JP2007009655A - Thermally insulating tile, its manufacturing method, and roof structure - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To improve thermal insulation of tile and reduce the work required in its manufacture and installation in addition to the enhancement of waterproofing functions of the tile and roof structure. <P>SOLUTION: Insulating tile 10 is installed in a manner connected together laterally and longitudinally on the roof backing surface 42 of a building. The main body 20 of each tile is made of a ceramic material and has a molded shape almost similar to a plate. Its sides have joints 24 to 27 overlapped on the upper or lower sides of other adjacent insulating tiles 10; and its upper side has a linking projection 21 protruded and located above the top surface of the joint 26 after laying the roof tile. A waterproofing and insulating portion 30 adhered and jointed to the whole rear surface of the main body 20 of the tile made of a molded body of a resin foam has a flat bottom surface 32 arranged along the roof backing surface 42; a joint 34 overlapped from the top to the bottom with the joint 26 of another insulating tile 10; and a linking dent 36 connected to a linking projection 21 of another insulating tile 10. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a heat insulating tile, a method for manufacturing the same, and a roof structure. More specifically, the heat insulating tile has a heat insulating function for preventing a solar heat from being transferred from the roof to the inside of the building. The present invention is directed to a tile, a method for manufacturing such a heat insulating tile, and a roof structure using such a heat insulating tile.

Performing tiled finishing as a roof structure of a house or the like is a technique that has been well known since ancient times.
In recent years, cement tiles in which cement or mortar is hardened or slate tiles in which fiber materials are blended have been used in place of traditional tiles in which clay is molded and fired. Such cement roof tiles can be made thinner and lighter than conventional clay roof tiles and are suitable for mass production. The weight reduction of tiles has the advantage that the load applied to the building structure including the roof can be reduced and the earthquake resistance can be easily enhanced.
However, a thin and light cement-based roof tile has a problem that heat insulation is inferior to a conventional thick clay roof tile. In order to solve this problem, various techniques have been proposed.

Patent Document 1 discloses a technique in which a heat insulating layer such as a polymer binder layer containing hollow particles or bubbles is laminated on the back surface of a roof tile. The polymer binder layer can be applied to the back side of the tile with a coating composition containing the polymer binder, or a heat-insulating sheet with the same coating composition applied to the fibrous base material can be applied to the back side of the tile. To do.
In Patent Document 2, a plate-like base material made of foam material, etc., and a tile base material made of foamed polystyrene, etc., whose upper surface shape corresponds to the back surface shape of the tile, are sequentially constructed on the roof ground, and the tile is placed on the base material. The mounting technique is shown. A plurality of tiles are arranged side by side on the front, back, left and right on a large rectangular base material and tile base material.
JP 2001-279877 A JP 2003-328508 A

Even the technology for improving the heat insulating property of the cement-based roof tile as described above has problems that it takes time to manufacture, construction is troublesome, and the heat insulating property is not sufficient. Moreover, the structure for improving heat insulation impairs the water-stopping property of the tile, and there is a problem that rainwater or the like easily enters the roof structure.
For example, in the technique of Patent Document 1, the shape accuracy of the joint portion that connects the side edges of the roof tiles up and down is deteriorated by adding a coating film or sheet of a heat insulating layer to the back surface of the roof tile. There is a gap in the part, making it easy to flood. The coating film and the fibrous sheet of the heat insulating layer cannot exhibit sufficient heat insulating properties unless they are considerably thickened. However, as the thickness is increased, the thickness variation increases and the flatness becomes inferior. If the shape accuracy of the heat insulating layer is deteriorated, a gap is likely to be generated in the joint portion described above. A gap is easily generated between the heat insulating layer and the roof base plate, and water enters the roof base plate or water remains. Water that enters the roof causes corrosion and deterioration of the internal structure.

If the moisture that has entered the back of the tiles or between the heat insulation layer and the roof base plate remains, the accumulated moisture repeats freezing and thawing due to the difference in temperature between day and night, and the expansion and contraction at that time, There is a problem that a large load is applied to the roof structure, and the tile and the heat insulating layer are lifted, deformed or cracked. In cold regions, freezing of moisture that has entered the roof structure is a major factor that reduces the durability of buildings.
As in Patent Document 2, it can be presumed that a sufficiently accurate shape accuracy can be achieved if the tile base material is formed in advance with polystyrene foam or the like. However, after a plate-like base material and a molded tile base material are attached in order, a multi-step process is required in which the tiles are arranged side by side for each surface unevenness of the tile base material. The roof tile must be fixed to the roof tile with an adhesive. As a result, labor for construction increases and workability decreases.

Moreover, in the work of bonding the tile to the tile base material on the roof, there is inevitably a variation in work accuracy, and a gap for water to enter between the tile and the tile base material is likely to occur. Even if the tile base material and the base material under the tile base material are not sufficiently water-stopped at locations where they are connected in the surface direction, water easily enters below the tile base material and the base material.
The object of the present invention is to improve the heat insulating property of the tile in the cement tile technology suitable for reducing the weight of the roof structure as described above, and to reduce the labor of manufacturing and construction. It is to improve the water stop function of the structure.

