Method for manufacturing a building sheet with an anti-condensation coating, one or two ends of which are without the anti-condensation coating.

Abstract

The invention relates to a simple and economical method for manufacturing a building sheet consisting of a metal sheet (1) with a hot-bonded anti-condensation coating (2), one or two ends (4, or 5, or 4 and 5) of which are without the anti-condensation coating. The method employs an electronic control module that orchestrates a suction unit mounted on a lifting device, an electric hot wire cutter also mounted on a lifting device, and a roll forming machine. The orchestration of the electronic control module aims to produce sheet metal sections without the anti-condensation coating. The cutting unit makes cuts within or at the ends of the sheet metal sections without the anti-condensation coating. A housing allows the anti-condensation coating coil unwinder to be positioned upstream of the sheet metal coil unwinder, thus enabling easy coil changeover. Figure for the abstract: FIG. 1

Description

Title of the invention: Method for manufacturing a sheet metal for buildings with an anti-condensation coating, one or both ends of which are devoid of an anti-condensation coating

[0001] The present invention relates to the field of methods for manufacturing construction materials, and more particularly sheets for buildings.

[0002] The present invention relates to a simple and economical method for manufacturing a sheet for buildings made of a metal sheet with an anti-condensation coating, hot-bonded, one or both ends of which are free from an anti-condensation coating.

[0003] Some buildings contain a humid environment and have roofs made of simple steel sheets, without thermal insulation. When the temperature outside these buildings is low, a thermal shock phenomenon can occur, causing condensation and dripping on the reverse side of the roofing sheets. This condensation and dripping phenomenon, generally referred to as "dripping", is a source of discomfort or even damage for people and property located in these buildings. This dripping phenomenon is amplified in buildings with a very high humidity environment, such as livestock buildings, wood storage buildings, or any other building containing damp foodstuffs.

[0004] In order to mitigate these dripping phenomena, and if these buildings do not require thermal insulation, the roofing of these buildings can be made of composite steel sheets coated with a non-woven textile film or felt, having capillary properties capable of preventing the dripping of condensed water. Such sheets are generally called "sheets with anti-condensation coating" or "sheets with condensation regulator" or "sheets with felt" or "sheets with textile film" or "sheets with drip attenuator". The textile film of the sheets with anti-condensation coating acts by absorbing and storing the condensates that form on the underside of the roofing when the dew point is exceeded, depending in particular on local meteorological data. When the hygrometric conditions are reversed, the textile film releases the stored water to the atmosphere, and thus prevents dripping and the resulting inconveniences.

[0005] The ends of sheets with anti-condensation coating are however subject to notable problems, in sheet-on-sheet overlap, and at the bottom of slopes. Humidity accumulates there, in one case by capillary rise, in the other due to weather conditions such as fog or driving rain, without the possibility of rapid desorption of the humidity into the ambient atmosphere. This wetting prolonged results from inconveniences such as mold or the peeling of the textile film at the ends of the sheets.

[0006] The prior art includes various solutions aimed at avoiding these inconveniences of mold or detachment of the textile film at the ends of sheets.

[0007] Conventionally, the textile film is manually neutralized on site at the top and bottom of the sheet metal. This is done either by removing it by burning with a heat gun, or by saturating the textile film by applying a varnish, or by applying hydrophobic products such as fluorocarbon resins. However, these manual neutralization processes have a number of drawbacks. Careful neutralization at each end of the sheet metal requires a significant amount of work time, in the order of two to three minutes per sheet metal. In addition, neutralizing the textile film by burning or by applying various products can lead to aesthetic problems or even premature corrosion of the sheet metal.

[0008] The prior art also includes various industrial processes.

[0009] Document EP 1 767 340 A1 describes an industrial process for manufacturing sheets provided with felt, the felt of which is neutralized at the ends of the sheets by melting the felt via gas nozzles typically occurring after the sheet cutting step. In said document, the felt is applied via a pre-adhesive felt reel, this reel being located on an unwinder located under the infeed table.

[0010] Document FR 3 109 595 is also known, which describes an industrial process for neutralizing the coating on the ends of sheets by applying a hydrophobic product, such as a C6 fluorocarbon.

[0011] Since these methods only involve neutralizing the coating by applying energy or a chemical product to the anti-condensation coating, they do not offer any useful information in the context of the intended application of the invention, in particular to lead to a simple and economical method for manufacturing a sheet as defined above. All these methods require applying forces and products to a superfluous anti-condensation coating. Furthermore, concerning the application of anti-condensation coating via pre-adhesive reels, this method generates additional costs due to the discontinuity in the production chain, or even technical problems during the rewinding of the kraft or PVC protecting the adhesive; it also generates a significant additional cost due to the fact that the kraft or PVC protecting the adhesive loses its economic value once unwound.Regarding the application of anti-condensation coating via coating reels whose unwinder is located under the infeed table, this method does not allow for rapid splicing of the coating at the end of the reel. Regarding the use of gas burners, their safe application is known to be complex, whether in a construction site environment or in an industrial environment, whether due to the risk of . burns as well as from the fumes resulting from the combustion of the coating. Regarding the application of varnish, the toxicity linked to the fumes of volatile organic compounds often proves problematic. Regarding the application of hydrophobic products, the risks linked to the bioaccumulation of perfluoro-n-hexanoic acids such as C6 in the environment will be recognized, especially in the context of agricultural use.

