Heat insulation structure and method for manufacturing the same

Abstract

To provide a heat insulation structure capable of improving the durability of an exterior heat insulation layer while increasing the thickness of the exterior heat insulation layer.SOLUTION: A heat insulation structure comprises: a column or a stud; a false material disposed on an outdoor side of the column or the stud; a sash frame supported by the column or the stud and the false material; a first heat insulation layer disposed on the outdoor side of the column or the stud and close to the false material; a water-resistant layer disposed on the outdoor side of the false material and the first heat insulation layer; and a second heat insulation layer disposed on the outdoor side of the water-resistant layer. The water-resistant layer is substantially flat.SELECTED DRAWING: Figure 1

Description

[Technical Field]

[0001] The present invention relates to a thermal insulation structure and a method for manufacturing a thermal insulation structure. [Background technology]

[0002] As described in Patent Document 1, a heat insulating structure is known in which a heat insulating material is provided in an exterior wall and a sash frame is arranged in an opening. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Publication No. 2023-065300 Summary of the Invention [Problem to be solved by the invention]

[0004] In the thermal insulation structure described in Patent Document 1, if the thickness of the exterior thermal insulation layer is increased, the surface and edge of the exterior thermal insulation layer may protrude outward beyond the outer surface of the window frame. In this configuration, there is a risk of the exterior thermal insulation layer being damaged.

[0005] Therefore, an object of the present invention is to provide an insulation structure that can improve the durability of an exterior insulation layer while increasing the thickness of the exterior insulation layer, and a method for manufacturing the insulation structure. [Means for solving the problem]

[0006] The heat insulating structure according to a first aspect of the present invention comprises: (1) a pillar or stud; A reinforcement material to be placed on the outdoor side of the pillar or stud; A sash frame supported by the pillar or stud and the roofing material; A first insulation layer disposed on the outdoor side of the column or stud and adjacent to the insulation material; A waterproof layer disposed on the outdoor side of the insulation material and the first insulation layer; A second insulating layer disposed on the outdoor side of the waterproof layer; Equipped with The waterproof layer is substantially flat. It has an insulated structure.

[0007] In a heat insulating structure according to one embodiment of the present invention, (2) In the thermal insulation structure described in (1) above, the first thermal insulation layer and the second thermal insulation layer each consist of a single thermal insulation panel in the out-of-plane direction of the waterproof layer.

[0008] In a heat insulating structure according to one embodiment of the present invention, (3) The thermal insulation structure according to (1) or (2) above, wherein the first insulation layer or the second insulation layer includes a foamed plastic insulation material.

[0009] A method for manufacturing a heat insulating structure according to a second aspect of the present invention includes: (4) A step for attaching a filler material to the outdoor side of the pillar or stud; a sash material mounting step of mounting a sash frame to the sash material; A first insulation layer installation step of installing a first insulation layer on the outdoor side of the column or stud and in proximity to the roofing material; A waterproof layer installation step of installing a waterproof layer on the outdoor side of the insulation material and the first insulation layer; A second insulation layer installation step of installing a second insulation layer on the outdoor side of the waterproof layer; Includes. [Effects of the Invention]

[0010] According to the present invention, it is possible to provide an insulation structure and a method for manufacturing an insulation structure that can improve the durability of an exterior insulation layer while increasing the thickness of the exterior insulation layer. [Brief explanation of the drawings]

[0011] [Figure 1] 1 is a horizontal cross-sectional view of a heat insulating structure according to a first embodiment of the present invention. [Figure 2] FIG. 2 is a horizontal cross-sectional view showing a modified example of the heat insulating structure shown in FIG. DETAILED DESCRIPTION OF THE INVENTION

[0012] DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS Hereinafter, embodiments of a heat insulating structure according to the present invention will be described with reference to the accompanying drawings. In the drawings, the same reference numerals are used to designate common components.

[0013] Fig. 1 is a diagram showing a thermal insulation structure 101 as a first embodiment of the thermal insulation structure according to the present invention. More specifically, Fig. 1 shows details of a building 100 including the thermal insulation structure 101. Fig. 1 is a horizontal cross-sectional view of the thermal insulation structure 101 of the building 100.

[0014] First, an overview of the building 100 will be described. The building 100 of this embodiment is, for example, a two-story detached house with a wooden framework. Although the building 100 of this embodiment is a detached house, it may also be, for example, an apartment building with multiple dwelling units. There is also no particular limitation on the number of floors of the building 100. The building 100 may have, for example, three or more floors.

[0015] The building 100 of this embodiment comprises a reinforced concrete foundation and a superstructure having a framework made up of framework members such as columns and beams and supported by the foundation. The superstructure of this embodiment has a wooden framework, but may also have, for example, a steel framework. Walls, floors, roofs, etc. may be constructed by nailing structural surface materials to the framework. The structure of the superstructure is not particularly limited.