  The heat insulating tile according to the present invention is a heat insulating tile laid on the roof foundation surface of the building by being connected to each other in the front, rear, left, and right directions, and is formed of a ceramic material-based molded body, and has a substantially plate-like tile body, A joint part that is provided on the side of the tile main body and is overlapped with the side of another heat-insulating tile that is disposed adjacent to the roof during construction, and the joint part is disposed on the upper side in the construction state. And a water stop heat insulating portion formed of a foamed resin molded body and in close contact with the entire back surface of the tile main body. A flat bottom surface that is provided in the water insulation portion and arranged along the roof base surface in the construction state, and a joint portion and upper and lower portions of another heat insulation tile that is provided in the waterstop insulation portion and arranged adjacent to the construction. A joint portion that is overlapped and connected to a joint portion of the water-stop heat insulating portion, and engages with a locking convex portion of the other heat-insulating tile. And a locking recess.

〔Building〕
As long as it is a building that uses a tiled roof, such as a general house, its structure and use are not limited.
As a general roof structure of a building, rafters are usually arranged on the surface of the rafters in a sloping state that is lowered from the ridges to the eaves along the roof surface based on pillars, beams, purlins, etc. A field board made of wood-based board material will be constructed. The base plate is the roof base. The surface of the field board is a flat surface having an inclination. In some cases, a crosspiece or a protrusion for positioning the tile or preventing the shift is provided on the surface of the base plate.

In some cases, roof base panels are constructed directly on pillars, beams, steel frames, etc. without using rafters and field boards.
On the roof foundation surface, waterproof construction and heat insulation construction can also be performed in the same manner as a normal roof structure, but in the case of the present invention, the heat insulation and water-stopping property of the heat insulation tile itself is excellent, In some cases, it is not necessary to perform heat insulation or waterproofing. Insulation and waterproofing can be simplified.
[Insulated tile]
The basic structure is the same as that of ordinary roof tiles. The roof base surface is laid by being connected to the front, rear, left and right.

The shape and structure of the insulating tile can be designed in consideration of the roof design and construction conditions. The overall shape of the heat insulating tile is usually a substantially rectangular thick plate. Although the thickness of the whole heat insulating tile changes also with construction conditions, it is 30-70 mm normally.
The heat insulating tile includes a tile main body and a water stop heat insulating portion.
[Tile body]
The exterior shape of the heat insulating tile is constructed, and the basic structural strength and environmental durability are borne.
Basically, the same material, structure and manufacturing technology as ordinary roof tiles can be applied.
The tile body is made of a ceramic body material. Ceramic materials include hydraulic materials such as cement as binders. May include aggregates such as fine aggregates and lightweight aggregates. It may contain a curable resin. It may also contain fiber materials such as glass fibers and inorganic particles. A colorant may be blended. In addition, various additives that are blended in ordinary ceramic building materials may be blended. A tile body can be obtained by molding and curing such a ceramic material. Conventionally, cement-based hardened materials used for various building materials can be used.

The shape of the tile body is generally plate-shaped. In general, the planar shape is a square or a rectangle. However, it is not a simple flat plate shape but also has a three-dimensional shape such as concavity and convexity that constitutes a connection structure such as a joint part, a connection structure with a water stop heat insulation part, a structure for fixing with a nail, etc. Yes.
The tile body is preferably relatively thin and lightweight. Of course, even if it is lightweight, it is necessary to have the required rigidity and structural strength. Although different depending on the composition of the ceramic material as the raw material, those having a weight per area of 15 to 22 kg / m ² are usually preferable.
A tile finishing layer can be provided on the upper surface of the tile body that is exposed to the exterior in the construction state, or a colored coating can be applied. If a reflective coating layer that reflects sunlight, particularly heat rays, is provided, it is possible to suppress the transmission of solar heat to the back side of the tile body.

<Fitting part>
The tile body has a joint portion for connecting the heat insulating tiles. A joint part is provided in the side of a roof tile main body, and is piled up and connected with the side of another heat insulation tile arrange | positioned adjacently at the time of construction.
As the arrangement structure of the joint portion, basically, a technique common to the joint portion in a normal roof tile can be applied. However, the structure which combined the joint part of the water stop heat insulation part mentioned later and the joint part of a tile main body respond | corresponds to the joint part in a normal roof tile.
As a basic structure of the joint part, among the side edges of the tile main body, on one side corresponding to each other, an upper joint part projecting with a certain width on the upper surface side in the thickness direction of the tile main body is provided on one side side. Provide the lower joint on the other side of the tile body in the thickness direction of the tile body with a certain width, and set the upper joint and the lower joint so that they overlap each other. I can leave. For example, in the case of a flat rectangular roof tile body, an upper joint portion may be provided on two sides of one corner and a lower joint portion may be provided on the remaining two sides.

