JP2020066976A - Metallic roof material and manufacturing method thereof - Google Patents

Abstract

To provide a metallic roof material capable of reducing a deflection of a front substrate while reducing a deterioration in a design of the metallic roof material, and a manufacturing method thereof.SOLUTION: A metallic roof material according to the invention is arranged to be disposed on a roof substrate so that a width direction extends in an eaves direction of the roof and a depth direction extends in an eaves ridge direction of the roof, and to be disposed overlapped with the metallic roof material of the eaves side relative to the eaves ridge direction of the roof. The metallic roof material comprises a front substrate having a metallic plate as a material, a top plate arranged on the front substrate, and a plurality of projecting parts 7 formed on the top plate and extending parallel each other in a linear shape along the depth direction. The plurality of projecting parts 7 comprise at least 2 types of projecting parts 71, 72, and a magnitude of residual stress remaining at a flexure shoulder part of at least 1 type of the projecting part 71 is different from a magnitude of residual stress remaining at a flexure shoulder part of other type of the projecting part 72.SELECTED DRAWING: Figure 4

Description

  The present invention relates to a metal roofing material having a metal front substrate and a method for manufacturing the same.

  As this type of metal roofing material that has been conventionally used, for example, the configuration shown in Patent Document 1 below can be cited. That is, the conventional metal roofing material is a metal roofing material for performing thatching, and a plurality of linear protrusions along the eaves direction when placed on the roof are top plates of the front substrate. It is formed on the (surface). The heights of the protrusions are equal to each other. By forming such a convex portion on the top plate, it is possible to improve the designability of the metal roofing material and smooth the flow of water such as rainwater or dew condensation water that propagates along the top plate of the metal roofing material. It is intended to improve the durability of the metal roofing material.

JP, 2005-71927, A

  In the conventional metal roof material as described above, a plurality of linear protrusions are formed on the top plate of the front substrate. When such a convex portion is formed on the top plate of the front substrate by embossing by press molding, the front substrate is warped after the front substrate is separated from the press mold. The warp of the front base material causes a defective shape such as bending in the metal roof material. Although the warp of the front substrate can be reduced by uniformly lowering the height of the protrusions, the uniformly lowering of the height of the protrusions deteriorates the design of the metal roofing material.

  The present invention has been made to solve the above problems, and an object thereof is to suppress a warp of a surface base material while suppressing a decrease in the designability of the metal roof material, and to manufacture the same. Is to provide a method.

  The metal roofing material according to the present invention is arranged on the roof substrate so that the width direction extends in the eaves direction of the roof and the depth direction extends in the eaves direction of the roof. It is a metal roofing material that is adapted to be placed on top of a metal roofing material on the eaves side, and is formed on the top plate and the top base material made of the metal plate, the top plate provided on the front base material. And a plurality of convex portions linearly extending in parallel with each other along the depth direction, the plurality of convex portions including at least two types of convex portions, and the bending shoulder portion of at least one type of convex portions. Of the residual stress remaining in the bent shoulder is different from the residual stress remaining in the bending shoulder of the convex portion of another type.

  Further, the metal roofing material according to the present invention is arranged on the roof base so that the width direction extends in the eaves direction of the roof, and the depth direction extends in the eaves direction of the roof. A metal roofing material that is adapted to be stacked on a metal roofing material on the eaves side with respect to the direction, and a front base material made of a metal plate, a top board provided on the front base material, and a top board. And a plurality of convex portions extending linearly in parallel to each other along the depth direction, the plurality of convex portions includes at least two types of convex portions, and at least two types of convex portions are The heights are different from each other.

  The method for manufacturing a metal roofing material according to the present invention is a step of forming at least two types of convex portions in a region corresponding to a top plate of a metal plate, and at least one type of convex portion is processed in another direction. And a step of making the magnitude of residual stress remaining in the bending shoulder of at least one type of convex different from the magnitude of residual stress remaining in the bending shoulder of another type of convex, which is different from the processing direction of the convex .

  Further, the method for producing a metal roofing material according to the present invention includes a step of forming at least two types of convex portions in a region corresponding to a top plate of a metal plate, and the heights of the at least two types of convex portions are different from each other. A press molding in which a metal plate is sandwiched between the upper mold and the lower mold by relative displacement of the upper mold and the lower mold, the upper mold and the lower mold having at least two types of protrusions and recesses corresponding to the protrusions and depressions, respectively. A plurality of convex portions are formed by a machine.

  According to the metal roofing material and the method of manufacturing the same of the present invention, the magnitude of residual stress remaining on the bending shoulder of at least one type of convex portion is different from the magnitude of residual stress remaining on the bending shoulder of another type of convex portion. Alternatively, since the heights of at least two types of convex portions are different from each other, it is possible to suppress the warp of the front base material while suppressing the deterioration of the designability of the metal roof material.

