JP2012046999A - Roof material - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a roof material with high impact resistance and processability, using a polypropylene resin material.SOLUTION: A roof material 1 comprises a fiber layer made from continuous fiber which is sandwiched with resin layers made of a polypropylene resin material to be integrated. A sheet body in which the fiber layer is evenly distributed along the surface direction is formed into a shape of connected roof tiles.

Description

  The present invention relates to a roof material used for a roof structure of a building such as a house.

  In Japan and other East Asian regions, buildings with sloping roof structures have been constructed since ancient times. Such roof structures have been traditionally made by using materials such as straw and husks, and by using tiles and stones, but the awning and husks are becoming difficult to obtain in recent years, except for historical buildings. Not used for. In addition, since tiles and stones are also heavy materials, it has been practiced to use a light material such as a metal plate or a slate instead.

  In addition to these materials, resin materials are also used as roofing materials. For example, Patent Document 1 describes a resin roof made of a thermosetting resin containing a non-combustible fiber, and a weather-resistant / heat-resistant pigment and a flame-retardant material are blended with the thermosetting resin. The point which made the color tone and flame resistance of the front and back sides uniform was described. Moreover, in patent document 2, the roof material integrally formed with the fiber reinforced plastic (FRP) is described so that the several tiles may be arranged in a row.

JP 2006-177078 A JP 2009-185559 A

  As described in the above-mentioned patent documents, although the weight is reduced by using a resin material as a roofing material, another material is used for weather resistance and coloring, and the manufacturing process is complicated. There is. Moreover, although it is necessary to maintain the intensity | strength enough to endure the impact when an operator walks on a roof material over a long period of time, such a point is not fully considered in the conventional roof material.

  Accordingly, an object of the present invention is to provide a roof material having high impact resistance and workability using a polypropylene resin material.

  The roofing material according to the present invention is characterized in that a sheet body mainly composed of a polypropylene resin material is formed into a roof tile shape. Furthermore, the polypropylene resin material is a propylene-ethylene block copolymer containing a propylene-ethylene random copolymer and an ethylene-propylene copolymer rubber using a propylene homopolymer as a matrix. Further, the sheet body is characterized in that the fiber material is uniformly distributed in the plane direction in the polypropylene resin material. Furthermore, the fiber material includes long fibers arranged along a plane direction. Furthermore, it is characterized in that a plurality of roof tiles are continuously formed.

  The roof structure according to the present invention arranges and fixes the above-mentioned roofing material on the construction surface.

  Since the present invention is a roof material molded using a polypropylene resin material having excellent impact resistance, it can withstand impacts during roof construction and repair management and without deterioration over a long period of time. The strength can be maintained.

  And since it forms so that a fiber material may be uniformly distributed along a surface direction in a polypropylene-type resin material, a lightweight roof material which improves a strength and cannot be damaged easily can be obtained.

  In addition, since the polypropylene-based resin material is easy to mold, it can be formed in a shape close to the shape of a conventional roof tile, and by molding into a shape in which a plurality of roof tiles are continuously provided, It is possible to easily construct the roof material without impairing the design of the roof structure.

It is an external appearance perspective view regarding embodiment which concerns on this invention. It is a top view regarding the embodiment concerning the present invention. It is a side view regarding the embodiment concerning the present invention. It is AA sectional drawing of FIG. It is BB sectional drawing of FIG. It is an external appearance perspective view which shows another continuous arrangement | positioning shape of a roof material. It is an external appearance perspective view which shows another continuous arrangement | positioning shape of a roof material. It is a top view regarding the sheet | seat body used for manufacture. It is explanatory drawing regarding the manufacturing process using a press molding machine.

  Hereinafter, embodiments according to the present invention will be described in detail. The embodiments described below are preferable specific examples for carrying out the present invention, and thus various technical limitations are made. However, the present invention is particularly limited in the following description. Unless otherwise specified, the present invention is not limited to these forms.

  FIG. 1 is an external perspective view of an embodiment according to the present invention. 2 and 3 are a plan view and a sectional view thereof, and FIGS. 4 and 5 are an AA sectional view and a BB sectional view of FIG. 1, respectively.

  The roof material 1 is molded into a shape in which a plurality of roof tiles are continuously provided. Therefore, by arranging and arranging the roofing materials 1 so that the peripheral edge portions overlap, it is possible to finish the roof design 1 in almost the same design as the roof concept in which the conventional roof tile is constructed.

  The roof material 1 has a plate thickness of 3 mm to 5 mm and is formed with a substantially uniform thickness throughout. The internal structure has a thin fiber layer 2 in which long fibers are arranged along the plane direction at the center, and the resin layer 3 is integrally formed so as to sandwich both sides of the fiber layer 2.

  The fiber material used for the fiber layer 2 is composed of high-strength long fibers, and examples thereof include polyester fibers, polyamide fibers, polyolefin fibers, vinylon fibers, carbon fibers, glass fibers, aramid fibers, boron fibers, and ceramic fibers. . The fiber material is a fiber bundle in which a plurality of long fibers are bundled and arranged in the plane direction. As an arrangement method, the fiber bundle may be arranged at equal intervals in the vertical and horizontal directions. It may be arranged as a thin woven or knitted fabric that has been woven or knitted in advance as a weft.

  A polypropylene resin material is used for the resin layer 3. Polypropylene-based resin materials are used in various fields such as automobile parts and electrical products because they are highly rigid and easy to mold and can be easily colored. In addition, an ultraviolet stabilizer or an ultraviolet absorber may be added to the polypropylene resin material in order to provide weather resistance against ultraviolet rays or the like.

