JP7302581B2 - METAL ROOF MEMBER AND MANUFACTURING METHOD THEREOF - Google Patents

Description

TECHNICAL FIELD The present invention relates to a metal roofing member, and more particularly to a metal roofing member provided with a stepped portion for providing an appearance resembling a tiled roof, and a method for manufacturing the same.

Corrugated plated steel sheets, which are resin-coated plated steel sheets that have been corrugated, are widely used as inexpensive and lightweight materials for the roofs of buildings.
Conventionally, corrugated plated steel sheets have waves with a pitch of about 30 mm, and are mainly used in buildings such as warehouses, factories, and stores, where exterior design is not considered important. Recently, however, improvements in plating and coating resins have dramatically improved weather resistance, and along with this, the use of corrugated plated steel sheets with waves with a pitch of 100 mm or more is expanding.

On the other hand, ordinary houses are required to have a high-class design compared to buildings such as warehouses, factories, and stores, and high-class roof materials such as roof tiles are used. Therefore, the use of the above-mentioned corrugated plated steel sheets for housing, where design is not considered important, has been limited.

However, the tiled roof requires the skill of construction technicians, and the construction takes a lot of man-hours. Therefore, as a substitute for roof tiles, a metal roof member 21 (see FIG. 7) has been developed that has an appearance like a tiled roof by providing a stepped portion to the above-described corrugated plated steel plate. The one shown in FIG. 7 is a corrugated plate having a corrugated cross-section (wavelength L, wave height H) in which crests and troughs are continuous and provided with a stepped portion 23. It is installed so as to be parallel to the direction of inclination.

Metal sheets are processed in this way to give the appearance of a tiled roof, and are also called 'long shaped metal roof tiles'. . In addition, by constructing long shaped metal tiles on the roof, the repeated shape of the tiles gives a luxurious appearance similar to that of a tiled roof.

Examples of the metal roof member 21 (metal elongate molded roof tile) having the stepped portion 23 as described above are disclosed in Patent Document 1 and Patent Document 2, for example.
In FIG. 1 of Patent Document 1, "five peaks 2 are formed in parallel at regular intervals in the width direction of the metal plate 1, ... (omitted) ... these are formed in the longitudinal direction of the metal plate 1. A "metal corrugated long roof tile" is shown in which steps are added to a plurality of steps, for example, six steps by bending a planar shape 4 along the cross-sectional shape of a metal plate" (see [Prior Art]).
In addition, FIG. 7 of Patent Document 2 shows a "metal molded roof tile" in which "five unit shapes (mountains) are connected in the slope direction of the roof" (see [0052]).

The forming method of the metal roof member having the stepped portion as described above, for example, in the case of the metal roof member 21 shown in FIG. 7, is performed as follows.
First, a corrugated sheet is formed by a process called roll forming, in which a flat plate material is passed between roll tools to gradually form a desired cross-sectional shape. In roll forming, a corrugated sheet having a corrugated cross section is formed by sequentially passing a flat plate material through a series of roll tool sets configured by combining a plurality of roll tools.

The metal roof member 21 is formed by pressing the corrugated plate formed by roll forming to form a stepped portion 23 so as to intersect the corrugated shape of the corrugated plate.

JP-A-2-104853 JP-A-11-62116

As mentioned above, the production of long metal roof tiles requires a large amount of equipment and processes because different methods are used: roll forming, which is used to form corrugated plates, and press working, which is used to form steps. must also be divided into several parts. Therefore, there has been a demand to reduce the burden on equipment and manufacturing man-hours.

Further, when forming the stepped portion 23 that intersects the corrugated plate in a corrugated shape, cracks may occur depending on the material, size, and processing conditions. This point will be described with reference to FIGS. 8 to 10. FIG. 8 to 10, the ridge side from the stepped portion 23 in the roof inclination direction is called an upper corrugated plate portion 25, and the eave side from the stepped portion 23 is called a lower corrugated plate portion 27. As shown in FIG.

8(a) is an enlarged perspective view of a part of the metal roof member 21 shown in FIG. 7, and FIG. 8(b) is a view of FIG. 8A is a view (hereinafter also referred to as a top view) viewed from above (viewing direction (z direction) in FIG. 8A) orthogonal to the above. In FIG. 8(b), the ridgeline of the crest in the uppermost portion of the wave shape is indicated by a dashed line, and the trough line of the trough in the lowermost portion is indicated by a broken line.

