JP7732043B2 - Building material panel and connected structure using building material panel - Google Patents

Description

The present invention relates to building material panels suitable for constructing roofs and exterior walls of building structures, connecting structures using building material panels, and methods for manufacturing building material panels.

Construction panels, which comprise a metal exterior skin and an insulating material (core material) fixed to the backside of the skin, are lightweight and strong, offering advantages such as high insulation efficiency and airtightness. Therefore, construction panels are used as roofing and exterior wall materials for architectural structures such as factories, warehouses, residential buildings, commercial facilities, and livestock barns. In connected structures in which multiple construction panels are arranged in the girder and ridge directions, cover caps extending in the ridge direction are attached across the vertical joints on each of two adjacent construction panels in the girder direction, covering the joints between the two adjacent panels (see, for example, Patent Document 1).

When multiple of the above-mentioned building panels are arranged in the girder direction, if a gap occurs between two adjacent building panels, the insulation efficiency and airtightness will decrease. Therefore, an airtight gasket is placed between two adjacent building panels to prevent gaps from occurring between the two adjacent building panels.

JP 2024-33775 A

After the airtight gasket is attached to the insulating material of a previously placed building panel, it is also attached to the insulating material of that building panel when a new building panel is placed in the girder direction. However, if the airtight gasket attached to the insulating material of the building panel is not properly attached, the airtight gasket may peel off from the insulating material of the building panel, or the peeling of the airtight gasket may damage the insulating material of the building panel. Furthermore, placing the building panel while attaching the airtight gasket to the insulating material of the building panel is a time-consuming task, resulting in poor work efficiency.

The present invention was made in consideration of the above-mentioned problems, and aims to provide a building material panel that can be easily installed on narrow sites using short-length products while ensuring insulation efficiency, airtightness, etc., as well as a connecting structure using such building material panels and a method for manufacturing building material panels.

One aspect of this building panel is a metal exterior skin with joints at both widthwise ends, and a core material fixed to the back surface of the exterior skin. After another building panel is placed adjacent to one of the widthwise ends of the exterior skin, a cover cap is engaged across the joint and the adjacent joint of the other building panel to link the panel together, thereby constructing a roof or wall of an architectural structure. The building panel is characterized in that at least one of the widthwise ends of the core material of the exterior skin protrudes outward beyond the upright piece erected at the outer edge of the joint.

The core material is preferably at least one insulating material, an insulating block with grooves formed to match the shape of the bottom surface of the outer skin material, and at least one insulating material is preferably fixed to the bottom surface of the outer skin material using adhesive.

Furthermore, the building material panels have a lower joint or an upper joint at one longitudinal end of the exterior skin material, or a lower joint at one longitudinal end of the exterior skin material and an upper joint at the other longitudinal end of the exterior skin material, and it is preferable that one building material panel and another building material panel are arranged adjacent to each other in the longitudinal direction, and that the lower joint of one building material panel overlaps the upper joint of the other building material panel.

In this case, the core material that makes up the building panel with a bottom joint is produced by heat welding at least two pieces of insulation material of different heights to the outer skin material in the longitudinal direction, and the insulation material is preferably fixed to the bottom surface of the outer skin material using an adhesive.

The connection structure of the present invention also includes the above-described building panels arranged adjacent to each other at least in the width direction of the exterior skin material, with the core materials of two adjacent building panels in the width direction of the exterior skin material abutting against each other, and cover caps engaged across the two joints provided at both ends of the building panels in the width direction of the exterior skin material that are closest to the adjacent building panels.

Furthermore, of the upright pieces provided at the outer ends of the joints provided at both ends of the building panel in the width direction of the exterior skin material, it is preferable that the two upright pieces closest to adjacent building panels are grasped by a grasping member, and the grasping member grasping the two upright pieces is fixed to the rafters or purlins together with the two adjacent building panels via the sheathing board.

It is also preferable that one building panel having at least a lower joint at one end is overlapped with another building panel having an upper joint at at least one end in the longitudinal direction of the exterior skin material and fixed thereto.

The manufacturing method for building panels of the present invention also includes the steps of roll-forming a metal plate to produce an outer skin with joints at both widthwise ends; groove-cutting a foam block to produce an insulating material with an upper surface that matches the shape of the bottom surface of the outer skin and at least one of both widthwise ends of the outer skin protruding outward beyond the end of the outer skin; applying adhesive to the bottom surface of the outer skin or the top surface of the insulating material; and applying heat and pressure to the bottom surface of the outer skin and the top surface of the insulating material while they are in contact, thereby adhering the insulating material to the outer skin.

It is also preferable to include a step of using a press machine to form a step at one longitudinal end of the outer skin material, forming a lower joint that is located below the surface of the outer skin material.

Furthermore, the process of producing the insulation preferably includes the steps of manufacturing a first insulation section located on the bottom surface of the outer skin material and a second insulation section located on the bottom surface of the lower joint, and joining the first insulation section and the second insulation section using a hot melt adhesive to produce the insulation.

This disclosure provides building material panels that can be easily installed on narrow sites using short-length products while ensuring insulation efficiency, airtightness, etc., as well as connecting structures using building material panels and methods for manufacturing building material panels.