[0012] The aim of the present invention is to overcome the problems mentioned above and to propose a simple and economical method for manufacturing a sheet consisting of a metal sheet with an anti-condensation coating, hot-bonded, one or both ends of which are devoid of an anti-condensation coating.The method is notably composed of a standard anti-condensation coating reel unwinder located upstream of a standard steel sheet reel unwinder, a box for the passage of the anti-condensation coating, a gluing device, a standard electric hot cutting wire placed on a lifting device intended to cut the anti-condensation coating, a suction box placed on a lifting device intended to stop the anti-condensation coating when it is not desired to apply it to the sheet, a sheet metal profiling-cutting machine, and electronic control modules capable of orchestrating the various components mentioned above in order to carry out a selective application of the anti-condensation coating.

[0013] Particularly advantageously, the method is economical, whether due to the saving of glue and anti-condensation coating compared to the prior art, or due to the use of standard components known to be inexpensive, reliable and easily interchangeable.

[0014] In another particularly advantageous way, the process is optimized on an industrial level thanks to the use of a box for the passage of the coating. This makes it possible to place the anti-condensation coating reel unwinder upstream of the sheet metal reel, allowing on the one hand an easy reel change via a forklift, and on the other hand production without scrap and rapid replenishment because the coating can be quickly joined without loss via the use of double-sided adhesive.

[0015] Advantageously, the method avoids polluting emissions. No chemical product is applied. In a particular configuration, the fiber of the coating is burned only over the 0.5 mm diameter of the cutting wire, in the case of a 100 g / m2 coating and for a 1000 mm wide coating, less than 50 mg of fiber is burned at each cut.

[0016] Advantageously, the cuts made on the coating are perfectly straight and avoid aesthetic problems.

[0017] Advantageously, the process avoids any neutralization work or manual application of product during implementation on site, generating additional savings.

[0018] Other characteristics and advantages of the invention will emerge from the detailed description which follows, with reference to the appended drawings in which:

[0019] [Fig-1] is a perspective view cut away from the back of an anti-condensation sheet according to the invention.

[0020] [Fig.2] is a schematic view of the manufacturing method according to the invention, the process working from left to right in this schematic view.

[0021] The invention provides a method for manufacturing an anti-condensation sheet. This sheet consists of a metal sheet (1) coated with an anti-condensation coating (2), one rib (3) and one or two ends (4, or 5, or 4 and 5) of which are devoid of anti-condensation coating in order to prevent the aforementioned inconveniences.

[0022] The manufacturing method uses a standard anti-condensation coating reel unwinder (10) which is located upstream of a standard steel sheet reel unwinder (11), thanks to a box in which the anti-condensation coating passes (12) which allows the coating to be supplied from below the steel sheet reel unwinder. The box has removable plates allowing maintenance to be carried out and the coating to be passed manually when the machine is first used. The sheet is unwound on an inlet table (14) which is aligned with a sheet metal profiler (19). The anti-condensation coating reel is slightly offset from the profiler, in order to keep a rib free of coating (3). By a roller return system, the anti-condensation coating is presented to a gluing device (13) which applies a film of adhesive product to the coating.A suction box placed on a lifting device (15) and an electric hot cutting wire placed on a lifting device (16) orchestrated by an electronic control module called "coating gluing controller" whose operation will be detailed in the description which follows. Alternately from this orchestration, either sheet metal on which anti-condensation coating is glued (17), or sections of sheet metal without anti-condensation coating (18) emerge. A profiling machine (19), gives shape to a profiled sheet metal (20) which is then cut by a cutting system (21).

[0023] According to the invention, a standard non-woven needle-punched polyester fibre coating reel with a mass of approximately 100 g / m2 is placed on the anti-condensation coating reel unwinder (10), and a coated steel sheet reel with a thickness of between 0.50 and 0.80 mm is placed on the sheet metal reel unwinder (11).

[0024] According to the invention, thanks to the box (12) the anti-condensation coating coil unwinder (10) is positioned upstream of the sheet metal coil unwinder (11), at a distance of up to several meters, which allows easy coil change by forklifts compared to the prior art. In addition, this positioning allows for waste-free production and rapid replenishment because the coating can be quickly spliced ​​without loss via the use of double-sided adhesive. Connected to a laser measuring device located above the coating unwinder (10), the profiler (19) is automatically slowed down and then paused when the coating runs out. The operator is then warned of the need to insert a new coil on the unwinder (10) via an "insert new coil and splice" message.The operator inserts a new reel of coating onto the unwinder (10), joins the end of the coating of the new reel to the coating fallen onto the box (12) using double-sided adhesive, then indicates to the profiler (19) that the operation has been carried out correctly, after which the profiler restarts.