When processing the stepped portion 23 in the corrugated sheet, the upper side portion is clamped with a pair of upper side dies, and the lower side portion is further clamped with a pair of lower side dies. The stepped portion 23 is formed by relatively moving the mold and the lower mold.
As shown in FIG. 8B, the shape of the stepped portion 23 when viewed from above is such that it extends linearly in a direction (x direction) perpendicular to the ridgeline direction (y direction) of the mountain. .

At the time of forming the stepped portion 23, the curved portion connecting the upper corrugated plate portion 25 and the stepped portion 23 at the top of the mountain (part c in FIG. 8), and the lower corrugated plate portion 27 and the stepped portion at the bottom of the valley There was a problem that the plate thickness was particularly reduced at the bent portion connecting the 23 (portion d in FIG. 8), and cracks were likely to occur.
This point will be described below with reference to FIG.

FIG. 9 is a partial enlarged view of the vicinity of the c portion in FIG.

As shown in FIG. 9, part c is on the ridge line of the mountain (see the dashed line) and on the upper side of the stepped portion. Since the material flows intensively from the c part, the thickness reduction at the c part becomes large. The mechanism of increasing the plate thickness reduction is the same in the portion d.
As described above, in the conventional metal roofing member 21, the c-part and the d-part become the apexes of the overhang in the step processing, and therefore are dangerous parts where the plate thickness is reduced intensively and cracks occur.

On the other hand, the purpose of additionally processing the stepped portion 23 on the corrugated plate is to create a high-class design similar to a tiled roof. From the viewpoint of design, it is preferable to make the stepped portion 23 easy to visually recognize. For that purpose, it is necessary to make the stepped portion 23 steeper. The shape of the step portion 23 will be specifically described below with reference to FIG. 10 .

FIG. 10 is a cross-sectional view taken along line BB in FIG.
In order to make the appearance of the stepped portion clearer, the height h of the stepped portion 23 shown in FIG. 10 should be increased, the inclination angle .theta. However, when the height h is increased, the inclination angle θ is increased, and the shoulder R is decreased, cracks are likely to occur due to the above-described plate thickness reduction at c and d during step processing.
Therefore, if a desirable design is aimed at from the standpoint of luxury, there is a problem that the plate thickness reduction due to the above-described step processing increases, and the risk of cracking increases.

The present invention has been made in order to solve such problems, and an object of the present invention is to provide a metal roof member that is excellent in design and can suppress cracking during forming of a stepped portion, and a method for manufacturing the same.

(1) A metal roof member according to the present invention has a flat plate portion and a stepped portion, and is installed on a roof so that the extending direction of the stepped portion is orthogonal to the inclination direction of the roof. The stepped portion is characterized in that, in the installed state, the upper side in the inclination direction is higher and the lower side is lower, and has a meandering shape with a predetermined meandering width and meandering pitch when viewed from above the eave height.

(2) In addition, in the above-mentioned (1), the meandering width at the step portion is 20 mm or more and 100 mm or less, the meandering pitch is 50 mm or more and 300 mm or less, and the height is 10 mm or more and 30 mm or less. It is something to do.

(3) Further, a method for manufacturing a metal roof member according to the present invention is for manufacturing the metal roof member according to (1) above, wherein a stepped portion is formed on a flat metal plate. a forming step, wherein the stepped portion forming step includes an upper mold that is disposed on the upper side of the stepped portion and that includes an upper upper mold and an upper lower mold having a step forming surface portion; The upper side of the stepped portion of the metal plate and the upper side of the stepped portion of the metal plate are formed by using a lower side mold that is arranged on the lower side of the stepped portion and is composed of a lower step side upper mold and a lower step side lower mold that have a stepped molding surface portion. The upper mold is clamped by the upper mold, and the lower mold is used to clamp the lower part of the stepped portion of the metal plate. By relatively moving downward, the stepped portion is formed by the stepped molding surfaces provided on the lower mold on the upper side and the upper mold on the lower side.

In the present invention, since the stepped portion has a meandering shape with a predetermined meandering width and meandering pitch when viewed from above perpendicular to the flat plate portion, the design is excellent and reduction in plate thickness during the manufacturing process can be suppressed.

