Heat-insulating and sound-proof roof structure

Abstract

To prevent deterioration in a heat insulation performance and a sound insulation performance without shifting to a discontinuous state of both performances when the heat insulation performance and a function for suppressing leakage of sound generated indoors to the outside of a building are imparted to a roof.SOLUTION: In a roof including a deck plate 2 laid on a skeleton material 1 configuring a roof frame and a roofing material 3 laid on the outdoor side of the deck plate 2, a flat plate part 21 placed on the skeleton material 1 and an erection part 22 arranged in parallel at an interval in one direction of the flat plate part 21, erected from the flat plate part 21 and having a top part with the same height are formed at the deck plate 2, a sound insulation material layer 5 comprising a material containing a cement-based material is formed directly or indirectly on the flat plate part 21 of the deck plate 2 at the top part of the erection part 22 or to its vicinity, and a porous material 6 is laid and supported on the top part of the erection part 22 and on a top end surface of the sound insulation material layer 5.SELECTED DRAWING: Figure 1

Description

[Technical field]

[0001] The present invention relates to a thermal insulation and soundproofing structure for a roof that has thermal insulation properties as well as the function of suppressing the leakage of sound generated indoors to the outside of the building. [Background technology]

[0002] For example, one method of imparting thermal insulation to a roof using folded plates is to sandwich a thermal insulation material between two folded plates (see Patent Documents 1 and 2). In order to impart sound insulation performance, particularly low-frequency sound insulation performance, to an insulated roof using such folded plates, a relatively heavy concrete plate such as an ALC plate is laid on the framework material that forms the framework of the roof structure, which is arranged on the indoor side of the double folded plates as shown in Figure 3.

[0003] If it is desired to provide sound insulation performance in the high frequency range in addition to the low frequency range, it is desirable to use, in addition to the concrete slab, a material that has sound insulation performance in the high frequency range and also acts as an insulating material with voids, such as glass wool (see Patent Document 3).

[0004] However, in the example of Patent Document 3, since the insulated floor units consisting of deck plates, concrete, and insulation are laid between adjacent frame members (beams), the insulation and sound insulation are discontinuous between adjacent units on the frame members, and the insulation and sound insulation are lost on the frame members. A stepped section is placed on the surface side between adjacent units, spanning both units, and a waterproof sheet is attached, ensuring waterproofing between the units.

[0005] In response to this, there is a method for ensuring the thermal insulation of roofs and walls by using a folded plate (deck plate) with a flat portion and a ribbed portion rising from the flat portion (see Patent Document 4). If this method is combined with Patent Document 3 and a concrete slab is laid on the folded plate and thermal insulation material, it appears that the discontinuous state of thermal insulation and sound insulation on the framework material as seen in Patent Document 3 can be avoided. [Prior art documents] [Patent documents]

[0006] [Patent Document 1] Japanese Utility Model Application Publication No. 54-52125 (specification, page 3, line 2 to page 5, line 1, Figure 1) [Patent Document 2] JP-A-10-292566 (paragraphs 0007-0012, Figures 1-3) [Patent Document 3] JP-A-4-131413 (Column 3, upper left column, line 7 to Column 4, upper left column, line 9, Figures 1 to 4) [Patent Document 4] JP 2005-76364 A (paragraphs 0010 to 0020, Figures 1 and 2) Summary of the Invention [Problem to be solved by the invention]

[0007] However, in the method of Patent Document 4, the insulation material is fixed to the rib portion of the folded plate with fasteners (paragraph 0020), which means that holes must be drilled in the rib portion as shown in Figure 4, resulting in a loss of insulation and soundproofing properties in the rib portion, leading to a decrease in both performance in this area.

[0008] In addition, even if the insulation is fixed to the ribs, it is not supported between the adjacent ribs, so it is prone to sagging, causing it to stretch and making the insulation and soundproofing performance of the insulation uneven in the in-plane direction. In addition, if water leaks in the roofing material located on the outdoor side of the insulation, it can leak under the deck plate.