1 is a schematic perspective view showing an example of a case where a connected structure in which a plurality of building material panels shown in this embodiment are arranged is used as a roof. FIG. FIG. 2 is an exploded perspective view showing the configuration of the eaves side panel. FIG. 2 is an exploded perspective view showing the configuration of the ridge-side panel. FIG. 2 is an explanatory diagram showing the configuration of a clip. FIG. 10 is a perspective view showing the position where the clip is attached. FIG. 2 is a perspective view showing the configuration of a cover cap. (a) is a plan view of the connecting structure, (b) is a front view of the continuous structure, (c) is a side view showing the cover cap exploded, and (d) is a side view showing the eaves side panel and ridge side panel exploded. 1A is a flowchart showing the manufacturing process of an eave-side panel, and FIG. 1B is a flowchart showing the manufacturing process of a ridge-side panel. This is a perspective view showing the state just before the eaves side panel and the ridge side panel are joined together. This is an end view showing the state just before the eaves side panels are placed adjacent to each other in the girder direction. FIG. 10 is an end view showing two adjacent eaves-side panels arranged in contact with each other. FIG. 10 is an end view showing two adjacent eaves-side panels joined together by a clip. FIG. 10 is an end view showing one of two adjacent eave-side panels fixed to a rafter with a clip. This is an end view showing the state in which a cover cap is attached across the vertical joint of two adjacent eaves side panels.

The building material panels shown in this embodiment and the connected structure using these building material panels will be described below with reference to the drawings. Figure 1 is a schematic perspective view showing an example of a connected structure in which multiple building material panels shown in this embodiment are arranged as a roof.

As shown in Figure 1, the building panel 10 of this embodiment is composed of two panels: an eave-side panel 20 arranged on the eave side, and a ridge-side panel 40 arranged on the ridge side. The eave-side panel 20 and the ridge-side panel 40 are arranged in this order from the eave side along the eave-ridge direction (or span direction). Figure 1 illustrates an example in which a connecting structure 100 is used as a roof, with three eave-side panels 20 and three ridge-side panels 40 arranged in the girder direction.

As shown in Figure 2, the eaves side panel 20 comprises an exterior skin 21 and insulating material 22. The exterior skin 21 is a metal member that forms the basic framework of the eaves side panel 20. The exterior skin 21 is a member whose outline shape is rectangular in a plan view. Hereinafter, in a plan view of the exterior skin 21, the direction along the short side is referred to as the width direction, and the direction along the long side is referred to as the longitudinal direction. Note that Figure 2 shows a case where the width direction of the exterior skin 21 is parallel to the girder direction, and the longitudinal direction of the exterior skin 21 is parallel to the ridge direction.

The outer skin material 21 is made of a zinc-plated steel sheet, an aluminum-zinc alloy-plated sheet, a stainless steel sheet, an aluminum sheet, a copper sheet, or a painted or coated metal sheet of these, with a thickness of approximately 0.2 to 1.0 mm, preferably approximately 0.4 mm. The outer skin material 21 is formed by subjecting a single sheet of material to forming processes such as roll forming.

Vertical joints 25 are provided at both widthwise ends of the outer skin material 21. The vertical joints 25 have inclined wall portions 26, 27, jaw portions 28, and base portions 29.

The inclined wall portion 26 slopes downward from one end of the outer skin material 21 in the width direction. The inclined wall portion 27 folds back from the lower end of the inclined wall portion 26 and slopes upward. In other words, the inclined wall portions 26 and 27 form a groove with a V-shaped cross section. This groove prevents rainwater from entering the interior of the cover cap 70.

The jaw portion 28 is connected to the upper end of the inclined wall portion 27 and engages with a locking piece 72 of the cover cap 70, which will be described later. The upper surface 28a of the jaw portion 28 is set slightly lower than the outer surface of the outer cover material 21 so that it is flush with the outer surface of the outer cover material 21 when the cover cap 70, which will be described later, is attached.

The base portion 29 has a seat 29a located below the outer surface of the exterior skin material 21 and above the other end of the inclined wall portion 26, and an upright piece 29b extending from the end of the seat 29a. The seat 29a functions as a seat onto which screws 85 are threaded to secure the eaves-side panel 20 to the rafters 82 via the sheathing boards 81 (see, for example, Figure 9). Therefore, it is preferable that the seat 29a be a horizontal surface. While the eaves-side panel 20 is secured to the rafters 82 via the sheathing boards 81, it can also be secured to the purlin.

A lower joint 32 is provided at one longitudinal end of the exterior skin material 21, via a stepped region 31 approximately the same thickness as the exterior skin material 21. The lower joint 32 is covered by an upper joint 51 provided on the exterior skin material 41 of the ridge-side panel 40 when the upper joint 51 is overlapped with the lower joint 32. The lower joint 32 has insertion portions 33 connected to the vertical joints 25 at both widthwise ends of the exterior skin material 21. The insertion portions 33 have a protrusion 33a connected to the jaw portion 28 and a gutter portion 33b connected to the base portion 29. When the upper joint 51 is overlapped with the lower joint 32, the protrusion 33a is inserted into a storage space 50 (see Figure 3) formed on the back side of the jaw portion 48 provided on the vertical joint 45. Additionally, when the upper joint 51 is placed on the lower joint 32, the base portion 49 provided on the vertical joint 45 fits into the gutter portion 33b.