It is a top view which shows the metal roofing material 1 by embodiment of this invention. It is a bottom view which shows the metal roofing material 1 of FIG. It is sectional drawing of the metal roofing material 1 which follows the line III-III of FIG. FIG. 4 is a cross-sectional view of the convex portion 7 taken along the line IV-IV in FIG. 1. It is sectional drawing which shows the modification of the convex part 7 of FIG. It is sectional drawing which shows another modification of the convex part 7 of FIG. It is a flowchart which shows the manufacturing method of the metal roofing material 1 by embodiment of this invention. It is explanatory drawing which shows the embossing by a general press molding machine. It is explanatory drawing which shows the embossing process implemented in the embossing process of FIG. It is a graph which shows the result of having measured the amount of curvature in an example. It is explanatory drawing which shows the result of having measured the shape in an Example. It is a graph which shows the height distribution in the position along the line XI-XI of FIG. It is a graph which shows the curvature height in the predetermined range of the width direction about the metal roofing material manufactured from the surface base materials (a) and (b) of FIG. It is explanatory drawing which shows distribution of the residual stress which remains in the bending shoulder part of the convex part 7 in a comparative example. It is explanatory drawing which shows the distribution of the residual stress which remains in the bending shoulder part of the 1st convex part 71 in an invention example.

  Hereinafter, modes for carrying out the present invention will be described with reference to the drawings. The present invention is not limited to each embodiment, and constituent elements can be modified and embodied without departing from the scope of the invention. Further, various inventions can be formed by appropriately combining a plurality of constituent elements disclosed in each embodiment. For example, some constituent elements may be deleted from all the constituent elements described in the embodiments. Furthermore, the constituent elements of different embodiments may be combined appropriately.

  1 is a plan view showing a metal roofing material 1 according to an embodiment of the present invention, FIG. 2 is a bottom view showing the metal roofing material 1 of FIG. 1, and FIG. 3 is taken along line III-III of FIG. It is sectional drawing of the metal roofing material 1.

  The metal roofing material 1 shown in FIGS. 1 to 3 is a rectangular member in a plan view having a width direction 1W (longitudinal direction) and a depth direction 1D (shorter direction), and is placed on a roof base of a building such as a house. It will be placed together with the metal roofing material. The metal roofing material 1 is adapted to be arranged so that the width direction 1W extends in the eaves direction of the roof and the depth direction 1D extends in the eaves direction of the roof. Further, the metal roofing material 1 is adapted to be placed so as to be overlapped with the metal roofing material on the eaves side in the eaves ridge direction of the roof. The metal roofing material 1 is tightly bound to the roof base by driving a fastening member such as a screw or a nail.

  As particularly shown in FIG. 3, the metal roofing material 1 has a front base material 2, a back base material 3, and a core material 4.

  The front substrate 2 is made of a metal plate, and is a member that appears on the outer surface of the roof when the metal roofing material 1 is placed on the roof substrate. Examples of the metal plate that is the material of the front substrate 2 are hot-dip Zn-plated steel plate, hot-dip Al-plated steel plate, hot-dip Zn-plated stainless steel plate, hot-dip Al-plated stainless steel plate, stainless steel plate, Al plate, Ti plate, and hot-dip Zn-painted plate. It is possible to use a coated steel sheet, a coated hot-dip Al plated steel sheet, a coated hot-dip Zn-plated stainless steel sheet, a coated hot-dip Al plated stainless steel sheet, a coated stainless steel sheet, a coated Al sheet or a coated Ti sheet.

  The front substrate 2 is provided with a box-shaped main body 5 having a top plate 50 and a peripheral wall 51. The main body 5 can be formed by subjecting a flat metal plate to a forming process including a drawing process or an overhanging process. The top plate 50 is a plate portion that appears on the surface of the front substrate 2, and has a substantially rectangular outer shape that extends in the width direction 1W and the depth direction 1D. The peripheral wall 51 is a wall extending from the outer edge of the top plate 50 toward the back surface side of the metal roofing material 1. The peripheral wall 51 of the present embodiment is continuous in the circumferential direction of the front substrate 2.

  The back base material 3 is a member arranged on the back side of the front base material 2 so as to close the opening of the main body 5. As the back substrate 3, a lightweight material such as aluminum foil, aluminum vapor-deposited paper, aluminum hydroxide paper, calcium carbonate paper, resin film or glass fiber paper can be used. By using these lightweight materials for the back substrate 3, it is possible to prevent the weight of the metal roofing material 1 from increasing. A metal plate similar to the front substrate 2 may be used as the back substrate 3.

  The core material 4 is made of, for example, foam resin, and is filled between the main body portion 5 of the front base material 2 and the back base material 3. The material of the core material 4 is not particularly limited, and urethane foam, phenol foam, isocyanurate foam or the like can be used. However, it is essential to use non-combustible certified materials for roofing materials. As the non-combustible material certification test, a heat generation test based on the ISO5660-1 cone calorimeter test method is carried out. When the foamed resin to be the core material 4 is urethane foam or the like that generates a large amount of heat, the thickness of the main body 5 can be reduced, or the foamed resin can contain inorganic foamed particles.

  Returning to FIG. 1, the top plate 50 of the main body portion 5 is provided with a plurality of driving display portions 6 and a plurality of convex portions 7.

