JP2020051142A - Metallic roofing material - Google Patents

Abstract

To provide a metallic roofing material excellent in wind endurance and workability and allowing weight to be lighter.SOLUTION: A metallic roofing material 1 is provided with a metallic front base material 2, a rear base material 3, and a core material 4 placed between the front base material 2 and the rear base material 3. In the metallic roofing material 1, the rear base material 3 is a laminated body in which a metallic foil 6 having Young's modulus equal to or higher than 12,000 Mpa is placed between two resin layers 5a, 5b.SELECTED DRAWING: Figure 1

Description

  The present invention relates to a metal roofing material.

In recent years, various roofing materials such as slate-based, cement-based, and metal-based materials have been increasingly used in place of clay tiles. Among them, a metal-based roofing material (hereinafter, “metal roofing material”) has attracted particular attention because of its advantages such as lightness, excellent waterproofness, and easy processing.
As conventional metal roofing materials, in Patent Documents 1 and 2, a metal front base, a back base, and a core material including a foamed resin disposed between the front base and the back base. There has been proposed a metal roofing material having the following.

JP 2016-186212 A JP-A-2017-96048

Generally, a roofing material is exposed to rain wind, and therefore needs to have characteristics that can withstand rain wind. In particular, since Japan is a country with many typhoons in the world, it is required that roof materials have excellent wind pressure resistance. The “wind pressure resistance” means a performance that can withstand strong wind without buckling. Therefore, Patent Documents 1 and 2 propose to increase the thickness of the front base material to improve the wind pressure resistance of the metal roofing material.
However, when the thickness of the front base material is increased, the metal roofing material becomes heavy. Therefore, in order to achieve both a reduction in weight and an improvement in wind pressure resistance, it is necessary to control the thickness of the surface base material within an appropriate range, which limits the degree of freedom in product design.

On the other hand, metal roofing materials are roofed manually by a craftsman such as a roofer. Note that “roofing” means processing roof materials, laying them down on a roof foundation, and fixing them.
Here, in the metal roofing materials of Patent Literatures 1 and 2, the backing substrate is formed of aluminum foil, aluminum evaporated paper, aluminum hydroxide paper, calcium carbonate paper, resin film, glass fiber paper, or the like. For this reason, the backing substrate is easily damaged during roofing, and careful work is required, which has been a factor of deteriorating workability.

  The present invention has been made to solve the above-described problems, and an object of the present invention is to provide a metal roofing material which is excellent in wind resistance and workability and can be reduced in weight.

  The present inventors have conducted intensive studies to solve the above-described problems, and as a result, a metal foil having a Young's modulus of 12,000 MPa or more was disposed between two resin layers as a backing material of a metal roofing material. It has been found that by using the laminated body, wind resistance can be improved, workability can be improved, and weight can be reduced, and the present invention has been completed.

  That is, the present invention is a metal roofing material comprising a metal front base material, a back base material, and a core material disposed between the front base material and the back base material, The material is a metal roofing material that is a laminate in which a metal foil having a Young's modulus of 12,000 MPa or more is disposed between two resin layers.

  ADVANTAGE OF THE INVENTION According to this invention, the metal roofing material which is excellent in wind pressure resistance and workability, and can be reduced in weight can be provided.

It is sectional drawing of the metal roofing material by embodiment of this invention. FIG. 2 is an enlarged cross-sectional view of the back substrate of FIG. 1.

  Hereinafter, preferred embodiments of the metal roofing material of the present invention will be described. However, the present invention should not be construed as being limited thereto, and should be understood by those skilled in the art without departing from the gist of the present invention. Various changes, improvements, and the like can be made based on this. A plurality of constituent elements disclosed in each embodiment can form various inventions by an appropriate combination. For example, some components may be deleted from all the components described in the embodiments, or components of different embodiments may be appropriately combined.

FIG. 1 is a cross-sectional view of the metal roofing material of the present embodiment.
As shown in FIG. 1, a metal roofing material 1 of the present embodiment includes a metal front base material 2, a back base material 3, and a core disposed between the front base material 2 and the back base material 3. Material 4.