The joint portion may be a simple band plate shape, or an uneven structure in which the upper joint portion and the lower joint portion are engaged with each other in the vertical direction or the horizontal direction can be added. .
<Locking convex part>
An engagement convex part which protrudes upwards can be provided in the upper surface of the joint part arranged on the upper side in the construction state among the joint parts.
For the arrangement structure of the locking projections, a technique common to the concavo-convex structure provided in the joint portion in a normal roof tile can be applied.

For example, if convex wall-shaped locking projections are adopted along the left-right direction in the construction state of the tile body, it is possible to effectively prevent the heat-insulating tiles from sliding down along the slope of the roof. In this case, the locking projections may be provided continuously in the length direction or may be provided intermittently.
[Waterproof insulation part]
It consists of a molded body of foamed resin and is in close contact with the entire back surface of the tile body. It fulfills the function of imparting heat insulation and water blocking properties to the insulating tile.
As the foamed resin, various foamed resins used for heat insulation in the field of building technology can be employed. For example, polyolefin-based foamed resins such as polystyrene and polypropylene can be used. In the foamed resin molded body, those having closed cells are superior to those having open cells in terms of heat insulation and water-stopping properties.

The larger the expansion ratio of the foamed resin molded article, the better the heat insulation, elastic deformation, lightness, and the like. In order to increase the water-stopping property, mechanical strength, rigidity, etc., a smaller foaming ratio is better. Usually, it is desirable to set the expansion ratio to 5 to 20 times.
As the shape of the water-stopping heat insulating portion, the entire shape of the heat insulating tile may be configured by combining with the roof tile main body so that it can be used as the heat insulating roof tile.
Since the water stop heat insulating part is attached so as to be fitted on the back side of the tile main body, the shape of the upper side of the water stop heat insulating part corresponds to the back surface shape of the tile main body.
<Flat bottom>
The still water heat insulation part can have a flat bottom surface arranged along the roof base surface in a construction state. The flat bottom surface is useful for stably and firmly attaching the heat insulating tile to the roof base surface. The waterproofing heat insulating part can be closely adhered to the roof base surface in a wide range without any gaps, so that the waterproofing function can be improved and the occurrence of condensation can be prevented. Although it is desirable to provide the flat bottom surface in the widest possible range of the water stop heat insulating portion, there are some places where the flat bottom surface is not provided due to the structure of the joint portion or the like.

<Fitting part>
A joint part similar to the joint part of the tile main body is provided in the water stop heat insulating part. In a state where it is combined with the joint portion of the tile main body, the insulating tiles can be connected. In particular, the joint portion of the water-stopping heat insulating portion is connected to the joint portion of another heat-insulating tile disposed adjacently at the time of construction in an overlapping manner. It is desirable that the joint portion of the still water heat insulation portion is in contact with the joint portion of the tile main body among the other heat insulating tiles. Since the joint portion of the water-stopping heat insulating portion that is easily deformed flexibly comes into contact with the joint portion of the tile body that forms a rigid body, it is possible to eliminate the gap between the two and satisfactorily prevent the entry of outside air and rainwater. By deforming the joint portion of the water-stopping heat insulating portion, it is possible to absorb variations in the shape and mounting position of the heat insulating tile, and to improve the mounting accuracy of the heat insulating tile and the finished appearance of the roof tile.

<Locking recess>
Corresponding to the locking projection provided in the joint portion of the tile main body, a locking recess that engages with the locking projection of another heat insulating tile is provided in the joint portion of the water-stopping heat insulating portion. Naturally, the arrangement structure of the locking recesses is set in accordance with the locking projections of the tile main body.
<Overhang at the bottom>
In a state where it is combined with the roof tile main body, the lower end of the water stop heat insulating portion can be projected downward from the lower end of the roof tile main body. In this way, when the heat insulating tile is attached to the roof base surface, the heat insulating tile is pressed against the roof base surface, and the water-stopping heat insulating part protruding from the lower end of the tile body is deformed, so that the heat insulating tile is It becomes easy to adhere to the ground without any gaps. The amount of the downward protrusion of the lower end of the water-stopping heat insulating portion with respect to the lower end of the tile body can be set to 15 to 40 mm.

[Manufacture of insulated tiles]
The heat insulating tile having the structure described above can be manufactured by applying a building material manufacturing technique such as a tile. Basically, a general roof tile manufacturing technique and a heat insulating member manufacturing technique may be combined.
The following steps can be combined as a method for manufacturing a heat insulating tile combining the tile main body and the water stop heat insulating portion.
<Process (a): Molding of tile body>
Ordinary cement roof tile manufacturing technology can be applied.

A method of press-molding ceramic materials including cement can be employed. The press molding apparatus and molding conditions may be the same as in the case of normal roof tile manufacturing. For example, the molding pressure can be set to a molding pressure of 9.8 to 14.7 MPa (100 to 150 kgf / cm ² ). It can also be heated during press molding.
The molded body obtained by molding has the shape of a tile body, but is not yet cured. If force is applied, it may be deformed or cracked.
The molded body of the tile body after the press molding can be immediately supplied to the next step.
<Process (b): Integration of tile main body and water stop heat insulation part>
The tile body molded body, which is obtained in the previous step (a) and is in a deformable state, is fitted into and supported by the upper part of a water-stop heat insulating portion made of a foamed resin molded body.

