Roof panel unit and roof manufacturing method

Abstract

To provide a roof panel unit and a roofing method that offer high workability and ensure adequate insulation and ventilation. [Solution] A roof panel unit according to one aspect of the present invention comprises a plate-shaped panel portion, a support frame fixed to the back side of the panel portion, and an insulating material connected to the support frame and positioned opposite the back side of the panel portion with a predetermined gap between them, wherein at least one of the panel portion and the support frame is fixed to the framework of the roof structure.

Description

Technical Field

[0001] The present invention relates to a roof panel unit and a method for manufacturing a roof.

Background Art

[0002] In a building used for a dwelling or the like, a roof structure is used in which a sub-floor such as a field board is assembled to a framework portion and a heat insulating material is provided on the back side of the sub-floor.

[0003] In such a roof structure, there is a demand for a roof structure that has high workability and can ensure heat insulation and ventilation properties. (For example, see Patent Document 1).

Prior Art Documents

Patent Documents

[0004]

Patent Document 1

Patent Document 2

Summary of the Invention

Problems to be Solved by the Invention

[0005] Therefore, an object of the present invention is to provide a roof panel unit and a method for manufacturing a roof that have high workability and can ensure heat insulation and ventilation properties.

Means for Solving the Problems

[0006] A roof panel unit according to an aspect of the present invention includes a plate-shaped panel portion, a support frame fixed to the back side of the panel portion, and a heat insulating material connected to the support frame and disposed opposite to the back surface of the panel portion with a predetermined gap formed therebetween, and at least one of the panel portion and the support frame is fixed to a framework portion of a roof structure.

Effects of the Invention

[0007] According to the present invention, it is possible to provide a roof panel unit and a method for manufacturing a roof that are easy to install and can ensure heat insulation and ventilation. [Brief explanation of the drawing]

[0008] [Figure 1] A perspective view showing the configuration of the framework of a roof structure according to the first embodiment of the present invention. [Figure 2] A perspective view showing a portion of the roof's structure. [Figure 3] A cross-sectional view showing the structure of a part of the roof. [Figure 4] A plan view showing the configuration of a portion of the roof. [Figure 5] A cross-sectional view showing the structure of a part of the roof. [Figure 6] A rear view of the roof panel unit according to the first embodiment. [Figure 7] A cross-sectional view showing the configuration of the roof panel unit. [Figure 8] A side view showing the configuration of a roof panel unit according to another embodiment. [Figure 9] A side view showing the configuration of a roof panel unit according to another embodiment. [Figure 10] A rear view of the configuration of a roof panel unit according to another embodiment. [Modes for carrying out the invention]

[0009] Hereinafter, the configuration of the roof structure 1 and the manufacturing method of the roof structure 1 according to the first embodiment of the present invention will be described with reference to Figures 1 to 8. Figure 1 is a perspective view showing the framework of a house. In each figure, the configuration is enlarged, reduced, or omitted as appropriate for explanatory purposes. In the figures, X, Y, and Z represent three mutually orthogonal directions.

[0010] The roof structure 1 comprises a frame section 10 having multiple beam members and multiple roof panel units 20 provided on the frame section 10. The roof structure 1 is provided on top of a building, such as a house. For example, in a building that has a foundation, base, columns, exterior walls, etc., the roof structure 1 is provided on top of the columns.

[0011] The framework part 10 is configured by assembling, for example, beam members as a plurality of framework members extending in a plurality of different directions. The plurality of beam members constituting the framework part 10 are arranged in a plurality of rows respectively in a first direction which is the inclination direction (vertical direction) of the panel 110 inclined from the ridge to the eaves tip, and a second direction which is the width direction (lateral direction) orthogonal or intersecting with the first direction. As an example, the framework part 10 includes a gable beam 11, a column 12, a climbing beam 14, an orthogonal beam 15, a receiving beam 16, a ridge beam 18, etc., and forms a panel installation surface inclined from the eaves side toward the ridge side. Note that some beam members in the framework part 10 may be omitted, or there may be other beam members. For example, the framework part 10 includes framework members along the vertical direction and horizontal members along the lateral direction.

[0012] The gable beam 11 is, for example, a long member extending in a horizontal lateral direction (second direction). The gable beam 11 is composed of steel, wood, composite materials, etc. The gable beam 11 is, for example, spanned across the upper ends of a plurality of columns erected along the vertical direction under the roof structure 1 in a house.

