Building material and building structure

Abstract

Provided are a building material to which a sheet-shaped member can be more firmly mounted with less hindrance to remounting work, and a building structure. The building material (1) comprises two protrusions (10) arranged in parallel and a flat surface part (20) formed between the two protrusions (10). Each of the two protrusions (10) has an undercut part (11) which is recessed inward of the protrusion (10) at a connection portion with the flat surface part (20) and into which an end part of a solar cell panel (PV) is inserted. The protrusions (10) are connected by a rod-shaped member (R) so as to overlap each other.

Description

Building material and building structure

[0001] The present disclosure relates to a building material and a building structure.

[0002] Conventionally, solar cell panels that perform 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 securing rigidity. When installing a solar cell panel on a roofing material having such protrusions, it is known to install a pedestal to form a flat portion (see, for example, Patent Documents 1 and 2).

[0003] However, when a pedestal is used, in addition to the problem of cost, wind blows between the pedestal and the roof, so the pedestal must be firmly attached to the roof to prevent the pedestal from coming off. Therefore, when the roof has a certain flat portion, adhering the solar cell panel to the flat portion has also been studied (see Patent Document 3).

[0004] Japanese Patent Application Laid-Open No. 2023-153673, Japanese Patent Application Laid-Open No. 2023-163978, Japanese Patent Application Laid-Open No. 2022-76585

[0005] When the technique of Patent Document 3 is adopted, it is important that wind does not blow between the solar cell panel and the roof over a long period of time, and the solar cell panel needs to be firmly adhered to the roof. Here, generally, the service life of a solar cell panel is shorter than the service life of a roof, and particularly flexible perovskite solar cell panels developed in recent years have a shorter service life. For this reason, work to remove the solar cell panel from the roof and reattach it is required.

[0006] However, since the solar cell panel is firmly adhered to the roof, the peeling work requires a great deal of labor, and if the adhesive residue is not removed cleanly, it becomes difficult to firmly attach the next solar cell 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] An object of one aspect of this disclosure is to provide building materials and building structures that allow for more secure attachment of sheet-like members with less hindrance to repeated installation work.

[0010] A building material according to one aspect of the present disclosure is a building material comprising 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, a building structure according to one aspect of the present 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 between them.

[0012] According to one aspect of this disclosure, it is possible to provide a building material or building structure that allows for more secure attachment of sheet-like members with less hindrance to subsequent installation work.

[0013] Figure 1 is a perspective view showing a building material according to the first embodiment. Figure 2 is a side view of the building material shown in Figure 1. Figure 3 is a building structure including the building material according to the first embodiment. Figure 4 is a partially enlarged side view of the building material according to the first embodiment, where (a) shows one protrusion and (b) shows the other protrusion. Figure 5 is a side view showing an example of the press-fit member shown in Figure 4. Figure 6 is a side view showing a modified undercut portion shown in Figure 4. Figure 7 is a configuration diagram showing 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). Figure 8 is a perspective view showing a retaining bracket according to a modified example. Figure 9 is a side view showing a building material according to the first modified example. Figure 10 is a side view showing a building material according to the second modified example. Figure 11 is a perspective view showing a solar panel installed on the building material according to the second modified example.

[0014] The present disclosure will be described below in accordance with preferred embodiments. However, the present disclosure is not limited to the embodiments shown below and may be modified as appropriate without departing from the spirit of the disclosure. Furthermore, in the embodiments shown below, some illustrations and descriptions of certain components are omitted. It goes without saying that, regarding the details of the omitted technologies, publicly known or well-known technologies are applied as appropriate, to the extent that they do not contradict the content described below.