About a water stop heat insulation part, a normal foam molding technique is applied and it manufactures beforehand.
If the flat bottom surface of the water-stopping heat insulating part is placed on a rigid support base or support plate, the water-stopping heat insulating part is stably supported and the work can be easily performed.
If the tile main body and the water stop heat insulating portion are in the shape as designed, the tile main body is smoothly fitted into the upper portion of the water stop heat insulating portion. Even if the shape of the tile body and the water stop heat insulation part do not match exactly due to manufacturing variations and dimensional errors, the tile body can be deformed before curing. Is easy to fit.
If an adhesive or a curable material is applied to the contact surface between the tile main body and the water stop heat insulating portion, the tile main body and the water stop heat insulating portion are strongly bonded. However, since the tile main body is later cured and cured, the tile main body is joined to the water-stopping heat insulating portion, so that an adhesive or the like may not be used.

The tile main body fitted in the water stop heat insulation part can be pressed against the water stop heat insulation part. The tile main body is deformed, and there is no gap left between the tile and the water-stopping heat insulating part, or the bondability with the water-stopping heat insulating part is increased. The surface of the tile main body is deformed according to the fine irregularities on the surface of the water-stopping heat insulating part made of the foamed resin molded body, so that the integrity of the tile main body and the water-stopping heat insulating part is improved.
As described above, when the lower end of the water-stopping heat insulating part protrudes downward from the lower end of the tile main body, when the tile main body is pressed from above to the water-stopping heat insulating part, the deformation of the tile main body is easy. Integration with the still water heat insulation part can be made favorable.
<Process (b): Curing the roof tile>
The molded body of the tile main body supported by the still water heat insulation part is cured and cured.

As a curing curing treatment apparatus and treatment conditions, a technique common to curing curing in the production of ordinary cement roof tiles can be applied.
In known roof tile manufacturing, a roof tile is placed on a support stand that can be supported so as not to lose its shape, and is carried into a curing apparatus and supported during curing. If the tile shaped body has a three-dimensional shape, the support base also needs a three-dimensional shape. If the shape of the roof tile is changed, the design of the support base also needs to be changed.
On the other hand, the tile main body supported by the water stop heat insulation part does not need a support base having the above three-dimensional shape. It can be handled by sending it to a curing device without changing the water insulation part that supports the tile body. Even if the flat bottom surface of the water insulation part that supports the tile body is placed on a support stand made of a flat plate, it becomes stable and even if it is subjected to vibration or tilting slightly during handling And will not be deformed.

As the curing treatment, heating in a processing chamber with a heater or the like, application of heated air, or steam curing with heated steam can be performed. The heating atmosphere can be replaced with a gas other than air. When heating is performed, the heating temperature is set so as not to exceed the heat resistance temperature of the water stop heat insulating portion. Natural curing is possible by leaving it in the air or placing it in a well-ventilated place without heating or adjusting the atmosphere.
In the curing treatment, the entire roof tile body is cured by the action of a curable material such as cement contained in the roof tile body.
When the tile main body is cured, a heat insulating tile in which the tile main body and the water stop heat insulating portion are integrally joined is obtained. It can be taken out from the curing device and used for construction work.

<Other processes>
In addition to the above-described steps, various processing and processing steps that are employed in normal roof tile manufacturing can be performed.
For example, the surface of the hardened tile body can be polished, unnecessary portions such as molding burrs can be removed, and the surface can be cleaned. The surface of the roof tile can be finished or coated. Metal fittings necessary for construction of heat insulating tiles can be attached, and mounting holes and uneven structures for mounting can be additionally processed.
[Roof structure]
A tiled roof structure can be constructed using the heat insulating tile having the above structure.

Basically, techniques common to roof structures in ordinary tiled buildings can be applied.
As a specific roof structure, the flat surface of the roof surface constructed on the roof of the building and the flat bottom surface of the water-insulating heat insulation part are in close contact with the roof base surface on the roof base surface, and the front and back are mutually connected by joints. And heat insulating tiles laid on both sides. In the adjacent part of the heat insulating tiles in the joint portion, the water stop and heat insulating portion of the other heat insulating tile is in close contact with the tile main body of one heat insulating tile and water is stopped.
The roof base surface can adopt the same structure as that of a roof base surface using a normal base plate. A waterproof sheet or a heat insulating board can be attached to the roof base surface, but if a heat insulating tile is used, the waterproof sheet or the heat insulating board may be omitted. There are cases where the back side of the roof base surface or the heat insulating layer or waterproof construction applied to the attic side can be simplified or omitted.