To ensure high thermal insulation and airtightness, the insulating material 22 can be a foamed plastic insulating material with a thickness of, for example, approximately 300 mm. Examples of foamed plastic insulating materials include isocyanate foam and rigid urethane foam. The thickness of the insulating material 22 is preferably in the range of 50 to 300 mm.

The insulating material 22 is a member fixed to the back side of the outer skin material 21. The insulating material 22 has a first insulating section 35 arranged on the back side of the outer skin material 21 and a second insulating section 36 arranged on the back side of the lower joint 32. The first insulating section 35 and the second insulating section 36 are each created by performing groove processing such as wire cutting on the insulating block. The first insulating section 35 and the second insulating section 36 are bonded using, for example, a hot-melt adhesive.

For example, the width W1 of the insulation material 22 in the girder direction is wider than the distance (width) W2 from the upright piece 29b located outward of the vertical joint 25 at one end of the skin material 21 in the width direction to the upright piece 29b located outward of the vertical joint 25 at the other end. Therefore, when the insulation material 22 is fixed to the back side of the skin material 21, both ends of the insulation material 22 protrude outward beyond both ends of the skin material 21.

Hereinafter, the length (protrusion amount) by which the left end of the insulation material 22 in the width direction protrudes from the left end of the outer skin material 21 will be referred to as W3L, and the protrusion amount by which the right end of the insulation material 22 in the width direction protrudes from the right end of the outer skin material 21 will be referred to as W3R. The sum of the protrusion amount W3L and the protrusion amount W3R will be referred to as the total protrusion amount W3.

The protrusion amounts W3L and W3R are set to lengths that allow the insulating materials 22 of two adjacent eaves side panels 20 to abut against each other without the upstanding pieces 29b of the outer covering materials 21 of the two adjacent eaves side panels 20 hitting each other when the multiple eaves side panels 20 are respectively arranged in predetermined positions. In more detail, the protrusion amounts W3L and W3R and the total protrusion amount W3 are set so that the protrusion amounts W3L and W3R are in the range of 0 to 1.5% of the width W1 of the insulating material 22, and the total protrusion amount W3 is in the range of more than 0% and not more than 1.5% of the width W1 of the insulating material 22, for example.

In the eaves-ridge direction, the length L1 of the first insulating section 35 of the insulating material 22 is shorter than the length L2 of the exterior skin material 21. Therefore, when the insulating material 22 is fixed to the back surface of the exterior skin material 21, no insulating material 22 is present on the back surface of one end of the exterior skin material 21 in the width direction (the portion indicated by reference symbol A1 in Figure 2) in the eaves-ridge direction. In other words, portion A1 functions as a drip edge when located at the eaves edge, and as an upper joint when covering the lower joint of another building panel.

Furthermore, in the eaves-ridge direction, the length L3 of the second insulating section 36 of the insulating material 22 is the same as the length L4 of the lower joint 32 of the exterior skin material 21. Here, the above-mentioned length L1 is, for example, L1 = 1650 mm, and the length L3 is, for example, L3 = 150 mm. Furthermore, the length L2 of the exterior skin material 21 is, for example, L2 = L1 + (20 to 145) mm.

As shown in Figure 3, the ridge-side panel 40 comprises an exterior skin 41 and an insulating material 42. The exterior skin 41 is a metal member that forms the basic framework of the ridge-side panel 40. The material of the exterior skin 41 is the same as the material of the exterior skin 21 of the eaves-side panel 20, so details about it will be omitted.

The exterior skin material 41 is a component with a rectangular outline in plan view. Hereinafter, as with the exterior skin material 21 of the eaves-side panel 20, the direction along the short side of the exterior skin material 41 in plan view will be referred to as the width direction, and the direction along the long side will be referred to as the longitudinal direction. Figure 3 shows a case where the width direction of the exterior skin material 41 is parallel to the girder direction, and the longitudinal direction of the exterior skin material 41 is parallel to the ridge direction.

Vertical joints 45 are provided at both widthwise ends of the exterior skin material 41. The cross-sectional shape of the vertical joints 45 perpendicular to the eaves-ridge direction is the same as the cross-sectional shape of the vertical joints 25 provided on the exterior skin material 21. That is, the vertical joints 45 have inclined wall portions 46, 47, jaw portions 48, and base portions 49. Note that because the shapes of the vertical joints 45 and the vertical joints 25 are the same, details about the shape of the vertical joints 45 will be omitted here.

Like insulation material 22, insulation material 42 is made of a foamed plastic insulation material, approximately 300 mm in height. Similar to insulation material 22, foamed plastic insulation materials include isocyanurate foam and rigid urethane foam. Insulation material 42 is grooved using wire cutting or other methods so that its top surface matches the shape of the back surface of outer skin material 41.

The width W4 of the insulation material 42 in the girder direction is wider than the distance (width) W5 from the upright piece 49b on one end of the outer skin material 41 to the upright piece 49b on the other end. Therefore, when the insulation material 42 is fixed to the back side of the outer skin material 41, both ends of the insulation material 42 protrude outward beyond both ends of the outer skin material 41 in the width direction of the outer skin material 41.

