Building materials and building structures

Abstract

To provide building materials and building structures that allow for more secure attachment of sheet-like members with minimal hindrance to repeated installation work. [Solution] The building material comprises two parallel protrusions 10 and a flat section 20 formed between the two protrusions 10. Each of the two protrusions 10 has an undercut section 11 that is recessed inward at the connection point with the flat section 20, into which the end of the solar cell panel PV is inserted. The building materials are connected by a rod-shaped member R such that the protrusions 10 overlap each other.

Description

Technical Field

[0001] The present disclosure relates to building materials and building structures. Background Art

[0002] Conventionally, solar cell panels for photovoltaic power generation are sometimes installed on the roof of a building. On the other hand, some building roofs have protrusions extending in the inclined direction from the viewpoint of ensuring rigidity. When installing a solar cell panel on a roofing material having such protrusions, it is known to install a frame to form a flat portion (see, for example, Patent Documents 1 and 2).

[0003] However, when a frame is used, in addition to cost problems, since wind blows between the frame and the roof, the frame must be firmly attached to the roof so that the frame does not come off. Therefore, when the roof has a certain flat portion, adhering a solar cell panel to the flat portion has also been studied (see Patent Document 3). Prior Art Documents Patent Documents

[0004] Patent Document 1 Japanese Unexamined Patent Application Publication No. 2023-153673 Patent Document 2 Japanese Unexamined Patent Application Publication No. 2023-163978 Patent Document 3 Japanese Unexamined Patent Application Publication No. 2022-76585 Summary of the Invention Problems to be Solved by the Invention

[0005] If the technology described in Patent Document 3 is adopted, it is important that wind does not blow between the solar panel and the roof over a long period of time, and the solar panel needs to be firmly bonded to the roof. However, generally, the lifespan of solar panels is shorter than that of roofs, and the flexible perovskite solar panels developed in recent years have an even shorter lifespan. Therefore, it becomes necessary to remove the solar panel from the roof and reinstall it.

[0006] However, because solar panels are firmly bonded to the roof, removing them requires a great deal of effort, and if the adhesive residue is not completely removed, it becomes difficult to firmly attach the next solar panel.

[0007] Furthermore, this problem is not limited to solar panels, but is a common issue when installing other sheet-like materials, including boards, sheets, and films, such as solar reflecting sheets, heat shielding sheets, heat collecting panels, photocatalytic and other artificial photosynthesis panels, desalination panels, and water purification panels, as long as their lifespan is shorter than that of roofing materials. In other words, the above problem is common to all sheet-like materials, whether they are used to utilize sunlight, to block sunlight, or installed for any other purpose.

[0008] Furthermore, the above problems are not limited to roofing materials, but are also common when attaching sheet-like components with shorter service lives to other building materials such as walls, eaves, shutters, shutter boxes, dormers, and rain shields.

[0009] The purpose of this disclosure is to provide building materials and building structures that allow for more secure attachment of sheet-like members with minimal hindrance to re-installation work. [Means for solving the problem]

[0010] The building material relating to this disclosure comprises two parallel protrusions and a flat portion formed between the two protrusions, wherein each of the two protrusions has an undercut portion recessed inward at the connection point with the flat portion, into which the end of a sheet-like member is inserted.

[0011] Furthermore, the building structure relating to this disclosure comprises the above-mentioned building material, a sheet-like member whose end is inserted into the undercut portion of each of the two protrusions of the building material and provided on the flat portion, and a press-fit member pressed between the undercut portion and the sheet-like member, or a caulking agent filled in between. [Effects of the Invention]

[0012] According to this disclosure, it is possible to provide building materials or building structures that allow for more secure attachment of sheet-like members with less hindrance to re-installation work. [Brief explanation of the drawing]