When the roof base is inclined, heat insulating tiles are attached from the low inclination side, that is, from the eaves side to the building side. For fixing the heat insulating tile, the same means as usual roof tile construction such as nailing and screwing can be adopted. If there are bars or protrusions on the roof base that lock the heat insulating tiles, they can be used. It is also possible to join the flat bottom surface of the water insulation part of the heat insulating tile to the roof base surface with an adhesive.
When installing a new heat insulating tile adjacent to the previously installed heat insulating tile, place the new heat insulating tile upper joint portion on the lower joint portion of the joint portion of the previous heat insulating tile. To be connected. At this time, the lower joint part of the previous heat insulating tile has a tile body on the upper surface, and the upper joint part of the new heat insulating tile has a water stop heat insulating part on the lower surface. Connected in contact. As a result, the adhesion or the integrity of the insulating tiles at the connecting portion is enhanced, and the intrusion of rainwater from the connecting portion and the inflow of outside air are reliably prevented. If the newly constructed heat insulating tile is pressed against the previous heat insulating tile from above, the water-stopping heat insulation part can be flexibly deformed, thereby making it possible to make the adhesion between the insulating tiles more reliable. it can.

If an adhesive or a sealant is interposed on the contact surface between the water-stopping heat insulating portion and the tile body at the connecting portion, a more reliable water-stopping function and heat-insulating function can be achieved.
In this way, the heat insulating tiles are sequentially attached while being connected in the horizontal direction and the upward direction of the inclination. If the entire roof base is covered with insulating tiles, a tiled roof structure is completed.
If the roof structure is viewed from the upper side, only the tile main body of the heat insulating tile exists, and the water stop heat insulating portion is covered with the tile main body. In terms of appearance, it can exhibit a good design that is the same as a normal tiled roof. The waterproof insulation part, which is relatively vulnerable to damage, is protected by the tile body, and damage and deterioration over time are unlikely to occur.

The heat insulating tile according to the present invention is bonded to the entire back surface of a tile main body made of a ceramic material molded body in close contact with a water stop heat insulating portion made of a foamed resin molded body.
Corresponding to the joint part and the locking convex part on the side of the tile body, the water-stopping heat insulating part also has the joint part and the locking concave part. If the parts are connected and constructed, the insulation tiles can be constructed easily and securely without any difference from ordinary tiles.
If the flat bottom surface of the still water heat insulating part is arranged along the roof base surface, the heat insulating tile can be stably and accurately attached. The gap from the tile body to the roof base surface through the water-stop heat insulating part is closely integrated, and it is difficult to form a gap in which moisture enters or stays.

In the joint part between the insulating tiles, the joint part of the tile body and the joint part of the water-stopping heat insulation part are arranged one above the other, and it is firmly in close contact with the tile body due to the elastic deformability of the water-stopping insulation part. Since it will be in a state, the penetration | invasion of the water from the connection part of heat insulation tiles to an inner side is blocked | prevented favorably. Compared to the contact between the roof tiles, which are rigid bodies, the water-stopping function is much superior.
As a result, after fully exploiting the advantages of ceramic tiles that are thin and lightweight, the presence of a water-stop heat insulation part not only greatly improves the heat insulation but also dramatically improves the water stop function. It becomes possible. In addition, there is no increase in labor for manufacturing and construction.

FIG. 1 shows a case where a heat insulating tile is used for a roof structure of a house.
The heat insulating tiles 10 are sequentially arranged on a field plate 42 constructed to cover the sloped roof 40 of the house. In this respect, it is no different from ordinary roof tiles.
[Insulated tile]
As shown in FIG. 2, the heat insulating tile 10 has a substantially rectangular thick plate shape as a whole, and includes a tile main body 20 and a water stop heat insulating portion 30. In the construction state shown in FIG. 1A, the upper side of the heat insulating tile 10 in FIG. 2A is arranged facing the ridge on the upper side of the inclined surface of the field plate 42.
<Tile body>
The roof tile body 20 is formed of a cemented material molded body. The water stop heat insulation part 30 consists of a molding of a closed cell polystyrene foam resin.

2A shows a plan view, and FIGS. 2B and 2D show shapes seen from the front and side. The tile body 20 has a shape in which two rectangular thick plates are obliquely shifted in the horizontal direction and overlapped. On the outer periphery of the roof tile body 20, two side edges 24 and 25 configured by an upper rectangle and two side edges 26 and 27 configured by a lower rectangle protrude. These side edges 24 to 27 serve as joint portions when the heat insulating tile 10 is connected to the front, rear, left and right. These are upper joint portions 24 and 25 and lower joint portions 26 and 27.
As shown in FIG. 2D, the upper rectangular thick plate portion of the roof tile body 20 has an inclined surface that is inclined so as to be lowered from one end to the other end. At the lowest position of the inclined surface, there is a wall-like locking convex portion 21 protruding upward.

As shown in FIG. 2 (a), mounting holes 12 penetrating in the vertical direction are provided at two points in the middle of the locking projection 21 extending to the left and right of the roof tile body 20. The mounting hole 12 is configured such that a nail for fixing the heat insulating tile 10 to the base plate 42 and the rafter 44 can be inserted. A similar mounting hole 12 passes through a portion along the side 27 of the tile body 20.
As shown in FIG. 2D or FIG. 1A, the ends of the roof tile body 20 are bent downward at both ends of the roof tile body 20 arranged in the vertical direction of the field plate 42 in the construction state. Yes. Inside the bent portion, the water stop heat insulating portion 30 is disposed on the entire back surface of the tile body 20.
<Waterproof insulation part>
The water stop heat insulation part 30 consists of a foamed polystyrene molded object of a closed cell.