  The front base material 2 is a portion that appears on the outer surface of the roof when the metal roofing material 1 is placed on a roof foundation, and a metal plate is used as a material. There is no particular limitation on the metal plate that is the material of the front substrate 2, and a metal plate known in the art can be used. Examples of the metal sheet include a hot-dip Zn-coated steel sheet, a hot-dip Al-coated steel sheet, a hot-dip Zn-plated stainless steel sheet, a hot-dip Al-plated stainless steel sheet, a stainless steel sheet, an Al plate, a Ti plate, a coated hot-dip Zn-plated steel sheet, and a hot-dip molten Al-plated steel sheet. Examples include a plated steel sheet, a painted molten aluminum-zinc alloy plated steel sheet, a painted molten Zn-based stainless steel sheet, a painted molten Al-plated stainless steel sheet, a painted stainless steel sheet, a painted Al sheet, a painted Ti sheet, and the like.

  The thickness of the surface substrate 2 is not particularly limited, but the upper limit is preferably 0.5 mm, more preferably 0.45 mm. By setting the thickness of the front base material 2 to 0.5 mm or less, it is possible to prevent the weight of the metal roofing material 1 from becoming too large. In particular, when devices such as a solar cell module, a solar water heater, an air conditioner outdoor unit, and snow melting-related devices are provided on a roof, it is advantageous because the total weight of the roof can be reduced. On the other hand, the lower limit of the thickness of the front substrate 2 is preferably 0.20 mm, more preferably 0.25 mm, and further preferably 0.27 mm. By setting the thickness of the surface base material 2 to 0.20 mm or more, it is possible to make it hard to be crushed while securing the strength required as a roof material. Further, as described below, the wind resistance of the metal roofing material 1 can be improved by the backing substrate 3. Furthermore, since the thickness of the front substrate 2 can be made smaller than before, the degree of freedom in product design can be increased.

The backing substrate 3 is a portion that comes into contact with the roof foundation when the metal roofing material 1 is arranged on the roof foundation.
Here, a cross-sectional view of the back substrate 3 is shown in FIG. As shown in FIG. 2, the back substrate 3 is a laminate in which a metal foil 6 having a Young's modulus of 12,000 MPa or more is disposed between two resin layers 5a and 5b.

  Since the laminate used as the backing substrate 3 includes the metal foil 6 having a high Young's modulus, the wind resistance of the metal roofing material 1 can be improved. In addition, since the laminate has the resin layers 5a and 5b provided on both surfaces of the metal foil 6, the metal foil 6 is hardly corroded and has good corrosion resistance. Further, since this laminate has a high piercing strength, it is hardly damaged during roofing, and the workability can be improved. Furthermore, since the thickness of the laminate can be reduced by combining the resin layers 5a and 5b and the metal foil 6, the weight can be reduced.

The metal foil 6 is not particularly limited as long as its Young's modulus is 12,000 MPa or more. Examples thereof include hard aluminum foil, stainless steel foil, steel foil, Ti foil, nickel foil, iron foil, and noble metal foil. Among them, it is preferable to use a hard aluminum foil as the metal foil 6 from the viewpoint of weight reduction.
In addition, "hard aluminum foil" means a state in which aluminum foil is rolled thinly into a foil and then is not annealed.

  The thickness of the metal foil 6 is not particularly limited, but the upper limit is preferably 200 μm, more preferably 150 μm, and still more preferably 100 μm. By setting the thickness of the metal foil 6 to 200 μm or less, the weight of the backing substrate 3 can be reduced, so that the weight of the metal roofing material 1 can be prevented from becoming too large. On the other hand, the lower limit of the thickness of the metal foil 6 is preferably 10 μm, more preferably 20 μm, and still more preferably 30 μm. By setting the thickness of the metal foil 6 to 10 μm or more, required Young's modulus and piercing strength can be ensured, so that wind resistance and workability of the metal roofing material 1 can be improved.

The resin layer 5a on the core 4 is not particularly limited, and a film formed from a resin known in the art can be used. Among them, the resin layer 5a is preferably a film formed of a resin having good adhesion to the core material 4.
Examples of the resin layer 5a include a film formed from a urethane resin, an epoxy resin, a polyester resin such as polyethylene terephthalate (PET), or the like.