[0009] In view of the above background, the present invention proposes a thermal insulation and sound insulation structure for a roof that, when attempting to provide a roof with sound insulation performance in both low and high frequency ranges, does not create a discontinuous state between the thermal insulation and sound insulation properties and does not cause a deterioration of both properties. [Means for solving the problem]

[0010] The thermal insulation and sound insulation structure for a roof according to claim 1 is a thermal insulation and sound insulation structure for a roof comprising a deck plate laid on a framework material constituting a roof structure, and a roofing material laid on the outdoor side of the deck plate, The deck plate has a flat plate portion placed on the framework material, and upright portions arranged in parallel with each other at intervals in one direction of the flat plate portion, standing upright from the flat plate portion, and having the same top height; The constituent elements of the deck plate are that a sound-proofing layer made of a material containing a cement-based material is formed directly or indirectly on the flat portion of the deck plate up to the top of the upright portion or near the top, and that a porous material is laid and supported on the top of the upright portion and on the top surface of the sound-proofing layer.

[0011] "The framework that constitutes the roof structure" refers to the beams (girders) that form the framework of the roof structure itself, the braces that connect the beams, and other structural materials, and beams include the components of trusses. Trusses include space trusses.

[0012] "Roofing material laid on the outdoor side of the deck plate" refers to roofing material 3 being laid on the outdoor side of deck plate 2 as shown in Figure 1-(a), with a distance (space) sufficient to place porous material 6 having a thickness required for sound insulation secured between the upper surface (top surface) of deck plate 2 and roofing material 3. When porous material 6 is placed on the upper surface of deck plate 2, if a gap is formed between porous material 6 and roofing material 3, this gap becomes air layer 7 (claim 3).

[0013] "The flat plate portion and the upright portion parallel to one side thereof" refers to the fact that the deck plate 2 has the flat plate portion 21 that is placed directly or indirectly on the framework material 1, and the upright portion 22 that stands up from the flat plate portion 21 when the flat plate portion 21 is used as a reference, and the shape and method of formation of each portion are not important. "In one direction of the flat plate portion" refers to one of the two directions when the flat plate portion 21 is viewed in a plan view. The flat plate portion 21 and the upright portion 22 become a sheathing when a material containing a fluid cement-based material is filled (cast). The upper surface (top surface) of the upright portion 22 becomes a reference surface for determining the laying height when the porous material 6 is laid, and becomes a reference surface for positioning the top surface when the fluid material is filled.

[0014] The fluid material is filled, for example, into adjacent upright portions 22, 22 and into the flat portion 21 between these upright portions 22, 22, and the sound-insulating material layer 5 is formed for each of these regions. In this case, the sound-insulating material layer 5 appears to be divided in the portion of the upright portion 22 rising from the flat portion 21 other than the upper portion on which the porous material 6 is placed, but if this rising portion is formed with the two plates in close contact with each other, the effect of the division is small, and if a through hole is formed in the rising portion, no division occurs.

[0015] Cement-based materials mainly refer to mortar and concrete, but may also include cement milk. "Materials containing cement-based materials" means that some admixtures may be mixed into the cement-based materials. The type and mixing ratio of the admixtures are not important.

[0016] "A sound insulation layer made of a material containing a cement-based material is formed" means that the sound insulation layer 5 may be formed by filling (injecting) a fluid cement-based material onto the flat plate portion 21 of the deck plate 2 at the site, or by installing a pre-formed product with the necessary thickness for sound insulation, such as a concrete slab. The porous material 6 refers to a material with many voids that also functions as a heat insulating material, such as glass wool, rock wool, or urethane foam.