As shown to Fig.2 (a), in the planar shape of the heat insulation tile 10, the water stop heat insulation part 30 is not exposed to the surface at all. It is housed inside the back side of the tile body 20 in a state of being completely covered with the tile body 20.
The shape of the water stop heat insulation part 30 is a shape substantially along the shape of the tile main body 20. Similar to the tile main body 20, two rectangular thick plates are obliquely shifted in the horizontal direction and stacked vertically. As shown in FIG. 2 (c), when viewed from the back side of the heat insulating tile 10, the bottom surface 32 in the rectangular portion on the bottom side of the water stop heat insulating portion 30 forms a flat rectangular shape. The flat bottom surface 32 is provided with a mounting hole 12 penetrating from the roof tile body 20 to the water stop heat insulating portion 30.

On the two sides of the flat bottom surface 32, an L-shaped projecting portion 34 having a step between the flat bottom surface 32 is provided. As illustrated in FIGS. 2B and 2D, the bottom surface of the overhang portion 34 is set at the same height as the top surfaces of the lower joint portions 26 and 27 of the roof tile body 20.
As shown in FIGS. 2 (c) and 2 (d), a groove-shaped locking recess that crosses the overhanging portion 34 is provided at a location on the back side of the side joint portion 26 of the roof tile body 20 in the overhanging portion 34. 36 is provided. The shape such as the width and depth of the locking recess 36 corresponds to the shape of the locking projection 21 of the roof tile 20. In FIG. 2 (a), corresponding to the portion of the locking projection 21 of the roof tile 20 that swells circularly around the mounting hole 12, the protruding portion 34 in FIG. 36 has a notch protruding to the side edge.

In FIG. 2 (c), the side end in the left-right direction of the water stop heat insulating portion 30 is exposed to the end surface until the side end position of the roof tile body 20. The side end in the vertical direction is sandwiched between the portions where the side end of the roof tile body 20 is bent downward.
As shown in FIG. 2D, a step G is provided between the lower end position of the downward bent portion at the side end of the roof tile body 20 and the lower end position at the side end of the water stop heat insulating portion 30. Only the step G is a state in which the water stop heat insulating portion 30 protrudes below the roof tile body 20.
[Insulation tile construction and roof structure]
The heat insulating tile 10 described above is applied to the roof structure.

As shown in FIG. 1 (a), the roof structure has a rafter 44 that is slanted from the ridge to the eave on the main house 46, and the rafter 44 covers the entire roof surface. The base plate 42 is pasted without any gaps. The surface of the field plate 42 is a flat inclined surface.
With respect to the posture of the heat insulating tile 10, the inclination direction on the upper surface of the tile main body 20 is opposite to the inclination of the field plate 42, and the locking convex portion 21 is arranged on the inclination side of the field plate 24. However, since the inclination of the upper surface of the tile main body 20 is gentle, the upper surface of the tile main body 20 is lowered from the ridge side to the eaves side in a state of being arranged along the inclined field plate 42.
When the heat insulating tile 10 is disposed on the surface of the field plate 42, the flat bottom surface 32 of the water stop heat insulating portion 30 is disposed so as to be in close contact with the surface of the field plate 42. Although not shown in FIG. 1, the heat insulating tile 10 can be nailed and fixed to the base plate 42 or the rafter 44 by nailing the mounting hole 21.

  At this time, on the lower surface of the heat insulating tile 10, the flat bottom surface 32 of the still water heat insulating portion 30 protrudes by a step G rather than the lower end of the tile main body 20, so that the heat insulating tile 10 is strongly pressed against the field plate 42, The water stop heat insulation part 30 deform | transforms in the thickness direction comparatively easily, and can improve the adhesiveness and water stop of the water stop heat insulation part 30 with respect to the field-shaped board 42. In addition, even if the heat insulating tile 10 is pressed firmly, the end of the tile body 20 hits the field plate 42 and is cracked or chipped unless the water stop heat insulating portion 30 is deformed so much that the step G is eliminated. There is no. The impact force such as nailing is also reduced by the impact absorbing action of the water stop heat insulating portion 30. Even when an operator on the roof moves by stepping on the heat insulating tile 20, the water stop heat insulating portion 30 absorbs the treading pressure and prevents the tile main body 20 from cracking or cracking. .

  As shown in FIG. 1 (a), when the next heat insulating tile 10 is installed after the one heat insulating tile 10 is installed, the rear surface of the new heat insulating tile 10 has a latching in the water stop and heat insulating portion 30. The recessed part 36 is attached so that it may fit in the latching convex part 21 of the upper surface of the heat insulating tile 10 constructed previously. A joint portion composed of a locking concave portion 36 of the water stop heat insulating portion 30 and a shape portion from the overhang portion 34 to the flat bottom surface 32, a shape portion extending from the locking convex portion 21 of the roof tile body 20 to the lower joint portion 26. In this state, the contact is made without any gap. However, in the upper joint portion 25 of the tile body 20 of the new heat insulating tile 10, there is a step G between the lower end of the upper joint portion 25 and the bottom surface of the overhang portion 34 of the water stop heat insulating portion 30. The lower end of the upper joint portion 25 does not abut against the tile body 20 previously constructed.