BRIEF DESCRIPTION OF THE DRAWINGS It is explanatory drawing explaining the metal roof member concerning Embodiment 1 of this invention, Fig.1 (a) is a perspective view of a metal roof member (part), FIG.1(b) is FIG.1(a) ) is a top view of the metal roof member shown in FIG. It is the elements on larger scale of the part a of FIG.1(b), and is explanatory drawing explaining the material flow in the part a. It is explanatory drawing explaining the manufacturing method of the metal roof members concerning Embodiment 2 of this invention. 4(a) is a cross-sectional view taken along line CC of FIG. 3(a), and FIG. 4(b) is FIG. 3(a). FIG. is a DD cross-sectional view. It is a figure which shows typically the installation state of the roof concerning Example 1 of this invention, and the example of a viewing direction. It is a figure which shows the metal roof members of the comparative example concerning Example 1 of this invention, an invention example, and a conventional example. FIG. 3 is a perspective view showing an example of a conventional metal roof member; 8(a) is an enlarged perspective view of a part of FIG. 7, and FIG. 8(b) is a metal roof member shown in FIG. 8(a). It is the figure which looked at the roof member from the upper surface. FIG. 8B is a partial enlarged view of the c part (upwardly projecting portion) of FIG. 8B, and is an explanatory diagram for explaining the material flow in the c part. FIG. 9 is a cross-sectional view taken along line BB of FIG. 8, showing the cross-sectional shape of the stepped portion in the roof inclination direction.

[Embodiment 1]
A metal roof member 1 according to an embodiment of the present invention has a flat plate portion 3 and a stepped portion 5 as shown in FIG. In the installed state, the stepped portion 5 is high on the upper side in the inclination direction and low on the lower side, and has a shape that meanders with a predetermined meandering width and meandering pitch when viewed from above the eave height. In addition, the stepped portion 5 is provided in a plurality of steps at a pitch of 15 cm to 60 cm, for example, in the direction of inclination of the roof.
Such a metal roof member 1 will be specifically described below.

FIG. 1 shows a part of the metal roof member 1, FIG. 1(a) is a perspective view, and FIG. 1(b) is a top view of FIG. 1(a). In FIG. 1, the flat plate portion 3 on the ridge side from the stepped portion 5 in the roof inclination direction is called an upper flat plate portion 3a, and the flat plate portion 3 on the eave side from the stepped portion 5 is called a lower flat plate portion 3b.

A conventional metal roof member 21 (see FIG. 8) is a corrugated plate provided with a stepped portion 23, but the metal roof member 1 of the present embodiment, as shown in FIG. A step portion 5 is provided on the flat plate. The stepped portion 5 in FIG. 1 and the stepped portion 23 in FIG. 8 have the same cross-sectional shape (height h, inclination angle θ, shoulder R (see FIG. 10)) in the roof inclination direction (y direction).

In addition, in the conventional metal roof member 21, the shape of the stepped portion 23 in a top view is linear (see FIG. 8(b)), whereas in the metal roof member 1 of the present embodiment, As shown in FIG. 1B, the shape of the stepped portion 5 in a top view is a meandering shape with a predetermined meandering width w and meandering pitch p (hereinafter sometimes referred to as "meandering shape").

By making the shape of the stepped portion 5 as described above, the appearance of the stepped portion 5 is similar to the appearance of the stepped portion 23 provided on a conventional corrugated plate, even though the stepped portion 5 is provided on a flat plate. It is possible to exhibit a high-class design similar to that of the conventional example.
Further, in the present embodiment, since it is not necessary to form the corrugated sheet by roll forming, it is possible to simplify the manufacturing process and reduce the number of facilities as compared with the conventional example.
Furthermore, the metal roof member 1 of the present embodiment can reduce the thickness reduction during step processing as compared with the conventional example. The reason why the plate thickness reduction is alleviated will be described below with reference to FIG. 2 .

FIG. 2 is a partial enlarged view of the vicinity of part a in FIG. 1(b), which corresponds to part c in FIG.

As shown in FIG. 9, the c part of the conventional metal roof member 21 is the top part of the crest of the corrugated sheet, so it is formed by overhanging. Material flow occurs in the leftward and rightward arrows in the figure). In addition, since the c portion is also a portion that connects the upper corrugated plate portion 25 and the stepped portion 23, the material flows from the upper corrugated plate portion 25 toward the lower corrugated plate portion 27 (see the downward arrow in the figure). This was the part where the outflow was concentrated and the plate thickness was likely to decrease.

On the other hand, since the upper flat plate portion 3a of the metal roof member 1 of the present embodiment has a flat shape, as shown in FIG. material flow does not occur, and plate thickness reduction is less likely to occur than at c.

