Method for customized production of roof detail parts

Abstract

A method for producing a roof detail part for sealing a roof element, the method comprising the steps of: (a) providing and / or obtaining a digital model of a roof element to be sealed; (b) producing, based on the digital model, a roof detail part which fits onto the outer shape of the roof element by additive manufacturing.

Description

Technical Field

[0001] The present invention relates to a method for producing roof detail parts for sealing roof elements and a method for sealing roof elements. Background Technology

[0002] Especially for flat roofs, sealing the roof area as a pre-construction measure is crucial to keeping the roof weatherproof. Therefore, prefabricated and custom-made roof details are often used for specific roof elements or areas, such as penetrations, wall cladding, corners, or pipes.

[0003] Custom roof details can be, for example, preformed tubes, angled parts, and so on. When custom roof details are watertightly attached to the sealing material (such as a membrane) of the main roof area, the entire roof area can be sealed in a reliable and durable manner.

[0004] Due to varying roof constructions, numerous specially designed roof detail components are required. Therefore, either so-called "universal shapes" that can fit a number of geometries are used, or custom components must be designed specifically for each situation. Universal shapes have the following drawbacks: they are often not perfectly suited to the actual geometry and are frequently subjected to stress or bending, posing a potential risk regarding watertightness. Therefore, these components must be installed and assembled with extreme care.

[0005] On the other hand, custom parts must be handmade, which makes them very expensive. Another drawback is that handmade parts are often welded together based on a basic shape, which introduces the risk of additional weld lines as potential weak points, especially when considering repeated seasonal heating-cooling cycles that cause thermal stress.

[0006] As an alternative to prefabricated components, a so-called "liquid-applied coating" can be used. However, the connection with other sealing materials on the roof (e.g., membranes) poses a potential weakness regarding watertightness, as the application hinges on proper technique.

[0007] Therefore, there is a need to provide improved solutions that overcome the above-mentioned shortcomings. Summary of the Invention

[0008] One object of the present invention is to provide a method for providing customized roof detail components that can be produced quickly and cost-effectively, regardless of the number of components required.

[0009] Surprisingly, it has been found that these objectives can be achieved through the technical solutions provided in this application. Therefore, the core of this invention is a method for producing roof detail components for sealing roof elements, the method comprising the following steps:

[0010] a) Provide and / or obtain digital models of the roof components to be sealed;

[0011] b) Based on the digital model, produce roof detail parts that are fitted onto the external shape of the roof element using additive manufacturing.

[0012] It has been proven that the combination of obtaining a digital model of the roof element to be sealed and additive manufacturing allows for the production of roof detail components that perfectly fit the roof element and can be manufactured in a cost-effective and efficient manner. Because production is based on a digital model of the actual roof element, every characteristic of the roof element is considered in the roof detail components.

[0013] In particular, the method of this invention allows for the one-piece production of roof detail components, even those with highly complex shapes. Since these roof detail components do not include weld lines or adhesively bonded sections, watertightness is not an issue.

[0014] In summary, the method of this invention provides an efficient way to produce personalized roof detail components. These components can be produced in a timely manner by anyone with basic technical expertise. Therefore, specialized technical training is not required.

[0015] Furthermore, producing roof detail components via additive manufacturing allows for the production of individual components at very low cost. Specifically, the cost of each component is essentially independent of batch size. Moreover, it can be ensured that the quality provided by these roof detail components is identical to that of a type of membrane typically used to seal large roof areas.

[0016] Other aspects of the invention are the subject matter defined in other aspects of this application. Particularly preferred embodiments are outlined throughout the specification and other aspects.

[0017] The following describes some ways of implementing the technical solution of the present invention:

[0018] A first aspect of the invention relates to a method for producing roof detail parts for sealing roof elements, the method comprising the steps of:

[0019] a) Provide and / or obtain digital models of the roof components to be sealed;

[0020] b) Based on the digital model, produce roof detail parts that are fitted onto the external shape of the roof element using additive manufacturing.

[0021] Preferably, the roof element is a roof element of a building.

[0022] The term "additive manufacturing" refers to a method of producing three-dimensional objects or shaped bodies by selective three-dimensional deposition, application, and / or solidification of materials. In this process, the deposition, application, and / or solidification of materials occur specifically based on a data model of the object to be produced, and particularly within layers. In additive manufacturing methods, each object is typically produced from one or more layers. Objects are typically manufactured using amorphous materials (e.g., liquids, powders, granules, pastes, etc.) and / or neutral-shaped materials (e.g., strips, wires) that have undergone chemical and / or physical processes (e.g., melting, polymerization, sintering, solidification, or hardening).