[0016] More specifically, the superstructure of the building 100 of this embodiment may include the above-mentioned framework and a heat-insulating structure 101.

[0017] The thermal insulation structure 101 may constitute an exterior wall that separates the indoor and outdoor spaces of the building 100. The thermal insulation structure 101 of the building 100 of this embodiment includes pillars or studs 21a, a roofing member 28, a sash frame 1, a first thermal insulation layer 21e1, a waterproof layer 21d, and a second thermal insulation layer 21e2. The thermal insulation structure 101 may further include a structural surface material 21b and a filling thermal insulation material 21c.

[0018] As shown in Fig. 1, an opening 101a is formed in the thermal insulation structure 101. Examples of the opening 101a in the thermal insulation structure 101 include a window and a doorway. The opening 101a shown in Fig. 1 is a window as an example, but it may also be a doorway that allows communication between an indoor space and an outdoor space.

[0019] In the opening 101a of the heat insulating structure 101, a sash frame 1 and a panel material fitted into this sash frame 1 may be arranged.

[0020] The sash frame 1 may be attached so as to cover the inner end surface of the opening 101a of the thermal insulation structure 101. A shoji screen may be fitted as a panel material into the sash frame 1 of this embodiment. The shoji screen as a panel material includes triple-layered glass panes and a frame portion attached to the peripheral edge of the glass panes, but is not limited to this configuration. The panel material may be, for example, a plate material that does not include glass panes. Furthermore, the panel material may be, for example, a fixed structure in which it is fixed so as not to move relative to the sash frame 1.

[0021] The sash frame 1 may be made of a metal such as aluminum, may be made of resin, or may be a composite sash frame containing metal and resin.

[0022] The sash frame 1 may be fastened to a pillar or stud 21a by a fastening member such as a screw 27, for example.

[0023] The pillars or studs 21a support the sash frame 1. The pillars or studs 21a may also support the structural panel 21b.

[0024] A structural surface material 21b may be placed on the outdoor side of the pillar or stud 21a and fastened to the pillar or stud 21a with fastening members such as screws.

[0025] The filling insulation material 21c is filled in the spaces between the pillars or studs 21a on the indoor side of the structural facing material 21b. The filling insulation material 21c may be, for example, a fibrous insulation material such as rock wool or glass wool. As mentioned above, the insulation structure 101 does not necessarily have to be provided with the filling insulation material 21c.

[0026] A reinforcement member 28 is disposed on the exterior side of the pillar or stud 21a. The reinforcement member 28 may be disposed on the exterior side of the structural surface member 21b. The reinforcement member 28 may be made of wood, porous material, foam material, steel, or the like. The pillar or stud 21a supports a sash frame 1 on one side (the left side in FIG. 1 ). The sash frame 1 may include a fin 1f extending along the surface of the reinforcement member 28. A screw 29 may pass through an opening formed in the fin 1f to fasten the sash frame 1 to the reinforcement member 28.

[0027] The first insulating layer 21e1 is disposed on the opposite side of the sash frame 1 from the insulator 28 (the right side in FIG. 1). The first insulating layer 21e1 may be adjacent to the insulator 28. The first insulating layer 21e1 may be fastened to the pillar or stud 21a with fastening members such as screws 24. The first insulating layer 21e1 may include a foamed plastic insulating material. Since foamed plastic insulating material has low thermal conductivity, including the insulator layer 21e1 insulates the insulating performance better. The first insulating layer 21e1 may be a panel-shaped insulating material such as phenolic foam. The first insulating layer 21e1 may also be a fibrous insulating material such as rock wool or glass wool. The thickness of the first insulating layer 21e1 may be, for example, 50 millimeters.

[0028] The first insulating layer 21e1 may consist of a single insulating panel in the out-of-plane direction (vertical direction in FIG. 1) of the waterproof layer 21d. This configuration can improve workability. The first insulating layer 21e1 may consist of multiple insulating panels in an orthogonal direction (horizontal direction in FIG. 1) perpendicular to the out-of-plane direction. Waterproof tape may be applied to the joints between adjacent insulating panels in the orthogonal direction.

[0029] Waterproof layer 21d is disposed on the outdoor side of piling material 28 and first insulating layer 21e1. Waterproof layer 21d may be laminated on the outdoor side of structural facing 21b. This configuration can protect piling material 28, first insulating layer 21e1, and structural facing 21b from moisture outdoors, etc. Waterproof layer 21d may be fixed to piling material 28 and first insulating layer 21e1 with a member such as a tacker and / or double-sided waterproof tape.

