JP2010112151A - Tile-roofing-like folded-plate roof material and manufacturing method for the same - Google Patents

Tile-roofing-like folded-plate roof material and manufacturing method for the same Download PDF

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JP2010112151A
JP2010112151A JP2008334994A JP2008334994A JP2010112151A JP 2010112151 A JP2010112151 A JP 2010112151A JP 2008334994 A JP2008334994 A JP 2008334994A JP 2008334994 A JP2008334994 A JP 2008334994A JP 2010112151 A JP2010112151 A JP 2010112151A
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JP4261619B1 (en
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Takatoshi Nagamatsu
孝俊 長松
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MARUDAI CO Ltd
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Abstract

<P>PROBLEM TO BE SOLVED: To provide a tile-roofing-like folded-plate roof material capable of being stably supported on a beam of a building and free from distortion. <P>SOLUTION: The tile-roofing-like folded-plate roof material comprises a long-sized folded metal sheet 10a folded in zigzag by mountain-folds 11 and valley folds 12 and including a step formed nearly perpendicularly to the mountain folds and valley folds. The lower section of the step 13 is provided with a mountain fold distortion alleviating section 14 formed by forming a recess 14a in part of the mountain fold by extending the step further downward and forming ribs 14b, 14c projected upward oppositely to the extending direction of the recess on right/left sides of the recess. The upper section of the valley fold is provided with a valley fold distortion alleviating section 15 formed by forming a protrusion 15a on part of the valley fold by extending the step further upward and forming recessed ribs 15b, 15c extending downward oppositely to the extending direction of the protrusion on right/left sides of the protrusion. The mountain fold distortion alleviating section and the valley fold distortion alleviating sections are alternately arranged on both sides of the step. <P>COPYRIGHT: (C)2010,JPO&INPIT

Description

本発明は住宅や工場などの屋根材に好適に使用される瓦葺状パターンが形成された瓦葺状折板屋根材及びその製造方法に関する。   TECHNICAL FIELD The present invention relates to a tile-shaped folded plate roof material on which a tile-shaped pattern suitably used for a roof material for a house, a factory, or the like, and a method for manufacturing the same.

従来、住宅や工場などに用いられる建物屋根材は、フラットな金属板をロール成形機やプレス機などにより折り曲げ加工して波板面を形成した金属製の折板屋根が用いられている。さらに、このような波板面に屋根瓦パターンを形成して、その外観を和風調にデザインした瓦葺状折板屋根材なども提供されている。
このような瓦葺状折板屋根材には、太陽光による輻射熱や屋根裏面に発生する結露を防ぐための断熱材もしくは屋根面に当たる雨音などを低減させるための吸音材として、発泡ポリエチレンやガラス繊維シートなどが貼付されている。例えば特許文献１には、平板状の鋼板に断熱材を貼り付けた後、ロールフォーミングなどの方法で折板屋根の形状に成形加工する断熱折板屋根の成形方法が記載されている。また、断熱材が厚いものでは鋼板に貼り付けて折板屋根に成形することが困難であるため、鋼板を折板屋根形状に成形した後に、手作業でこれを貼り付けるものもある。また、折板成形した２枚の鋼板の間に断熱材を積層させたり、鋼板にシート状断熱材を貼って成形した屋根材の裏側に天井を兼ねた断熱材を敷き並べたりする工法などが用いられているものもある。
また、特許文献２には、屋根板の流れ方向の軒先側に、裏面に向けて折り曲げた折曲げ部が形成され、折返し重合部の折曲げ部の周辺に流れ方向と平行な突条部が局所的に形成されている屋根構造が記載されている。
さらに、特許文献３には、長さ方向に沿って突設された複数本の平行な山部と、山部と直交する向きに互いに間隔を置いて成形された多数の段部を有し、山部がテーパー形の段付き波形金属屋根板が記載されている。特許文献３に記載のような屋根材は、長尺の金属板の長さ方向に沿って平行な山部を有する波形金属屋根板に、山部と直交する向きの段部を等間隔に設け、瓦葺き屋根と同じようなデザインの屋根材としている。このような段付き波形金属屋根板は、屋根の上から下までの距離が１枚の長尺板により上下方の接合部がなく葺ける縦葺き用として作られるため、成形に際してはまず長尺板にロールフォーミングによって長さ方向に平行な山折部及び谷折部を設け、しかる後プレス工程において山折部及び谷折部に対して直交する向きの段差部を等間隔でプレス成形する手順を経る。
特開平６−３３６７９１号公報 特開２００１−３４９０１２号公報 実開昭５９−７７５１６号公報 2. Description of the Related Art Conventionally, building roof materials used in houses, factories, and the like have used metal folded plate roofs in which a corrugated plate surface is formed by bending a flat metal plate with a roll forming machine or a press machine. Furthermore, a tile roof-like folded roof material having a roof tile pattern formed on such a corrugated surface and its exterior designed in a Japanese style is also provided.
Such roof tile-like roofing materials include foamed polyethylene and glass fiber as a heat-absorbing material to prevent radiant heat from sunlight and condensation that occurs on the back of the roof, or a sound-absorbing material to reduce the sound of rain on the roof. Sheets are affixed. For example, Patent Document 1 describes a method for forming a heat insulating folded plate roof in which a heat insulating material is attached to a flat steel plate and then formed into a shape of a folded plate roof by a method such as roll forming. Moreover, since it is difficult to affix to a steel plate and shape | mold into a folded-plate roof with the thing with a thick heat insulating material, after shaping | molding a steel plate in a folded-plate roof shape, there exist some which affix this manually. In addition, there is a method of laminating a heat insulating material between two folded steel plates, or placing a heat insulating material also serving as a ceiling on the back side of a roof material formed by sticking a sheet heat insulating material to a steel plate. Some are used.
Moreover, in patent document 2, the bending part bent toward the back surface is formed in the eaves end side of the flow direction of a roofing board, and the protrusion part parallel to a flow direction exists in the circumference | surroundings of the bending part of a folding | superposition overlap part. A locally formed roof structure is described.
Furthermore, Patent Document 3 has a plurality of parallel ridges projecting along the length direction, and a large number of steps formed at intervals from each other in a direction perpendicular to the ridges, A stepped corrugated metal roofing board with a tapered peak is described. The roof material as described in Patent Document 3 is provided with corrugated metal roof plates having parallel mountain portions along the length direction of the long metal plate, with stepped portions oriented in the direction orthogonal to the mountain portions at equal intervals. The roofing material has the same design as a tiled roof. Such a stepped corrugated metal roofing board is made for vertical winding where the distance from the top to the bottom of the roof is such that there is no joint between the upper and lower sides by a single long board. The plate is provided with a mountain fold portion and a valley fold portion parallel to the length direction by roll forming, and after that, in a pressing process, a step portion is formed at equal intervals in a direction orthogonal to the mountain fold portion and the valley fold portion. .
JP-A-6-336791 JP 2001-349012 A Japanese Utility Model Publication No. 59-77516

しかし、予め成形された山折部及び谷折部の上に後の工程として段差部を形成する場合には、段差部を境とした領域に絞りじわが生ずることとなり、瓦葺状折板屋根材の美観を損ねたりするといった問題点があった。特に、前記従来の瓦葺状折板屋根材のような、折り曲げ加工された波板面の深さ（山折部と谷折部との寸法差）が小さい場合は、長さ方向に形成された山折部及び谷折部と直交する向きの段部は比較的容易に形成されるが、ロールフォーミングなどの方法で成形加工された一枚の折板屋根に多数の山折部及び谷折部が形成されたものや、山折部と谷折部との寸法差が大きい（山谷の深さが深い）場合は、山折部と直交する向きに互いに間隔を置いて段差部（段部）を形成すると、段差部の周囲に発生する成形歪みが大きくなり、段差部周辺だけでなく傾斜部にも絞りじわが波及し、折板屋根全体的に歪みが生じプレス成形そのものを阻害するという問題点を有していた。   However, when forming a stepped portion as a subsequent process on a pre-formed mountain fold portion and a valley fold portion, a wrinkle will occur in the region with the stepped portion as a boundary, There was a problem of detracting from aesthetics. In particular, when the depth of the folded corrugated sheet surface (the dimensional difference between the mountain fold and the valley fold) is small, such as the conventional tile-shaped folded board roof material, the mountain fold formed in the length direction Steps that are perpendicular to the section and the valley fold are formed relatively easily, but a large number of mountain folds and valley folds are formed on a single folded plate roof formed by a method such as roll forming. If there is a large dimensional difference between the mountain fold and the valley fold (depth of the valley), forming a step (step) at a distance from each other in the direction perpendicular to the fold The molding distortion that occurs around the part becomes large, and the wrinkle spreads not only around the step part but also on the inclined part, and the entire folded plate roof is distorted and has the problem of inhibiting press molding itself. It was.