Hereinafter, the length (protrusion amount) by which the left end of the insulation material 42 in the width direction protrudes from the left end of the outer skin material 41 will be referred to as W6L, and the protrusion amount by which the right end of the insulation material 42 in the width direction protrudes from the right end of the outer skin material 41 will be referred to as W6R. The sum of the protrusion amount W6L and the protrusion amount W6R will be referred to as the total protrusion amount W6.

The protrusion amounts W6L and W6R are set to lengths such that, when multiple eaves-side panels 20 are positioned in their respective predetermined positions, the upright pieces 49b of the exterior covering materials 41 of two adjacent ridge-side panels 40 do not collide with each other, and the insulating materials 42 of two adjacent ridge-side panels 40 can abut against each other. Specifically, the protrusion amounts W6L and W6R and the total protrusion amount W6 are set so that, for example, the protrusion amounts W6L and W6R are in the range of 0 to 1.5% of the width W4 of the insulating material 42, and the total protrusion amount W6 is in the range of, for example, more than 0% and not more than 1.5% of the width W4 of the insulating material 42. The protrusion amounts W6L, W6R and the total protrusion amount W6 may be the same as or different from the protrusion amounts W3L, W3R and the total protrusion amount W3.

Furthermore, in the eaves-ridge direction, the length L5 of the insulation material 42 is shorter than the length L6 of the outer skin material 41. Therefore, when the ridge-side end of the outer skin material 41 is aligned with the ridge-side end of the insulation material 42 in the eaves beam direction and the insulation material 42 is fixed to the outer skin material 41, the eaves-side end of the outer skin material 41 (the portion indicated by reference numeral 51 in Figure 3) is a portion to which the insulation material 42 is not fixed. This portion 51 functions as an upper joint that is overlapped above the lower joint 32 provided on the outer skin material 21 of the eaves-side panel 20 when the ridge-side panel 40 is installed. Note that when the upper joint 51 is overlapped above the lower joint 32 provided on the outer skin material 21 of the eaves-side panel 20, the insertion portion 33 provided on the lower joint 32 of the eaves-side panel 20 is inserted into the storage space 50 provided on the back side of the jaw portion 48 of the vertical joint 45 that extends to the upper joint 51. The length L5 of the heat insulating material 42 described above is, for example, L5 = 1655 mm. Furthermore, the length L6 of the outer skin material 41 is, for example, L6 = 1800 mm.

Of the multiple eaves side panels 20 and ridge side panels 40 arranged as the connecting structure 100, two adjacent eaves side panels 20, 20 or two adjacent ridge side panels 40, 40 are connected by clips 60.

Figure 4(a) is a perspective view of the clip, Figure 4(b) is a front view of the clip, Figure 4(c) is a top view of the clip, Figure 4(d) is a left side view of the clip, and Figure 4(e) is a bottom view of the clip. As shown in Figures 4(a) to 4(e), clip 60 is a hat-shaped member when viewed from the front. Note that the left side view and right side view of clip 60 have the same shape, so they are omitted from Figure 4.

The clip 60 connects two adjacent eaves-side panels 20, 20 or two ridge-side panels 40, 40, and also functions as a retaining clip that maintains the installation position of the cover cap 70. With the two adjacent panels connected, the clip 60 is fixed to the rafter 82 via the sheathing board 81 together with one of the two adjacent panels using a screw 85.

The clip 60 has a double-clip type clip body 61 and tongues 62, 62 connected to the lower end of the clip body 61. The clip body 61 elastically deforms due to springback, clamping the two adjacent upright pieces 29b, 29b of the upright pieces 29b provided on two adjacent eaves-side panels 20, 20, or the two adjacent upright pieces 49b, 49b of the upright pieces 49b provided on two adjacent ridge-side panels 40, 40, connecting the two adjacent panels.

The tongues 62, 62 come into surface contact with the seating surfaces 29a of the base portions 29 provided on two adjacent eaves side panels 20, 20, or the seating surfaces 49a of the base portions 49 provided on two adjacent ridge side panels 40, 40, thereby maintaining a constant position of the clip 60 relative to the two adjacent eaves side panels 20, 20 or the two adjacent ridge side panels 40, 40.

One or two insertion holes 63 are provided in each of the tongues 62, 62. Screws 85 are inserted through the insertion holes 63 to secure the clips 60 connecting two adjacent panels to the rafters 82 via the sheathing boards 81.

Multiple clips 60 are arranged at predetermined intervals in the eaves-ridge direction of the connecting structure 100. As shown in Figure 5, when three eaves-side panels 20 and three ridge-side panels 40 are arranged, two adjacent eaves-side panels 20, 20 are connected using one clip 60. Furthermore, two adjacent ridge-side panels 40, 40 are connected using two clips 60, 60. Note that the positions at which the clips 60 are attached in the eaves-ridge direction are not limited to those shown in Figure 5 and can be set as appropriate.