[0013] The column 12 is erected on the gable beam 11. The column 12 is arranged along the vertical direction. The column 12 is, for example, attached to the upper part of the gable beam 11 or the column constituting the building by fixtures or welding, etc.

[0014] The climbing beam 14 is provided at the upper end of the column 12. The plurality of climbing beams 14 are, for example, vertical members extending along the inclination direction (first direction) inclined from the gable beam 11 toward the ridge beam 18. The climbing beam 14 is composed of steel, wood, composite materials, etc.

[0015] The orthogonal beam 15 is a beam member extending in the lateral direction (second direction). The orthogonal beam 15 is a horizontal member. For example, the front surface of the orthogonal beam 15 is arranged at a position on the back side, that is, the inner side of the house, rather than the front surface of the climbing beam 14. That is, the orthogonal beam 15 is arranged at a predetermined gap G away from the back side of the panel 110 fixed to the surface of the climbing beam 14.

[0016] The receiving beam 16 is a member that extends in the inclined direction (the first direction) parallel to the climbing beam 14 in the space formed between the climbing beams 14. As an example, as shown in FIG. 2, two receiving beams 16 are arranged at equal intervals between a pair of adjacent climbing beams 14.

[0017] The ridge beam 18 is provided along the lateral direction (the second direction) at the upper ends of the plurality of climbing beams 14. It is arranged at the top of the roof.

[0018] As an example in this embodiment, the framework portion 10 includes a plurality of vertical members extending in the inclined direction and a plurality of horizontal members extending in the lateral direction. That is, as the vertical members, it includes the climbing beams which are large beams arranged along the inclined direction, and a plurality of receiving beams 16 extending in the vertical direction between a pair of climbing beams, and as the horizontal members, it includes the orthogonal beams 15 which are a plurality of small beams extending in the lateral direction. And an example is shown where two roof panel units 20 arranged in the inclined direction are installed between a pair of climbing beams 14. For example, in this embodiment, it is not limited to the climbing beams 14, and it may be attached to other members such as the purlins 17. Further, the target beam member may not be inclined.

[0019] The roof panel unit 20 includes a panel 110, a support frame 120 provided on the back side of the panel 110, and a heat insulating member 130 arranged on the back side of the support frame 120. The roof panel unit 20 may further have other members such as a heat shielding sheet and a ventilation member. The roof panel unit 20 is installed on the framework portion 10 by fixing at least one of the panel portion and the support frame 120 to the framework portion 10 of the roof structure.

[0020] Panel 110 is a plate-shaped member that constitutes the roof underlayment. For example, panel 110 is a board material such as softwood plywood, and is constructed with a thickness of, for example, 9 mm to 12 mm and has a rectangular shape. As an example, two panels 110 are arranged side by side in the direction of inclination in the space formed by a pair of rafters 14. Panel 110 is fastened to the rafters 14 with nails or the like. Panel 110 is fastened or glued to the rafters 14 and support beams 16 at multiple points using adhesive, hot melt, or connecting members such as nails. For example, panel 110 functions as roof sheathing that is fixed to the framework. For example, by arranging multiple panels 110 vertically and horizontally, an underlayment composed of multiple roof sheathing boards is formed. For example, one panel 110 may form part of the roof sheathing, or an underlayment composed of multiple roof sheathing boards may be composed of multiple panels 110.

[0021] For example, panel 110 is made of a so-called 3x6 sheet with dimensions of 910 mm in the first direction, the vertical direction (inclined direction), and 1820 mm in the second direction, the horizontal direction, and is formed with a thickness dimension of 12 mm perpendicular to the vertical and horizontal directions. In other words, two panels 110 are placed side by side in the inclined direction to form a square shape with sides of 1820 mm. Roofing material is placed on top of the front side of panel 110 and fixed with fasteners such as screws or adhesive.

[0022] The support frame 120 is a frame material provided on the back surface of the panel 110. For example, multiple support frames 120 are arranged along the first direction. For example, the support frame 120 is made of insulation material or wood, has a rectangular cross-section, and is configured as a rectangular parallelepiped with its longitudinal direction aligned with the first direction. As an example, the height (thickness) dimension of the support frame 120 in the third direction is 30 mm, the width dimension along the lateral direction is 40 mm, and the length dimension along the vertical direction is 1820 mm. Multiple support frames 120 are arranged along the inside of a pair of ascending beams 14 and along both sides of the two support beams 16.