  The driving-in display part 6 is a structure for indicating the position at which the binding member is driven into the metal roofing material 1, and is arranged apart from each other in the width direction 1W of the metal roofing material 1. The drive-in display unit 6 of the present embodiment is formed by a concave portion having a circular shape in plan view. However, the driving-in display unit 6 can also adopt other modes such as a convex portion, an opening, or a printed or engraved symbol that allows the operator to visually or tactually recognize the driving position of the binding member.

  The plurality of convex portions 7 are portions projected from the base surface 50a of the top plate 50. The base surface 50a corresponds to the bottom surface of the concave portion between the convex portions 7. Each convex portion 7 extends linearly in parallel with each other along the depth direction 1D. The fact that the respective convex portions extend in parallel to each other means that the respective convex portions extend exactly in parallel to each other, and also that the respective convex portions extend in substantially parallel to each other (along the same direction). Including. Moreover, each convex part 7 is arrange | positioned mutually mutually in the width direction 1W. Although the widths of the respective convex portions 7 in the width direction 1W are shown to be equal to each other in FIG. 1, the widths of the respective convex portions 7 may be different from each other. Further, in FIG. 1, the side of each convex portion 7 is shown to be a straight line along the depth direction 1D, but the side of each convex portion 7 may extend in the depth direction 1D while fluctuating. . The plurality of protrusions 7 as a whole form a flow pattern capable of smoothing the flow of water such as rainwater or condensed water along the depth direction 1D.

  Next, FIG. 4 is a cross-sectional view of the convex portion 7 taken along the line IV-IV in FIG. 1. As shown in FIG. 4, the convex portion 7 of the present embodiment includes a first convex portion 71 and a second convex portion 72. These 1st and 2nd convex parts 71 and 72 have a pair of side walls 71a and 72a and top surfaces 71b and 72b, respectively. The pair of side walls 71a and 72a are separated from each other in the width direction 1W and extend from the base surface 50a of the top plate 50. The top surfaces 71b and 72b connect between the upper ends of the pair of side walls 71a and 72a.

  The first and second convex portions 71 and 72 form two types of convex portions having different heights. The height of the first convex portion 71 is lower than the height of the second convex portion 72. The heights of the first and second convex portions 71, 72 are the base surface 50a of the top plate 50 and the top surface 71b of the first and second convex portions 71, 72 in the direction perpendicular to the base surface 50a of the top plate 50. , 72b. For example, the height of the 2nd convex part 72 can be 0.3 mm, and the height of the 1st convex part 71 can be 0.2 mm, 0.15 mm, or 0.1 mm. Further, for example, the height of the second convex portion 72 can be 0.2 mm, and the height of the first convex portion 71 can be 0.1 mm.

  As will be described later in detail, in the metal roofing material 1 of the present embodiment, the magnitude of the residual stress remaining in the bending shoulder portion of the first convex portion 71 is larger than the magnitude of the residual stress remaining in the bending shoulder portion of the second convex portion 72. Different from In FIG. 4, a pair of arc-shaped arrows attached to the first and second convex portions 71 and 72, respectively, indicate that the metal roofing material 1 is caused by residual stress remaining in the bending shoulder portions of the first and second convex portions 71 and 72. The magnitude of the moment that causes the warp of the is schematically shown.

  In the metal roofing material 1 of the present embodiment, the first and second convex portions 71, 72 are alternately arranged in the width direction 1W. In metal roofing material 1 of the present embodiment, adjacent convex portions 7 have different heights in the width direction 1W. Second convex portions 72 having a high height are arranged on both sides of the first convex portion 71 having a low height.

  Next, FIG. 5 is a cross-sectional view showing a modified example of the convex portion 7 of FIG. In FIG. 4, one first convex portion 71 is arranged between the pair of second convex portions 72, but as shown in FIG. 5, two first convex portions 72 are arranged between the pair of second convex portions 72. Alternatively, three or more first protrusions 71 may be arranged.

  Next, FIG. 6 is a cross-sectional view showing another modified example of the convex portion 7 of FIG. Although it has been described in FIG. 4 that two types of protrusions 7 (first and second protrusions 71 and 72) are provided, the number of types of protrusions 7 may be three or more. FIG. 6 shows an example in which three types of convex portions 7 are provided. That is, the third convex portion 73 is provided in addition to the first and second convex portions 71 and 72. The height of the third convex portion 73 is higher than the height of the first convex portion 71 and lower than the height of the second convex portion 72. For example, the height of the second convex portion 72 can be 0.3 mm, the height of the third convex portion 73 can be 0.2 mm, and the height of the first convex portion can be 0.1 mm. In the example of FIG. 6, the first to third convex portions 71 to 73 are arranged in the order of the second convex portion 72, the third convex portion 73, the second convex portion 72, the first convex portion 71, and the second convex portion 72. ing. The first to third convex portions 71 to 73 may be repeatedly arranged in this order. That is, three or more types of convex portions 7 may be sequentially arranged in a predetermined order.