The cover cap 70a is attached to the vertical joints 25, 25 of two adjacent eaves side panels 20 and the vertical joints 45, 45 of two ridge side panels 40, connecting the vertical joints 25, 25 of the two adjacent eaves side panels 20 and the vertical joints 45, 45 of the two ridge side panels 40. At this time, it covers the clips 60 connecting the two adjacent eaves side panels 20 and two ridge side panels 40, as well as the vertical joints 25, 25, 45, 45.

As shown in Figures 6 and 7, the cover cap 70a comprises a base 71 extending in the eaves-ridge direction and locking pieces 72, 72 provided on both ends of the base 71 in the girder direction. The locking piece 72 is zigzag folded downward to form a jaw portion 72a and an operating portion 72b. The jaw portion 72a elastically deforms when attached to the vertical joint 25 and the vertical joint 45, engaging with the jaw portion 28 of the vertical joint 25 and the jaw portion 48 of the vertical joint 45. The operating portion 72b is operated to disengage the jaw portion 72a of the locking piece 72 from the jaw portion 28 of the vertical joint 25 and the jaw portion 48 of the vertical joint 45, respectively.

A joint 73 is provided at one longitudinal end (ridge side) of the cover cap 70a. The joint 73 covers the eaves side end of the cover cap 70b when the cover cap 70b is attached to the vertical joints 45, 45 of the two ridge side panels 40. This prevents rainwater and other water flowing from the ridge side of the roof toward the eaves side from entering the interior.

Cover cap 70b differs from cover cap 70a in that it does not have joint 73, but otherwise has the same configuration as cover cap 70a. Therefore, a description of the configuration of cover cap 70b will be omitted. Cover cap 70b is attached to the vertical joints 45, 45 of two adjacent ridge-side panels 40.

Note that Figure 7 shows an example in which one cover cap 70a and one cover cap 70b are placed in the eaves-ridge direction, but if multiple cover caps are placed in the eaves-ridge direction, multiple cover caps 70a can be placed from the eaves side, and cover cap 70b can be placed in the position closest to the ridge.

Note that this embodiment illustrates the use of a cover cap 70a equipped with a joint 73 and a cover cap 70b covering the joint 73, but the configuration of the cover cap is not limited to the cover cap of this embodiment.

Next, the process for manufacturing the building panel 10 will be described. As described above, the building panel 10 has an eaves-side panel 20 and a ridge-side panel 40. First, the process for manufacturing the eaves-side panel 20 will be described.

As shown in Figure 8(a), the process for manufacturing the eaves-side panel 20 includes an outer skin manufacturing process S100, an insulation material manufacturing process S200, and a joining process S300.

The skin material manufacturing process S100 includes a roll forming process S101 and a lower joint processing process S102. The roll forming process S101 is a process in which a single plate material is roll formed using a roll forming machine. By performing the roll forming process S101, the skin material 21 used for the eaves side panel 20 is produced. The lower joint processing process S102 is a process in which a step is processed using a press machine when adding a lower joint 32 to the eaves side panel 20.

The insulation manufacturing process S200 includes a groove processing process S201 and a joining process S202. The groove processing process S201 is a process in which an insulation block of a predetermined size is processed using a method such as wire cutting to create an insulation material that matches the shape of the outer skin material 21. By performing the groove processing process S201, the first insulation section 35 and the second insulation section 36 of the insulation material 22 are created.

The joining process S202 is a process of joining the first insulating section 35 and the second insulating section 36 manufactured in the groove processing process S201 using, for example, a hot melt adhesive.

The joining process S300 includes an adhesive application process S301 and a heating and pressurizing process S302. The adhesive application process S301 is a process in which an automatic adhesive application device is used to apply adhesive to the bottom surface of the exterior skin material 21 or the top surface of the insulation material 22. The heating and pressurizing process S302 is a process in which a press machine is used to bond the exterior skin material 21 and the insulation material 22 together. By performing this joining process S300, the eaves-side panel 20 described above is produced.

The process for manufacturing the ridge-side panel 40 also differs from the process for manufacturing the eave-side panel 20 in the following respects. As described above, the ridge-side panel 40 does not have a lower joint in the exterior skin 41, and the insulation 42 attached to the exterior skin 41 does not have a stepped portion that matches the lower joint. Therefore, as shown in Figure 8(b), when manufacturing the ridge-side panel 40, the lower joint processing step S102 is omitted from the exterior skin manufacturing step S100. Similarly, the joining step S202 is omitted from the insulation manufacturing step S200.

Note that while Figure 8 separately describes the manufacturing of eaves-side panels 20 and ridge-side panels 40, it is conceivable that a mixture of eaves-side panels 20 and ridge-side panels 40 may be manufactured. In such cases, for example, between the roll-forming process S101 and the lower joint processing process S102 in Figure 8(a), it is possible to add a determination process as to whether the building material panel 10 to be manufactured is an eaves-side panel 20 or a ridge-side panel 40. That is, if it is determined in this determination process that an eaves-side panel 20 will be manufactured, the lower joint processing process S102 is performed. Furthermore, if it is determined in this determination process that a ridge-side panel 40 will be manufactured, the lower joint processing process S102 can be omitted.

Similarly, in the insulation manufacturing process S200, a process for determining whether the building panel 10 being manufactured is an eaves-side panel 20 or a ridge-side panel 40 must be added between the groove processing process S201 and the joining process.