[0023] In the assembled state, the back surface of the panel 110 and the front surface of the support beam 16 are joined facing each other between a pair of support frames 120 arranged on both sides of the support beam 16, and both sides of the support beam 16 are joined facing each other to the sides of the pair of support frames 120.

[0024] The thermal insulation member 130 is a thermal insulation panel placed between multiple inclined frames. The thermal insulation member 130 is, for example, a board-type thermal insulation material, made of a foamed plastic material having a predetermined thickness, and is provided on the back side of the panel 110 via a support frame 120.

[0025] The thermal insulation member 130 is attached to the back side of the support frame 120. In other words, the thermal insulation member 130 is suspended and supported on the back side of the panel 110 via the support frame 120. Therefore, the thermal insulation member 130 is positioned opposite the back side of the panel 110 with a predetermined gap G corresponding to the thickness dimension of the support frame 120. The gap G forms a ventilation layer and opens on both sides of the panel 110 in the direction of inclination. The height (thickness) of the support frame 120 in the third direction is 30 mm, and the height (thickness) dimension of the gap G in the ventilation layer is 30 mm. The thermal insulation member 130 has, for example, a height (thickness) t = 90 mm or more in the third direction.

[0026] For example, the thermal insulation member 130 is arranged in multiple locations on the back surface of the panel, avoiding the positions of the opposing frame members. For example, in this embodiment, the thermal insulation member 130 is arranged avoiding the lateral edges on both sides facing the pair of ascending beams 14, the lateral edge on one side facing the orthogonal beam 15, and the two vertical line-shaped areas facing the support beam 16. In other words, when viewed from the back surface, the areas facing the orthogonal beam 15, the ascending beam 14, and the support beam 16 form an installation area where the back surface of the panel 110 is visible, and each frame member is fixed to the installation area of ​​the panel 110 by means of adhesive, fastening, etc. In this embodiment, the installation area between the pair of inclined frames is divided into multiple divided areas in the lateral direction by the support beam 16. Also, two panel units are provided in the vertical direction within one installation area. Therefore, the thermal insulation member 130 is configured in the shape of a rectangular plate corresponding to the shape obtained by further dividing the three divided areas in the vertical direction into two equal parts.

[0027] For example, in this embodiment, two support beams 16 are arranged along the vertical direction in the region between a pair of ascending beams 14, dividing the region into three horizontal rows. One thermal insulation member 130 is placed in each of the three divided areas, which are vertically divided into two sections, and a total of six thermal insulation members 130 from two panel units are placed in one installation area.

[0028] For example, the thermal insulation member 130 is positioned inward from the outer edge of the panel 110 by a distance of about half the width of the orthogonal beams 15, within the installation area between a pair of orthogonal beams 15 arranged in the lateral direction. For example, both the thermal insulation member 130 and the orthogonal beams 15 have their front surfaces facing the panel 110 at the same position in the thickness direction, and a gap G is formed between the panel 110 and the front surfaces of the orthogonal beams 15 and the thermal insulation member 130.

[0029] In this embodiment, the orthogonal beam 15 is positioned on the back side, for example, in the thickness direction (front-to-back direction), compared to the rising beam 14. Therefore, in the assembled state, a gap is created between the panel 110, which is positioned opposite the rising beam 14, and the orthogonal beam 15, forming a ventilation passage from the eaves to the ridge.

[0030] For example, the heat insulating member 130 may be fixed to the panel 110 by, for example, a fixing tape 150, as shown in Figure 7. The fixing tape 150 is configured in a strip shape and has, for example, an adhesive layer on one main surface. The fixing tape 150 is attached across the back surface of the panel 110 and the outer surface of the heat insulating member 130. The adhesive surface of the fixing tape 150 is attached across the back surface of the panel 110 and the back surface of the heat insulating member 130, with the heat insulating member 130 positioned at a predetermined location on the panel 110, thereby supporting the heat insulating member 130 on the panel 110.