  As shown in FIGS. 4 to 6, it is preferable to arrange at least two types of convex portions 7 alternately or sequentially in the width direction 1W, but at least two types of convex portions 7 may be arranged in a random order. It is preferable that at least two types of convex portions 7 are arranged alternately or sequentially as shown in FIGS. 4 to 6 over the entire width direction 1W of the top plate 50, but at least 2 in at least a part of the width direction 1W of the top plate 50. The types of convex portions 7 may be arranged as described above. As with the arc-shaped arrow in FIG. 4, the arc-shaped arrows shown in the bent shoulders of the first convex portion 71, the second convex portion 72, and the third convex portion 73 in FIGS. It is a diagram schematically showing the magnitude of the moment generated by the residual stress remaining in each bending shoulder.

  Next, FIG. 7 is a flowchart showing a method for manufacturing the metal roofing material 1 according to the embodiment of the present invention. The metal roofing material 1 shown in FIG. 1 and the like can be manufactured by the method for manufacturing the metal roofing material 1 shown in FIG. 7. The method for manufacturing the metal roofing material 1 according to the present embodiment includes a main body 5 forming step (step S1), an embossing step (step S2), a resin injecting step (step S3), and a rear base material 3 arranging step (step). S4) and a foaming process (step S5) are included.

  The step of forming the main body portion 5 (step S1) is a step of forming the main body portion 5 by subjecting a metal plate, which is a material of the front substrate 2, to a forming process. The forming process includes drawing process or overhanging process. At the same time when the main body portion 5 is formed, the driving display portion 6 can be formed on the top plate 50. The driving-in display portion 6 may be formed before or after the formation of the main body portion 5.

  The embossing step (step S2) is a step of forming a plurality of convex portions 7 on the top plate 50. This embossing process will be described later in detail. Hereinafter, the top plate 50 on which a plurality of protrusions 7 are formed is referred to as a front base material.

  In the resin injection step (step S3), a foaming resin is injected into the main body portion 5 of the front base material body. In the step of disposing the back base material 3 (step S4), the back base material 3 is placed on the back side of the front base material body so as to close the opening of the main body portion 5. In the foaming step (step S5), the foamed resin is foamed while applying pressure to the back base material 3 with the back base material 3 placed on the back side of the front base material body, and the core material 4 is provided inside the main body portion 5. Is formed.

  Next, FIG. 8 is an explanatory view showing embossing (press embossing) by a general press molding machine. FIG. 8 shows a case (comparative example) in which one type of convex portion 7 having the same height is formed by a press molding machine having an upper die 80 and a lower die 81. The upper mold 80 and the lower mold 81 are provided with irregularities corresponding to the convex portions 7, respectively, and the metal plate 82 is interposed between the upper mold 80 and the lower mold 81 due to the relative displacement of the upper mold 80 and the lower mold 81. By sandwiching, the plurality of convex portions 7 shown in FIG. 8D are formed.

  The lower mold 81 is provided with a lower convex mold 81 a corresponding to each convex portion 7. The upper die 80 is provided with an upper convex die 80 a corresponding to the concave portion between the convex portions 7.

  As shown in (a) of FIG. 8, before the press embossing is started, the metal plate 82, which is the material of the front substrate 2, is placed on the top surface of the downward convex mold 81a. As shown in FIG. 8B, when the upper die 80 is lowered, the region of the metal plate 82 which is in contact with the top surface of the upper convex die 80a is pushed down. Further, as this region is pushed down, the regions of the metal plate 82 in contact with the top surface of the lower convex mold 81a are started with both ends of the region of the metal plate 82 in contact with the top surface of the lower convex mold 81a as starting points. Both sides of the are bent downward. Such pressing and bending are performed until the metal plate 82 is filled between the upper die 80 and the lower die 81 as shown in FIG. 8C. Arc-shaped arrows shown in (b) and (c) of FIG. 8 indicate bending stress acting on the metal plate 82 during press embossing.

  As shown in (d) of FIG. 8, when the metal plate 82 is removed from the upper die 80 and the lower die 81, the opposite sides of the bending stress during press embossing are applied to both sides of the top surface 7b of the convex portion 7. Residual stress remains. The arc-shaped arrow shown in (d) of FIG. 8 indicates the moment generated by the residual stress remaining in the bending shoulder of each protrusion 7. This moment causes the metal plate 82 to warp as shown in FIG.

  Next, FIG. 9 is an explanatory diagram showing the embossing (press embossing) performed in the embossing step (step S2) of FIG. 7. In the embossing according to the embodiment of the present invention, two types of convex portions 7 having different heights are formed by a press molding machine having an upper die 80 and a lower die 81. As shown in (e) of FIG. 9, the convex portion 7 includes a first convex portion 71 and a second convex portion 72 having a height higher than that of the first convex portion 71. One first convex portion 71 is arranged between the pair of second convex portions 72. The upper mold 80 and the lower mold 81 are provided with irregularities corresponding to the first and second convex portions 71 and 72, respectively, and the relative displacement of the upper mold 80 and the lower mold 81 causes the upper mold 80 and the lower mold 81 to move. By sandwiching the metal plate 82 between 81, the first and second convex portions 71 and 72 are formed.