[0023] Terms such as "generative manufacturing," "additive manufacturing," or "3D printing" are also used to refer to additive manufacturing methods. Additive manufacturing, or 3D printing, follows a fundamentally different manufacturing approach compared to conventional techniques that create objects by molding / casting or subtracting / machining materials from an original object. The processes used in additive manufacturing extend its conceptual origins in inkjet printing to a third dimension with other materials. The design of each object can be altered without increasing manufacturing costs, thus providing customized solutions for a wide range of products.

[0024] A "digital model" is a digital representation of a real object (i.e., a roof element) that accurately replicates the shape of the object. Typically, digital models are stored in computer-readable data storage, particularly in data files. Data file formats may include, for example, Computer-Aided Design (CAD) file formats, G-code (also known as RS-274) file formats, and / or STL file formats. Specifically, the digital model is at least a digital representation of the external shape of the roof element.

[0025] Specifically, roof elements include roof trim, roof drain pipes, roof edges, roof extension joints, roof cladding, roof penetrations, roof sleepers, roof transitions, roof corners, roof tie-ins, and / or roof walls.

[0026] In particular, roof detailing is a cover, hood, cap, or cladding for roof elements, especially for roof trim, roof drains, roof edges, roof extension joints, roof cladding, roof penetrations, roof sleepers, roof transitions, roof corners, roof connectors, and / or roof walls.

[0027] In step b), the control system can be used to generate control data from the digital model to control the additive manufacturing process. Such a control system is known and commercially available. The control system can be part of an additive manufacturing device (e.g., a 3D printer), or it can be part of a separate data processing unit (e.g., a computer system).

[0028] When producing the roof detail component in step b) of the method of the present invention, the digital model is considered as the basis for producing the roof detail component by additive manufacturing. In particular, the roof detail component is produced to have an internal shape corresponding to the negative shape of the digital model.

[0029] Specifically, in step b), another digital model of the roof detail component to be produced is generated, wherein the other digital model is calculated based on the digital model of the roof element. For example, the other digital model can be obtained by taking the outer surface of the digital model of the roof element and generating a surface with a negative shape as the inner surface of the other digital model of the roof detail component. For example, the outer surface of the other model of the roof detail component can be generated by adding a certain wall thickness to the area behind the inner surface of the other digital model.

[0030] Preferably, in step a), a digital model of the roof element is obtained by 3D scanning of the roof element. 3D scanning is a process of analyzing real-world objects (e.g., roof elements) to collect data about their shape. The collected data can then be used to construct a digital model of the object. Therefore, a control system can be used to generate a digital model from the collected data. The control system can be part of the 3D scanner, or it can be part of a separate data processing unit (e.g., a computer system).

[0031] 3D scanning allows for the direct scanning of actual roof components directly onto the roof. This ensures that the digital model is an accurate representation of the actual roof component to be sealed. Overall, the combination of 3D scanning and additive manufacturing (especially using 3D printers) provides an efficient way to produce personalized roof detail components with high precision.

[0032] However, in principle, a digital model can also be obtained by manually measuring all the lengths and angles of the roof elements and manually generating a digital model in modeling software. However, this is time-consuming and more prone to errors.

[0033] Many different 3D scanners are available on the market that can be used for 3D scanning. Preferably, handheld and / or portable 3D scanners are used to perform scanning of roof components. Handheld and / or portable 3D scanners do not require complex installation and allow for quick and easy scanning of roof components to be sealed.

[0034] Preferably, the 3D scanner is designed to capture objects with a length of 1 cm to 20 m, particularly 20 cm to 10 m.

[0035] Specifically, 3D scanners are non-contact 3D scanners. Such scanners emit some form of radiation, such as light, ultrasound, or X-rays, and detect the radiation reflected from or passing through the object being scanned in order to detect the object.

[0036] For example, the 3D scanner is a "calibry 3D scanner" type scanner manufactured by Thor3d Company (companyThor3d, Varshavskoe Sh.33, Moscow, Russia) in Varshavskoe Sh.33, Russia.

[0037] Preferably, additive manufacturing is achieved through 3D printing, particularly through fused deposition modeling (FDM) or fused particle fabrication (FPF). FDM is a process that typically uses continuous filaments of thermoplastic materials. FPF is similar to FDM, but it uses microparticles (such as granules) instead of continuous filaments as the feed material. FPF is also known as fused granular fabrication (FGF).

[0038] Thus, the filament is fed through a moving, heated printer extruder head and deposited onto the growing object. The printer extruder head moves under computer control to define the printed shape. Typically, the head moves in two dimensions to deposit one horizontal plane or layer at a time. Then, the object and / or the printer extruder head are moved vertically in small increments to begin a new layer.