It should be noted that the long shaped metal tiles such as the metal roof member 1 in the present embodiment may be required to have a unique design that is not found in tiled roofs. For example, the meandering pitch p (see FIG. 1) should be set to 50 mm or more and 300 mm or less, and the height h (see FIGS. 1 and 10) should be set to 10 mm or more and 30 mm or less. The reason is as follows.

In a tiled roof, the individual curved tiles are arranged in a direction orthogonal to the roof inclination direction, so the curved shape appears to be continuous and wavy.
The meandering pitch p of the stepped portion 5 in this embodiment corresponds to the pitch of the continuous curved shape, that is, the width of each tile. It is preferable because an appearance close to the shape of the roof can be obtained.
Moreover, since the height h of the stepped portion 5 corresponds to the thickness of the roof tile, setting the height h to 10 mm or more and 30 mm or less is preferable because an appearance close to the thickness of the roof tile can be obtained.
The meandering width w (see FIG. 1) of the stepped portion 5 is preferably set to 20 mm or more and 100 mm or less in a top view (viewed from above orthogonal to the flat plate portion 3). The reason for this will be explained later in the examples.

As described above, in the present embodiment, the flat plate is used as the material, and the stepped portion 5 having a meandering shape when viewed from above is provided. Exhibits an appearance with an excellent sense of quality.

[Embodiment 2]
In this embodiment, a manufacturing method for manufacturing the metal roof member 1 described in Embodiment 1 will be described. The method for manufacturing the metal roof member 1 according to the present embodiment includes a stepped portion forming step of forming the stepped portion 5 on a flat metal plate.

As shown in FIGS. 3 and 4, the stepped portion forming step is performed by forming an upper mold 9 disposed on the flat metal plate 7 on the upper side of the stepped portion 5 and the lower side of the stepped portion 5. A lower-stage mold 11 that is arranged at a position where the
FIG. 3 is a view showing the forming process of the portion corresponding to the AA section of the metal roof member 1 shown in FIG. 1(a). 4(a) is a sectional view taken along line CC of FIG. 3(a), and FIG. 4(b) is a sectional view taken along line DD of FIG. 3(a). In FIG. 4, illustration of the metal plate is omitted in order to make the shape of the mold easy to understand.
Each mold will be specifically described below.

The upper mold 9 is composed of an upper upper mold 13 arranged above the upper part of the stepped portion 5 and a lower upper mold 15 arranged below. As shown in FIG. 3A, the upper-stage lower die 15 has clamping surfaces 13a and 15a for clamping the metal plate 7. As shown in FIG.

The lower-side mold 11 is composed of a lower-side upper mold 17 arranged above the lower-side part of the stepped portion 5 and a lower-side lower mold 19 arranged below. Like the upper upper mold 13 and the lower lower mold 15 , the lower mold 19 has clamping surfaces 17 a and 19 a for clamping the metal plate 7 .

Further, as shown in FIG. 4B, the lower-stage upper mold 17 has a stepped molding surface portion 17b having a shape corresponding to the stepped portion 5 described in the first embodiment. Similarly, the upper-stage-side lower mold 15 also has a stepped molding surface portion 15b having a shape corresponding to the stepped portion 5. As shown in FIG. The upper mold 13 on the upper stage and the lower mold 19 on the lower stage also have surfaces with shapes corresponding to the stepped molding surface portions 15b and 17b, respectively. When the die 9 and the lower die 11 are viewed from above, the gap between them has a meandering shape as shown in FIG. 4(b).
In this state, the upper mold 9 and the lower mold 11 clamp the metal plate 7 and can move relative to the surface of the metal plate 7 in the vertical direction.

Next, a method of forming the stepped portion 5 using the upper mold 9 and the lower mold 11 as described above will be described with reference to FIG.
First, the portion of the metal plate 7 that will be the upper side of the stepped portion 5 is clamped by the clamping surface portions 13a and 15a of the upper mold 9, and the portion of the metal plate 7 that will be the lower side of the stepped portion 5 is clamped to the lower side. It is clamped by the clamping surfaces 17a and 19a of the mold 11 (see FIG. 3(a)).

With the metal plate 7 clamped by the upper mold 9 and the lower mold 11 as described above, the upper mold 9 is relatively moved upward and the lower mold 11 is moved downward (Fig. 3 ( b) see).