[0017] "The sound-insulating material layer is formed up to the top of the standing portion or in the vicinity thereof" means that the sound-insulating material layer 5 is formed up to the top (upper surface) of the standing portion 22, or close to the top while not reaching the top. "Very close to the top" means that when the porous material 6 is placed on the top of the deck plate 2 and the top surface of the sound-insulating material layer 5, the porous material 6 is formed to a height such that there is substantially no sagging in the section of the sound-insulating material layer 5. By forming the sound-insulating material layer 5 up to the vicinity of the top of the standing portion 22, a state is achieved in which the porous material 6 is supported (shared) by the top of the deck plate 2 and the sound-insulating material layer 5.

[0018] "A sound-insulating material layer is formed directly or indirectly on the flat plate portion" means that the sound-insulating material layer 5 is formed directly on the flat plate portion 21 as shown in Figure 1, and that another porous material 10 that also serves as a heat insulating material is laid directly on the flat plate portion 21 as shown in Figure 2, and the sound-insulating material layer 5 is formed on this porous material 10.

[0019] Since the porous material 6 is supported by the top of the deck plate 2 and the top surface of the sound insulation material layer 5, it is not necessary to fix the porous material 6 using screws as in Patent Document 4 when laying and supporting the porous material 6 on the deck plate 2, and it is not necessary to drill holes in the top of the deck plate 2. Since there is no need to form holes in the deck plate 2, there is no leakage of heat insulation and sound insulation caused by the formation of holes, and there is no decrease in heat insulation and sound insulation. Furthermore, even if water leaks into the roofing material 3, water leakage through the deck plate 2 is avoided.

[0020] Furthermore, unlike Patent Document 4, in which the porous material is supported only by the top of the deck plate, the porous material 6 is shared between the top and the sound-insulating material layer 5 on the deck plate 2, thereby preventing the porous material 6 from sagging between adjacent tops, as occurs when the porous material is supported only by the tops. This prevents the insulating and sound-insulating performance of the porous material 6 from becoming uneven in the in-plane direction.

[0021] The deck plate 2, on which the sound-proofing material layer 5 is formed on the flat plate portion 21, is supported by the framework 1 erected below it, and so the roofing material 3 laid on the outdoor side of the deck plate 2 is supported by the purlin material 8 erected on the framework 1 as shown in Figure 1-(b). When the deck plate 2 is laid on the framework 1 with the axial direction of the upright portion 22 oriented in the axial direction of the framework 1 supporting the deck plate 2 as shown in Figure 1-(a), the deck plate 2 is divided at the position of the purlin material 8.

[0022] Here, if the purlin material 8 is, for example, an H-shaped steel, if a cement-based material is filled on-site onto the flat plate portion 21, and if the top surface of the sound-insulating material layer 5 is aligned, the thickness of the sound-insulating material layer 5 will be uneven at the lower flange portion of the purlin material 8, and a sharp step will be generated on the underside of the sound-insulating material layer 5 between the lower flange portion and the flat plate portion 21. Furthermore, if the sound-insulating material layer 5 is a pre-cast concrete slab, it may not be possible to place the concrete slab horizontally on the flat plate portion 21.

[0023] Therefore, by using plate 81 as (the main body of) purlin material 8 (claim 2), even in the case of materials filled on-site, the thickness of sound-proofing material layer 5 does not change until it hits purlin material 8, and it becomes possible to install a concrete slab horizontally on flat plate portion 21. Since there is no sudden change in the thickness of sound-proofing material layer 5 in the part close to purlin material 8, it becomes possible to make the sound-proofing performance of sound-proofing material layer 5 uniform overall.

[0024] In this case, the purlin material 8 that directly supports the roofing material 3 is erected with its axial direction facing a direction intersecting the axial direction of the rising part 22 of the deck plate 2, and is erected on the upper surface of the framework material 1 that supports the deck plate 2 (Claim 2). The "intersecting direction" is mainly a perpendicular direction, but is not necessarily perpendicular. Plate 81 is joined to the upper surface of the framework material 1 that directly supports the purlin material 8, with its axial direction facing the axial direction of the framework material 1.