  The lower die 81 is provided with a first lower convex die 81 a corresponding to the first convex portion 71 and a second lower convex die 81 b corresponding to the second convex portion 72. The upper mold 80 is provided with an upper convex mold 80a corresponding to a concave portion between the first and second convex parts 71 and 72.

  As shown in FIG. 9A, before the press embossing is started, the metal plate 82, which is the material of the front substrate 2, is placed on the top surface of the second downward convex mold 81b. As shown in FIG. 9B, when the upper die 80 is lowered, the region of the metal plate 82 which is in contact with the top surface of the upper convex die 80a is pushed down. Further, as this region is pushed down, the metal plate 82 in contact with the second lower convex mold 81b is started from both ends of the region of the metal plate 82 in contact with the top surface of the second lower convex mold 81b. Both sides of the area are bent downward.

  In the state shown in FIG. 9B, tension acts on the metal plate 82 between the pair of upper convex molds 80a. When the upper mold 80 is further lowered from this state, the metal plate 82 is pushed between the pair of upper convex molds 80a together with the first lower convex mold 81a as shown in FIG. 9C. At this time, the region of the metal plate 82 that is in contact with the top surface of the first downward convex mold 81a is pushed up. That is, the processing direction of the first convex portion 71 is different from the processing direction of the second convex portion 72. Such pushing up is performed until the metal plate 82 is filled between the upper die 80 and the lower die 81 as shown in FIG. Arc-shaped arrows shown in (b) to (d) of FIG. 9 indicate bending stress acting on the metal plate 82 during press embossing.

  When the metal plate 82 is removed from the upper die 80 and the lower die 81, the residual stress opposite to the bending stress during press embossing is applied to both sides of the top surfaces 71b and 72b of the first and second convex portions 71 and 72. Remains, which may cause the metal plate 82 to warp. However, in the example shown in FIG. 9, the magnitude of the residual stress remaining in the bending shoulder portion of the first convex portion 71 is different from the magnitude of the residual stress remaining in the bending shoulder portion of the second convex portion 72. Specifically, the magnitude of the residual stress remaining in the bending shoulder portion of the first convex portion 71 is smaller than the residual stress remaining in the bending shoulder portion of the second convex portion 72. In (e) of FIG. 9, the arc-shaped arrows shown in the bending shoulders of the first convex portion 71 and the second convex portion 72 indicate the magnitude of the moment generated by the residual stress remaining in the bending shoulders. Is schematically shown. In the metal plate 82 of FIG. 9, the magnitude of the residual stress in the bending shoulders of the first convex portion 71 and the second convex portion 72 is different, so that the moment generated in the metal plate 82 compared to the example shown in FIG. Becomes smaller, and as a result, the warp of the metal plate 82 is reduced.

  Next, examples will be given. It was confirmed that it is possible to suppress the warp of the metal plate after forming the protrusions by forming at least two types of protrusions having different heights linearly along the short side direction of the metal plate. In order to do so, under the conditions shown in Table 1, the embossed metal plate was subjected to a test production by subjecting the material metal plate to the press embossing described with reference to FIGS. 8 and 9. The embossed metal plate referred to here is a plate-like body that does not have the box-shaped main body 5 like the metal roofing material 1. In addition, in order to investigate the influence of the arrangement of the convex portions having different heights on the amount of warp of the embossed metal plate, as shown in Table 2, seven types of embossed metal plates of different type A to type G having different arrangements of the convex portions are used. Was manufactured.

(Measuring method of warp of embossed metal plate)
After the press embossing, the embossed metal plate on which the embossed convex portions were formed was taken out from the press machine and left standing on the plate. At that time, although the center portion in the width direction of the embossed metal plate was in contact with the constant plate, a gap was formed between both end portions in the width direction and the constant plate due to warpage. The warp direction was perpendicular to the extending direction of the embossed protrusions. In that state, the shape of the embossed metal plate was measured from above the embossed metal plate using a non-contact 3D shape measuring machine to determine the amount of warpage.

(Warp measurement result)
The result of measuring the amount of warpage is shown in FIG. The influence of the distribution of the embossed convex portions on the warp amount of the embossed metal plate can be summarized as follows.

1) Comparison between type A and type B In type A, the height of the embossed protrusions was 0.3 mm, and the amount of warpage was more than 13 mm. On the other hand, the height of the embossed protrusion of type B was 0.2 mm, which was lower than that of type A, and the amount of warpage was about 4 mm. That is, if the height of the convex portion forms one kind of convex portion, it is possible to effectively reduce the warp amount of the embossed metal plate by lowering the height of the convex portion. I understand. However, if the heights of all the convex portions are simply lowered, the designability will be deteriorated.

2) Comparison of types A, C, D and E (maximum height of convex part: 0.3 mm)
Based on the type A embossed metal plate, the three types C, D, and E are two types in which the maximum height of the protrusion is 0.3 mm and the height of some protrusions is low. It is an embossed metal plate having the height of the convex portion of.