Further, by moving the upper mold 9 and the lower mold 11 to relatively move the distance corresponding to the height h of the stepped portion 5, the step molding surface portion 15b of the upper lower mold 15 and the lower upper mold 15 are moved. A stepped portion 5 is formed in the gap between the stepped molding surface portions 17b of the mold 17 (see FIG. 3(c)).

By the above manufacturing method, it is possible to manufacture the metal roof member 1 having the stepped portion 5 whose top view shape described in Embodiment 1 meanders with a predetermined meandering width and meandering pitch.

In the present invention, the appearance of the stepped portion is an important aspect, so prior to the description of the embodiments, an installation example of a roof of a typical Japanese house and how it looks will be described.
Residential roofs come in a variety of shapes, from horizontal to steeply sloping roofs, but most Japanese roofs have a slope of 4 to 6 inches (horizontal direction: vertical direction = 10: x slope = x size). It is called a gradient), and when converted to an inclination angle from the horizontal direction, it is approximately 22 to 31 degrees.
Fig. 5 schematically shows an example of a roof with a slope of 5 cm (inclination angle of 26.6 degrees).

As shown in FIG. 5, since the roof is installed at a position higher than the line of sight of a person standing on the ground, the appearance of the upper surface cannot be seen from the line of sight (a) near the building. Also, from the line of sight (b) far from the building, the upper surface of the roof can be seen, but it is difficult to recognize the details of the design due to the distance from the roof.
On the other hand, when the roof is viewed from above at an angle of 45 degrees, such as the line of sight (c) corresponding to the case of looking down from a nearby tall building, the design of the roof is easily recognized in detail.
Therefore, the design appearance of the roof member is an important factor that strongly influences the sense of luxury of the house, especially when looking down from above the eaves as in line of sight (c).

Based on the above points, an experiment was conducted to confirm the effects of the metal roofing member of the present invention, and the results will be described below.
In this example, various long metal tiles were molded and compared using resin-coated AlZn-plated steel sheets with a thickness of 0.3 mm as materials.

As a comparative example, a metal roof member 29 having a linear stepped portion 23 formed in a flat plate-like material was molded. A perspective view of the comparative example is shown in FIG. 6(a-1), and a top view of a part of FIG. 6(a-1) is shown in FIG. 6(a-2). The perspective view of FIG. 6(a-1) corresponds to the case where the roof with a 5-inch slope (inclination angle of 26.6 degrees) explained in FIG. The same applies to subsequent perspective views.

As Inventive Example 1, a metal roof member 1 was formed by forming a stepped portion 5 having a meandering shape (meandering pitch p=140 mm, meandering width w=10 mm) in a top view on the flat material. A perspective view of Invention Example 1 is shown in FIG. 6(b-1), and a top view of part of FIG. 6(b-1) is shown in FIG. 6(b-2).

Further, as invention examples 2 and 3, the stepped portion 5 of invention example 1 was formed by changing the meandering pitch p to 20 mm or 30 mm only with the same meandering pitch p. Perspective views of Invention Examples 2 and 3 are shown in FIGS. 6(c-1) and 6(d-1), and a top view of a part of FIGS. are shown in FIGS. 6(c-2) and 6(d-2), respectively.

As Conventional Example 1, a metallic roof member 21 having a linear stepped portion 23 formed in a corrugated plate shape (wavelength L=140 mm, wave height H=30 mm) was molded. A perspective view of Conventional Example 1 is shown in FIG. 6(e-1), and a top view of part of FIG. 6(e-1) is shown in FIG. 6(e-2).
The stepped portions 5 of Invention Examples 1 to 3 and the stepped portions 23 of Comparative Example and Conventional Example 1 have the same cross-sectional shape (see FIG. 10) (height h=15 mm, inclination angle θ=70 degrees, shoulder R=5mmR).

Table 1 also shows the shape and dimensions of the stepped portions 5 and 23 in the comparative example, the inventive example, and the conventional example, and the measurement results of the plate thickness reduction rate after step processing.
The plate thickness reduction rate was measured by measuring the plate thickness at 10 points each at the upper end and the lower end of the stepped portion 23 in the comparative example, and by measuring the plate thickness at 10 points each in parts a and b in FIG. 1 in the invention example. In the conventional example, the plate thickness was measured at 10 locations c and d in FIG.