[0013] [Figure 1] This is a perspective view showing a building material according to the first embodiment. [Figure 2] Figure 1 is a side view of the building material shown. [Figure 3] This is a building structure including building materials according to the first embodiment. [Figure 4] This is a partially enlarged side view of a building material according to the first embodiment, where (a) shows one protrusion and (b) shows the other protrusion. [Figure 5] Figure 4 is a side view showing an example of a press-fit member. [Figure 6] Figure 4 is a side view showing a modified example of the undercut section. [Figure 7] This is a diagram showing the building structure according to the second embodiment, where (a) is a side view and (b) is a perspective view showing a part of the structure of (a). [Figure 8] This is a perspective view showing a modified retaining clip. [Figure 9]It is a side view showing a building material according to a first modification. [Figure 10] It is a side view showing a building material according to a second modification. [Figure 11] It is a perspective view showing a state where a solar cell panel is installed on the building material according to the second modification. MODE FOR CARRYING OUT THE INVENTION

[0014] The present disclosure will be described below based on preferred embodiments. The present disclosure is not limited to the embodiments described below, and can be appropriately modified without departing from the spirit of the present disclosure. In addition, in the embodiments described below, illustrations and descriptions of some configurations are omitted in some parts, and it goes without saying that publicly known or well-known techniques are appropriately applied to the details of the omitted techniques within a scope that does not conflict with the content described below.

[0015] Figure 1 is a perspective view showing a building material according to a first embodiment, and Figure 2 is a side view of the building material shown in Figure 1. Figure 3 shows a building structure including the building material according to the first embodiment. As shown in Figure 1 and Figure 2, the building material 1 is, for example, a roofing material provided on a sloped structure at the upper part of a building, and is configured as a so-called sandwich panel including a metal plate M and a heat insulating material I. That is, in the building material 1, the metal plate M is bent into a predetermined shape so as to cover the periphery of the heat insulating material I, and the heat insulating material I is positioned in the space S formed by the bent metal plate M, whereby the building material 1 is formed into a substantially plate shape having a predetermined thickness.

[0016] Such a building material 1 is formed by bending a metal plate M, and has two protruding ridges 10 and a flat portion 20. The two protruding ridges 10 are portions protruding upward of the generally plate-shaped building material 1. When the building material 1 is used for an inclined structure at an upper part of a building, the two protruding ridges 10 are provided in parallel along the inclined direction as shown in Fig. 1. The two protruding ridges 10 are formed at predetermined intervals in the width direction orthogonal to the inclined direction to ensure the rigidity of the building material 1 and reduce the risk of rainwater intrusion from the insertion hole of the rod-shaped member R described later. In the side view shown in Fig. 2, the two protruding ridges 10 have a substantially trapezoidal shape tapering upward.

[0017] As shown in Fig. 2, in the building material 1, one of the two protruding ridges 10 is filled with a heat insulating material I, and the other is not filled with the heat insulating material I and is formed of a single metal plate M. The building material 1 is arranged such that the other protruding ridge 10b, which is a single metal plate M shown in Figs. 2 and 3, is overlapped on one protruding ridge 10a filled with the heat insulating material I. Further, in this arranged state of the building material 1, as shown in Figs. 1 and 3, a rod-shaped member R such as a screw is inserted into the one protruding ridge 10a from above the single metal plate M that is the other protruding ridge 10b, so that the protruding ridges are firmly connected.

[0018] Here, as shown in Fig. 1, some of the rod-shaped members R, which are designated as rod-shaped members Ra, have a length extending to the frame F of the building. Therefore, the building material 1 is not only connected by the rod-shaped members Ra, but also firmly fixed to the building itself.

[0019] It should be noted that although the building material 1 according to Fig. 2 is configured by bending a single metal plate M, it may also be configured by bending two or more metal plates M and then welding them or the like. In addition, the building material 1 is not limited to being made of the metal plate M, and may be made of a resin plate or a wood plate if possible. Further, the building material 1 is not limited to those provided with the heat insulating material I. In addition, the building material 1 may be provided so as to be overlapped on another building material already provided on the upper part of the building. In this case, some of the rod-shaped members Ra only need to have a length that reaches at least the other building material.

[0020] Furthermore, as shown in Figure 3, the building structure 100 is, for example, a roof structure and is further equipped with a solar cell panel (sheet-like member) PV. The solar cell panel PV may be a rigid material of a predetermined thickness, or it may be a film-like material such as a perovskite solar cell panel; its thickness is not specified. The solar cell panel PV is installed on a flat section 20 formed between two protrusions 10.