[0030] The waterproof layer 21d may be substantially flat. In other words, the surface of the waterproof layer 21d facing the covering material 28 and the first insulating layer 21e1, and the surface of the waterproof layer 21d facing the second insulating layer 21e2 may be substantially flat. "Substantially flat" here refers to a flatness that does not cause the waterproof layer 21d to break. This configuration can prevent damage to the waterproof layer 21d, allowing the insulating structure 101 to reliably exhibit waterproof performance. The waterproof layer 21d may be a sheet-like member such as asphalt roofing. The waterproof layer 21d may be flat.

[0031] The second insulating layer 21e2 is disposed on the outdoor side of the waterproof layer 21d. The second insulating layer 21e2 may have a configuration similar to that of the first insulating layer 21e1. The thickness of the second insulating layer 21e2 may be, for example, 50 millimeters.

[0032] In the thermal insulation structure 101, the second insulating layer 21e2 may be disposed on the outdoor side of the waterproof layer 21d. The second insulating layer 21e2 may be located close to the insulator 28. This configuration ensures the thickness of the insulating layer and improves thermal insulation performance. Furthermore, since the insulator 28 supports the sash frame 1, the sash frame 1 can be disposed closer to the outdoor side, reducing the protrusion of the first insulating layer 21e1 and the second insulating layer 21e2 toward the outdoor side. This reduces damage to the first insulating layer 21e1 and the second insulating layer 21e2. Furthermore, as shown in FIG. 1, the first insulating layer 21e1 and the second insulating layer 21e2 can be combined to form a stepped member with no corners (the lower left corner in FIG. 1) that can be easily constructed. For example, this eliminates the need for processing to remove the corners of the first insulating layer 21e1 and the second insulating layer 21e2.

[0033] In this specification, the second insulating layer 21e2 being "close to" the filling material 28 includes not only the state in which the second insulating layer 21e2 is in contact with the filling material 28, but also the state in which the gap between the second insulating layer 21e2 and the filling material 28 is small enough that the waterproof layer 21d can be attached almost flat.

[0034] The first insulating layer 21e1 may be arranged on the opposite side of the insulating material 28 from the sash frame 1 (the right side in FIG. 1). The first insulating layer 21e1 may be in contact with the insulating material 28. The outdoor surface of the first insulating layer 21e1 may be flush with the outdoor surface of the insulating material 28.

[0035] As shown in Figure 2, the first insulating layer 21e1 may be composed of two members 21e11 and 21e12. The members 21e11 and 21e12 may be made of the same material. The member 21e11 is disposed on the outdoor side of the insulating material 28. This configuration can improve the insulating performance between the insulating material 28 and the waterproof layer 21d. Even with this configuration, the waterproof layer 21d is substantially flat.

[0036] The ends of the first insulating layer 21e1 and the second insulating layer 21e2 in the width direction (left direction in FIG. 1) may be covered with a plate material 23. A cylindrical backup material 22b may be sandwiched between the plate material 23 and the sash frame 1. A sealing material 22a may be filled on the outdoor side (upper side in FIG. 1) of the backup material 22b.

[0037] The plate 23 may join the second insulating layer 21e2 and the sealing material 22a. More specifically, the plate 23 may include an intervening plate portion 23a interposed between the second insulating layer 21e2 and the sealing material 22a, and an extending plate portion 23b extending from the intervening plate portion 23a. The plate 23 may be made of a resin such as polyvinyl chloride. The intervening plate portion 23a may extend along the end surface of the second insulating layer 21e2. The extending plate portion 23b may be perpendicular to the intervening plate portion 23a in the cross-sectional view shown in FIG. 1 and extend along the outer surface of the second insulating layer 21e2. In other words, the plate 23 covers the end portion, including the corner between the end surface and the outer surface of the second insulating layer 21e2. This prevents the end portion from being deformed or damaged due to contact or the like.

[0038] Two extended plate portions may be provided, each extending from both ends of the intervening plate portion 23a. In other words, the plate material 23 shown in FIG. 1 has an L-shaped cross-sectional outline in a horizontal cross section, but may also have a U-shaped cross-sectional outline in the same cross section. In such a case, the intervening plate portion of the plate material 23 covers the end face of the second insulating layer 21e2. Furthermore, one extended plate portion extends along the front surface of the second insulating layer 21e2, and the other extended plate portion extends along the back surface of the second insulating layer 21e2.

[0039] The intervening plate portion 23a may be fixed to the sealing material 22a at a first fixing surface, which is, for example, the entire surface facing the sealing material 22a.

[0040] A second fixing surface opposite to the fixing surface of the intervening plate portion 23a may be fixed to the second heat insulating layer 21e2.

[0041] The intervening plate portion 23a can be fixed by, for example, bonding using an adhesive. The first fixing surface may be bonded to the wet sealing material 22a without adhesive. In other words, the first fixing surface may be bonded to the sealing material 22a due to the viscosity of the sealing material 22a.