As can be seen by comparing FIG. 6(b-1) and FIG. 6(e-1), the meandering pitch p of the stepped portion 5 of Invention Example 1 is 140 mm, which is the same as the wavelength L of the corrugated plate of the material of Conventional Example 1. Therefore, the step portion 5 of Invention Example 1 and the step portion 23 of Conventional Example 1 are similar.
Therefore, in the appearance when viewed from the line of sight (c) in FIG. 5, the stepped portion 5 of Invention Example 1 and the stepped portion 23 of Conventional Example 1 have a design that makes the steps equally clear. Recognize.

Next, as can be seen from a comparison between Invention Example 1 and Invention Examples 2 and 3, the larger the meandering width w, the more clearly the shape of the stepped portion 5 can be recognized.
It can be seen that it is more preferable that the meandering width w of the stepped portion 5 is 20 mm or more for a clear design.

In addition, the comparative example provided with the stepped portion 23 that is linear in top view has a monotonous appearance (see FIG. 6(a-1)), whereas the steps of Invention Examples 1 to 3 resemble a wave shape. Since the part 5 can be clearly recognized, when it is constructed as a roof of a house, the appearance is more similar to a tiled roof and the sense of quality is improved.

Next, Table 1 will be used to explain the effect of suppressing the reduction in plate thickness when forming the stepped portion.
As shown in Table 1, when a flat plate material is stepped, Comparative Example 1 has the lowest thickness reduction rate, followed by Invention Example 1 < Invention Example 2 < Invention Example 3. is getting bigger. In invention examples 1 to 3, the plate thickness reduction rate increases as the meandering width w of the stepped portion 5 increases.

That is, the stepped portion of the metal roofing member of the present invention has an appearance similar to or more distinct than that of the conventional metal roofing member, and furthermore, the thickness reduction is suppressed, so that the stepped portion is more stable. Enables step processing.

In this example, various long shaped metal roof tiles were formed from resin-coated ferritic stainless steel plates with a thickness of 0.5 mm and compared.

As Inventive Examples 4 to 10, metal roof members 1 were molded in which stepped portions 5 having a meandering shape (meandering pitch p=300 mm, meandering width w changed) were formed on the flat material.

As Conventional Example 2, a metal roof member 21 having a linear stepped portion 23 formed in a corrugated plate shape (wavelength L=300 mm, wave height H=37 mm) was molded from the above material.
The stepped portion 5 of Invention Examples 4 to 10 and the stepped portion 23 of Conventional Example 2 have the same cross-sectional shape (see FIG. 10) (height h=25 mm, inclination angle θ=80 degrees, shoulder R=7 mmR). )I have to.

Table 2 also shows the shape and dimensions of the stepped portion 5 of Inventive Examples 4 to 10 and the stepped portion 23 of Conventional Example 2, and the measurement results of the plate thickness reduction rate after step processing.
The method of obtaining the sheet thickness reduction rate is the same as in the first embodiment.

As shown in Table 2, in Invention Examples 4 to 10, the plate thickness reduction rate increases as the meandering width w of the stepped portion 5 increases. .
Also in the present embodiment, the larger the meandering width w, the clearer the appearance of the stepped portion 5 and the higher the quality.

In addition, in Invention Example 5 and Conventional Example 2, the meandering shape of the stepped portion 5 of Invention Example 5 (meandering pitch p = 300 mm, meandering width w = 37 mm) and the corrugated shape of the corrugated plate of the material of Conventional Example 2 (wavelength L = 300 mm, wave height = 37 mm), but the plate thickness reduction rate of Invention Example 5 is smaller than that of Conventional Example 2. In addition, invention example 10, which has the largest plate thickness reduction rate among invention examples 4 to 10, also has a plate thickness reduction rate smaller than that of conventional example 2, and the plate thickness reduction is suppressed in the present invention example.
In other words, it can be seen that all of Invention Examples 4 to 10 are capable of stably molding by suppressing reduction in plate thickness as compared with Conventional Example 2 while aiming for a high-quality design.

However, if the meandering width w increases to 110 mm as in Example 10, the plate thickness reduction rate is about the same as in Conventional example 2. Therefore, in order to obtain the effect of suppressing the plate thickness reduction, the meandering width w should be set to 100 mm or less. preferably.

In this example, various metal elongated roof tiles were molded and compared using resin-coated ferritic stainless steel sheets with a thickness of 1.0 mm.