[0021] Figure 4 is a partially enlarged side view of the building structure 100 according to the first embodiment, where (a) shows one protrusion 10a and (b) shows the other protrusion 10b. As shown in Figure 4(a), one protrusion 10a has an undercut portion 11 recessed on the inside of the protrusion 10a at the connection point with the flat portion 20. Similarly, as shown in Figure 4(b), the other protrusion 10b has an undercut portion 11 recessed on the inside of the protrusion 10b at the connection point with the flat portion 20. The two undercut portions 11 formed on each protrusion 10 are, for example, symmetrical in the width direction, but are not limited to this.

[0022] Each of the two protrusions 10 has an undercut portion 11 for inserting the end of the solar cell PV. Therefore, if the solar cell PV inserted into the undercut portion 11 is particularly rigid, it will be less likely to come out upwards. Specifically, it is preferable that the undercut portion 11 has a depth of 5 mm or more (a recessed length in the width direction) and is configured so that the end of the solar cell PV can be inserted by 3 mm or more.

[0023] In addition, the building structure 100 according to the first embodiment is equipped with a press-fit member P. The press-fit member P is a bead material (bead, trim) formed of, for example, an elastically deformable material (e.g., rubber). The press-fit member P is preferably configured to be long enough to correspond to the length of the undercut portion 11 which is continuously formed in an inclined direction along the protrusion 10. The shape of the press-fit member P is not particularly limited as long as it has the function of pressing the solar cell panel PV against the flat portion 20 in the undercut portion 11, but it is preferable that it has a return portion as shown in Figure 5.

[0024] Figure 5 is a side view showing an example of the press-fit member P shown in Figure 4. As shown in Figure 5, the press-fit member P has a return portion P1 that is inclined in the direction of press-fitting into the undercut portion 11 and has a pointed shape on the open side of the undercut portion 11. Such a return portion P1 has the function of preventing the press-fit member P from easily coming off when a force is applied to the press-fit member P to pull it out of the undercut portion 11.

[0025] Furthermore, the press-fit member P is not limited to a specific material and may be a metal or resin spring, or a rubber seal using a metal or resin spring.

[0026] Figure 6 is a side view showing a modified version of the undercut portion 11 shown in Figure 4. In the undercut portion 11 shown in Figure 4, the opening area is largest at the entrance 11a, and decreases towards the bottom 11b. In contrast, the undercut portion 11 according to the modified version shown in Figure 6 has a curved structure in which the upper wall 11c bends upward, and has a portion 11d where the gap with the flat portion 20 is larger than that of the entrance 11a. With such a structure, once the press-fit member P is pressed in up to portion 11d, it is prevented from easily coming out because the entrance 11a is narrower than portion 11d.

[0027] Here, the member that holds the solar cell panel PV in the undercut portion 11 is not limited to the press-fit member P, but may also be a sealant. This is because the sealant is removable but does not come off easily, and thus exhibits the same effect as the press-fit member P.

[0028] Next, the manufacturing method of the building structure 100 according to the first embodiment, that is, the work performed by the worker, will be described. First, multiple building materials 1 are prepared. Then, the worker places the multiple building materials 1 on the building frame F with the protrusions 10 of the building materials 1 aligned with each other.

[0029] Subsequently, the worker connects the building materials 1 together using rod-shaped members R. At this time, the worker uses some long rod-shaped members Ra to connect the building materials 1 together and fix the building materials 1 to the structural frame F.

[0030] Subsequently, the worker inserts the solar cell PV into the undercut portions 11 formed in the two protrusions 10 of the building material 1. If the solar cell PV is a film, the worker inserts the end of the solar cell PV into the undercut portion 11 from the width direction. If the solar cell PV is rigid, the worker inserts the end of the solar cell PV into the undercut portion 11 by sliding it in from an inclined direction, for example.

[0031] Subsequently, the worker inserts the press-fitting member P into the gap between the upper wall 11c of the undercut portion 11 and the solar panel PV. The worker may also use a sealant instead of the press-fitting member P.

[0032] Furthermore, the solar panels PV can be removed from such building structures 100 relatively easily by removing the press-fit member P or the solidified sealant.