[0025] "Framework material 1 directly supporting purlin material 8" means that, among the multiple frame materials 1 that make up the roof structure, the purlin material 8 is supported by frame material 1 that is positioned above the frame material 1. The purlin material 8 is provided with a plate 81 and receiving portions 82 that are joined to both sides of the upper part of the plate in the thickness direction and that receive the roofing material 3 (Claim 2).

[0026] Porous materials are characterized by their high sound absorption performance for mid- to high-frequency sounds, and it is known that the effect of this sound absorption rate can be improved by forming an air layer on the rear side of the sound source that is sandwiched between the porous material (Japan Acoustic Materials Association, How to Use Acoustic Materials and Technical Data Collection, Acoustic Technology No. 159, 2012, p. 12).

[0027] Therefore, by providing an air layer 7 between the upper surface of the porous material 6 and the lower surface of the roofing material 3 as shown in FIG. 1 (claim 3), it is possible to improve the sound absorption (sound insulation) performance of the porous material 6 against mid- to high-frequency sounds.

[0028] In the example of Patent Document 3, a concrete layer is placed on the outdoor side of the insulation, and in the example of Figure 3 of Patent Document 4, a waterproof sheet layer is placed on the outdoor side of the insulation, so it is not possible to expect improved sound absorption performance as would be the case if an air layer were formed directly on the outdoor side of the insulation.

[0029] As mentioned above, purlin materials 8 that directly or indirectly support the roofing materials 3 are erected on the framework materials 1 as shown in Fig. 1-(b), and the upper end surface of the purlin material 8 is located above the upper surface of the porous material 6, so that the thickness of the air layer 7 secured on the outdoor side of the porous material 6 can be adjusted depending on how the height of the purlin material 8 is set. Effect of the Invention

[0030] A sound insulation layer made of a material containing a cement-based material is formed on the flat plate of a deck plate that is laid on a framework material and has a flat plate portion and a standing portion that rises from the flat plate portion and has the same height as the top of the standing portion, and a porous material is laid on the top of the standing portion and on the top surface of the sound insulation layer to support it. Therefore, there is no need to fix the porous material using screws when laying and supporting the porous material on the deck plate. Therefore, there is no need to drill holes on the top of the deck plate, and as a result, there is no leakage of insulation and sound insulation caused by the formation of holes in the deck plate, and there is no decrease in insulation and sound insulation. In addition, even if water leaks into the roofing material, water leakage through the deck plate can be avoided.

[0031] In addition, the porous material is not supported only by the top of the deck plate, but is supported on the deck plate by the top and the sound-insulating material layer, which prevents the porous material from sagging between adjacent tops, as would occur if the porous material was supported only by the tops. This prevents the insulating and sound-insulating performance of the porous material from becoming uneven in the in-plane direction. [Brief description of the drawings]

[0032] [Figure 1] (a) is a longitudinal cross-sectional view seen in the axial direction of the rising part, showing a state in which a sound-proofing layer made of a material containing cement-based materials is formed directly on the deck plate, and a porous material is laid on top of that, and (b) is a longitudinal cross-sectional view seen in a direction perpendicular to (a). [Diagram 2] This is a vertical cross-sectional view in a direction perpendicular to the axial direction of the upright portion, showing the situation in which a sound-proofing material layer made of a material containing a cement-based material is formed on a porous material that also serves as an insulating material laid on a deck plate, and a porous material is laid on top of the sound-proofing material layer. [Diagram 3] This is a vertical cross-sectional view of a conventional structure showing a concrete slab laid on a framework material that forms the framework of the roof structure, which is arranged on the indoor side of a double folded slab. [Figure 4] FIG. 1 is a vertical cross-sectional view showing a state in which a heat insulating material is laid on a rib portion of a deck plate of Patent Document 4 and fixed to the rib portion with fasteners. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0033] Figures 1-(a) and (b) show an example of a thermal insulation and soundproofing structure for a roof, which includes a deck plate 2 laid on framework material 1 that constitutes the roof structure, and roofing material 3 laid on the outdoor side of the deck plate 2. Figure 1 shows an example in which folded plates are used as the roofing material 3. (a) shows the folded plate as seen in the axial direction (flow direction), and (b) shows the view in the perpendicular direction.