[0015] Figure 1 is a perspective view showing a building material according to the first embodiment, and Figure 2 is a side view of the building material shown in Figure 1. Figure 3 is a building structure including the building material according to the first embodiment. As shown in Figures 1 and 2, the building material 1 is, for example, a roofing material, which is installed on the sloping structure at the top of a building, and is configured as a so-called sandwich panel comprising a metal plate M and an insulating material I. That is, the building material 1 is formed in a roughly plate-like shape of a predetermined thickness by bending the metal plate M into a predetermined shape so as to cover the periphery of the insulating material I, and positioning the insulating material I within the space S formed by the bent metal plate M.

[0016] Such a building material 1 has two protrusions 10 and a flat portion 20, formed by bending a metal plate M. The two protrusions 10 are parts that project upward from the generally plate-shaped building material 1. When the building material 1 is used in the inclined structure of the upper part of a building, the two protrusions 10 are provided in a parallel state along the direction of inclination, as shown in Figure 1. The two protrusions 10 are formed at a predetermined interval in the width direction perpendicular to the direction of inclination in order to ensure the rigidity of the building material 1 and to reduce the risk of rainwater intrusion from the insertion hole of the rod-shaped member R described later. In the side view shown in Figure 2, the two protrusions 10 have a generally trapezoidal shape that tapers upward.

[0017] As shown in Figure 2, the building material 1 has two protrusions 10, one of which is filled with thermal insulation material I, and the other protrusion 10 is not filled with thermal insulation material I, and is a single metal plate M. The building material 1 is arranged so that the other protrusion 10b, which is a single metal plate M as shown in Figures 2 and 3, overlaps the one protrusion 10a that is filled with thermal insulation material I. In this arrangement, the building material 1 is firmly connected to the one protrusion 10a by inserting a rod-shaped member R, such as a self-tapping screw, from above the one metal plate M which is the other protrusion 10b, as shown in Figures 1 and 3.

[0018] Here, as shown in Figure 1, some of the rod-shaped members R, specifically the rod-shaped members Ra, are of a length that extends to the building's frame F. Therefore, the building material 1 is not only connected by the rod-shaped members Ra, but is also firmly fixed to the building itself.

[0019] In addition, although the building material 1 shown in Figure 2 is constructed by bending a single metal plate M, it may also be constructed by bending and welding two or more metal plates M together. Furthermore, the building material 1 is not limited to a metal plate M, but may be made of resin plates or wooden plates if possible. Moreover, the building material 1 is not limited to one that includes an insulating material I. In addition, the building material 1 may be installed so as to be placed on top of another building material already installed 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 a requirement. The solar cell panel PV is provided on a flat portion 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 so as 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 the portion 11d, it is prevented from easily coming out because the entrance 11a is narrower than the portion 11d.

[0027] Here, the member that holds the solar panel PV in place at 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, a plurality of building materials 1 are prepared. Then, the worker places the plurality of 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 with 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 the 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. For this reason, if, for example, a press-fitting member P is pressed between the undercut portion 11 and the solar cell panel PV, or if a sealant is filled in between, the press-fitting member P and the sealant will be 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, the solar cell panel PV, and the press-fit member P or sealant are included. 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 configuration diagram showing 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 opposing 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] The washer 210 has an opening 212a, but it is not limited to this, and a stud bolt may 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 Fig. 8, the pressing bracket 240 is configured as an elongated member extending between the two protrusions 10. In this pressing bracket 240, the contact plate 244 extends from the open side of the undercut portion 11 (see Fig. 7) of one protrusion 10a, passes through the intermediate position MP between the two undercut portions 11, and extends to the open side of the undercut portion 11 of the other protrusion 10b. Therefore, the pressing bracket 240 can be configured to collectively press the side portion PV1 of the solar panel PV. In particular, the elongated pressing bracket 240 can also suppress wind blowing from joints.

[0045] Here, when manufacturing the building structure 200 according to the second embodiment, an operator drives the rod-shaped member R through the washer 210 when connecting a plurality of building materials 1 with the rod-shaped member R. Then, after inserting the end of the solar panel PV into the undercut portion 11, the operator press-fits the press-fitting member P. Next, the operator attaches the pressing brackets 220 and 240 via the screw members 230.