  Among them, propylene-ethylene random copolymer and propylene-ethylene block copolymer containing propylene-ethylene random copolymer and ethylene-propylene copolymer rubber with propylene homopolymer as a matrix are excellent in impact resistance and are strong even when used outdoors for a long time. Can be maintained.

  Therefore, even when it is used as a roofing material, it can sufficiently withstand an impact applied during construction of the roof or during repair management. And since thickness can be made thin, it becomes possible to attain weight reduction and construction of a roofing material can be performed efficiently.

  Further, even when the roof material becomes a waste material, the polypropylene resin material can be recycled, so that the roof material can be recovered and regenerated into a new product.

  The shape of the surface of the roofing material 1 is a continuous curved shape 10 simulating the shape of a conventional roof tile, and is finished in almost the same appearance design as when four roof tiles are constructed.

  The roofing material 1 is formed so as to have substantially the same thickness as a whole, and the lower edges are extended at the side edge portions 11 and 12 so as to be in contact with the construction surface R such as a field plate of the roof structure, The side edge parts 13 and 14 are extended below by the same width as the thickness of the conventional roof tile.

  Further, through holes 11 a and 11 b and through holes 12 a and 12 b for inserting a fixing member such as a nail are formed in the center of the portion corresponding to the curved shape 10 of the side edge portions 11 and 12. And the thickness of the part in which each through-hole was formed is formed thickly.

  Notches 11c and 11d and notches 12c and 12d are formed in the portions corresponding to the corners of the curved shape 10 of the side edges 11 and 12, respectively, when they overlap with the roof material adjacent to the right side and the upper side, respectively. The notches 11d and 12c engage with each other, and the notches 11c and 12d engage with the roof material adjacent to the diagonally lower right side and the diagonally upper left side.

  On the lower surface of the central portion of the roof material 1, linear ribs 15 are formed along the side edges of the curved shape 10, and the ribs 15 are formed in parallel with the side edges 11 and Similarly, the lower edge extends so as to contact the construction surface R.

  When fixing the roofing material 1 to the construction surface R, the side edges 13 and 14 are set so as to overlap the adjacent roofing material, and the side edges 11 and 12 are in contact with the construction surface and penetrated. A fixing member such as a nail is inserted into the holes 11a and 11b and the through holes 12a and 12b and fixed to the construction surface R.

  Since the roof material 1 is thinly formed as a whole, the roof material 1 can be reduced in weight and can be easily constructed on the roof structure, so that the work can be performed efficiently.

  FIG.6 and FIG.7 is an external appearance perspective view which shows another continuous connection shape regarding a roof material. In FIG. 6, the roof material 1 ′ is formed into a shape in which three roof tiles are arranged in a row in a row, and in FIG. 7, the roof material 1 ″ is formed into a shape in which three pieces are arranged in rows and columns. In this way, the continuous shape of the roofing material may be set according to the scale and shape of the construction surface of the roof structure to be constructed, and can be formed into various sizes and shapes.

  In addition, it may be used in the shape of a conventional roof tile, and can be formed into a new design different from the conventional roof tile, and can easily cope with the use and design of buildings. it can.

  In the example described above, the roof material has a fiber layer between the resin layers. However, when the roof material does not require much strength at the construction site, only the resin layer without the fiber layer is used for the roof material. You may make it comprise.

  Next, the manufacturing process of the roof material will be described. FIG. 8 is a plan view showing the resin sheet body S and the fiber sheet body T used for manufacturing the roofing material. The resin sheet S is obtained by cutting a polypropylene resin material formed into a flat plate having a predetermined thickness into a rectangular shape having a predetermined size. The fiber sheet T is obtained by cutting a woven fabric woven by plain weaving into a rectangular shape using a band-like fiber bundle made of carbon fibers for warp and weft. In this example, a combination of the resin sheet body S and the fiber sheet body T corresponds to the sheet body. When the fiber layer is not provided on the roof material, only the resin sheet S may be used.

  FIG. 9 is an explanatory diagram relating to a manufacturing process using a press molding machine. The fiber sheet T is placed between the upper and lower mold bodies 100 and 101 of the press molding machine so as to be sandwiched between a pair of resin sheet bodies S (FIG. 9A). Then, the mold body 100 is lowered and the fiber sheet body T and the resin sheet body S are pressed and press-molded (FIG. 9B). The mold may be heated so that the molding temperature is 120 ° C to 180 ° C. After press molding, the mold body 100 is raised and the molded roofing material H is taken out (FIG. 9C).

  In this example, although the manufacturing process by press molding was demonstrated, you may make it manufacture a roof material by injection molding.

1 Roofing material 2 Fiber layer 3 Resin layer
10 Curved shape
11 Side edge
12 Side edge
13 Side edge
14 Side edge
15 Ribs
100 type
101 type

Claims (6)

  A roof material comprising a sheet body mainly composed of a polypropylene-based resin material formed into a roof tile shape.   The roof material according to claim 1, wherein the polypropylene resin material is a propylene-ethylene block copolymer containing a propylene-ethylene random copolymer and an ethylene-propylene copolymer rubber using a propylene homopolymer as a matrix.   The roof material according to claim 1 or 2, wherein the sheet body has a fiber material uniformly distributed in a plane direction in a polypropylene resin material.   The roofing material according to any one of claims 1 to 3, wherein the fiber material includes long fibers arranged along a plane direction.   The roof material according to any one of claims 1 to 4, wherein the roof material is formed in a shape in which a plurality of roof tiles are continuously arranged.   The roof structure which arranged and fixed the roof material in any one of Claim 1 to 5 on the construction surface.

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