本発明は前記従来の課題を解決するためになされたもので、金属板をロール成形及びプレス成形して屋根瓦パターンを形成するに際して、金属板に生じる歪みを効率的に緩和して、屋根材の成形加工を安定的に行うことができ、美観に優れた瓦葺状折板屋根材及びその製造方法を提供することを目的とする。   The present invention has been made in order to solve the above-described conventional problems. When a roof tile pattern is formed by roll-forming and press-molding a metal plate, the strain generated in the metal plate is effectively reduced, and the roof material is obtained. It is an object of the present invention to provide a tile-shaped folded-plate roof material that can stably perform the molding process and a manufacturing method thereof.

（１）本発明の瓦葺状折板屋根材は、山折部と谷折部によりジグザグ状に折り曲げて形成された長尺の折曲げ金属板の山折部と谷折部にそれぞれ略直交する段差部が形成された瓦葺状折板屋根材であって、
前記山折部の段差部の下方には、該段差部をさらに下方へ張り出して山折部の一部に凹部を形成するとともに、該凹部の左右側部に凹部の張り出し方向とは反対の上方へ張り出した凸状のリブを形成した山折歪緩和部を設け、
前記谷折部の段差部の上方には、該段差部をさらに上方へ張り出して谷折部の一部に凸部を形成するとともに、該凸部の左右側部に凸部の張り出し方向とは反対の下方へ張り出した凹状のリブを形成した谷折歪緩和部を設け、
前記山折歪緩和部と谷折歪緩和部とは、前記段差部を挟んで互い違いに設けられていることを特徴とする。 (1) The tile-shaped folded plate roofing material of the present invention is a step portion that is substantially orthogonal to the mountain folded portion and the valley folded portion of the long folded metal plate formed by bending the mountain folded portion and the valley folded portion in a zigzag shape. Is a tile-shaped folded board roofing material,
Below the step portion of the mountain fold portion, the step portion is further projected downward to form a recess in a part of the mountain fold portion, and the left and right side portions of the recess are projected upward opposite to the direction in which the recess extends. Provided with a mountain fold strain relief part formed with a convex rib,
Above the step portion of the valley fold portion, the step portion is further projected upward to form a convex portion at a part of the valley fold portion, and the protruding direction of the convex portion on the left and right side portions of the convex portion is On the opposite side, a valley fold strain relief part is formed that forms a concave rib projecting downward,
The mountain fold strain relief portions and the valley fold strain relief portions are provided alternately with the step portion interposed therebetween.

（２）本発明の瓦葺状折板屋根材は前記（１）において、前記折曲げ金属板における梁材当接面となる山折部及び谷折部の裏面に制振シートを添着し、前記制振シートを添着した裏面全部を断熱シートで被覆したことを特徴とする。 (2) The tile-shaped folded plate roofing material according to the present invention is the above-mentioned (1), wherein a damping sheet is attached to the back surface of the mountain fold portion and the valley fold portion serving as the beam material contact surface in the bent metal plate. The entire back surface to which the vibration sheet is attached is covered with a heat insulating sheet.

（３）本発明の瓦葺状折板屋根材の製造方法は、前記（１）又は（２）の瓦葺状折板屋根材の製造方法であって、
（ａ）折曲げ金属板における山折部となる裏面の所定位置に制振シートを貼着する制振シート貼着工程と、
（ｂ）前記金属板における裏面全体に断熱シートを貼着する断熱シート貼着工程と、
（ｃ）前記制振シート及び前記断熱シートがそれぞれ貼着された前記金属板を複数のロールにより挟圧変形させて山折部及び谷折部によりジグザグ状に折り込まれた折曲げ金属板に成形するロール成形工程と、
（ｄ）前記折曲げ金属板の山折部及び谷折部に直交する方向の段差部を長尺状型枠を用いて順次プレス成形して、山折部の段差部の下方に、段差部をさらに下方へ張り出して山折部の一部に凹部を形成するとともに、該凹部の左右側部に該凹部の張り出し方向とは反対の上方へ張り出した凸状のリブを形成した山折歪緩和部を設け、
谷折部の段差部の上方に、段差部をさらに上方へ張り出して谷折部の一部に凸部を形成するとともに、該凸部の左右側部に該凸部の張り出し方向とは反対の下方へ張り出した凹状のリブを形成した谷折歪緩和部を設けるプレス成形工程と、を有することを特徴とする。 (3) The method for producing the tile-shaped folded board roof material of the present invention is the method for producing the tile-shaped folded board roof material of (1) or (2),
(A) a damping sheet adhering step for adhering the damping sheet to a predetermined position on the back surface to be a mountain fold in the bent metal plate;
(B) a heat insulating sheet attaching step of attaching a heat insulating sheet to the entire back surface of the metal plate;
(C) The metal plate to which the vibration-damping sheet and the heat-insulating sheet are respectively bonded is deformed by pressing with a plurality of rolls, and is formed into a bent metal plate that is folded in a zigzag manner by a mountain fold and a valley fold. Roll forming process;
(D) A stepped portion in a direction orthogonal to the mountain folded portion and the valley folded portion of the bent metal plate is sequentially press-formed using a long formwork, and a stepped portion is further provided below the stepped portion of the mountain folded portion. Protruding downward and forming a concave portion in a part of the mountain fold portion, and providing a mountain fold strain relief portion formed on the left and right side portions of the concave portion with a convex rib projecting upward opposite to the protruding direction of the concave portion,
Above the stepped portion of the valley folded portion, the stepped portion is further projected upward to form a convex portion at a part of the valley folded portion, and the protruding direction of the convex portion is opposite to the left and right side portions of the convex portion. And a press forming step of providing a valley fold strain relief portion in which a concave rib projecting downward is formed.

本発明によれば、山折部と谷折部によりジグザグ状に折り曲げて形成された長尺の折曲げ金属板の山折部と谷折部にそれぞれ略直交する段差部が形成された瓦葺状折板屋根材において、山折部の段差部の下方には、段差部をさらに下方へ張り出して山折部の一部に凹部を形成するとともに、凹部の左右側部に凹部の張り出し方向とは反対の上方へ張り出した凸状のリブを形成した山折歪緩和部を設け、谷折部の段差部の上方には、段差部をさらに上方へ張り出して谷折部の一部に凸部を形成するとともに、凸部の左右側部に凸部の張り出し方向とは反対の下方へ張り出した凹状のリブを形成した谷折歪緩和部を設け、山折歪緩和部と谷折歪緩和部とは、段差部を挟んで互い違いに設けられているので、金属板をロール成形又はプレス成形して屋根瓦状パターンを形成するに際して、金属板に生ずる歪みを効率的に吸収緩和して、屋根材の成形加工を安定的に行うことができ、美観に優れた瓦葺状折板屋根材とすることができる。   According to the present invention, a tile-shaped folded plate in which stepped portions that are substantially orthogonal to the mountain folded portion and the valley folded portion of the long bent metal plate formed by zigzag bending by the mountain folded portion and the valley folded portion are formed. In the roofing material, below the step portion of the mountain fold portion, the step portion is further projected downward to form a recess in a part of the mountain fold portion, and on the left and right sides of the recess, upward opposite to the direction in which the recess extends. A mountain fold strain relief portion is provided that has a protruding rib that protrudes. Above the step portion of the valley fold, the step portion is further projected upward to form a convex portion at a part of the valley fold. The valley fold strain relief part is formed on the left and right sides of the part. The valley fold strain relief part is formed with a concave rib projecting downward opposite to the projecting direction of the convex part. The mountain fold strain relief part and the valley fold strain relief part sandwich the step part. Since it is provided in a staggered manner, roll or press molding the metal plate When forming a root tile-like pattern, the distortion generated in the metal plate can be efficiently absorbed and relaxed, and the roofing material can be stably molded, and the roof tile-like folded plate roofing material has an excellent aesthetic appearance. Can do.