  In the type C in which the convex portions having a height of 0.3 mm and the convex portions having a height of 0.2 mm are alternately arranged, the warp amount is about 7 mm, which is about half the warp amount of the embossed metal plate of the type A. . Similarly, in the type D in which the convex portions having a convex portion height of 0.3 mm and the convex portions having a height of 0.15 mm are alternately arranged, the warpage amount was suppressed to about 7 mm. The amount of warpage was 1 mm or less in the type E in which the protrusions having a height of 0.3 mm and the protrusions having a height of 0.1 mm were alternately arranged. It was confirmed that the maximum convex height was 0.3 mm, which is the same as that of type A, but the warpage of the embossed metal plate was significantly reduced by lowering the height of some convex portions. did it.

3) Comparison between type B and F (maximum height of convex part: 0.2 mm)
Based on the type B embossed metal plate, the type F has two types of convex heights, in which the maximum convex height is 0.2 mm and some convex heights are reduced. It is an embossed metal plate. When the amount of warp of type B was about 4 mm, the amount of warp of type F, in which convex portions having a height of 0.2 mm and convex portions having a height of 0.1 mm were alternately arranged, was only about 0.3 mm. Also in this case, it was confirmed that the warp amount of the embossed metal plate was significantly reduced by lowering the height of some of the convex portions.

4) Comparison of Types A, C and G Type G has the maximum height of protrusions of 0.3 mm as in Type A, but the heights of protrusions are 0.3 mm and 0.2 mm instead of 2 types. And 0.1 mm. Further, 0.2 mm and 0.1 mm were alternately arranged between 0.3 mm and 0.3 mm (0.3 mm, 0.2 mm, 0.3 mm, 0.1 mm, 0.3 mm, 0.2 mm, 0). .3 mm, 0.1 mm ...). The warp height in this case was about 1 mm. Also in this case, since at least two types of convex portions having different convex heights are formed, the warp amount of the embossed metal plate can be significantly reduced as compared with the type A in which the convex height is only 0.3 mm. It was

Note that the four types of embossed metal plates of types C, D, E, and G were not inferior in appearance to the embossed metal plate of type A. It is considered that this is because the maximum height of the protrusions is 0.3 mm. Similarly, regarding the two types of type B and type F, the appearance design of type F was not inferior to that of type B. It is considered that this is also because the maximum height of the convex portions is 0.2 mm.
That is, it was possible to reduce the amount of warpage of the metal plate after forming the convex portion without reducing the maximum height of the convex portion of the emboss.

  Next, the metal roofing material 1 was evaluated.

(Formation of front substrate before embossing)
Drawing processing was performed using the materials shown in Table 3, and a front base material of a metal roofing material having a box-shaped main body 5 was formed. The size and height of the molded front substrate are as shown in Table 3. Then, the warp amount of the front base material before press embossing was measured by a warp amount measuring method described later. The number of measured surface base materials is 30.

(Press embossing)
Press embossing (embossing by a press molding machine) was performed on the top plate 50 of the main body 5 so that the plurality of convex portions 7 were formed linearly and in parallel along the depth direction 1D. At this time, two types of embossing were performed by changing the embossing mold (comparative example and invention example). As a comparative example, like the type A metal plate shown in Table 2 above, one having all the convex portions 7 having a height of 0.3 mm was produced. As an example of the invention, a metal plate of type G shown in Table 2 was prepared in which convex portions 7 having the following heights were sequentially arranged. In addition, the number of the convex portions 7 was 54 in both the comparative example and the invention example.
Arrangement of the convex portion 7 of the invention example: 0.3 mm, 0.2 mm, 0.3 mm, 0.1 mm, 0.3 mm, 0.2 mm, 0.3 mm, 0.1 mm ...

(Warp measurement method)
The surface of the front substrate before or after press embossing is allowed to stand on a fixed plate, and in that state, the shape of the front substrate is measured from above the front substrate using a non-contact 3D shape measuring machine. The amount of warpage was determined by measuring. The shape measurement was performed on the entire front base material in the eaves ridge direction 410 mm × width 910 mm.

  The shape measurement result is shown in FIG. (C) is a front base material before embossing, (a) is a front base material of a comparative example, (b) is a front base material of an invention example. The surface base material (c) before embossing has a substantially flat plane portion, although only the four corners are slightly higher. However, in the embossed surface base material (a) of the comparative example, a large swelling is recognized in the substantially central portion of the flat surface portion. The embossed surface base material (b) of the invention example does not have a large swelling as in (a), but rather the flat portion is almost flat like the front base material (c) before embossing.

Further, in order to compare the warp amounts of (a) to (c), the height distribution at the position of the line XI-XI in FIG. 1 is shown in FIG. 12 from the shape measurement results, and (a) and (b). 13 shows the warp height within a predetermined range in the width direction. The position of the line XI-XI corresponds to a position of 182 mm from the eaves end toward the ridge end, and when stacking in the eaves ridge direction when constructing the metal roofing material on the roof, the eaves end of the upper metal roofing material Is the position that overlaps the lower metal roofing material. The warp height is an index calculated by the following formula.
Warp height (mm) = maximum height (mm) -minimum height (mm)

In the embossed surface base material (a) of the comparative example, a large undulation (swelling) is recognized in the substantially central portion of the plane portion also in FIG. The embossed surface base material (b) of the invention example does not have a large swell, but rather the flat portion is almost flat like the front base material (c) before embossing.
Comparing the warp heights, as shown in FIG. 13, the warp height of the embossed surface base material (a) of the comparative example is large, but the embossed surface base material (b) of the invention example is large. In (), the warp height can be greatly reduced.