[0031] In the roof panel unit 20 configured as described above, support frames 120 are arranged at predetermined locations on the back surface of the panel 110. Then, on the back surface of the panel 110, the rafter beams 14 and support beams 16 are arranged in areas where the support frames 120 are not formed. For example, as shown in Figure 3, in this embodiment, five support frames 120 (121-125) are arranged in a row in the lateral direction. Each support frame 120 is positioned laterally inward from the outer edge of the panel 110, at a distance corresponding to the width dimension of the beam material of the rafter 14 to which it is attached, for example, half the width dimension. As a result, the outer edge of the panel 110 protrudes outward from the support frame 120, and a corner portion is formed between the back surface of the panel 110 and the outer surface of the support frame 120, having two surfaces facing the front and side surfaces of the rafter 14 and the support beam 16. The front and side surfaces of the rafter 14 are joined to the flange portion formed by the edge of the panel 110, thereby firmly fixing the roof panel unit 20 and the rafter 14 on two surfaces.

[0032] For example, at the continuous joint between a pair of adjacent roof panel units 20 arranged horizontally, two opposing corner sections are formed, and the surface and both sides of the rising beam 14 are sandwiched between the pair of corner sections.

[0033] Roofing material is assembled to the surface side of panel 110. For example, the roofing material can be various types such as tiles, slates, or steel plates. For example, the roofing material is arranged in multiple rows in the first direction, which is the direction of inclination (vertical direction), and in the second direction, which is the direction of width (horizontal direction). For example, multiple roofing materials are arranged in the direction of inclination (first direction), with some overlapping, and are fixed to panel 110 with fastening members such as fastening nails. A waterproof sheet member may be placed between panel 110 and the roofing material. For example, the sheet member is fastened to panel 110.

[0034] In the assembly process of the roof structure 1, for example, the roof panel units 20 are sequentially attached to the vertical frame members of the pre-assembled frame section 10. As an example, the roof panel units 20 are installed by placing two roof panel units 20 side by side in the direction of inclination and covering an installation area formed by a pair of adjacent rafters 14 provided in the direction of inclination. Here, in the frame section 10, the multiple rafters 14 are arranged side by side with predetermined intervals in the horizontal direction, and two support beams 16 are placed between a pair of rafters 14. Therefore, the installation area is divided into three locations in the horizontal direction by the pair of rafters 14 and the pair of support beams 16. Accordingly, each roof panel unit 20 is placed over the three horizontally aligned areas such that three rows of insulation members 130 are arranged in each of them. At this time, the rafters 14 and support beams 16 are positioned to the side of the support frame 120, and the roof panel unit 20 is attached to the frame members by fixing the panel 110 to the rafters 14 and support beams 16 from the front side of the panel 110 with fastening members such as nails. Furthermore, a sheet member such as a waterproof sheet is fastened on the panel 110, and the roofing material is placed on top of it and fixed in place.

[0035] According to the roof structure 1 and roof manufacturing method configured in this way, by assembling a roof panel unit 20, in which an insulating member 130 is suspended and fixed to a panel 110 via a support frame 120, to a frame member, the roof structure is simplified and the insulating and ventilation layers can be constructed simultaneously. Therefore, an air layer can be easily formed while improving workability. Thus, improved work efficiency and cost reduction can be achieved. By leaving a gap between the orthogonal beam 15 and the panel 110, ventilation can be ensured.

[0036] It should be noted that the present invention is not limited to the embodiments described above, and can be modified in various ways during implementation without departing from its essence. The material, shape, dimensions, etc., of various components can be changed as appropriate.

[0037] For example, in other embodiments, such as the roof panel unit 20A shown in Figures 8 and 9, various airtight members may be provided on a part of the outer surface of the insulation member 130. For example, in the roof panel unit 20A shown in Figure 8, flat first airtight panels 160 are provided on both ends of the insulation member 130 in the first direction as airtight materials, and second airtight panels 170 are provided on both ends of the insulation member 130 in the second direction. The airtight panels 160 and 170 are made of polyethylene foam, for example. As an example, the first airtight panel 160 covers half of the area on the panel 110 side in the third direction on the surface of both ends of the insulation member 130 in the first direction. For example, the first airtight panel 160 is configured as a rectangular flat plate corresponding to the height dimension of the front half of the end faces on both sides of the insulation member 130 in the first direction, with a width dimension of 535 mm, a height of 50 mm, and a thickness dimension of 2 mm perpendicular to each end face. The second airtight panel 170 is configured as a rectangular flat plate with the same shape as the end faces on both sides in the second direction of the insulation member 130, with a length dimension of 860 mm in the first direction, a height dimension of 100 mm in the third direction, and a thickness dimension of 2 mm perpendicular to each end face.