In this state, similarly to the above, a new insulating tile 10 is pressed against the base plate 42 and fixed with a nail or the like. By the force of pressing the heat insulating tile 10, the back surface of the overhanging portion 34 from the locking recess 36 of the water stop heat insulating portion 30 is brought into strong contact with the tile main body 20 of the heat insulating tile 10 previously constructed. Even if the still water heat insulating portion 30 is compressed in the thickness direction, the upper and lower roof tile bodies 20 do not come into contact with each other as long as the stepped portion G is not compressed.
In the horizontal direction orthogonal to FIG. 1 (a), as shown in FIG. 1 (b), the upper part in the thickness direction is provided on the tile body 20 of the new insulated tile 10 with respect to the previously installed insulated tile 10. The upper joint portion 24 in the shape of protruding on the side and the overhang portion 34 of the water-stop heat insulating portion 30 are placed on the lower joint portion 27 in the shape of protruding on the lower side in the thickness direction in the heat-insulated roof tile 10 previously constructed. Try to overlap. Also in this case, the still water heat insulating portion 30 of the upper heat insulating tile 10 abuts on the tile body 20 of the lower heat insulating tile 10. If the upper heat insulating tile 10 is strongly pressed in the thickness direction, the water stop heat insulating portion 30 is strongly adhered to the lower tile main body 20 and exhibits a good water stop function.

In this way, the roof structure of the tile roof is constructed by fixing the heat-insulating tile 10 side by side while being connected to the front and rear, left and right on the surface of the field plate 42. Although illustration is omitted, in the ridge portion and the eaves portion of the roof structure, roof tiles suitable for those structures, so-called ridge roof tiles and eaves roof tiles, may be constructed. For these ridge roof tiles and eaves roof tiles, the structure of the heat insulating tile 10 provided with the tile main body 20 and the water stop heat insulating portion 30 can be used with some modifications.
[Manufacture of insulated tile 10]
FIG. 3 shows the steps of manufacturing the heat insulating tile 10 step by step from (a) to (e).
<Step (a)>
The tile body 20 is molded. A pair of upper and lower molding dies 72 and 74 is supplied with a molding material 28 in a dumpling shape by kneading a raw material such as cement. The molds 72 and 74 have mold surfaces corresponding to the shape of the roof tile body 20.

<Step (b)>
When the molds 72 and 74 are closed and a press pressure is applied, the molding material 28 is molded into a shape corresponding to the cavity shape of the molds 72 and 74, that is, the shape of the roof tile body 20.
After molding, the molds 72 and 74 are opened, and the molded tile body 20 is taken out.
However, the tile main body 20 immediately after molding is not yet cured and remains in a plastic state. Handling should be done carefully so that the soft roof tile body 20 is not deformed or damaged.
<Step (c)>
On the support stand 76, the water stop heat insulation part 30 previously resin-molded is placed. About manufacture of the water stop heat insulation part 30, what is necessary is just to apply a normal type | mold foam molding technique. A part of the foamed block-like foam may be cut or cut to produce a predetermined water-stop heat insulating portion 30.

Since the flat bottom surface 32 of the water stop heat insulation part 30 is mounted on the flat support stand 76, the water stop heat insulation part 30 is placed in a stable state without being inclined or deformed.
The tile main body 20 molded in the previous step (b) is disposed on the water stop heat insulating portion 30. Since the back surface shape of the tile main body 20 corresponds to the outer shape of the water-stop heat insulating portion 30, the tile main body 20 fits into the water-stop heat insulating portion 30 exactly. In particular, the roof tile body 20 is not yet completely cured and can be deformed to some extent. Therefore, the roof tile body 20 is slightly deformed in accordance with the shape of the water-stop heat insulating portion 30 to be fitted. The work can be facilitated, and a gap with the water stop heat insulating portion 30 can be eliminated. If each part of the tile main body 20 is pressed strongly against the water-stopping heat insulating part 30, the adhesion between the tile main body 20 and the water-stopping heat insulating part 30 becomes extremely good. If the back surface of the tile main body 20 is pressed and fitted into the fine irregularities or holes of the foam constituting the water-stop heat insulating portion 30, the unity of both becomes stronger.

If necessary, if an adhesive is applied to the contact surface between the water stop heat insulating portion 30 and the tile body 20, or if the same cement slurry as the molding material of the tile body 20 is applied, The joining force between the tile main body 20 and the water-stop heat insulating portion 30 is increased, and the integrity is enhanced.
<Step (d)>
The tile body 20 is cured and cured in a state where the water stop heat insulating portion 30 and the tile body 20 are integrated.
Curing and curing are usually performed in a curing room 78 in which the inside can be heated or heated steam can be supplied. Before the curing process in the curing room 78, a drying process for removing excess moisture from the roof tile body 20 may be performed. The drying process is natural drying or forced drying by a drying oven.