  Next, the operation and effect of the present invention will be described with reference to the distribution of residual stress obtained by simulation.

  FIG. 14 is an explanatory diagram showing a distribution of stress remaining in the bending shoulder portion of the convex portion 7 in the comparative example. FIG. 14 shows the stress generated in the bending shoulder portion of the convex portion 7 when the plural convex portions 7 are formed on the metal plate by the method shown in FIG. That is, the convex portions 7 having the same height are formed on the metal plate by press embossing. As shown in FIG. 14A, the height of the convex portion 7 is unified to 0.15 mm. In this aspect, the top surface 7b of the convex portion 7 is not processed, and the side wall 7a of the convex portion 7 and the base surface 50a are pushed down to form the convex portion 7 (see FIG. 8). FIG. 14B is a state corresponding to FIG. 8C, and occurs in the bending shoulder portion of the convex portion 7 in a state where the metal plate 82 is filled between the upper die 80 and the lower die 81. The distribution of stress is shown. At this time, as shown in FIG. 14B, compressive stress is generated in the bending inside R portion 7c of the convex portion 7, and tensile stress is generated in the bending outside R portion 7d of the convex portion 7. ing.

  The paired arrow symbols on the outside of the outline of the metal plate schematically indicate whether the stress generated in each bending shoulder is a tensile stress or a compressive stress. . A symbol with an arrow pointing to the outside indicates that tensile stress is occurring in the bending shoulder, and a symbol with an arrow pointing to the inside indicates that compressive stress is occurring in the bending shoulder. There is.

  FIG. 15 is an explanatory diagram showing a distribution of residual stress remaining in the bending shoulder portion of the first convex portion 71 in the invention example. FIG. 15 shows residual stress remaining in the bending shoulder of the first convex portion 71 when the first and second convex portions 71, 72 are formed on the metal plate by the method shown in FIG. That is, the first and second convex portions 71 and 72 are formed on the metal plate by press embossing. As shown in FIG. 15A, the height of the first convex portion 71 is 0.15 mm and the height of the second convex portion 72 is 0.35 mm. The first convex portion 71 is arranged between the pair of second convex portions 72. In this aspect, the side wall 71a and the base surface 50a of the first convex portion 71 are pushed down (see FIG. 9B), and the top surface 71b of the first convex portion 71 is pushed up (see FIG. 9C). Therefore, the first convex portion 71 is formed.

  As shown in FIG. 15B, compressive stress is generated in the bending inner side R portion 71c of the first convex portion 71, and tensile stress is generated in the bending outer side R portion 71d of the first convex portion 71. Generation of such tensile and compressive stress is similar to that of the comparative example shown in FIG. However, as can be seen by comparing the tensile and compressive stresses of the invention example shown in FIG. 15 with the tensile and compressive stress of the comparative example shown in FIG. The tensile and compressive stresses are smaller than those of the comparative example. Particularly, the tensile stress of the bending outside R portion 71d in the invention example is smaller than the tensile stress of the bending outside R portion 7d in the comparative example.

  The height of the first protrusion 71 in FIG. 15 is the same as the height of the protrusion 7 in FIG. That is, the reduction of the stress thus generated is not simply due to the reduction of the height of the convex portion 7, but the processing direction of the first convex portion 71 is opposite to the processing direction of the second convex portion 72. I understand that it is involved.

  14 (c) and 15 (c) schematically show the moments generated at the bending shoulders with the metal plate 82 removed from between the upper die 80 and the lower die 81, respectively. Specifically, it corresponds to the state of FIG. 8D which is a comparative example and the state of FIG. 9E which is an example of the invention. In the state where the metal plate 82 is removed from between the upper mold 80 and the lower mold 81, residual stress in the direction opposite to the tensile or compressive stress generated in the bending shoulder remains, so that FIG. In (c), since the tensile and compressive stresses that are generated are smaller than those in (c) of FIG. 14 which is a comparative example, the residual stress in the state where the metal plate is removed is also small, and as a result, the bending shoulder Since the moment generated at is also small, the warp is reduced.

  Note that, for example, if another device such as an embossing roll is used, the processing direction of the first convex portion 71 can be made the same as the processing direction of the second convex portion 72. Even if the processing directions are the same, by mixing the first protrusions 71 having a low height in the second protrusions 72 having a high height, the stress that tends to warp the metal plate or the metal roofing material is somewhat increased. Can be reduced.

  Further, even if all the convex portions 7 have the same height, for example, when a plurality of molds are used or divided molds are used, the processing direction of a certain convex portion 7 is set to that of another convex portion 7. It can be opposite to the processing direction. In this case, the magnitude of the residual stress remaining in the bending shoulder portion of a certain convex portion 7 is different from the magnitude of the residual stress remaining in the bending shoulder portion of another convex portion 7. Even if a plurality of types of convex portions 7 having different residual stresses are formed by such a method, the stress that tends to warp the metal plate or the metal roof material can be reduced.