本実施形態の瓦葺状折板屋根材は、山折部と谷折部によりジグザグ状に折り曲げて形成された長尺の折曲げ金属板の山折部と谷折部にそれぞれ略直交する段差部が形成され、山折部の段差部の下方には、段差部をさらに下方へ張り出して山折部の一部に凹部を形成するとともに、凹部の左右側部に凹部の張り出し方向とは反対の上方へ張り出した凸状のリブを形成した山折歪緩和部を設け、谷折部の段差部の上方には、段差部をさらに上方へ張り出して谷折部の一部に凸部を形成するとともに、凸部の左右側部に凸部の張り出し方向とは反対の下方へ張り出した凹状のリブを形成した谷折歪緩和部を設け、山折歪緩和部と谷折歪緩和部とは、段差部を挟んで互い違いに設けられている。
これによって、金属板をロール成形及びプレス成形して屋根瓦パターンを有した瓦葺状折板屋根材を製造するに際して、折曲げ金属板には成形加工時における歪みを分散吸収することができ、歪みのない屋根材を効率的に形成させることができる。 The tile-shaped folded plate roofing material of the present embodiment is formed with step portions that are substantially orthogonal to the mountain folded portion and the valley folded portion of the long folded metal plate formed by bending the mountain folded portion and the valley folded portion in a zigzag shape. The step part is further projected downward below the step part of the mountain fold part to form a recess in a part of the mountain fold part, and projecting upward on the left and right sides of the recess opposite to the direction of the extension of the recess. Provided with a mountain fold strain relief portion formed with a convex rib, projecting the step portion further upward above the step portion of the valley fold portion to form a convex portion at a part of the valley fold portion, A valley fold strain relief part is formed on the left right side, which is formed with a concave rib projecting downward opposite to the projection direction of the convex part. The mountain fold strain relief part and the valley fold strain relief part are staggered across the step part. Is provided.
This makes it possible to disperse and absorb the distortion during the forming process in the folded metal plate when manufacturing the tile-shaped folded plate roof material having the roof tile pattern by roll forming and press forming the metal plate. It is possible to efficiently form a roofing material without any material.

また、屋根材を建物に施工するに際して、建物梁部に屋根材を確実に密着固定させて安定的に載置することができ、屋根材に当接する雨音を低減する制振性や、輻射熱や結露に対抗する断熱性、屋根施工におけるコスト性及び、作業性に優れた瓦葺状折板屋根材を提供することができる。   In addition, when constructing roofing material in a building, the roofing material can be securely and securely mounted on the building beam, and it can be stably placed. In addition, it is possible to provide a tile-shaped folded-plate roof material that is superior in heat resistance against heat and condensation, cost in roof construction, and workability.

折曲げ金属板とする金属板としては、例えば、横巾約１〜３ｍ、長手方向３〜１０ｍ、厚み約１〜２ｍｍ程の矩形状に形成された亜鉛メッキ鋼板などが挙げられる。この金属板をロールフォーミング加工やプレス成形加工などによりジグザグ状に折り曲げて形成される。このような亜鉛メッキ鋼板などの板面には防音効果の高い制振材や断熱材を予め被覆したものなどを適用できる。   As a metal plate used as a bent metal plate, for example, a galvanized steel plate formed in a rectangular shape with a lateral width of about 1 to 3 m, a longitudinal direction of 3 to 10 m, and a thickness of about 1 to 2 mm can be cited. The metal plate is formed in a zigzag shape by roll forming or press forming. A plate surface of such a galvanized steel plate or the like that has been previously coated with a vibration damping material or a heat insulating material having a high soundproofing effect can be applied.

屋根瓦パターンは、例えば、縦横４０ｃｍ程度の山形の瓦状に形成したユニットが多数縦横に配列されたパターンのものをいう。このような屋根瓦パターンは折曲げ金属板を所定のプレス型を用いてプレス成形することによって、すなわち、折曲げ金属板の山折部と谷折部とにそれぞれ直交する段差部を、長手方向に３０〜５０ｃｍ程度の間隔で配置することで実現することができる。
なお、実施の形態では、屋根瓦パターンを形成する折曲げ金属板の山折部の間隔は約１５〜２５ｃｍ程度とし、山折部と谷折部との差（深さ）は８〜１５ｃｍ程度とすることが好ましい。 The roof tile pattern is, for example, a pattern in which a large number of units formed in a mountain-shaped tile shape with a height and width of about 40 cm are arranged vertically and horizontally. Such a roof tile pattern is formed by press-forming a bent metal plate using a predetermined press die, that is, stepped portions that are orthogonal to the mountain folded portion and the valley folded portion of the folded metal plate, respectively, in the longitudinal direction. It can implement | achieve by arrange | positioning at the space | interval of about 30-50 cm.
In addition, in embodiment, the space | interval of the mountain fold part of the bending metal plate which forms a roof tile pattern shall be about 15-25 cm, and the difference (depth) of a mountain fold part and a valley fold part shall be about 8-15 cm. It is preferable.

山折歪緩和部は、山折部の段差部の下方に設けられ、段差部をさらに下方へ張り出して山折部の一部を凹状に形成し凹部としたものであり、凹部の左右側部に凹部の張り出し方向とは反対の上方へ張り出した凸状のリブを形成している。谷折歪緩和部は、谷折部の段差部の上方に設けられ、段差部をさらに上方へ張り出して谷折部の一部を凸状に形成し凸部としたものであり、凸部の左右側部に凸部の張り出し方向とは反対の下方へ張り出した凹状のリブを形成している。山折歪緩和部及び谷折歪緩和部は、折曲げ金属板の山折部及び谷折部において、段差部周囲に生ずるしわなどの歪みを吸収する部分である。
上記のように、山折部及び谷折部の段差部において、張り出し凹部及びその両側にリブを形成することで、表面績を大きくし段差部周囲に生ずるしわをこの部分に集中することにより見栄えをよくすることができるのである。
なお、段差部の高さとしては、プレス加工で形成できる高さで２ｃｍ〜１０ｃｍ程度のものである。 The mountain fold strain relief portion is provided below the step portion of the mountain fold portion, and projects the step portion further downward to form a part of the mountain fold portion as a concave shape, forming a concave portion on the left and right side portions of the concave portion. Convex ribs projecting upward opposite to the projecting direction are formed. The valley fold strain relief portion is provided above the step portion of the valley fold portion, and further protrudes upward to form a part of the valley fold portion into a convex shape. A concave rib projecting downward opposite to the projecting direction of the convex portion is formed on the left right side portion. The mountain fold strain relief portion and the valley fold strain relief portion are portions that absorb distortion such as wrinkles generated around the step portion in the mountain fold portion and the valley fold portion of the bent metal plate.
As described above, in the step portion of the mountain fold portion and the valley fold portion, by forming the overhanging concave portion and ribs on both sides thereof, the surface finish is increased, and the wrinkles generated around the step portion are concentrated on this portion. You can do it well.
In addition, as a height of a level | step-difference part, it is a thing of about 2 cm-10 cm by the height which can be formed by press work.

本実施形態の瓦葺状折板屋根材は、前記折曲げ金属板における梁材当接面となる山折部及び谷折部の裏面に、ゴム、熱可塑性エラストマー、熱可塑性樹脂、無機粉体などを含む制振シートが添着され、制振シートが添着された裏面全部を、さらに発泡ポリエチレン樹脂などからなる断熱シートで被覆することもできる。これによって、風雨や温度変化による材質劣化を起こし難い制振シートや断熱シートを積層することにより、耐候性及び遮音性能に優れた瓦葺状折板屋根材を提供することができる。
制振シートには断熱シートが積層貼付されているので、雨などの落下物を瓦葺状折板屋根材に貼付された制振シートが直接受けて衝撃吸収することが可能となり、良好な遮音性能を発揮するとともに、断熱シートの働きによって輻射熱を遮断して、結露を防止するとともに制振シートにおける材質劣化を防止することも可能となる。 The tile-shaped folded plate roofing material of the present embodiment is made of rubber, thermoplastic elastomer, thermoplastic resin, inorganic powder, etc. on the back surface of the mountain fold portion and the valley fold portion that become the beam material contact surface in the bent metal plate. It is also possible to cover the entire back surface to which the vibration damping sheet is attached with the insulating sheet made of foamed polyethylene resin or the like. Thus, by stacking a vibration damping sheet and a heat insulating sheet that are unlikely to cause material deterioration due to wind and rain and temperature changes, it is possible to provide a roof tile-like folded plate roof material having excellent weather resistance and sound insulation performance.
Since the insulation sheet is laminated on the damping sheet, it is possible for the damping sheet attached to the roof tile-like roofing material to directly receive shocks and absorbs shocks, resulting in good sound insulation performance. In addition, it is possible to block the radiant heat by the action of the heat insulating sheet, prevent condensation and prevent material deterioration in the vibration damping sheet.

制振シートは、例えば、ゴム、熱可塑性エラストマー、熱可塑性樹脂、無機粉体などを含む混合体からなる弾力性に優れたテープ状素材からなり、建物梁材によって支持される瓦葺状折板屋根材における山折部又は谷折部巾と略同じ巾でそれらの内側長手方向に沿って貼着され、屋根面に雨粒が当たる際に発生する振動を吸収する防音効果を備えたものである。
このような瓦葺状折板屋根材に貼付される遮音性能に優れた薄肉樹脂製の制振シートは、亜鉛メッキ鋼板などの金属板を瓦葺状折板屋根材に二次加工する際に、金属板の加工に追随して変形し、剥離や破断を起こさないことが要求される。 The vibration damping sheet is made of a tape-like material having excellent elasticity made of a mixture containing rubber, thermoplastic elastomer, thermoplastic resin, inorganic powder, etc., and is a tile-shaped folded plate roof supported by a building beam. It is attached along the inner longitudinal direction with the same width as a mountain fold or valley fold in the material, and has a soundproofing effect to absorb vibration generated when raindrops hit the roof surface.
A vibration damping sheet made of thin-walled resin with excellent sound insulation performance that is affixed to such a tile-shaped folded-plate roof material is a metal that is used when a metal plate such as a galvanized steel sheet is secondarily processed into a tile-shaped folded-plate roof material. It is required to be deformed following the processing of the plate and not to peel off or break.