  The thickness of the resin layer 5a is not particularly limited, but the upper limit is preferably 40 μm, more preferably 30 μm, and further preferably 25 μm. By setting the thickness of the resin layer 5a to 40 μm or less, the weight of the backing substrate 3 can be reduced, so that the weight of the metal roofing material 1 can be prevented from becoming too large. Further, by specifying the upper limit of the thickness of the resin layer 5a as described above, it becomes easier to obtain certification as a noncombustible material. On the other hand, the lower limit of the thickness of the resin layer 5a is preferably 2 μm, more preferably 5 μm, and still more preferably 12 μm. By setting the thickness of the resin layer 5a to 2 μm or more, it is possible to sufficiently block substances that corrode the metal foil 6 while ensuring adhesion to the core material 4.

The resin layer 5b on the underside of the roof is not particularly limited, and a film formed from a resin known in the art can be used. The resin used for the resin layer 5b may be the same resin as the resin layer 5a or a different resin. Among them, the resin layer 5b is preferably a layer formed of a resin having good toughness from the viewpoint of improving the piercing strength of the back substrate 3.
Examples of the resin layer 5b include a film formed of a urethane resin, an epoxy resin, a polyester resin such as PET, or the like. Among them, the resin layer 5b is preferably a PET film from the viewpoint of toughness, and more preferably a biaxially stretched PET film.

  The thickness of the resin layer 5b is not particularly limited, but the upper limit is preferably 40 μm, more preferably 30 μm, and further preferably 25 μm. By setting the thickness of the resin layer 5b to 40 μm or less, the weight of the backing substrate 3 can be reduced, so that the weight of the metal roofing material 1 can be prevented from becoming too large. Further, by specifying the upper limit of the thickness of the resin layer 5b as described above, it becomes easier to obtain certification as a noncombustible material. On the other hand, the lower limit of the thickness of the resin layer 5b is preferably 5 μm, more preferably 10 μm, and still more preferably 12 μm. By setting the thickness of the resin layer 5b to 5 μm or more, the substance that corrodes the metal foil 6 can be sufficiently blocked while securing the toughness of the resin layer 5b and improving the piercing strength.

  The two resin layers 5a and 5b and the metal foil 6 may be directly bonded, or may be bonded using an adhesive. The adhesive is not particularly limited as long as it has water resistance.

The backing substrate 3 having the above-described structure preferably has a piercing strength of 18 N or more, and more preferably 20 N or more. When the piercing strength is within the above range, it is difficult to be damaged during roofing, and the workability can be improved. The upper limit of the piercing strength is not particularly limited, but is preferably 60 N, more preferably 50 N, and further preferably 40 N.
Here, the term “piercing strength” as used herein means a value measured in accordance with JIS Z1707: 1997. Specifically, a needle having a diameter of 1.0 mm and a tip having a semicircular shape with a radius of 0.5 mm is pierced at a rate of 50 mm / min from the resin layer 5b side into the back substrate 3 until the needle penetrates. The maximum stress is defined as the piercing strength. In the present embodiment, the measurement was performed using a universal material tester (Strograph V10-D) manufactured by Toyo Seiki Seisakusho under an environment of a temperature of 23 ° C. and a humidity of 50% RH. The puncture strength was determined by setting the number of tests to 3 to 5, and the average value thereof was used as the result.

The backing substrate 3 preferably has a tensile strength of 140 N or more, and more preferably 150 N or more. When the tensile strength is in the above range, the wind resistance of the metal roofing material 1 can be improved. The upper limit of the tensile strength is not particularly limited, but is preferably 600 N or less, more preferably 500 N.
Here, in the present specification, “tensile strength” means a value measured in accordance with JIS K7127: 1999. Specifically, a tensile tester (AG-X-5) manufactured by Shimadzu Corporation was used to pull a test piece having a width of 30 mm at a tensile speed of 100 mm / min under an environment of a temperature of 23 ° C. and a humidity of 50% RH. This is the strength when the test piece breaks. Moreover, the tensile strength made the number of tests into 3 to 5, and made the average value the result.