  In the metal roofing material 1 and the manufacturing method thereof as described above, since the plurality of convex portions 7 include at least two types of convex portions 7 having different residual stresses remaining in the bending shoulder portion, the designing property of the metal roofing material is improved. The warp of the front substrate can be reduced while suppressing the decrease.

  Moreover, since the heights of the at least two types of convex portions 7 are different from each other, the magnitude of the residual stress remaining in the bending shoulder portion of each convex portion 7 can be more surely made different.

  Furthermore, with respect to the width direction 1W, a convex portion 7 (second convex portion 72) having a height higher than that of the convex portion 7 (first convex portion 71) is provided on both sides of one convex portion 7 (first convex portion 71) of the plurality of convex portions. Since they are arranged, it is possible to more reliably suppress the warp of the front base material while suppressing the deterioration of the designability of the metal roof material.

  Furthermore, since the heights of the plurality of convex portions 7 are two types, there are an upper mold and a lower mold each provided with irregularities corresponding to the two types of convex parts, and the relative shapes of the upper mold and the lower mold. It is necessary to use multiple dies or split dies because a press molding machine that inserts a metal plate between the upper mold and the lower mold can form two types of convex parts with different heights. Therefore, the manufacturing cost can be reduced.

  Further, since the heights of the adjacent convex portions 7 in the width direction are different from each other, it is possible to more reliably suppress the warp of the front base material while suppressing the deterioration of the designability of the metal roof material.

  Furthermore, since at least two types of convex portions 7 are arranged alternately or sequentially in the width direction 1W, it is possible to more reliably reduce the warp of the front base material while suppressing the deterioration of the designability of the metal roof material.

DESCRIPTION OF SYMBOLS 1 Metal roofing material 2 Surface base material 7 Convex part 50 Top plate 71, 72 1st and 2nd convex part 80 Upper mold 81 Lower mold 82 Metal plate

Claims (10)

It is placed on the roof base so that the width direction extends in the eaves direction of the roof and the depth direction extends in the eaves direction of the roof. A metal roofing material adapted to be placed,
A table base material made of a metal plate,
A top plate provided on the front substrate,
A plurality of convex portions formed on the top plate and linearly extending in parallel to each other along the depth direction,
The plurality of protrusions include at least two types of protrusions,
A metal roofing material in which the magnitude of residual stress remaining in the bending shoulder of at least one type of convex portion is different from the magnitude of residual stress remaining in the bending shoulder portion of another type of convex portion. The at least two types of protrusions have different heights from each other,
The metal roofing material according to claim 1. It is placed on the roof base so that the width direction extends in the eaves direction of the roof and the depth direction extends in the eaves direction of the roof. A metal roofing material adapted to be placed,
A table base material made of a metal plate,
A top plate provided on the front substrate,
A plurality of convex portions formed on the top plate and linearly extending in parallel to each other along the depth direction,
The plurality of protrusions include at least two types of protrusions,
The at least two types of protrusions have different heights from each other,
Metal roofing material. With respect to the width direction, a convex portion having a height higher than the convex portion is disposed on both sides of one convex portion of the plurality of convex portions,
The metal roofing material according to claim 2 or 3. The plurality of convex portions are of two types,
The metal roofing material according to claim 4. The heights of the convex portions adjacent to each other in the width direction are different from each other,
The metal roofing material according to any one of claims 1 to 5. The at least two types of convex portions are arranged alternately or sequentially in the width direction,
The metal roofing material according to any one of claims 1 to 6. A method for producing a metal roofing material for producing the metal roofing material according to any one of claims 1 to 7,
A step of forming the at least two types of convex portions in a region corresponding to the top plate of the metal plate, wherein the processing direction of at least one type of convex portion is different from the processing direction of another type of convex portion. And a step of varying the magnitude of residual stress remaining on the bending shoulder portion of the at least one type of convex portion from the magnitude of residual stress remaining on the bending shoulder portion of another type of convex portion.
Manufacturing method of metal roofing material. The at least two types of protrusions have different heights,
It has an upper mold and a lower mold which are respectively provided with irregularities corresponding to the at least two types of convex portions, and the metal plate is provided between the upper mold and the lower mold by relative displacement of the upper mold and the lower mold. Forming a plurality of the convex portions by a press molding machine sandwiching,
The method for manufacturing a metal roofing material according to claim 8. A method for producing a metal roofing material for producing the metal roofing material according to claim 4, claim 5, claim 6, or claim 7,
A step of forming the at least two types of convex portions in a region corresponding to the top plate of the metal plate,
The at least two types of protrusions have different heights,
It has an upper mold and a lower mold which are respectively provided with irregularities corresponding to the at least two types of convex portions, and the metal plate is provided between the upper mold and the lower mold by relative displacement of the upper mold and the lower mold. Forming a plurality of the convex portions by a press molding machine sandwiching,
Manufacturing method of metal roofing material.