[0033] In this way, according to the building material 1 of the first embodiment, each of the two protrusions 10 has an undercut portion 11 at the connection point with the flat portion 20. Therefore, it is possible to fit the solar cell panel PV into the undercut portion 11 of each of the two protrusions 10, thereby reducing the need for strong adhesion with adhesive. As a result, it is possible to provide a building material 1 that does not require a great deal of effort to remove the solar cell panel PV or remove adhesive residue, has fewer obstacles to reinstallation work, and allows for stronger attachment of the solar cell panel PV.

[0034] Furthermore, it is preferable that the undercut portion 11 has a portion 11d where the gap with the flat portion 20 is larger than that of the entrance portion 11a. Therefore, for example, when a press-fit member P is pressed between the undercut portion 11 and the solar cell panel PV, or when a sealant is filled in between, the press-fit member P and the sealant become less likely to come off. Thus, it is possible to provide a building material 1 that allows for a more secure attachment of the solar cell panel PV.

[0035] Furthermore, according to the building structure 100 of the first embodiment, the building material 1 comprises the solar cell panel PV and a press-fit member P or a sealant. Therefore, the solar cell panel PV is inserted into the undercut portion 11 of the building material 1 and then secured with the press-fit member P or sealant. This allows both ends of the solar cell panel PV to be held in place without the use of adhesive, reducing the need for adhesive. In addition, the press-fit member P and sealant are easier to remove than adhesive. Therefore, removing the solar cell panel PV and removing any adhesive residue does not require a great deal of effort. Consequently, it is possible to provide a building structure 100 that allows for more secure attachment of the solar cell panel PV with fewer obstacles to reinstallation.

[0036] In addition, since the solar panel PV can be in contact with the flat surface 20 of the building material 1 while both ends of the solar panel PV can be secured with the press-fitting member P and sealant, it is easier to ensure airtightness between the solar panel PV and the building material 1. Therefore, it is possible to prevent wind from entering the back side of the solar panel PV.

[0037] Next, a second embodiment will be described. The building structure according to the second embodiment is similar to that of the first embodiment, but some components differ. The differences will be described below. In the following description, elements that are the same as or similar to those in the first embodiment will be denoted by the same reference numerals and their descriptions will be omitted.

[0038] Figure 7 is a diagram showing the configuration of a building structure according to the second embodiment, where (a) is a side view and (b) is a perspective view showing a part of the configuration of (a). As shown in Figures 7(a) and 7(b), the building structure 200 according to the second embodiment further includes a washer 210, a retaining bracket (pressing member) 220, and a screw member 230, in addition to those of the first embodiment.

[0039] The washer 210 is a component connected to a rod-shaped member (fixing member) R for fixing the protrusions 10 of multiple building materials 1 together. The rod-shaped member R referred to here is not limited to a portion of the rod-shaped member Ra that extends to the structural frame F. As shown in Figure 7(b), the washer 210 has a first plate portion 211 to which the screw head portion of the rod-shaped member R is connected, and a second plate portion 212 to which the retaining bracket 220 is connected. The first plate portion 211 and the second plate portion 212 are of different heights, and the second plate portion 212 is provided on both ends of the first plate portion 211.

[0040] The retaining bracket 220 is a component connected to the washer 210. The retaining bracket 220 has a rectangular upper plate 221 with two openings 222 formed near the opposite corners of the rectangle. The washer 210 also has an opening 212a formed in the second plate portion 212 so as to communicate with these two openings 222. Therefore, the retaining bracket 220 is connected to the rod-shaped member R via the washer 210 by using a screw member 230 (including a nut) that connects these openings 222 and 212a.

[0041] Here, the retaining bracket 220 comprises a side plate 223 that extends diagonally downward from the upper plate 221, and a contact plate 224 that extends from the side plate 223 substantially parallel to the flat portion 20. The side plate 223 extends diagonally downward to follow the shape of the substantially trapezoidal protrusion 10. The contact plate 224 holds the solar cell panel PV in place on the open side of the undercut portion 11. This contact plate 224 further reduces the possibility of the solar cell panel PV coming loose.