断熱シートは、発泡ポリエチレン樹脂などからなる樹脂シート体であって、瓦葺状折板屋根材の裏面全部に被覆されていることが望ましい。   The heat insulating sheet is a resin sheet body made of foamed polyethylene resin or the like, and is preferably covered on the entire back surface of the tile-shaped folded-plate roof material.

本実施形態の瓦葺状折板屋根材の製造方法は、前記瓦葺状折板屋根材の製造方法であって、
（ａ）折曲げ金属板における山折部となる裏面の所定位置に制振シートを貼着する制振シート貼着工程と、
（ｂ）金属板における裏面全体に断熱シートを貼着する断熱シート貼着工程と、
（ｃ）制振シート及び断熱シートがそれぞれ貼着された金属板を複数のロールにより挟圧変形させて山折部及び谷折部によりジグザグ状に折り込まれた折曲げ金属板に成形するロール成形工程と、
（ｄ）折曲げ金属板の山折部及び谷折部に直交する方向の段差部を長尺状型枠を用いて順次プレス成形して、山折部の段差部の下方に、段差部をさらに下方へ張り出して山折部の一部に凹部を形成するとともに、凹部の左右側部に凹部の張り出し方向とは反対の上方へ張り出した凸状のリブを形成した山折歪緩和部を設け、
谷折部の段差部の上方に、段差部をさらに上方へ張り出して谷折部の一部に凸部を形成するとともに、凸部の左右側部に凸部の張り出し方向とは反対の下方へ張り出した凹状のリブを形成した谷折歪緩和部を設けるプレス成形工程と、を有するように構成される。
これによって、金属板を素材としてロール成形やプレス成形により屋根瓦パターンを有した瓦葺状折板屋根材を効率的に製造することができる。特に、瓦葺状折板屋根材に山折歪緩和部や谷折歪緩和部を設けることにより、段差部を加工する際に発生する歪みを効果的に吸収することができるため、美観に優れた瓦葺状折板屋根材を製造方法することができる。 The manufacturing method of the tile-shaped folded board roofing material of the present embodiment is a manufacturing method of the tile-shaped folded board roofing material,
(A) a damping sheet adhering step for adhering the damping sheet to a predetermined position on the back surface to be a mountain fold in the bent metal plate;
(B) a heat insulating sheet attaching step of attaching a heat insulating sheet to the entire back surface of the metal plate;
(C) A roll forming step in which a metal plate to which the vibration damping sheet and the heat insulating sheet are respectively attached is deformed by a plurality of rolls and formed into a bent metal plate that is folded in a zigzag manner by a mountain fold and a valley fold. When,
(D) A stepped portion in a direction perpendicular to the mountain folded portion and the valley folded portion of the bent metal plate is sequentially press-formed using a long formwork, and the stepped portion is further lowered below the stepped portion of the mountain folded portion. Protruding to form a recess in a part of the mountain fold, and provided with a mountain fold strain relief portion formed on the left and right sides of the recess formed convex ribs protruding upward opposite to the direction of protrusion of the recess,
Above the stepped portion of the valley fold, the stepped portion is further projected upward to form a convex portion at a part of the valley folded portion, and downward on the left and right sides of the convex portion opposite to the protruding direction of the convex portion. And a press forming step of providing a valley fold strain relief portion in which protruding concave ribs are formed.
As a result, it is possible to efficiently produce a tile-shaped folded plate roof material having a roof tile pattern by roll forming or press forming using a metal plate as a raw material. In particular, by providing a mountain fold strain relief portion and a valley fold strain relief portion on the tile-shaped folded plate roofing material, it is possible to effectively absorb the strain generated when processing the stepped portion, so that the tile roof has an excellent aesthetic appearance. It is possible to produce a folded plate roofing material.

さらに、本実施形態の瓦葺状折板屋根材の製造方法において、前記屋根瓦パターンを形成させる長尺状型枠がセラミックス質骨材（Ａ）に合成樹脂成分（Ｂ）を混合硬化させて形成した樹脂硬化体からなる上下一対のプレス型とすることもできる。
これによって、従来のような金属製のモールド型を用いた瓦葺状折板屋根材の製造方法に比べて、加工素材となる金属板をクッション性を有したプレス型によってソフトに変形させることができ、加工傷や加工歪みの発生を軽減して、成形歩留りに優れた瓦葺状折板屋根材の製造方法を提供できる。 Furthermore, in the manufacturing method of the roof tile-shaped folded plate roof material of the present embodiment, the long formwork for forming the roof tile pattern is formed by mixing and curing the synthetic resin component (B) on the ceramic aggregate (A). A pair of upper and lower press molds made of a cured resin body can also be used.
This makes it possible to softly deform a metal plate as a processed material with a press die having a cushioning property, compared to a conventional method for producing a tile-shaped folded plate roof material using a metal mold die. Further, it is possible to provide a method for producing a tile-shaped folded-plate roof material excellent in forming yield by reducing the occurrence of processing scratches and processing distortion.

長尺状型枠の合成樹脂成分としては、例えば、ポリアミド、エポキシ、ポリエーテル、ポリテトラフロロエチレンなどの機械的強度に優れたエンジニアリングプラスチック材や、比較的軟質の熱可塑性プラスチック材などを適用することができる。
セラミックス質骨材は、前記合成樹脂成分の硬度や剛性を補完して長尺状型枠に所定の機械的特性を付与するための成分であり、例えば、粒度調整した砕石粉末やシリカ、アルミナなどの金属酸化物粉末などを適用することができる。
なお、セラミックス質骨材の粒度は、特に限定されるものではないが、その平均粒子径が約０．２〜２ｍｍの範囲とすることが好ましい。セラミックス質骨材の平均粒子径が０．２ｍｍ未満であると、単位重量当たりの粒子数が多くなって混合工程に長時間を要するようになり、逆に平均粒子径が２ｍｍを超えると、瓦葺状折板屋根材のプレス成形時に表面の荒れや貼付された断熱シートや制振シートの破断等をきたす原因となることがある。 As the synthetic resin component of the long formwork, for example, engineering plastic materials having excellent mechanical strength such as polyamide, epoxy, polyether, polytetrafluoroethylene, and relatively soft thermoplastic materials are applied. be able to.
The ceramic aggregate is a component for complementing the hardness and rigidity of the synthetic resin component and imparting predetermined mechanical properties to the long formwork, for example, crushed stone powder with adjusted particle size, silica, alumina, etc. A metal oxide powder or the like can be applied.
The particle size of the ceramic aggregate is not particularly limited, but the average particle size is preferably in the range of about 0.2 to 2 mm. If the average particle size of the ceramic aggregate is less than 0.2 mm, the number of particles per unit weight increases and a long time is required for the mixing process. Conversely, if the average particle size exceeds 2 mm, When press-molding the folded plate roof material, the surface may be roughened or the attached heat insulating sheet or vibration damping sheet may be broken.

屋根瓦パターンが形成される長尺状型枠において、そのセラミックス質骨材（Ａ）と合成樹脂成分（Ｂ）との質量混合比率（Ａ／Ｂ）は、１：５〜１：２の範囲とすることが好ましい。この理由は、質量混合比率（Ａ／Ｂ）が１：５より小さくなると、折曲げ金属板をプレス加工により瓦葺状折板屋根材にする成形する際の耐摩耗性が不足して、長尺状型枠のメンテナンス交換頻度が高くなりコスト性の悪化傾向が生じるためである。逆に、質量混合比率（Ａ／Ｂ）が１：２を超えて大きくなると、プレス成形時における長尺状型枠との摩擦抵抗が増大するとともに、加工傷の発生が顕著となって歩留り低下の一因ともなるからである。   In the long formwork on which the roof tile pattern is formed, the mass mixing ratio (A / B) of the ceramic aggregate (A) and the synthetic resin component (B) is in the range of 1: 5 to 1: 2. It is preferable that The reason for this is that when the mass mixing ratio (A / B) is smaller than 1: 5, the wear resistance at the time of forming the folded metal sheet into a roof tile-shaped folded sheet roof material by pressing is insufficient, and the long length This is because the maintenance replacement frequency of the shape molds is increased, and the cost tends to deteriorate. On the other hand, when the mass mixing ratio (A / B) exceeds 1: 2, the frictional resistance with the long formwork during press molding increases, and the occurrence of processing flaws becomes significant, resulting in a decrease in yield. It is also a cause.

