 49b) are fixed to the rafters 82 via sheathing boards 81 together with the two adjacent eaves side panels 20, 20 (or ridge side panels 40, 40).

[0077] This allows the distance from the end face of the abutting insulation material 22 (42) to the position where the screw 85 is tightened to be increased, thereby preventing damage such as cracks in the insulation material 22 (42) when the eaves side panel 20 (or ridge side panel 40) is fixed to the rafters 82 via the sheathing board 81.

[0078] In addition, the manufacturing method for the building panel 10 (20, 40) of this embodiment is characterized by comprising the steps of: roll-forming a metal plate to produce the outer skin 21, 41 with joints at both widthwise ends; groove-cutting an insulating block to produce the insulating material 22, 42 having an upper surface that matches the shape of the bottom surface of the outer skin 21, 41 and at least one of both widthwise ends of the outer skin 21, 41 protruding outward beyond the end of the outer skin 21, 41; applying adhesive to the bottom surface of the outer skin 21, 41 or the top surface of the insulating material 22, 42; and applying heat and pressure to the bottom surface of the outer skin and the top surface of the insulating material while they are in contact, thereby adhering the insulating material 22, 42 to the outer skin 21, 41.

[0079] This method uses an adhesive to bond pre-formed insulation blocks with grooves to the outer skin, preventing the formation of voids (air bubbles) when a foaming agent is injected to form the insulation, as well as the resulting deformation of the outer skin. Furthermore, the curing time of the adhesive used to bond the insulation to the outer skin is shorter than the curing time of the foaming agent, improving the manufacturing efficiency of building panels. Furthermore, by manufacturing the building panel from the process of bonding the insulation to the outer skin, the thickness of the insulation can be freely selected, making it possible to manufacture building panels of the desired thickness. [Explanation of symbols]

[0080] 10 Building Material Panels 20 Eaves side panel 21,41 Outer skin material 22,42 Insulation material (core material) 25,45 Vertical joint 29b,49b Standing piece 40 Building side panel 60 clips 70 Cover Cap 100 linked structures

Claims

1. a step of roll-forming a metal plate material to produce an outer skin material having joints at both ends in the width direction; a step of forming grooves in the foam block to produce a heat insulating material having an upper surface that matches the shape of the bottom surface of the outer skin material, and at least one of both end portions in the width direction of the outer skin material protruding outward beyond the end portion of the outer skin material; applying an adhesive to the bottom surface of the outer skin material or the top surface of the heat insulating material; and applying heat and pressure to the bottom surface of the outer skin material and the top surface of the insulating material while they are in contact, thereby adhering the insulating material to the outer skin material.

2. 2. The method for manufacturing a building panel according to claim 1, further comprising the step of forming a step for a lower joint located below the surface of the skin material at one end of the skin material in the longitudinal direction using a press machine.

3. The method for manufacturing a building material panel described in claim 2, characterized in that the process of producing the insulation material includes a process of manufacturing a first insulation section located on the bottom surface of the outer skin material and a second insulation section located on the bottom surface of the lower joint, and a process of joining the first insulation section and the second insulation section using a hot melt adhesive to produce the insulation material.

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