[0046] In this way, according to the building material 1 and the building structure 200 according to the second embodiment, similarly to the first embodiment, it is possible to provide the building material 1 and the building structure 200 that cause less hindrance to re-installation work and can mount the solar panel PV more firmly.

[0047] Furthermore, it is preferable that the building structure 200 according to the second embodiment includes the pressing brackets 220 and 240 that are connected via the washer 210 to the rod-shaped member R for fixing the protrusions 10 of the plurality of building materials 1 to each other, and press the solar panel PV on the open side of the undercut portion 11. For this reason, the pressing brackets 220 and 240 are connected to the rod-shaped member R that connects the plurality of building materials 1 to each other, which is a structure that is not easily detached from the building materials 1, and then press the solar panel PV. Therefore, it is possible to provide the building structure 200 that can mount the solar panel PV even more firmly.

[0048] It is also preferable that the pressing fitting 240 is formed as an elongated member extending across between the two protrusions 10. This makes it possible to press not only the vicinity of the open side of the undercut portions 11, but also the intermediate position MP of the undercut portions 11 of each of the two protrusions 10. Accordingly, it is possible to provide a building structure 200 that allows the solar cell panels PV to be attached more firmly, by continuously pressing the side portions PV1 of the solar cell panels PV at joints between the solar cell panels PV or the like.

[0049] The present disclosure has been described above based on the embodiments, but the present disclosure is not limited to the above embodiments. Changes may be made to the present disclosure without departing from the scope of the gist thereof, and known or well-known techniques may be combined to the extent possible.

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

[0051] Although the rib 30 is configured as an elongated member continuous in the same direction as the two protrusions 10, the configuration is not particularly limited thereto, and the rib 30 may be formed intermittently in the same direction. Furthermore, the rib 30 is not limited to being provided at the intermediate position MP, and may be provided at a position separated from the intermediate position MP.

[0052] Furthermore, as shown in Figure 10, the building material 3 according to a second modified example has a raised structure in which the flat portion 20 is inclined and the center thereof is raised. The apex of the raised portion is denoted by reference sign AP. The apex (a portion protruding upward) AP corresponds to the intermediate position MP between the two protrusions 10, and is raised upward at a height lower than that of the two protrusions 10. Note that the apex AP may have a slight rounded shape. Furthermore, the apex AP is not limited to being located at the intermediate position MP, and may be located at a position separated from the intermediate position MP.

[0053] Figure 11 is a perspective view showing a solar cell PV installed on a building material 3 according to the second modified example. The solar cell PV installed on the building material 3 according to the second modified example is assumed to be in film form. The solar cell PV is also installed similarly on the 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 panel PV is 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 panel PV has a crystalline row, and if dirt caused by rainwater adheres along this crystalline row, 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 crystalline row, 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 having insulation material I, the material is not limited to this, and could also be standing seam metal roofing, or it could be sandwich panels.

[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 reflective 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 the 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 a concern.

[0058] 1-3: Building material 10: Two protrusions 11: Undercut section 11a: Entrance 11d: Part 20: Flat section 30: Rib (upwardly protruding part) 100, 200, 300: Building structure 220, 240: Retaining bracket (pressing member) AP: Apex (upwardly protruding part) MP: Intermediate position P: Press-fit member PV: Solar cell panel (sheet-like member) R, Ra: Rod-like member (fixing member)

Claims

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

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

3. A building structure comprising: a building material according to claim 1; a sheet-like member provided on the flat portion, with its end inserted into the undercut portion of each of the two protrusions of the building material; and a press-fit member pressed between the undercut portion and the sheet-like member, or a caulking agent filled between them.

4. The building structure according to claim 3, further comprising a pressing member connected to a fixing member for fixing the respective protrusions of the plurality of 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.

5. The building structure according to claim 4, characterized in that 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.

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

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