In any case, the unitary body of the water stop heat insulating portion 30 and the roof tile body 20 is transferred and carried into the curing chamber 78 while being placed on the support base 76. Handling is easy without touching the tile main body 20 or applying a force to peel off the tile main body 20 and the water stop heat insulating portion 30.
In the curing chamber 78, the roof tile body 20 heated at a predetermined temperature for a predetermined time becomes a roof tile body 20 made of a hardened body by curing a curing material such as cement contained in the molding material. At the same time as the tile main body 20 is cured, the tile main body 20 is strongly bonded to the water stop heat insulating portion 30.

<Step (e)>
When the curing and curing process is completed, the heat insulating tile 10 including the hardened tile main body 20 and the water stop heat insulating portion 30 is completed.
Until the tile main body 20 that has been heated by heating is sufficiently cooled, the heat insulating tile 10 may be left on the support base 76.
After the tile main body 20 is sufficiently cooled, the heat insulating tile 10 may be removed from the support base 76 and sent to operations such as packing and shipping. If necessary, remove the burr at the time of molding remaining on the tile body 20, remove the burrs from the tile body 20, attach the necessary metal fittings during construction, and install holes and grooves for fitting the metal. Processing to form can also be performed. A finish can be applied to the surface of the tile body 20.

  The heat insulating tile of the present invention is used, for example, for constructing a tile roof of a house. While being lightweight and easy to construct, the roof has excellent heat insulation and water blocking properties. It can solve the problems caused by freezing of intruded water inside the roof in cold district houses, which are often exposed to sub-freezing temperature environments, greatly improving the quality and performance of residential buildings in such cold districts. You can contribute. In addition, even in a house with intense sunlight in summer, the interior of the roof structure and the indoor space are not overheated.

Sectional drawing in the different direction of the roof structure showing embodiment of this invention Plan view (a), front view (b), rear view (c) and side view (d) of heat insulating tile Schematic cross-sectional view showing the manufacturing process of insulated tiles step by step

Explanation of symbols

DESCRIPTION OF SYMBOLS 10 Heat insulation tile 12 Mounting hole 20 Tile body 21 Locking convex part 24, 25 Upper joint part 26, 27 Lower joint part 30 Water stop heat insulation part 32 Flat bottom surface 34 Overhang part 36 Locking recessed part 40 Inclined roof 42 Field plate 44 Rafter G Step

Claims (5)

The roof tiles of the building are insulated tiles that are connected to each other in the front, back, left, and right,
A tile body consisting of a ceramic body shaped body, which is roughly plate-shaped,
A joint part that is on the side of the tile main body and is connected to be overlapped with the side of another heat-insulating tile that is arranged adjacently at the time of construction,
Among the joint parts, it has an upper surface of the joint part arranged on the upper side in the construction state, and a locking convex part protruding upward.
A water-stop heat insulating part formed of a foamed resin molded body and bonded in close contact with the entire back surface of the tile body,
A flat bottom surface that is disposed along the roof foundation surface in the construction state, in the water stop heat insulating part,
A joint part that is connected to the joint part of another heat-insulating tile that is disposed adjacently at the time of construction and is connected to the water-stopping heat-insulating part.
A heat-insulating roof tile comprising a locking recess that engages with a locking protrusion of the other heat-insulating roof tile, which is provided in a joint portion of the water-stop heat insulating section. The total thickness of the heat insulating tile is 30 to 70 mm,
The molded body of the ceramic material used as the tile body is made of a cement-based cured material, and the weight per area is 15 to 22 kg / m ² .
The molded body of the foamed resin that becomes the water stop heat insulating part is made of a closed cell polystyrene foam having a foaming ratio of 5 to 20 times,
The heat-insulating roof tile according to claim 1, wherein a lower end of the water-stop heat insulating portion projects 15 to 40 mm downward from a lower end of the tile body. The heat-insulating tile according to claim 1 or 2, further comprising a reflective coating film layer on an upper surface of the tile main body. A method for producing the insulated tile according to any one of claims 1 to 3,
A step (a) of obtaining a molded body having the shape of the tile main body by press molding the ceramic material;
A step (b) of fitting and supporting the molded body of the tile main body obtained in the previous step (a) on the upper part of a water-stopping heat insulating part made of a molded body of foamed resin,
A method for producing a heat-insulating roof tile, comprising a step (c) of curing and curing the molded body of the roof tile body obtained in the step (b) and supported by the water-stop heat insulating portion. A roof structure using the heat insulating tile according to any one of claims 1 to 3,
A roof foundation surface composed of an inclined surface with a flat surface, which is constructed on the roof of a building;
On the roof base surface, the flat bottom surface of the water-stopping heat insulating portion is in close contact with the roof base surface, and the heat insulating tiles laid to be connected to each other front and rear and left and right by the joint portion, and
In the adjacent part of the heat insulating tiles in the joint part, the roof structure in which the water insulating heat insulating part of the other heat insulating tile is in close contact with the tile main body of one heat insulating tile.

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