[0042] Although the washer 210 has an opening 212a, it is not limited to this, and a stud bolt may also be formed therein. In this case, the stud bolt of the washer 210 is inserted through the opening 222 of the retaining bracket 220 and tightened with a nut, thereby connecting the two.

[0043] Figure 8 is a perspective view showing a modified example of a retaining bracket. As shown in Figure 8, for example, when multiple solar cell panels (PV) are arranged in a slanted direction, it is preferable to use a long retaining bracket (pressing member) 240 at the joint portion.

[0044] As shown in Figure 8, the retaining bracket 240 is configured as a long member extending between the two protrusions 10. The contact plate 244 of this retaining bracket 240 extends from the open side of the undercut portion 11 (see Figure 7) of one protrusion 10a, through the intermediate position MP between the two undercut portions 11, to the open side of the undercut portion 11 of the other protrusion 10b. Therefore, the retaining bracket 240 can be configured to hold down the edges PV1 of the solar panel PV all at once. In particular, the long retaining bracket 240 can also suppress wind from blowing in through the joints.

[0045] Here, when manufacturing the building structure 200 according to the second embodiment, the worker drives in the rod-shaped members R via washers 210 when connecting multiple building materials 1 with rod-shaped members R. Then, the worker inserts the end of the solar panel PV into the undercut portion 11 and presses in the press-fitting member P. Next, the worker attaches the retaining brackets 220 and 240 via screw members 230.

[0046] In this way, the building material 1 and building structure 200 according to the second embodiment provide building materials 1 and building structures 200 that, like the first embodiment, have fewer obstacles to repeated installation work and allow for more secure attachment of solar panels PV.

[0047] Furthermore, the building structure 200 according to the second embodiment has retaining brackets 220 and 240 that are connected via washers 210 to rod-shaped members R for fixing the protrusions 10 of a plurality of building materials 1, and that hold down the solar panel PV on the open side of the undercut portion 11. Therefore, the retaining brackets 220 and 240 are connected to a structure that is difficult to detach from the building materials 1, namely the rod-shaped members R that connect the plurality of building materials 1, and then hold down the solar panel PV. Thus, it is possible to provide a building structure 200 that can attach the solar panel PV even more securely.

[0048] Furthermore, since the retaining clip 240 is formed as a long member extending between the two protrusions 10, it can secure not only the vicinity of the open side of the undercut portion 11, but also the intermediate position MP of each of the two protrusions 10's undercut portions 11. Therefore, it is possible to provide a building structure 200 that can securely attach solar panels PV by continuously securing the edges PV1 of the solar panels PV at joints and other points.

[0049] Although the present disclosure has been described above based on embodiments, the present disclosure is not limited to the above embodiments, and modifications may be made, and publicly known or well-known technologies may be combined to the extent possible, without departing from the spirit of the present disclosure.

[0050] For example, the building material 1 is not limited to the above-described form and can be modified in various ways. Figures 9 and 10 are side views showing building materials according to modified forms. As shown in Figure 9, the building material 2 according to the first modified form further includes a rib (a part that protrudes upward) 30. The rib 30 is provided at the intermediate position MP between the two protrusions 10 and protrudes upward at a lower height than the two protrusions 10. In this building material 2, both sides of the rib 30 constitute a flat portion 20.

[0051] Although the rib 30 is configured as a long, continuous structure in the same direction as the two protrusions 10, it is not limited to this configuration and may be formed intermittently in the same direction. Furthermore, the rib 30 may be provided at a position separated from the intermediate position MP, not just at the intermediate position MP.

[0052] Furthermore, as shown in Figure 10, the building material 3 according to the second modified example has a raised structure in which the flat portion 20 is inclined and the center is raised. The apex of the raised section is indicated by the symbol AP. The apex (the part that protrudes upward) AP corresponds to the intermediate position MP between the two protrusions 10, and rises upward at a lower height than the two protrusions 10. The apex AP may be slightly rounded. Also, the apex AP is not limited to the intermediate position MP and may be located at a distance from the intermediate position MP.