Finally, the procedure for arranging multiple building panels 10 described above to create a connected structure 100 will be described. The eaves-side panel 20 and ridge-side panel 40 are arranged along the eaves beam direction from the eaves side of the top surface of the sheathing board 81 on which the underlayment 83 is placed. As shown in Figure 9, the ridge-side panel 40 is arranged so that the upper joint 51 of the ridge-side panel 40 overlaps the lower joint 32 of the eaves-side panel 20. At this time, the protrusion 33a of the insertion portion 33 provided on the lower joint 32 of the eaves-side panel 20 is inserted into the storage space 50 provided in the vertical joint 45 extending to the upper joint 51 provided on the ridge-side panel 40. This joins the eaves-side panel 20 and the ridge-side panel 40 together. The upper joint 51 of the ridge-side panel 40 is arranged so that it overlaps the lower joint 32 of the eaves-side panel 20.

As shown in Figures 10 and 11, once the eaves side panels 20 and ridge side panels 40 are joined together, new eaves side panels 20 and ridge side panels 40 are placed along the eaves beam direction at positions offset in the beam direction. The newly placed eaves side panels 20 and ridge side panels 40 are then joined together. In this way, a predetermined number of eaves side panels 20 and ridge side panels 40 are placed on the sheathing board 81. The eaves side panels 20 and ridge side panels 40 are placed in predetermined positions on the sheathing board 81.

As described above, the width W1 of the insulation 22 of the eaves-side panel 20 is wider than the width W2 of the exterior skin 21, and both ends of the insulation 22 protrude outward beyond the upright pieces 29b of the exterior skin 21. Therefore, when the eaves-side panel 20 is placed in a predetermined position on the sheathing board 81, the insulation 22 of two adjacent eaves-side panels 20 abut against each other. The insulation 42 of two adjacent ridge-side panels 40 also abut against each other. By maintaining the insulation of two adjacent building panels in this abutting state, insulation efficiency and airtightness can be ensured without the need for an airtight gasket (joint gasket) between the two building panels.

In addition, since there is no need to install airtight gaskets (joint gaskets), work efficiency can be improved when placing building panels and roofing. Furthermore, by having the insulation material 22 protrude outward beyond the upright pieces 29b of the exterior skin material 21, the edge distance from the abutting end face of the insulation material 22 to the position where the screws 85 are tightened can be increased, preventing damage such as cracks in the insulation material 22 when the eaves-side panel 20 is fixed to the rafters 82 via the sheathing boards 81.

In addition, even if the building material panel 10 is a ridge-side panel 40, the same effects as those of the eaves-side panel 20 can be obtained.

As shown in Figure 11, after the eaves-side panel 20 and the ridge-side panel 40 are placed in the predetermined positions on the sheathing board 81, of the upright pieces 29b provided on the two adjacent eaves-side panels 20, 20, the two adjacent upright pieces 29b, 29b are clamped with clips K. Similarly, of the upright pieces 49b provided on the two adjacent ridge-side panels 40, 40, the two adjacent upright pieces 49b, 49b are clamped with clips K. This connects the two adjacent eaves-side panels 20, 20 and the two adjacent ridge-side panels 40, 40.

The tongue 62 of the clip 60 has an insertion hole 63 for inserting a screw 85. Therefore, as shown in Figures 12 and 13, when two adjacent eaves side panels 20, 20 or two adjacent ridge side panels 40, 40 are connected, the eaves side panel 20 or ridge side panel 40 is fixed to the rafter 82 together with the clip 60 via the sheathing board 81 using the screw 85.

Finally, as shown in Figure 14, cover caps 70a, 70b are attached across the two vertical joints 25, 25 that are closest to the adjacent eaves side panels 20, 20, out of the vertical joints 25 of two adjacent eaves side panels 20, 20. At the same time, cover caps 70a, 70b are attached across the two vertical joints 45, 45 that are closest to the adjacent ridge side panels 40, 40, out of the vertical joints 45 of two adjacent ridge side panels 40, 40. This connects the two adjacent eaves side panels 20, 20 and the two adjacent ridge side panels 40, 40. At the same time, the clips 60 connecting two adjacent eaves side panels 20, 20 or two adjacent ridge side panels 40, 40, as well as the two adjacent vertical joints 25, 25 and vertical joints 45, 45, are covered by the cover caps 70a, 70b.

In this embodiment, the eave-side panel 20 and the ridge-side panel 40 have the insulating materials 22, 42 protruding outward from the upright pieces 29b, 49b of the outer skin materials 21, 41 at both ends in the girder direction. However, it is not necessary for the insulating materials to protrude from the upright pieces of the outer skin materials at both ends in the girder direction. It is sufficient for the insulating materials to protrude outward from the upright pieces of the outer skin materials at at least one of both ends in the girder direction.