  The laminate having the above-described features is obtained by thermocompression bonding the two resin layers 5a and 5b to the metal foil 6, or by bonding the two resin layers 5a and 5b to the metal foil 6 using an adhesive. Can be manufactured. The manufacturing conditions at that time are not particularly limited, and may be appropriately adjusted according to the materials used.

The core member 4 is disposed between the front base member 2 and the back base member 3, and can improve the performance required for the roofing material such as the effect of reducing rain noise, heat insulation, and crush resistance.
The material of the core material 4 is not particularly limited, and examples thereof include foamed resins such as urethane foam, phenol foam, and nurate foam such as polyisocyanurate foam. These can be used alone or in combination of two or more. However, it is essential to use non-combustible materials for roofing materials. The non-combustible material qualification test is performed by an exothermic test based on the ISO 5660-1 corn calorimeter test method. When the foamed resin serving as the core material 4 is urethane foam or the like that generates a large amount of heat, the thickness of the core material 4 can be reduced, or the foamed resin can contain inorganic particles.

  The thickness of the core material 4 is not particularly limited, but the lower limit is preferably 3 mm or more. By setting the thickness of the core material 4 to 3 mm or more, it is possible to secure the rain sound reducing effect, the heat insulation property, and the crush resistance. On the other hand, the upper limit of the thickness of the core material 4 is preferably 8 mm. By setting the thickness of the core material 4 to 8 mm or less, it becomes easier to obtain certification as a noncombustible material.

It is preferable that the metal roofing material 1 of the present embodiment having the above-described features has a lift coefficient of 8.3 N / mm or more. When the lift coefficient is within the above range, the wind resistance of the metal roofing material 1 can be improved. The upper limit of the lift coefficient is not particularly limited, but is preferably 50 N / mm.
Here, in the present specification, the “lift coefficient” means a value obtained based on the strength test method of the metal roofing material 1 described in JP-A-2017-166896. Specifically, after the metal roofing material 1 is tied to the base, a load for lifting is applied to an end of the metal roofing material 1 tied to the base, and the metal roofing material 1 corresponding to the load is lifted. Measure the amount of lift at the end. Then, based on the measurement results, a graph representing the relationship between the load (Y-axis) and the lift (X-axis) is created, and then the change in the load is divided by the change in the lift to obtain a lift coefficient. Can be calculated.

  Further, the metal roofing material 1 of the present embodiment may have a feature known in the art, as long as the effect of the present invention is not impaired. For example, a portion or the like for indicating a position where the binding member is driven into the front base material 2 may be provided.

  The metal roofing material 1 according to the present embodiment having the above-described structure is obtained by injecting a material (liquid foamed resin material) that becomes the core material 4 between the front base material 2 and the back base material 3, It can be formed by foaming and curing a material. Conditions such as the foaming temperature and time may be appropriately adjusted depending on the material used, and are not particularly limited.

  Hereinafter, the present invention will be described more specifically with reference to examples, but the present invention is not limited to these examples.

(Example 1)
A metal roofing material 1 shown in FIGS. 1 and 2 was produced.
First, a painted molten aluminum-zinc alloy-plated steel sheet having a thickness of 0.3 mm was prepared as the front substrate 2. Also, as the backing substrate 3, a laminate in which the resin layers 5a and 5b were a PET film having a thickness of 12 μm, and the metal foil 6 was a hard aluminum having a thickness of 50 μm (Young's modulus: 12,000 MPa). Here, the PET film and the hard aluminum foil were bonded using a nonflammable adhesive.
Next, a core material 4 was formed by injecting a foamed resin material between the front base material 2 and the back base material 3, foaming and curing. Nurate foam was used as the material of the core material 4, and the thickness of the core material 4 was 5 mm.

(Example 2)
Example 1 except that a resin layer 5a was a 5 μm thick urethane resin film, a resin layer 5b was a 12 μm thick PET film, and a metal foil 6 was a 70 μm thick hard aluminum foil. Metal roofing material 1 was obtained in the same manner as described above.

(Example 3)
Example 1 except that a resin layer 5a was a 2 μm-thick urethane resin film, a resin layer 5b was a 25 μm-thick PET film, and a metal foil 6 was a 70 μm-thick hard aluminum foil as the backing substrate 3. Metal roofing material 1 was obtained in the same manner as described above.