（実施例１）
以下、本発明の実施例を図面を参照して説明する。
図１は本実施例の瓦葺状折板屋根材の施工例を示す斜視図であり、図２は本実施例の瓦葺状折板屋根材の平面図であり、図３は図２における矢視Ａ−Ａ断面図である。
実施例１の瓦葺状折板屋根材１０は図１〜図３に示すように、山折部１１と谷折部１２を設けてジグザグ状に折り曲げられた折曲げ金属板１０ａの山折部と谷折部に、それぞれ略直交する直線状に形成された段差部１３（１３ａ〜１３ｅ）が所定間隔で複数配置されて構成されている。
このような瓦状折板屋根材１０は図１に示すように、建物梁材２０の当接支持面２１上に載置されて固定支持されることで建物の屋根部分が形成されるようになっている。 Example 1
Embodiments of the present invention will be described below with reference to the drawings.
FIG. 1 is a perspective view showing a construction example of the tile-shaped folded board roof material of the present embodiment, FIG. 2 is a plan view of the tile-shaped folded board roof material of the present embodiment, and FIG. 3 is an arrow view in FIG. It is AA sectional drawing.
As shown in FIGS. 1 to 3, the roof tile-like folded roof material 10 according to the first embodiment is provided with a mountain fold portion 11 and a valley fold portion 12, and is folded in a zigzag shape so that the mountain fold portion and the valley fold are formed. A plurality of step portions 13 (13a to 13e) formed in a straight line substantially orthogonal to each other are arranged at predetermined intervals.
As shown in FIG. 1, such a tile-like folded-plate roof material 10 is placed on the contact support surface 21 of the building beam material 20 and fixedly supported so that the roof portion of the building is formed. It has become.

段差部１３は、折曲げ金属板１０ａに形成された約５ｃｍの高さの段差が形成された部分であり、折曲げ金属板１０ａの山折部及び谷折部に直交するようにプレス成形などにより形成されている。この５ｃｍの高さは、凹部１４ａ，凸部１５ａを形成した山折部及び谷折部での段差の寸法であり、山折部及び谷折部の両脇の傾斜部での段差寸法はこれよりも少し小さく、例えば４ｃｍとなっている。
図４に示すように、山折部１１において、各段差部１３ａ〜１３ｅの下方に、段差部をさらに下方に張り出して山折部１１の一部に凹部１４ａを形成するとともに、凹部１４ａの左右側部に凹部１４ａの張り出し方向（図４では下方）とは反対の上方へ張り出した凸状のリブ１４ｂ、１４ｃを形成した山折歪緩和部１４が配設されている。このリブ１４ｂ、１４ｃの形状は凹部１４ａの左右側部に沿って細長状に形成されている。
また、谷折部１２において、各段差部１３ａ〜１３ｅの上方に、段差部をさらに上方へ張り出して谷折部１２の一部に凸部１５ａを形成するとともに、凸部１５ａの左右側部に凸部１５ａの張り出し方向（図４では上方）とは反対の下方へ張り出した凹状のリブ１５ｂ、１５ｃを形成した谷折歪緩和部１５が配設されている。このリブ１５ｂ、１５ｃの形状は凹部１５ａの左右側部に沿って細長状に形成されている。
これにより、山折部１１と谷折部１２によりジグザグ状に形成された折曲げ金属板１０ａをさらに直交する方向で段差部１３を形成させる際に生ずる折曲げ金属板１０ａの不均一な歪みを、山折歪緩和部１４と谷折歪緩和部１５に集中させ、折曲げ金属板１０ａの他の部分に歪みを生じさせないようにすることができるのである。
また、これによって折曲げ金属板１０ａの全面に屋根瓦パターン４０が形成されて、瓦葺状折板屋根材１０における形状安定性や美観などが確保されるようにできる。
さらに、本実施例では、山折部１１と谷折部１２の段差部に連接して設けられる歪緩和部は、各段差部１３ａ〜１３ｅの上下に互い違いに設けられているが、各段差部に連接した全てに設けることもできる。すなわち、山折部１１の段差部の上方に、谷折部１２の段差部の上方に設けた谷折歪緩和部１５と同様の形状の歪緩和部を設け、谷折部１２の段差部の下方に、山折部１１の段差部の下方に設けた山折歪緩和部１４と同様の形状の歪緩和部を設けることにより、段差部１３を形成させる際に生ずる折曲げ金属板１０ａの不均一な歪みを、より山折歪緩和部１４と谷折歪緩和部１５に集中させることができる。
ここで、屋根瓦パターン４０とは、図２の破線で示すように、山折部１１と左右両端の谷折部１２とで挟まれ、かつ、上の段差部１３と下の段差部１３とで囲まれた部分をいう。 The step portion 13 is a portion formed on the bent metal plate 10a having a height of about 5 cm, and is formed by press molding so as to be orthogonal to the mountain fold portion and the valley fold portion of the bent metal plate 10a. Is formed. The height of 5 cm is the size of the step at the mountain fold and the valley fold where the concave portion 14a and the convex 15a are formed, and the step size at the inclined portions on both sides of the mountain fold and the valley fold is larger than this. It is a little small, for example 4cm.
As shown in FIG. 4, in the mountain fold portion 11, the step portion is further projected downward below each step portion 13 a to 13 e to form a recess 14 a in a part of the mountain fold portion 11, and the left and right side portions of the recess 14 a In addition, a mountain fold strain relief portion 14 is provided in which convex ribs 14b and 14c projecting upward opposite to the projecting direction of the recess 14a (downward in FIG. 4) are formed. The ribs 14b and 14c are formed in an elongated shape along the left and right sides of the recess 14a.
Moreover, in the valley fold part 12, while projecting a level | step-difference part further upwards above each level | step-difference part 13a-13e, while forming the convex part 15a in a part of valley | fold part 12, the left-right side part of the convex part 15a is formed. A valley distorted relaxation portion 15 is provided in which concave ribs 15b and 15c projecting downward opposite to the projecting direction of the projecting portion 15a (upward in FIG. 4) are formed. The ribs 15b and 15c are formed in an elongated shape along the left and right sides of the recess 15a.
Thereby, the uneven distortion of the bent metal plate 10a generated when the stepped portion 13 is formed in a direction orthogonal to the bent metal plate 10a formed in a zigzag shape by the mountain fold portion 11 and the valley fold portion 12, It can concentrate on the mountain fold distortion relaxation part 14 and the valley fold distortion relaxation part 15, and it can prevent generating a distortion in the other part of the bending metal plate 10a.
In addition, the roof tile pattern 40 is formed on the entire surface of the folded metal plate 10a, thereby ensuring the shape stability, aesthetics, and the like of the tile-shaped folded plate roof material 10.
Furthermore, in this embodiment, the strain relief portions provided to be connected to the step portions of the mountain fold portion 11 and the valley fold portion 12 are provided alternately above and below the step portions 13a to 13e. It can also be provided in all connected areas. That is, a strain relief portion having the same shape as the valley fold strain relief portion 15 provided above the step portion of the valley fold portion 12 is provided above the step portion of the mountain fold portion 11, and below the step portion of the valley fold portion 12. In addition, by providing a strain relief portion having the same shape as the mountain fold strain relief portion 14 provided below the step portion of the mountain fold portion 11, non-uniform distortion of the bent metal plate 10 a that occurs when the step portion 13 is formed. Can be more concentrated in the mountain fold strain relief portion 14 and the valley fold strain relief portion 15.
Here, as shown by the broken line in FIG. 2, the roof tile pattern 40 is sandwiched between the mountain fold portion 11 and the valley fold portions 12 at both left and right ends, and the upper step portion 13 and the lower step portion 13. The enclosed part.

折曲げ金属板１０ａの裏面１０ｂ側における建物梁材との当接支持面となる谷折部１２には矩形テープ状に形成された合成樹脂材からなる制振シート１６が貼着され、このような制振シート１６が貼付けられた折曲げ金属板１０ａの裏側全面に断熱シート１７でさらに被覆されている。なお、瓦葺状折板屋根材１０における建物梁材２０との当接支持部材が山折部１１に当接するような場合には、この山折部１１に制振シートが配置されるようにしている。   A vibration damping sheet 16 made of a synthetic resin material formed in a rectangular tape shape is attached to the valley fold 12 serving as a contact support surface with the building beam material on the back surface 10b side of the bent metal plate 10a. Further, the entire back side of the bent metal plate 10a to which the vibration damping sheet 16 is attached is further covered with a heat insulating sheet 17. In addition, when the contact support member with the building beam material 20 in the roof tile-shaped folded-plate roof material 10 contacts the mountain fold part 11, the vibration damping sheet is arranged in the mountain fold part 11.