[0034] The deck plate 2 has a flat plate portion 21 placed on the framework material 1, and upright portions 22 that are arranged in parallel with a gap in one direction on the plane of the flat plate portion 21, stand up from the flat plate portion 21, and have the same top height. In FIG. 1-(a), the flat plate portion 21 and the upright portions 22 are formed by bending a single plate, but the method of forming the deck plate 2 and the shapes of the flat plate portion 21 and the upright portions 22 are arbitrary. In the example of FIG. 1, the deck plate 2 has a cross-sectional shape like a unicursal path by bending a single plate such as a steel plate, and the two plates overlap and are in close contact with each other except for the upper part of the upright portion 22. The top of the upright portion 22 refers to the upper part of the closed cross-sectional shape at the top, especially the upper surface.

[0035] A sound-proofing material layer 5 made of a material containing a cement-based material is formed directly on the flat plate portion 21 of the deck plate 2 as shown in Fig. 1, or indirectly on the flat plate portion 21 as shown in Fig. 2, up to the top of the standing portion 22 or nearby the top. A porous material 6 that also functions as a heat insulating material is laid on the top (upper surface) of the standing portion 22 and on the top end surface of the sound-proofing material layer 5, supporting the standing portion 22 and the sound-proofing material layer 5. The sound-proofing material layer 5 exhibits sound insulation performance against low-frequency sounds that cannot be exhibited by the porous material 6 or roofing material 3.

[0036] Figure 1 shows an example in which, when H-shaped steel is used as the truss component as the frame member 1, a deck plate 2 is laid on the upper flange 1a and on the top surface (top surface) of a horizontal brace or other connecting material (horizontal member) as the frame member 1 erected between adjacent truss components in one direction, and a fluid material is filled on the flat plate portion 21 of the deck plate 2 to form a sound insulation material layer 5. When the frame member 1 is an H-shaped steel, the deck plate 2 rests on and is supported by the upper flanges 1a of different frame members 1, 1 erected facing in two directions. Figure 1 shows an example in which "the sound insulation material layer 5 is formed directly on the flat plate portion 21 of the deck plate 2."

[0037] In the example shown in Fig. 1, the H-shaped steel as the framework material 1 indicates the upper chord that constitutes a plane truss or a space truss. In the example shown in Fig. 1, as shown in Fig. 1-(b), the purlin material 8 is joined (fixed) along the axial direction of the framework material 1 to the upper flange 1a of the H-shaped steel as the framework material 1, which is a connecting material that is horizontally erected between the adjacent truss components, and a folded plate as the roofing material 3 is supported on the top surface (top surface) of this purlin material 8. The roofing material (folded plate) 3 is directly or indirectly fixed and supported by the support material 4, which is fixed on the top surface of the purlin material 8 and has a cross-sectional shape that follows the cross-sectional shape of the folded plate. In the example shown in Fig. 1, the heat insulating material 9 is laid horizontally on the roofing material 3.

[0038] In particular, in the example of Figure 1, in order to keep the thickness of the sound insulation material layer 5 formed on the flat portion 21 of the deck plate 2 constant up to the purlin material 8, the purlin material 8 is made up of a plate 81 joined by welding or the like onto the upper flange 1a of the framework material 1 that directly supports the purlin material 8, and receiving portions 82 such as channel steel joined to both sides of the upper portion in the thickness direction to receive the roofing material 3. The main body of the purlin material 8 is the plate 81, and by welding or the like onto the framework material 1, the sound insulation material layer 5 is formed with a uniform thickness on the flat portion 21 until it hits the side of the purlin material 8 (plate 81).