[0038] For example, in the roof panel unit 20B shown in Figure 9, first airtight panels 180 are provided on both ends of the insulation member 130 in the first direction as airtight members, and second airtight panels 190 are provided on both ends of the insulation member 130 in the second direction. The airtight panels 180 and 190 are made of polyethylene foam, for example. For example, the first airtight panel 180 covers the back half of the surface of both ends of the insulation member 130 in the first direction, opposite to the panel 110 in the third direction. For example, the first airtight panel 180 is configured as a rectangular flat plate corresponding to the height dimension of the back half of both end faces of the insulation member 130 in the first direction, with a width dimension of approximately 529 mm, a height dimension of 50 mm, and a thickness dimension of 2 mm perpendicular to each end face.

[0039] The second airtight panel 190 is a cover member that covers the corners on both sides of the back side of the heat insulating member 130. The second airtight panel 190 has an L-shaped cross-section perpendicular to the first direction. The second airtight panel 190 is integrally formed by a first piece 191 positioned opposite the side and a second piece 192 positioned opposite the edge of the back surface, connected via a bent portion 193. The first piece 191 is a rectangular plate with a dimension of 30 mm in the third direction and a dimension of 852 mm in the first direction. The second piece 192 is a rectangular flat plate with a width of 20 mm in the lateral direction and a length of 852 mm in the first direction. The thickness dimension of the first piece 191 and the second piece 192 perpendicular to the surface direction is 2 mm.

[0040] In the above embodiment, an example of attachment to a rising beam 14 was shown, but it is not limited to this, and can also be applied to configurations where a roof is formed with rafters and purlins, and can be applied to various beam members. Furthermore, it is not limited to inclined frame members, but can also be applied to horizontally arranged members. For example, in the above embodiment, an example of being divided into three by a support beam was shown, but it is not limited to this. For example, a support beam 16 may not be provided, in which case one insulation member may be provided in one roof panel unit 20.

[0041] Furthermore, each embodiment may be combined as appropriate, and in that case, the combined effects can be obtained. Moreover, the above embodiments include various inventions, and various inventions can be extracted by selecting combinations from the multiple constituent elements disclosed. For example, if the problem can be solved and effects obtained even if some constituent elements are deleted from all the constituent elements shown in the embodiment, then the configuration with these constituent elements deleted can be extracted as an invention. [Explanation of Symbols]

[0042] 1...Roof structure, 10...Framework, 11...Eaves beam, 12...Column, 14...Rising beam, 15...Orthogonal beam, 16...Support beam, 18...Ridge beam, 20, 20A...Roof panel unit (panel unit), 110...Panel, 120...Support frame, 130...Insulation material, 150...Fixing tape, 160...First airtight panel, 170...Second airtight panel, 180...First airtight panel, 190...Second airtight panel.

Claims

1. A plate-shaped panel section, A support frame fixed to the back side of the panel portion, The panel portion comprises an insulating material connected to the support frame and positioned opposite to it, forming a predetermined gap on the back surface of the panel portion, A roof panel unit in which at least one of the panel portion and the support frame is fixed to the framework portion of the roof structure.

2. The aforementioned panel is a base plate, The aforementioned frame section has a plurality of frame members, The aforementioned frame member is at least one of a beam, rafter, ascending beam, or support beam, provided along a predetermined first direction. The roof panel unit according to claim 1, wherein the support frame is provided along the first direction.

3. The aforementioned frame section has a plurality of frame members, The aforementioned insulation material is placed between the plurality of frame members, The panel portion is arranged on the front side of the plurality of frame members, The roof panel unit according to claim 2, wherein the gap opens on both sides of the panel portion in the first direction.

4. The aforementioned frame section comprises multiple frame members, The roof panel unit according to claim 3, wherein the insulating material is arranged in multiple locations on the back surface of the panel portion, avoiding positions facing multiple frame members.

5. The roof panel unit according to claim 1, further comprising an airtight panel covering the outer surface of the aforementioned insulation material.

6. The roof panel unit according to claim 1, further comprising fixing tape that is attached across the back surface of the panel portion and the outer surface of the insulation material.

7. The aforementioned frame comprises vertical members along a first direction and horizontal members along a second direction intersecting the first direction. The aforementioned horizontal structural members are positioned on the back side of the aforementioned vertical structural members. A gap is formed between the horizontal structural member and the back side of the panel portion. The roof panel unit according to claim 2, wherein the gap opens on both sides of the panel portion in the first direction.

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