ここで制振シート１６は、スチレン−イソプレンブロック共重合体１００重量部、エチレン−酢酸ビニル共重合体１００重量部、並びに、粘土粉末３５０重量部からなる樹脂組成物を加熱混練して、約１ｍｍ厚みのシート状に押出成形して作成したものが好ましく用いられる。なお、制振シートの片面にゴム系接着剤などを用いて、アルミニウム箔などを積層して断熱性を高めるようにしてもよい。瓦葺状折板屋根材１０は、この得られたシート体を一方の面を金属板となる亜鉛メッキ鋼板に貼付した後、さらに断熱シート１７で被覆したものをロール成形及びプレス成形の工程を経て図１に示すような形状に加工したものである。   Here, the vibration damping sheet 16 is prepared by heating and kneading a resin composition comprising 100 parts by weight of a styrene-isoprene block copolymer, 100 parts by weight of an ethylene-vinyl acetate copolymer, and 350 parts by weight of clay powder, Those prepared by extrusion molding into a sheet having a thickness are preferably used. In addition, you may make it heat insulation improve by laminating | stacking aluminum foil etc. on the single side | surface of a damping sheet, using a rubber adhesive. The tile-shaped folded plate roofing material 10 is obtained by sticking one side of the obtained sheet body to a galvanized steel plate serving as a metal plate, and then covering the sheet body with a heat insulating sheet 17 through roll forming and press forming processes. It is processed into a shape as shown in FIG.

実施例１の瓦葺状折板屋根材１０は以上のように構成され、折曲げ金属板１０ａには、その成形加工時における歪みを分散吸収するための山折歪緩和部１４、谷折歪緩和部１５が、段差部１３を挟んで互い違いに設けられているので、歪みのない屋根材を効率的に形成させることができる。
こうして、屋根材を建物に施工するに際して建物梁材２０に密着固定させて安定的に載置して、屋根材に当たる雨音を低減する制振性や、輻射熱や結露に対抗する断熱性、屋根施工におけるコスト性、作業性に優れた瓦葺状折板屋根材１０を提供することを可能としている。 The tile-shaped folded plate roofing material 10 of the first embodiment is configured as described above, and the bent metal plate 10a includes a mountain fold strain relief portion 14 and a valley fold strain relief portion for dispersing and absorbing strain during the forming process. 15 are provided alternately with the stepped portion 13 in between, so that a roof material without distortion can be efficiently formed.
Thus, when constructing the roofing material on the building, it is firmly fixed to the building beam material 20 and stably placed, and the vibration control property to reduce the rain sound hitting the roofing material, the heat insulating property against radiant heat and condensation, the roof It is possible to provide the roof tile-like roofing material 10 excellent in cost and workability in construction.

（実施例２）
図５は本発明の実施例２における瓦葺状折板屋根材の製造方法の一例を示す説明図であり、図６は実施例２の製造方法において折曲げ金属板に段差部を形成させるプレス成形の模式図であり、図７は実施例２のプレス成形における型枠の模式説明図である。
実施例２における瓦葺状折板屋根材３０の製造方法は、図５に示すように（ａ）制振シート貼着工程、（ｂ）断熱シート貼着工程、（ｃ）ロール成形工程、（ｄ）プレス成形工程を主たる構成要素として有している。以下、図面を参照しながら瓦葺状折板屋根材３０の製造方法について説明する。 (Example 2)
FIG. 5 is an explanatory view showing an example of a method for manufacturing a tile-shaped folded plate roofing material in Example 2 of the present invention, and FIG. 6 is a press forming in which a step portion is formed on a bent metal plate in the manufacturing method of Example 2. FIG. 7 is a schematic explanatory view of a mold in press forming of Example 2.
As shown in FIG. 5, the manufacturing method of the tile-shaped folded-plate roof material 30 in Example 2 includes (a) a vibration damping sheet attaching step, (b) a heat insulating sheet attaching step, (c) a roll forming step, (d ) It has a press molding process as the main component. Hereinafter, the manufacturing method of the tile-shaped folded board roof material 30 is demonstrated, referring drawings.

制振シート貼着工程は、瓦葺状折板屋根材の素材となるロール巻きされた金属板である亜鉛メッキ鋼板３０ａを所定長さに裁断して、瓦葺状折板屋根材の裏面３０ｂの山折部及び／又は谷折部となる位置に、テープ状の制振シート３１を、折部の巾と略同じ巾で折部長手方向に貼着する工程である。この工程では、塗布された接着材を介して制振シート３１を亜鉛メッキ鋼板３０ａの裏面３０ｂに貼付することによって、瓦葺状折板屋根材に雨音などに対する防音効果や遮音効果が付与されるようにしている。   The vibration damping sheet sticking step cuts a galvanized steel plate 30a, which is a rolled metal plate, which is a material of the tile-shaped folded plate roof material, into a predetermined length, and then folds the back surface 30b of the tile-shaped folded plate roof material This is a step of sticking the tape-shaped vibration damping sheet 31 in the longitudinal direction of the folded part at a position that becomes a part and / or a valley folded part with substantially the same width as the width of the folded part. In this step, the vibration damping sheet 31 is attached to the back surface 30b of the galvanized steel sheet 30a via the applied adhesive, thereby providing the soundproofing effect and the sound insulation effect against rain sound and the like on the roof tile-shaped folded plate roofing material. I am doing so.

断熱シート貼着工程は、制振シート３１が貼付された亜鉛メッキ鋼板３０ａの裏面３０ｂ全体をさらに被覆するように、無機質粉末を含有分散させた合成樹脂材などからなる幅広の断熱シート３２を貼着して、瓦葺状折板屋根材に結露防止効果や保温効果を保持させるようにしている。   In the heat insulating sheet sticking step, a wide heat insulating sheet 32 made of a synthetic resin material containing inorganic powder is dispersed so as to further cover the entire back surface 30b of the galvanized steel sheet 30a to which the vibration damping sheet 31 is attached. Wearing it, the roof tile-like roofing material keeps the effect of preventing condensation and keeping warm.

、
ロール成形工程では、制振シート３１及び断熱シート３２がそれぞれ貼着された亜鉛メッキ鋼板３０ａを、亜鉛メッキ鋼板の上下に配設された複数の加工ロール３３を通すことによって、その上下方向よりジグザグ状に順次挟圧加工する。こうして図３に示す実施例１と同様（但し、段差部はまだ形成されていない）の山折部と谷折部とからなるジグザグ状断面を有した折曲げ金属板３４が得られる。 ,
In the roll forming process, the galvanized steel sheet 30a to which the vibration damping sheet 31 and the heat insulating sheet 32 are respectively attached is passed through a plurality of processing rolls 33 disposed above and below the galvanized steel sheet, thereby zigzag from the vertical direction. Are sequentially pressed into a shape. In this way, a bent metal plate 34 having a zigzag cross section composed of a mountain fold portion and a valley fold portion similar to Example 1 shown in FIG. 3 (however, the step portion is not formed yet) is obtained.

プレス成形工程は、図６に示すように、折曲げ金属板３４の山折部及び谷折部に直交する方向の段差部３５を、一段毎に長尺状型枠３６を用いて順次プレス成形させて屋根瓦パターン４０を形成し、瓦葺状折板屋根材３０を成形する工程である。
図７に示すように、上下一対の長尺状型枠３６は、折曲げ金属板３４に段差部３５を順次形成するとともに、この段差部３５に、山折歪緩和部３７ａ及び谷折歪緩和部３７ｂを形成させるための対となる凸部３６ａ１、３６ｄ１及び凹部３６ｂ１、３６ｃ１を備えたプレス型である。
長尺状型枠３６には、折曲げ金属板３４の山折部及び谷折部に形成させる歪緩和部の位置にそれぞれ対応させて、山折歪緩和用型枠部３６ａ、３６ｂと谷折歪緩和用型枠部３６ｃ、３６ｄとが配置されている。 In the press forming step, as shown in FIG. 6, the stepped portions 35 in the direction orthogonal to the mountain folded portion and the valley folded portion of the bent metal plate 34 are sequentially pressed using a long formwork 36 for each step. In this step, the roof tile pattern 40 is formed, and the tile roof folded roof material 30 is formed.
As shown in FIG. 7, the pair of upper and lower elongated molds 36 sequentially form stepped portions 35 on the bent metal plate 34, and the stepped portion 35 has a mountain fold strain reducing portion 37 a and a valley fold strain reducing portion. This is a press die having a pair of convex portions 36a1 and 36d1 and concave portions 36b1 and 36c1 for forming 37b.
The long formwork 36 is associated with the positions of the strain relief portions formed at the mountain fold and the valley fold of the bent metal plate 34, respectively, and the mountain fold strain relief mold parts 36a and 36b and the valley fold strain relief. Formwork portions 36c and 36d are disposed.