[0053] Figure 11 is a perspective view showing a solar cell PV installed on building material 3 according to the second modified example. The solar cell PV installed on building material 3 according to the second modified example is assumed to be in film form. Similarly, the solar cell PV is also installed on building material 2 according to the first modified example.

[0054] As shown in the building structure 300 in Figure 11, the building material 3 according to the second modified example has the intermediate position MP of the two protrusions 10 protruding upward. Therefore, the solar cell panels PV are installed in a sloping manner in the width direction along a straight line extending from the upwardly protruding apex AP to each undercut portion 11. Here, the solar cell panels PV have crystal rows, and if dirt caused by rainwater adheres along these crystal rows, the power generation efficiency will decrease significantly. However, when there is a sloping structure at the top of the building, rainwater flows in the diagonal direction shown in Figure 11. As a result, dirt caused by rainwater is less likely to form along the crystal rows, and an extreme decrease in power generation efficiency can be suppressed.

[0055] Furthermore, although building materials 1 to 3 in the above description are all sandwich panels with insulation material I, the material is not limited to this, and could also be standing seam metal roofing, or it could be a standing seam metal roofing board, or it could be anything other than a sandwich panel.

[0056] In addition, the planar portion 20 of the building materials 1 to 3 is assumed to be a part that extends in only one predetermined direction from the undercut portion 11 when viewed from the side, but it is not limited to this. Furthermore, although a solar cell panel PV was described above as an example of a sheet-like member, it is not limited to this, and may also be solar radiation reflecting sheets, heat shielding sheets, heat collecting panels, photocatalytic or other artificial photosynthesis panels, desalination panels, and water purification panels, etc., which utilize the sun, or conversely, which are installed for the purpose of blocking the sun, or which are installed for other purposes. In other words, the thickness of the sheet-like member is not a concern, but it is sufficient if it has sides or a diameter that exceeds its thickness and is installed on the roof with an area of ​​a predetermined size or larger.

[0057] Furthermore, in the above embodiment, an example was described in which building materials 1 to 3 are roofing materials, and an example was described in which building structures 100, 200, and 300 are the roof structure of a building, but the invention is not limited to this. For example, building materials 1 to 3 may be other building materials such as walls, eaves, shutters, shutter boxes, dormers, and rain shields. Also, building structures 100, 200, and 300 may be the wall structure, eaves structure, and shutter structure of a building, etc. In addition, although the sheet-like members are provided in the direction of inclination along the slope of the roof, their orientation is not restricted. [Explanation of Symbols]

[0058] 1~3: Building materials 10: Two protrusions 11: Undercut section 11a: Entrance 11d: Part 20: Flat part 30: Rib (the part that protrudes upward) 100,200,300: Building structure 220,240: Retaining clip (pressing member) AP: Apex (the part that protrudes upward) MP: intermediate position P: Press-fit member PV: Solar cell panel (sheet-like component) R, Ra: Rod-shaped member (fixing member)

Claims

1. A building material comprising two parallel protrusions and a flat portion formed between the two protrusions, Each of the two protrusions has an undercut portion recessed on the inside of the protrusion at the connection point with the flat portion, into which the end of the sheet-like member is inserted. A building material characterized by the following features.

2. The undercut portion has a portion where the gap with the flat portion is larger than that of the entrance. The building material according to feature 1.

3. The building material described in claim 1, A sheet-like member provided on the flat surface, with its end inserted into the undercut portion of each of the two protrusions of the building material, A press-fit member pressed between the undercut portion and the sheet-like member, or a sealant filled between them, A building structure characterized by having the following features.

4. The system further comprises a pressing member connected to a fixing member for fixing the protrusions of each of the multiple building materials, and which contacts the sheet-like member on the open side of the undercut portion of the building material to press down the sheet-like member. The building structure according to feature 3.

5. The pressing member is formed as a long member extending between the two protrusions, and presses the sheet-like member both near the open side of the undercut portion of each of the two protrusions and at an intermediate position between the undercut portions of each of the two protrusions. The building structure according to feature 4.

6. The building material has a portion that protrudes upward between the two protrusions, The sheet-like member is installed in an inclined state along a straight line extending from the aforementioned portion to each undercut portion. The building structure according to feature 3.

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