[0039] Many different 3D printers that can be used for the methods of this invention are available on the market.

[0040] Preferably, the roof details are made of plastic materials, especially thermoplastic materials. In particular, the melting point of the plastic material is between 120°C and 300°C, preferably between 140°C and 250°C.

[0041] Specifically, the plastic material is selected from thermoplastic polyolefins (TPO), polyvinyl chloride (PVC), and / or ketone ester (KEE).

[0042] These materials can be formulated with antioxidants, fillers, pigments, reinforcing materials, and / or other thermoplastic polymers. Reinforcing materials can be selected from fibers, such as carbon fibers, polyethylene fibers, and / or glass fibers. The additional thermoplastic polymer preferably has a melting point between 50°C and 300°C, more preferably between 80°C and 250°C.

[0043] Roofing details made of plastic materials, especially thermoplastics, are best compatible with common sealing materials used for roofs, such as membranes. Specifically, roofing details made of thermoplastics can be easily welded to thermoplastic membranes to achieve a watertight connection.

[0044] In particular, the roof details are manufactured with a single-layer structure. Such a structure is physically stable and can be reliably produced using additive manufacturing.

[0045] Preferably, the roof details are integral components. With integral components, there is no risk of leakage due to weld lines or the like. Therefore, integral components are more reliable than components composed of several interconnected sections.

[0046] Specifically, the wall thickness of the manufactured roof detail components ranges from 0.1 to 10 mm, particularly 1 to 5 mm. Such components have proven to be physically stable and watertight, while remaining sufficiently flexible for installation. However, roof detail components with other wall thicknesses may also be suitable for specific applications.

[0047] Another aspect of the invention relates to a method for sealing roof components, comprising the following steps:

[0048] (i) Perform the method of the present invention as described above in order to obtain roof detail parts fitted onto the roof element;

[0049] (ii) Install the roof detail components onto the roof element;

[0050] (iii) Optionally, the installed roof detail component may be connected to another sealing element on the roof, particularly by heat welding.

[0051] In step (iii), the other sealing element may be, for example, another roof detail component and / or sealing material for the main area of ​​the roof, such as a membrane and / or waterproof sheet.

[0052] Using this method, the entire roof area can be sealed with sealing materials and roof detail components that are interconnected in a watertight manner.

[0053] Preferably, the material of the roof detail component is selected such that it can be heat-welded to the other sealing element. In particular, both the roof detail component and the other sealing element are made of thermoplastic material, preferably the material described above.

[0054] However, other combinations can also be applied to specific applications. Alternative joining methods, such as adhesive bonding and / or clamping, can be used instead of thermal welding.

[0055] Further advantageous configurations of the invention are apparent from exemplary embodiments. Attached Figure Description

[0056] The accompanying drawings, used to explain and illustrate the embodiments, show:

[0057] Figure 1 A schematic diagram of a section of a flat roof with a pipe extending through a membrane, wherein the pipe is scanned using a 3D scanner to obtain a digital model of the pipe;

[0058] Figure 2 This is a schematic diagram of the 3D printing process for roof detail components, the 3D printing process being based on... Figure 1 Digital models;

[0059] Figure 3 for Figure 1 The flat roof section in Figure 2 A schematic diagram showing the roof detail components installed on the pipe and the roof detail components thermally welded to the membrane to create a watertight connection;

[0060] Figure 4 Existing technical methods for models of sealing the corners of complex shapes on flat roofs using numerous small pieces of roofing membrane; and

[0061] Figure 5 for Figure 4 3D scanning of the corner of the model.

[0062] In the figures, the same components are given the same reference numerals. Detailed Implementation

[0063] exist Figure 1 On the left, a section of the flat roof is shown. Specifically, a thermoplastic membrane 2 is arranged on top of the flat roof, wherein roof elements in the form of cylindrical pipes 1 extend vertically. Figure 1 In this case, pipe 1 extends through the circular opening 2.1 in membrane 2.

[0064] Using a portable 3D scanner 3, a laser 4 is used to scan the pipe 1 to collect data about its shape. The collected data is processed within the control unit of the scanner 3 and stored as a digital model 6 of the pipe 1 in a data file 5. For example, the data file 5 is in CAD file format.

[0065] like Figure 2As shown, a data file 5, including a digital model 6 of the pipe 1, is transferred to a 3D printer 7. Within the control unit 8 of the 3D printer 7, another digital model 10, based on the digital model 6 of the pipe 1, is generated to form a roof detail component fitted onto the pipe 1, and this other digital model is stored in another data file 9. Therefore, the negative shape of the outer surface of the digital model 6 of the pipe 1 corresponds to the inner surface of the other digital model 10 of the roof detail component.