山折歪緩和用型枠部３６ａ、３６ｂ及び谷折歪緩和用型枠部３６ｃ、３６ｄは、プレス成形される折曲げ金属板３４の山折部と谷折部の段差部３５に対応する位置に配置されている。
ここで、山折部と谷折部の段差部に対応する位置とは、折曲げ金属板の山折部の段差部に山折歪緩和部を形成させるように長尺状型枠３６に山折歪緩和用型枠部３６ａ、３６ｂを設けた位置をいい、折曲げ金属板の谷折部の段差部に谷折歪緩和部を形成させるように長尺状型枠３６に谷折歪緩和用型枠部３６ｃ、３６ｄを設けた位置をいう。
長尺状型枠３６を用いて折曲げ金属板３４の山折部及び谷折部に直交する方向の段差部３５を一段毎に順次プレス成形させ、屋根瓦パターンを有した瓦葺状折板屋根材を製造する際に、山折歪緩和部及び谷折歪緩和部に歪緩和部分を集中させ、瓦葺状折板屋根材の段差部成形加工時における歪みを吸収する機能を有している。 The mountain fold strain relief mold portions 36a and 36b and the valley fold strain relief mold portions 36c and 36d are arranged at positions corresponding to the step portions 35 of the fold and trough fold portions of the bent metal plate 34 to be press-formed. Has been.
Here, the positions corresponding to the step portions of the mountain fold portion and the valley fold portion are for the purpose of reducing the mountain fold strain in the long form frame 36 so that the mountain fold strain relief portion is formed in the step portion of the mountain fold portion of the bent metal plate. The position where the mold parts 36a and 36b are provided, and a valley fold strain reducing mold part is formed on the long form frame 36 so that a valley fold strain reducing part is formed in the step part of the valley fold part of the bent metal plate. This is the position where 36c and 36d are provided.
A tile-shaped folded plate roofing material having a roof tile pattern in which a stepped portion 35 in a direction orthogonal to a mountain folded portion and a valley folded portion of a bent metal plate 34 is sequentially press-formed using a long form frame 36 step by step. In manufacturing, the strain relief portion is concentrated on the mountain fold strain relief portion and the valley fold strain relief portion, and has a function of absorbing strain at the time of forming the step portion of the roof tile-shaped folded plate roofing material.

なお、長尺状型枠３６は、炭素鋼などからなる金属型の他に、平均粒径約１ｍｍのシリカアルミナ質骨材にエポキシ樹脂成分を１：３の質量混合比率で混合硬化させて形成した樹脂硬化体とすることもできる。このようなセラミックス質骨材含有の樹脂型とすることによって、薄肉鋼板からなる折曲げ金属板３４への長尺状型枠３６の当たりをソフトにして、段差部１３の形成にあたっての成形歩留りに優れたものとすることができる。   In addition to the metal mold made of carbon steel or the like, the long form frame 36 is formed by mixing and curing an epoxy resin component at a mass mixing ratio of 1: 3 on silica alumina aggregate having an average particle diameter of about 1 mm. It can also be set as a cured resin. By using such a ceramic aggregate-containing resin mold, the contact of the long form frame 36 with the bent metal plate 34 made of a thin steel plate is softened, and the molding yield in forming the stepped portion 13 is increased. It can be excellent.

実施例２における瓦葺状折板屋根材の製造方法によれば、樹脂組成物などで形成した制振シートを亜鉛メッキ鋼板の裏面に積層して安定的に配置することができるので、遮音効果や騒音抑制効果を高めることができる。また、制振シートの厚みを薄くすることによって平板状の金属板裏面に制振シートを積層した後に亜鉛メッキ鋼板を折曲形成することができ、簡単な作業工程で複雑な形状の瓦葺状折板屋根材を製造することができる。   According to the manufacturing method of the tile-shaped folded-plate roof material in Example 2, since the damping sheet formed with the resin composition or the like can be laminated and stably disposed on the back surface of the galvanized steel sheet, Noise suppression effect can be enhanced. In addition, by reducing the thickness of the damping sheet, it is possible to bend the galvanized steel sheet after laminating the damping sheet on the back of the flat metal plate. A plate roofing material can be manufactured.

（実施例３）
図８は本発明の実施例３における瓦葺状折板屋根材を巾方向に２枚重ねた状態を示す概略断面図であり、図２における矢視Ｂ−Ｂ断面図である。
実施例３の瓦葺状折板屋根材５０は図８に示すように、２枚の山折部１１の端部どうしを重ね巾方向に拡張しされて構成されている。
実施例３の瓦状折板屋根材５０は、図８に示すように、重ね部分５１において下側になる瓦状折板屋根材の山折歪緩和部１４に形成された凸状のリブ１４ｂ、１４ｃの一方が形成されていない。リブを片方だけ形成することにより、重ね部分５１における重ねあわせをより密着させることができる。 (Example 3)
FIG. 8 is a schematic cross-sectional view showing a state in which two tile-shaped folded-plate roof materials in Example 3 of the present invention are stacked in the width direction, and is a cross-sectional view taken along the line BB in FIG.
As shown in FIG. 8, the tile-shaped folded-plate roof material 50 according to the third embodiment is formed by extending the end portions of two mountain folded portions 11 in the width direction.
As shown in FIG. 8, the tile-shaped folded board roof material 50 according to the third embodiment has convex ribs 14 b formed on the mountain-folded strain relief portion 14 of the tile-shaped folded board roof material that is on the lower side in the overlapping portion 51. One of 14c is not formed. By forming only one of the ribs, the overlapping in the overlapping portion 51 can be more closely adhered.

以上説明したように本発明は、山折歪緩和部及び谷折歪緩和部を瓦葺状折板屋根材に設けることによって、金属加工により生じる歪みを吸収緩和して、歪みのない屋根材とすることができる。
なお、本発明は、歪みのない瓦葺状折板屋根材を提供することを要旨としたものであり、これに該当するものは本発明の権利範囲に属する。
例えば、本実施例では、瓦葺状折板屋根材の素材として電気亜鉛メッキ鋼板を例に説明したが、溶融亜鉛メッキ鋼板やアルミメッキ鋼板、樹脂塗装鋼板、ラミネート鋼板、プライマコート鋼板などの表面処理鋼板を適用することもできる。また、折曲げ金属板のジグザグ状断面はその一例を示すものであって、本発明の瓦葺状折板屋根材は実施例の形態のものに限定されるものではない。 As described above, the present invention provides a roof material without distortion by absorbing and relaxing distortion caused by metal processing by providing a mountain fold strain relief part and a valley fold relief part on a roof tile-like folded board roof material. Can do.
In addition, this invention made it the summary to provide a tile-shaped folded-plate roof material without a distortion, and what corresponds to this belongs to the scope of the right of this invention.
For example, in the present embodiment, an electrogalvanized steel sheet has been described as an example of a tile-shaped folded plate roofing material, but surface treatment of a hot dip galvanized steel sheet, an aluminized steel sheet, a resin-coated steel sheet, a laminated steel sheet, a primer coated steel sheet, etc. A steel plate can also be applied. Moreover, the zigzag cross section of the bent metal plate shows an example thereof, and the tile-shaped folded plate roofing material of the present invention is not limited to the embodiment.

実施例１の瓦葺状折板屋根材の施工例を示す斜視図である。It is a perspective view which shows the construction example of the tile-shaped folded-plate roof material of Example 1. FIG. 実施例１の瓦葺状折板屋根材の平面図である。It is a top view of the tile-shaped folded board roof material of Example 1. FIG. 図２における矢視Ａ−Ａ断面図である。It is arrow AA sectional drawing in FIG. 実施例１の山折歪緩和部及び谷折歪緩和部の詳細を説明した拡大斜視図である。It is the expansion perspective view explaining the detail of the mountain fold distortion relaxation part of Example 1, and a valley fold distortion relaxation part. 本発明の実施例２における瓦葺状折板屋根材の製造方法の一例を示す説明図である。It is explanatory drawing which shows an example of the manufacturing method of the tile-shaped folded-plate roof material in Example 2 of this invention. 実施例２の製造方法の段差部を形成させるプレス成形工程の模式図である。It is a schematic diagram of the press molding process in which the level | step-difference part of the manufacturing method of Example 2 is formed. 実施例２のプレス成形工程における型枠の模式説明図である。6 is a schematic explanatory diagram of a mold in a press molding step of Example 2. FIG. 本発明の実施例３における瓦葺状折板屋根材を巾方向に２枚重ねた状態を示す概略断面図である。It is a schematic sectional drawing which shows the state which piled up the tile-shaped folded board roof material in Example 3 of this invention in the width direction.