As invention examples 11 to 14, metal roof members 1 were formed by forming stepped portions 5 having different heights h on the flat material. (The values of the cross-sectional shape of the step portion 5 (height h, inclination angle θ, shoulder R) in Examples 11 to 14 are shown in Table 3). The stepped portions 5 of Inventive Examples 11 to 14 all have the same meandering shape (meandering pitch p=60 mm, meandering width w=46 mm) when viewed from above.

As conventional examples 3 and 4, metal roof members 21 were molded in which stepped portions 23 with different heights h were formed in the corrugated material (wavelength L = 60 mm, wave height H = 46 mm). (The respective values (height h, inclination angle θ, shoulder R) of the cross-sectional shape of the step portion 23 in Conventional Examples 3 and 4 are shown in Table 3). The stepped portion 23 of Conventional Examples 3 and 4 has the same linear shape when viewed from the top.
The meandering shape of the stepped portion 5 (meandering pitch p = 60 mm, meandering width w = 46 mm) in invention examples 11 to 14 when viewed from above, and the wave shape of the corrugated plate of the material in conventional examples 3 and 4 (wavelength L = 60 mm, wave height = 46 mm) has a similar shape.

Table 3 also shows the shape and dimensions of the stepped portions 5 of Invention Examples 11 to 14 and the stepped portion 23 of Conventional Example 3, and the measurement results of the plate thickness reduction rate after step processing.
The method of obtaining the sheet thickness reduction rate is the same as in the first embodiment.

As shown in Table 3, in Examples 11 to 14, the higher the height h of the step portion 5, the greater the plate thickness reduction rate. .
In addition, in the present embodiment, the higher the height h of the stepped portion 5, the more clearly the appearance of the stepped portion 5 becomes easier to recognize, and the higher the quality.

Further, in Conventional Example 3, in which the height h of the step portion is the same as that of Invention Example 13, the plate thickness reduction rate is larger than that of Invention Example 13, and necking occurs.
Similarly, Conventional Example 4, in which the height h of the step portion is the same as that of Invention Example 14, cracked.

That is, all of Invention Examples 11 to 14 aim for a high-class design in which the stepped portion is clearly recognized, and at the same time, suppress the decrease in plate thickness compared to Conventional Examples 3 and 4, thereby stably forming. is possible.

As can be seen from the above examples, the metal roofing member according to the present invention has a distinct shape of the stepped portion while suppressing the thickness reduction compared to the conventional metal roofing member in which the corrugated sheet material is step-processed. It can be seen that a high-class appearance design property can be obtained.

1 metal roof member 3 flat plate portion 3a upper flat plate portion 3b lower flat plate portion 5 stepped portion 7 metal plate 9 upper mold 11 lower mold 13 upper upper mold 13a clamp surface 15 lower lower mold 15a clamp surface 15b step forming surface portion 17 lower upper mold 17a clamp surface portion 17b step forming surface portion 19 lower lower mold 19a clamp surface portion 21 metal roof member (conventional example)
23 stepped portion (conventional example)
25 Upper corrugated plate portion 27 Lower corrugated plate portion 29 Metal roof member (comparative example)

Claims (3)

A metal roof member having a flat plate portion and a stepped portion, and installed on a roof so that the extending direction of the stepped portion is orthogonal to the inclination direction of the roof,
The metal roof member, wherein the stepped portion is high on the upper side in the inclined direction and low on the lower side in the installed state, and has a meandering shape with a predetermined meandering width and meandering pitch when viewed from above the eave height. 2. The metal roof member according to claim 1, wherein the meandering width of the step portion is 20 mm or more and 100 mm or less, the meandering pitch is 50 mm or more and 300 mm or less, and the height is 10 mm or more and 30 mm or less. A method for manufacturing a metal roof member according to claim 1, comprising:
Equipped with a stepped portion forming step for forming a stepped portion on a flat metal plate,
The stepped portion forming step comprises an upper mold which is arranged on the upper side of the stepped portion and which includes an upper upper mold and an upper lower mold having a step forming surface portion, and a lower side of the stepped portion. Using a lower-side mold consisting of a lower-side upper mold and a lower-side lower mold having a stepped molding surface portion,
A portion of the metal plate on the upper side of the stepped portion is clamped by the upper mold, and a portion of the metal plate on the lower side of the stepped portion is clamped by the lower mold,
By relatively moving the upper mold upward and the lower mold downward, the stepped portion is formed by the step forming surface portions provided on the upper lower mold and the lower upper mold. A method for manufacturing a metal roof member.

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