[0066] Based on the other digital model 10, the control unit 8 of the 3D printer 7 generates control data for the print head 11, thereby producing a roof detail component 12 assembled onto the pipe 1. The material used for printing is a thermoplastic polymer with a melting point of, for example, 160°. Figure 2 As seen on the right, the roof detail component 12 is a monolithic hollow cylinder that is closed at the top and open at the bottom.

[0067] Once the roof detail 12 is ready, it can be installed onto pipe 1, such as... Figure 3 As shown in the diagram. Thus, the roof detail component 12 is connected to the membrane 2 in the area of ​​the opening 2.1 by surrounding heat welding, so as to provide a watertight connection between the roof detail component 12 and the membrane 2.

[0068] Figure 4 This paper illustrates a prior art method for sealing the corners of a complex-shaped flat roof. The corner is thus covered with several small pieces of roofing membrane, which are joined together by thermal welding. Therefore, this method results in a "patchy" cover with several weak points (weld lines) regarding watertightness.

[0069] Figure 5 Show Figure 4 3D scanning of the model's corners. Similar to... Figure 1-3 The process shown involves collecting data to assemble a digital model of the corner, which is then fed into a 3D printing system that uses a suitable thermoplastic compound to produce monolithic detailed parts.

[0070] Therefore, those skilled in the art will understand that the invention can be embodied in other specific forms without departing from the spirit or essential characteristics of the invention. Consequently, the embodiments disclosed herein are to be considered illustrative rather than restrictive in all respects.

Claims

1. A method for producing a roof detail component (12) for sealing a roof element (1), the method comprising the steps of: (a) Provide and / or obtain a digital model (6) of the roof element (1) to be sealed, by means of a 3D scan of the roof element (1); (b) Based on the digital model (6), a roof detail component (12) is produced by additive manufacturing and assembled onto the outer shape of the roof element (1), the roof detail component (12) being produced to have an internal shape corresponding to the negative form of the digital model (6) of the roof element (1); The roof detail components are manufactured to have a single-layer structure; Among them, the roof element (1) is a roof trim, a roof drain pipe, a roof edge, a roof extension joint, a roof wall, a roof penetration, a roof sleeper, a roof transition piece, a roof corner, a roof connector and / or a roof wall; The roof detail component (12) is a cover, shroud, cap, or paving for the roof element.

2. The method according to claim 1, wherein, The scanning of the roof element (1) is performed using a handheld and / or portable 3D scanner (3).

3. The method according to claim 1, wherein, Additive manufacturing is achieved through 3D printing.

4. The method according to claim 1, wherein, Additive manufacturing is achieved through fused deposition modeling (FDM) or fused particle fabrication (FPF).

5. The method according to claim 1, wherein, The roof detail component (12) is made of plastic material.

6. The method according to claim 5, wherein, The plastic material is a thermoplastic material.

7. The method according to claim 6, wherein, The thermoplastic material is thermoplastic polyolefin (TPO), polyvinyl chloride (PVC), and / or ketene ester (KEE).

8. The method according to claim 5, wherein, The plastic material further includes antioxidants, fillers, pigments, reinforcing materials and / or other thermoplastic polymers.

9. The method according to claim 1, wherein, The roof element is the roof element of the building.

10. The method according to claim 1, wherein, The wall thickness of the produced roof detail components (12) is 0.1mm-10mm.

11. The method according to claim 10, wherein, The wall thickness of the produced roof detail component (12) is 1mm-5mm.

12. The method according to claim 1, wherein, The roof detail component (12) is produced such that the outer surface of the roof detail component (12) is similar to the outer surface of the roof element, that is: the outer surface of the roof detail component (12) represents a uniformly scaled shape of the outer surface of the roof element (1).

13. The method according to any one of claims 1-12, wherein, In step (b), based on the digital model (6) of the roof element (1), another digital model (10) of the roof detail component (12) to be produced is generated.

14. A method for sealing a roof element (1), comprising the following steps: (i) Perform the method according to any one of claims 1-13 to obtain a roof detail component (12) fitted onto the roof element (1). (ii) Install the roof detail component (12) onto the roof element (1).

15. The method according to claim 14, wherein, The method further includes: (iii) Connect the installed roof detail (12) to another sealing element (2) on the roof.

16. The method according to claim 15, wherein, The installed roof detail component (12) is connected to another sealing element (2) on the roof by hot welding.

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