符号の説明Explanation of symbols

１０ 実施例１の瓦葺状折板屋根材
１０ａ 折曲げ金属板
１０ｂ 裏面
１１ 山折部
１２ 谷折部
１３、１３ａ〜１３ｅ 段差部
１４ 山折歪緩和部（歪緩和部）
１４ａ 凹部
１４ｂ、１４ｃ 凸状のリブ
１５ 谷折歪緩和部（歪緩和部）
１５ａ 凸部
１５ｂ、１５ｃ 凹状のリブ
１６ 制振シート
１７ 断熱シート
２０ 建物梁材
２１ 当接支持面
３０ 実施例２における瓦葺状折板屋根材
３０ａ 亜鉛メッキ鋼板（金属板）
３０ｂ 裏面
３１ 制振シート
３２ 断熱シート
３３ 加工ロール
３４ 折曲げ金属板
３５ 段差部
３６ 長尺状型枠
３６ａ、３６ｂ 山折歪緩和用型枠部
３６ｃ、３６ｄ 谷折歪緩和用型枠部
３６ａ１ 凸部
３６ｂ１ 凹部
３６ｃ、３６ｄ 谷折歪緩和用型枠部
３６ｃ１ 凹部
３６ｄ１ 凸部
３７ 歪緩和部
３７ａ 山折歪緩和部
３７ｂ 谷折歪緩和部
４０ 屋根瓦パターン
５０ 実施例３の瓦葺状折板屋根材
５１ 重ね部分 10 Roof tile-like folded-plate roof material of Example 1 10a Folded metal plate 10b Back surface 11 Mountain folded portion 12 Valley folded portion 13, 13a-13e Stepped portion 14 Mountain folded strain relief portion (strain relief portion)
14a Concave part 14b, 14c Convex rib 15 Valley fold strain relaxation part (strain relaxation part)
15a Convex 15b, 15c Concave rib 16 Damping sheet 17 Heat insulation sheet 20 Building beam material 21 Abutting support surface 30 Tile-like folded plate roof material 30a in Example 2 Galvanized steel sheet (metal plate)
30b Back surface 31 Damping sheet 32 Heat insulation sheet 33 Work roll 34 Bending metal plate 35 Stepped part 36 Long form frame 36a, 36b Form part 36 for mountain fold distortion reduction 36c, 36d Form part 36d for valley fold distortion 36a1 Convex part 36b1 Concave part 36c, 36d Form part for relief of valley fold strain 36c1 Concave part 36d1 Convex part 37 Strain relief part 37a Mountain fold strain relief part 37b Valley fold relief part 40 Roof tile pattern 50 Tile-like folded plate roofing material of Example 3 51 Stacking portion

Claims (3)

山折部と谷折部によりジグザグ状に折り曲げて形成された長尺の折曲げ金属板の山折部と谷折部にそれぞれ略直交する段差部が形成された瓦葺状折板屋根材であって、
前記山折部の段差部の下方には、
該段差部をさらに下方へ張り出して山折部の一部に凹部を形成するとともに、
該凹部の左右側部に凹部の張り出し方向とは反対の上方へ張り出した凸状のリブを形成した山折歪緩和部を設け、
前記谷折部の段差部の上方には、
該段差部をさらに上方へ張り出して谷折部の一部に凸部を形成するとともに、
該凸部の左右側部に凸部の張り出し方向とは反対の下方へ張り出した凹状のリブを形成した谷折歪緩和部を設け、
前記山折歪緩和部と谷折歪緩和部とは、前記段差部を挟んで互い違いに設けられていることを特徴とする瓦葺状折板屋根材。 It is a roof tile-like folded plate roof material in which step portions substantially orthogonal to the mountain folded portion and the valley folded portion of the long folded metal plate formed by bending in a zigzag shape by the mountain folded portion and the valley folded portion, respectively,
Below the step portion of the mountain fold,
While projecting the step further downward to form a recess in a part of the mountain fold,
Provided with a mountain fold strain relief portion formed with convex ribs projecting upward opposite to the projecting direction of the recesses on the left and right side portions of the recesses,
Above the stepped portion of the valley fold,
While projecting the stepped portion further upward to form a convex portion at a part of the valley fold,
Provided with a valley fold strain relief portion formed on the left and right sides of the convex portion is a concave rib projecting downward opposite to the projecting direction of the convex portion,
The tile-folded folded roof material, wherein the mountain fold strain relief portions and the valley fold strain relief portions are provided alternately with the stepped portion in between. 前記折曲げ金属板における梁材当接面となる山折部及び谷折部の裏面に制振シートを添着し、
前記制振シートを添着した裏面全部を断熱シートで被覆したことを特徴とする請求項１記載の瓦葺状折板屋根部材。 Attaching a vibration damping sheet to the back surface of the mountain fold and the valley fold that become the beam material contact surface in the bent metal plate,
The roof tile-shaped folded-plate roof member according to claim 1, wherein the entire back surface attached with the vibration damping sheet is covered with a heat insulating sheet. 請求項１又は２記載の瓦葺状折板屋根材の製造方法であって、
（ａ）折曲げ金属板における山折部となる裏面の所定位置に制振シートを貼着する制振シート貼着工程と、
（ｂ）前記金属板における裏面全体に断熱シートを貼着する断熱シート貼着工程と、
（ｃ）前記制振シート及び前記断熱シートがそれぞれ貼着された前記金属板を複数のロールにより挟圧変形させて山折部及び谷折部によりジグザグ状に折り込まれた折曲げ金属板に成形するロール成形工程と、
（ｄ）前記折曲げ金属板の山折部及び谷折部に直交する方向の段差部を長尺状型枠を用いて順次プレス成形して、
山折部の段差部の下方に、
段差部をさらに下方へ張り出して山折部の一部に凹部を形成するとともに、
該凹部の左右側部に該凹部の張り出し方向とは反対の上方へ張り出した凸状のリブを形成した山折歪緩和部を設け、
谷折部の段差部の上方に、
段差部をさらに上方へ張り出して谷折部の一部に凸部を形成するとともに、
該凸部の左右側部に該凸部の張り出し方向とは反対の下方へ張り出した凹状のリブを形成した谷折歪緩和部を設けるプレス成形工程と、
を有することを特徴とする瓦葺状折板屋根材の製造方法。 A method for producing a tile-shaped folded-plate roof material according to claim 1 or 2,
(A) a damping sheet adhering step for adhering the damping sheet to a predetermined position on the back surface to be a mountain fold in the bent metal plate;
(B) a heat insulating sheet attaching step of attaching a heat insulating sheet to the entire back surface of the metal plate;
(C) The metal plate to which the vibration-damping sheet and the heat-insulating sheet are respectively bonded is deformed by pressing with a plurality of rolls, and is formed into a bent metal plate that is folded in a zigzag manner by a mountain fold and a valley fold. Roll forming process;
(D) Press-molding stepped portions in a direction perpendicular to the mountain folded portion and the valley folded portion of the bent metal plate using a long formwork,
Below the step of the mountain fold,
While projecting the step further downward to form a recess in a part of the mountain fold,
Provided on the left and right sides of the recess are mountain fold strain relief portions formed with convex ribs protruding upward opposite to the direction in which the recess extends.
Above the step of the valley fold,
While projecting the step further upward to form a convex part in the valley fold,
A press molding step of providing a trough strain relief portion formed with a concave rib projecting downward opposite to the projecting direction of the projecting portion on the left and right side portions of the projecting portion;
A method for producing a tile-shaped folded-plate roof material, comprising:
JP2008334994A 2008-10-08 2008-12-26 Tile-like folded plate roofing material and method for manufacturing the same Expired - Fee Related JP4261619B1 (en)

Priority Applications (3)

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JP2008334994A JP4261619B1 (en) 2008-10-08 2008-12-26 Tile-like folded plate roofing material and method for manufacturing the same
CN2009101772060A CN101713238B (en) 2008-10-08 2009-09-25 Terra-cotta roofing shape folded plate roof and manufacturing method therefor
HK10109121.1A HK1142570A1 (en) 2008-10-08 2010-09-24 Tile-roofing-like bent plate roofing and manufacturing method of that

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KR101263301B1 (en) 2012-09-25 2013-05-10 (유)대한철강 Metal shingle sheet

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CN113134537A (en) * 2021-04-21 2021-07-20 哈尔滨工业大学 Ultrathin metal corrugated board forming device and forming method

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CN2126265U (en) * 1992-06-02 1992-12-30 谢荣裕 Permeating-proof corrugated plate
DE9402943U1 (en) * 1994-02-25 1994-04-14 Magass, Walter, 69207 Sandhausen Kit for covering roofs with metal profile elements
CN2323053Y (en) * 1997-12-26 1999-06-09 张福海 Large span arch corrugated roof metal sheet
CN2367668Y (en) * 1999-04-12 2000-03-08 太仓兴钢建材有限公司 Built-in buckling type fixed steel plate
CN1266358C (en) * 2001-03-07 2006-07-26 布卢斯科普钢铁有限公司 Construction at panel

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
KR101263301B1 (en) 2012-09-25 2013-05-10 (유)대한철강 Metal shingle sheet

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