In this embodiment, the panels 20, 40 are positioned so that the insulating materials 22, 22 of two adjacent eaves-side panels 20, 20 or the insulating materials 42, 42 of two adjacent ridge-side panels 40, 40 abut against each other. However, depending on the abutment state of the insulating materials described above, it is possible that two adjacent upright pieces 29b, 29b or upright pieces 49b, 49b may abut against each other. Therefore, for example, when the insulating materials 22, 22 abut against each other, it is possible to place a sealant (buffering material) between the two adjacent upright pieces 29b, 29b to prevent the two adjacent upright pieces 29b, 29b from abutting against each other. In this case, it is sufficient to place a sealant (buffering material) between the upright pieces 49b, 49b not only between the two adjacent eaves-side panels 20, 20, but also between the two adjacent ridge-side panels 40, 40.

In this embodiment, the building panel 10 is described as being composed of two panels, the eaves-side panel 20 and the ridge-side panel 40. However, three or more building panels may be arranged in the eaves-ridge direction. In such a case, the building panel may be composed of three types of panels: a panel arranged at the eaves-side end, a panel arranged at the ridge-side end, and one or more panels arranged between these two panels. In this case, the panel arranged at the eaves-side end is a building panel with an exterior skin material having a lower joint at one longitudinal end. Similarly, the panel arranged at the ridge-side end is a building panel with an exterior skin material having an upper joint at one longitudinal end, as in this embodiment. Furthermore, the panel arranged between the panel arranged at the eaves-side end and the panel arranged at the ridge-side end is a building panel with an exterior skin material having a lower joint at one longitudinal end and an upper joint at the other longitudinal end.
<Summary of effects>

The building panel 10 (20, 40) shown in this embodiment comprises a metal skin 21 (41) with vertical joints 25 (45) at both widthwise ends, and an insulating material 22 (42) fixed to the back surface of the skin 21 (41). After another building panel is placed adjacent to one of the widthwise ends of the skin 21 (41), a cover cap 70 is engaged across the vertical joint 25 (45) and the adjacent joint of the other building panel to connect it to the other building panel, thereby constructing a roof or wall of an architectural structure. A feature of this embodiment is that at least one end of the insulating material 22 (42) at both widthwise ends of the skin 21 (41) protrudes outward beyond the upright piece 29b (49b) erected on the outer edge of the vertical joint 25 (45).

As a result, when the building panels are placed in a predetermined position on the sheathing board 81, the insulating material of two adjacent building panels in the beam direction is held in contact with each other. Therefore, insulation efficiency and airtightness can be ensured without using airtight gaskets (joint gaskets) between the two adjacent building panels in the beam direction.

The core material is at least one insulating material 22 (42) formed by groove-processing an insulating block to match the shape of the bottom surface of the outer skin material 21 (41), and it is preferable that at least one insulating material 22 (42) is adhered to the bottom surface of the outer skin material 21 (41) or the top surface of the insulating material 22 (42) using an adhesive.

Conventional building panels have a structure in which insulation is placed between the outer and inner skin materials. Building panels with this structure are manufactured by heating and pressurizing the space between the outer and inner skin materials while injecting a foaming agent, which is the raw material for the insulation. However, building panels manufactured by injecting a foaming agent can have voids (air bubbles) in the insulation, which can cause deformation of the outer skin material. Furthermore, conventional building panels are manufactured using a multi-stage press to inject the foaming agent, but this has problems such as being unable to manufacture building panels thicker than a certain thickness and requiring a long curing time for the injected foaming agent.

However, in this embodiment, by using an adhesive to adhere pre-made insulation blocks with grooves to the exterior skin, there is no need to consider the occurrence of voids or the resulting deformation of the exterior skin. Furthermore, the hardening time of the adhesive used to adhere the insulation to the exterior skin is shorter than the hardening time of the foaming agent, improving manufacturing efficiency. Furthermore, by adhering the insulation to the exterior skin, it is possible to manufacture building panels of the desired thickness.

In addition, the connecting structure 100 of this embodiment arranges the eaves-side panels 20 or ridge-side panels 40 that make up the building panel 10 adjacent to each other at least in the width direction of the exterior skin 21 (41), and with the insulating materials 22, 22 (42, 42) of two adjacent eaves-side panels 20, 20 (or ridge-side panels 40, 40) in the width direction of the exterior skin 21 (41) abutting against each other. Of the vertical joints 25 (45) provided at both ends of the eaves-side panel 20 (or ridge-side panel 40) in the width direction of the exterior skin 21 (41), a cover cap 70 is engaged across the two vertical joints 25, 25 (45, 45) closest to the adjacent eaves-side panel 20 (or ridge-side panel 40).

As a result, when the building material panel is placed in a predetermined position on the sheathing board 81, the insulating materials 22, 22 (42, 42) of two adjacent eaves side panels 20, 20 (or ridge side panels 40, 40) abut against each other, connecting these two eaves side panels 20, 20 (or ridge side panels 40, 40). This prevents gaps from forming between the two adjacent eaves side panels 20, 20 (or ridge side panels 40, 40). As a result, insulation efficiency and airtightness are ensured.

Of the upright pieces 29b (49b) provided on the vertical joints 25, 25 (45, 45) of two adjacent eaves-side panels 20, 20 (or ridge-side panels 40, 40), the two adjacent upright pieces 29b, 29b (49b, 49b) are held by clips 60, and the clips 60 holding the two upright pieces 29b, 29b (49b, 49b) are fixed to the rafters 82 via sheathing boards 81 together with the two adjacent eaves-side panels 20, 20 (or ridge-side panels 40, 40).