[0039] When the cementitious material has fluidity, it is injected (filled) onto the flat plate portion 21 before the deck plate 2 is delivered to the site, or after the deck plate 2 is laid on the framework material 1 at the site. Sometimes, part of the cementitious material is injected before delivery, and the remainder is injected on site while adjusting the level. Pre-formed concrete or ALC panels may be laid on the flat plate portion 21, and in this case, the concrete panels can be laid in a state where they abut against the side surface in the thickness direction of the plate 81 of the purlin material 8. However, in order to form the sound insulation material layer 5 on the flat plate portion 21 without any gaps, it is more efficient to inject a cementitious material with fluidity.

[0040] An air layer 7 is secured between the upper surface (top surface) of the porous material 6 supported by the rising portion 22 of the deck plate 2 and the sound-proofing material layer 5, and the lower surface of the folded plate which is the roofing material 3. The porous material 6 has sound-proofing performance mainly against mid- to high-frequency sounds, but it is known that the larger (thicker) the air layer 7 secured on the rear side of the sound source across the porous material 6, the higher the sound absorption coefficient of the porous material 6 against low-frequency sounds (Japan Acoustic Materials Association, How to Use Acoustic Materials and Technical Data Collection, Acoustic Technology No. 159, 2012, p. 12).

[0041] For this reason, the air layer 7 formed on the outdoor side of the porous material 6, together with the layering on the sound-insulating material layer 5, ensures sound insulation performance against sounds from low to high frequencies. Because the porous material 6 can contain air, it is also possible to increase the sound absorption coefficient for sounds in the low frequency range by increasing the thickness of the porous material 6 itself. The thickness (layer thickness) of the air layer 7 between the upper surface of the porous material 6 and the lower surface of the roofing material 3 can be freely set by adjusting the length (height) of the purlin material 8 described above, as shown in Figure 1-(b).

[0042] Fig. 2 shows an example in which a porous material 10, which also serves as a heat insulating material and is different from the porous material 6 described above, is laid on the flat plate portion 21 of the deck plate 2, a sound insulation material layer 5 is formed on this porous material 10, and the porous material 6 in the example of Fig. 1 is laid on the sound insulation material layer 5. Fig. 2 shows an example in which "the sound insulation material layer 5 is indirectly formed on the flat plate portion 21 of the deck plate 2." In this example, a heat insulating material 9 is sandwiched between two folded plates as the roofing material 3. [Explanation of symbols]

[0043] 1...frame material, 1a...flange, 2: deck plate, 21: flat plate portion, 22: standing portion, 3...Roofing material, 4...Support material, 5...sound insulation layer, 6...porous material, 7...air layer, 8... purlin, 81... plate, 82... support part, 9. Thermal insulation 10... Porous material.

Claims

1. A thermal insulation and sound insulation structure for a roof comprising a deck plate laid on a framework material constituting a roof structure, and a roofing material laid on the outdoor side of the deck plate, The deck plate has a flat plate portion placed on the framework material, and upright portions arranged in parallel with each other at intervals in one direction of the flat plate portion, standing upright from the flat plate portion, and having the same top height; A soundproofing layer made of a material containing a cement-based material is formed directly or indirectly on the flat portion of the deck plate up to the top of the upright portion or its vicinity, and a porous material is laid and supported on the top of the upright portion and on the top surface of the soundproofing layer.

2. The roof insulation structure of claim 1, characterized in that a purlin material that directly supports the roofing material is erected on the upper surface of the framework material that supports the deck plate, with an axial direction facing in a direction intersecting the axial direction of the upright portion of the deck plate, and this purlin material is equipped with a plate whose axial direction faces the axial direction of the framework material and which is joined to the upper surface of the framework material that directly supports the purlin material, and a receiving portion that is joined to the upper part of the plate and receives the roofing material.

3. 3. The heat-insulating and sound-insulating roof structure according to claim 1, wherein an air layer is secured between the top of the porous material and the underside of the roofing material.

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