(Example 4)
Example 1 was repeated except that the resin layer 5a was a 12 μm thick PET film, the resin layer 5b was a 20 μm thick PET film, and the metal foil 6 was a 50 μm thick hard aluminum foil. Similarly, a metal roofing material 1 was obtained.

(Example 5)
Example 1 was repeated except that the resin layer 5a was a 12 μm thick PET film, the resin layer 5b was a 38 μm thick PET film, and the metal foil 6 was a 40 μm thick hard aluminum foil. Similarly, a metal roofing material 1 was obtained.

(Comparative Example 1)
A metal roofing material 1 was obtained in the same manner as in Example 1 except that a hard aluminum foil having a thickness of 50 μm was used as the backing substrate 3.

(Comparative Example 2)
A metal roofing material 1 was obtained in the same manner as in Example 1 except that a PET film having a thickness of 12 μm was used as the backing substrate 3.

(Comparative Example 3)
A metal film was formed in the same manner as in Example 1 except that a resin layer 5a was a PET film having a thickness of 12 μm and a metal foil 6 was a hard aluminum foil having a thickness of 50 μm (without a resin layer 5b). The roof material 1 was obtained.

(Comparative Example 4)
A metal was formed in the same manner as in Example 1 except that a resin layer 5b was a PET film having a thickness of 12 μm, and a metal foil 6 was a hard aluminum foil having a thickness of 50 μm (without the resin layer 5a). The roof material 1 was obtained.

The piercing strength and tensile strength of the back substrate 3 used in the above Examples and Comparative Examples were evaluated in advance. The specific evaluation method was as described above.
Further, with respect to the metal roofing materials 1 obtained in the above Examples and Comparative Examples, the lifting coefficient was evaluated and the weight was measured. The specific evaluation method was as described above.
Table 1 shows the results.

As shown in Table 1, in Examples 1 to 5, the piercing strength and tensile strength of the backing substrate 3 were high, and the lift coefficient as the metal roofing material 1 was also high. The metal roofing materials 1 of Examples 1 to 5 had the same weight as the metal roofing materials 1 of Comparative Examples 1 to 4.
On the other hand, in Comparative Examples 1 to 4, the piercing strength and the tensile strength of the back substrate 3 were low, and the lift coefficient as the metal roofing material 1 was low.

  As can be seen from the above results, according to the present invention, it is possible to provide a metal roofing material having excellent wind pressure resistance and workability and capable of reducing the weight.

DESCRIPTION OF SYMBOLS 1 Metal roof material 2 Front base material 3 Back base material 4 Core material 5a, 5b Resin layer 6 Metal foil

Claims (11)

A metal front base material, a back base material, a metal roofing material including a core material disposed between the front base material and the back base material,
A metal roofing material, wherein the backing substrate is a laminate in which a metal foil having a Young's modulus of 12,000 MPa or more is disposed between two resin layers.   The metal roofing material according to claim 1, wherein the piercing strength of the backing substrate is 18N or more.   The metal roofing material according to claim 1 or 2, wherein the backing substrate has a tensile strength of 140N or more.   The metal roofing material according to any one of claims 1 to 3, wherein the metal foil has a thickness of 10 to 200 µm.   The metal roofing material according to any one of claims 1 to 4, wherein the metal foil is a hard aluminum foil.   The metal roof according to any one of claims 1 to 5, wherein the resin layer of the laminate provided on the core material side is a film formed of a resin having good adhesion to the core material. Wood.   The metal roofing material according to claim 6, wherein the film is a film formed of a urethane resin, an epoxy resin, or a polyester resin.   The metal roofing material according to any one of claims 1 to 7, wherein the resin layer of the laminate provided on the side opposite to the core material side is a film formed of a polyester resin.   The metal roofing material according to any one of claims 1 to 8, wherein the thickness of the resin layer of the laminate provided on the core material side is 2 to 40 µm.   The metal roofing material according to any one of claims 1 to 9, wherein the thickness of the resin layer of the laminate provided on the side opposite to the core material side is 5 to 40 m.   The metal roofing material according to any one of claims 1 to 10, wherein a lifting coefficient is 8.3 N / mm or more.

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