This allows for a longer distance from the end face of the abutting insulation material 22 (42) to the position where the screw 85 is tightened, preventing damage such as cracks in the insulation material 22 (42) when the eaves-side panel 20 (or ridge-side panel 40) is fixed to the rafters 82 via the sheathing board 81.

The manufacturing method for the building panel 10 (20, 40) of this embodiment is characterized by including the following steps: roll-forming a metal plate to produce the outer skin 21, 41 with joints at both widthwise ends; groove-cutting an insulating block to produce the insulating material 22, 42, which has an upper surface that matches the shape of the bottom surface of the outer skin 21, 41 and at least one of both widthwise ends of the outer skin 21, 41 protrudes outward beyond the end of the outer skin 21, 41; applying adhesive to the bottom surface of the outer skin 21, 41 or the top surface of the insulating material 22, 42; and applying heat and pressure to the bottom surface of the outer skin and the top surface of the insulating material while they are in contact, thereby adhering the insulating material 22, 42 to the outer skin 21, 41.

This method uses an adhesive to bond pre-formed insulation blocks with grooved insulation to the exterior skin, preventing the formation of voids (air bubbles) when injecting a foaming agent to create the insulation, as well as the resulting deformation of the exterior skin. Furthermore, the curing time of the adhesive used to bond the insulation to the exterior skin is shorter than the curing time of the foaming agent, improving the manufacturing efficiency of building panels. Furthermore, by manufacturing the building panels from the process of bonding the insulation to the exterior skin, the thickness of the insulation can be freely selected, making it possible to manufacture building panels of the desired thickness.

10 Building material panel 20 Eaves side panel 21, 41 Outer skin material 22, 42 Heat insulating material (core material)
25, 45 Vertical joint 29b, 49b Upright piece 40 Ridge side panel 60 Clip 70 Cover cap 100 Connecting structure

Claims (7)

A building material panel for constructing a roof or wall of a building structure, comprising: a metal skin material having joints at both ends in the width direction; and a core material fixed to the back surface of the skin material;
The joint is
a first inclined wall portion that slopes downward from one end portion in the width direction of the outer skin material;
a second inclined wall portion that is bent back from a lower end of the first inclined wall portion and inclined upward, and that forms a V-shaped groove together with the first inclined wall portion;
a jaw portion that is connected to the upper end of the second inclined wall portion and that engages with a locking piece provided on a cover cap that links the building panel with another adjacent building panel when the building panel is installed;
a base portion including a seat surface provided outward of the jaw portion in the width direction of the exterior skin material, and located below the outer surface of the exterior skin material and above the lower end of the first inclined wall portion, and an upright piece provided upright from the end of the seat surface, and clamped by a clip that connects the exterior skin material of another adjacent building panel when the building panel is installed;
and
At least one end of each of the two ends of the core material in the width direction of the outer skin material protrudes outward beyond the upright piece ,
A building material panel characterized in that the amount by which the ends of the core material protrude outward from the upright pieces at each of both widthwise ends of the outer skin material is set to 0 to 1.5% of the width of the core material. Both end portions of the core material in the width direction of the outer skin material protrude outward beyond the upright pieces provided on the joints provided on both end portions of the outer skin material in the width direction,
The building panel according to claim 1, characterized in that the total amount of protrusion of both ends of the core material outward beyond the upright pieces provided at each of the joints provided at both ends of the outer skin material in the width direction is set to a range exceeding 0% and not exceeding 1.5% of the width of the core material . The building material panel has a lower joint or an upper joint at one end of the longitudinal direction of the exterior skin material, or has a lower joint at one end of the longitudinal direction of the exterior skin material and an upper joint at the other end of the longitudinal direction of the exterior skin material,
The building material panel according to claim 1, characterized in that one building material panel and another building material panel are arranged adjacent to each other in the longitudinal direction, and the upper joint of the other building material panel is configured to overlap the lower joint of the one building material panel. The building panel according to claim 3, characterized in that the core material constituting the building panel having the lower joint is composed of at least two insulating materials of different heights that are arranged along the longitudinal direction of the outer skin material and joined with hot melt adhesive . A connection structure characterized in that the building material panels described in any one of claims 1 to 4 are arranged adjacent to each other at least in the width direction of the exterior skin material, and the core materials of two adjacent building material panels in the width direction of the exterior skin material are abutted against each other, and cover caps are engaged across two joints provided at both ends of the building material panels in the width direction of the exterior skin material that are closest to the adjacent building material panels. a clip for clamping, across the two adjacent building panels, one of the two upright pieces provided on each of the two building panels that is closest to the adjacent building panel when the two building panels are arranged along the width direction of the exterior skin material ,
6. A connecting structure according to claim 5, wherein the clip clamping the two upright pieces is fixed to the rafter or purlin via the sheathing board using a screw . Using the building material panel according to claim 3 or 4,
6. The connection structure according to claim 5, characterized in that one building material panel having at least a lower joint at one end is overlapped with another building material panel having at least an upper joint at one end in the longitudinal direction of the exterior skin material and fixed thereto.