[0042] The first fixing surface or the second fixing surface extends along the depth direction of intervening plate portion 23a and sealing material 22a (a direction perpendicular to the plane of the paper in FIG. 1). In other words, the first fixing surface or the second fixing surface extends along the inner end surface of opening 101a.

[0043] The extension plate portion 23b is fixed to the second insulating layer 21e2 by a first fixing portion. This fixing may be performed by bonding using an adhesive, for example. This fixing may prevent liquids such as rainwater from penetrating between the plate material 23 and the second insulating layer 21e2.

[0044] An outer surface layer 26 may be formed on the outdoor side of the second heat insulating layer 21e2 using, for example, a finishing coating material.

[0045] Hereinafter, one embodiment of a method for manufacturing a thermal insulation structure according to the present invention will be described. Here, the construction direction for the thermal insulation structure 101 shown in Fig. 1 will be described, but the manufacturing method of the present invention can also be applied to other thermal insulation structures according to the present invention, such as the thermal insulation structure 101' shown in Fig. 2.

[0046] The method for manufacturing a thermally insulated structure includes a step of attaching a filler material, a step of attaching a sash material, a step of attaching a first thermal insulation layer, a step of attaching a waterproof layer, and a step of attaching a second thermal insulation layer.

[0047] In the step of attaching the insulating material, the insulating material 28 is attached to the exterior side of the pillar or stud 21a. The insulating material 28 may be attached to the pillar or stud 21a via the structural surface material 21b.

[0048] In the sash material mounting step, the sash frame 1 is mounted on one side (the left side in FIG. 1 ) of the extension material 28. Referring to FIG. 1 , in a configuration in which the sash frame 1 includes a fin 1 f, the sash frame 1 may be fastened to the extension material 28 by a screw 29 passing through an opening formed in the fin 1 f.

[0049] In the first insulation layer installation step, the first insulation layer 21e1 is installed on the outdoor side (upper side in FIG. 1 ) of the pillar or stud 21a and adjacent to the covering material 28. The first insulation layer 21e1 may be fastened to the pillar or stud 21a with screws, nails, adhesive, tape, or a combination thereof. After the first insulation layer installation step is completed, the outdoor surface of the first insulation layer 21e1 may be flush with the outdoor surface of the covering material 28.

[0050] In the waterproof layer installation step, the waterproof layer 21d is installed on the outdoor side of the expansion material 28 and the first insulating layer 21e1. The waterproof layer 21d is installed so as to be substantially flat. The waterproof layer 21d may be fixed to the expansion material 28 and the first insulating layer 21e1 with a member such as a stapler. Waterproof tape may be applied across the fin 1f of the sash frame 1, the expansion material 28, and the first insulating layer 21e1.

[0051] In the second insulating layer mounting step, the second insulating layer 21e2 is mounted on the outdoor side of the waterproof layer 21d. The second insulating layer 21e2 may be fastened to the waterproof layer 21d with screws 24, or with screws 24 and washers 25 as shown in Figures 1 and 2. The diameter of the washers 25 may be equal to or greater than the diameter of the heads of the screws 24. The washers 25 are preferably made of resin such as polypropylene, but are not particularly limited to such resins. [Explanation of symbols]

[0052] 1: Sash frame 1F: Fin 100: Building 101: Insulated structure 101a: Opening 21a: Pillar or stud 21b: Structural surface material 21c: Filler insulation 21d: Waterproof layer 21e1, 21e11, 21e12: First insulation layer 21e2: Second insulation layer 22a: Sealant 22b: Backup material 23: Board material 23a: Interposed plate part 23b: Extension plate part 24, 27, 29: Bis 25: Washer 26: Outer surface layer 28: Puffing material

Claims

1. a pillar or stud; A reinforcement material to be placed on the outdoor side of the pillar or stud; A sash frame supported by the pillar or stud and the roofing material; A first insulation layer disposed on the outdoor side of the column or stud and adjacent to the insulation material; A waterproof layer disposed on the outdoor side of the insulation material and the first insulation layer; A second insulating layer disposed on the outdoor side of the waterproof layer; Equipped with The waterproof layer is substantially flat. Insulated structure.

2. The first insulation layer and the second insulation layer each consist of one insulation panel in the out-of-plane direction of the waterproof layer. The thermal insulation structure of claim 1 .

3. the first insulation layer or the second insulation layer comprises foamed plastic insulation; The heat insulating structure according to claim 1 or 2.

4. A step for attaching a filler material to the outdoor side of the pillar or stud; a sash material mounting step of mounting a sash frame to the sash material; A first insulation layer installation step of installing a first insulation layer on the outdoor side of the column or stud and in proximity to the piling material; A waterproof layer installation step of installing a waterproof layer on the outdoor side of the insulation material and the first insulation layer; a second insulation layer mounting step of mounting a second insulation layer on the outdoor side of the waterproof layer; A method for manufacturing a thermal insulation structure, comprising:

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