[0025] According to the invention, the gluing device (13) is preferably, and not limited to, a device for applying "hot-melt" glue via nozzles, a synthetic rubber-based hot-melt glue which is in the form of solid blocks at room temperature and is particularly inexpensive. It is understood that the gluing device (13) could also use a roll of double-sided adhesive tape, or any other gluing method.

[0026] According to the invention, the suction box (15) used is a box with a hole on the top, connected to a vacuum cleaner, mounted on a pneumatic arm type lifting device.

[0027] According to the invention, the hot cutting wire (16) used is a standard electrical resistance cutting wire with a diameter of approximately 0.50 mm, mounted on a pneumatic arm type lifting device.

[0028] According to the invention, the operator of the machine defines the desired length of the sheets via the human-machine interface of the profiling machine (19). In order for the cutting system (21) to make its cuts in the sections without anti-condensation coating (18), the profiling machine is connected to an electronic control module called "gluing controller", to which the profiling machine sends ex ante, a few meters before a cut, an impulse aimed at producing a section of sheet without anti-condensation coating.

[0029] According to the invention, the "gluing controller" operates as follows. In the default situation, the controller places the suction box (15) and the hot cutting wire (16) in the low positions, as illustrated in [Fig.l]. When the "gluing controller" receives an impulse from the profiler to produce a section of sheet metal without anti-condensation coating (18), it starts the following orchestration. First of all the "glue controller" asks the profiler to start pause via an electrical impulse. Then the "gluing controller" puts the suction box (15) under air depression via the power supply of its vacuum cleaner and the resistance of the hot cutting wire (16) into heating via a power supply. Then the "glue controller" lifts the hot cutting wire (16) against the anti-condensation coating, which instantly cuts the coating, the coating then falls onto the suction box (15) which holds it by air suction. Then the "glue controller" cuts the current to the hot cutting wire resistor (16) and lowers its lifting device. Then the "gluing controller" asks the profiling machine to start up for profiling a section of sheet metal without anti-condensation coating (18) whose length is defined by the operator via the profiling machine's human-machine interface. Usually, a length of 40 cm is defined for these sections when we want to produce sheets whose two ends are without anti-condensation coating over 20 cm, but we can also define a length of 20 cm if we want, for example, to produce sheets whose only one end is without anti-condensation coating over 20 cm. Other lengths can be defined if necessary. Then, once the section of sheet without anti-condensation coating (18) has been profiled to the desired length, the "gluing controller" asks the profiling machine to pause. Then the "gluing controller" lifts the suction box (15) against the sheet metal, which sticks the anti-condensation coating to the sheet metal. Then the "glue controller" asks the profiler to start up again. Finally, the "glue controller" cuts the power to the vacuum cleaner in the suction box (15) and lowers its lifting device after a few centimeters of profiling to ensure good adhesion of the anti-condensation coating to the sheet metal.

[0030] According to the invention, the cutting system (21) makes its cuts inside or at the end of the sections without anti-condensation coating, generally at the beginning, in the center or at the end of these, which results in sheets of which one or two ends (4, or 5, or 4 and 5) are devoid of anti-condensation coating.

[0031] According to the invention, the "gluing controller" coupled with a standard profiling machine equipped with a standard servo-converter and a standard gluing roller allows a precision of production of the sections of the order of ±5 mm. On a standard 5-wave profiling machine 20 meters per minute with 10 kW motorization, the orchestration once optimized allows to produce a section of sheet without anti-condensation coating (18) of 40 cm in approximately 12 seconds.

[0032] In short, the implementation of the invention solves the problems of the state of the technique. It is economical in terms of the quantity of products applied, uses components known to be inexpensive, reliable and easily interchangeable, and allows rapid production in very large series.

[0033] The method according to the invention makes it possible to produce an anti-condensation sheet, one or two ends of which (4, or 5, or 4 and 5) are devoid of anti-condensation coating, for the covering of buildings with a high humidity environment.

Claims

Claims

1. Method for manufacturing a sheet metal for anti-condensation buildings, characterized in that it uses: - a standard anti-condensation coating reel unwinder (10) 9 - a standard steel sheet reel unwinder (11); - a gluing device (13); - a cutting system (21) and; - an electronic control module orchestrating: a suction box placed on a lifting device (15), an electric hot cutting wire placed on a lifting device (16) and a profiling machine (19) to produce sections of sheet metal without anti-condensation coating (18). The coating reel unwinders (10) and sheet metal (11) are arranged so that the coating is supplied from below the sheet metal. The coating is presented to the gluing device (13) which applies a film of adhesive product to the coating before it is applied to the sheet metal.The suction box (15) and the hot cutting wire (16) are placed on lifting devices, which via electronic orchestration, allow the production of either sheet metal on which the coating is glued (17), or sections of uncoated sheet metal (18); the profiling machine (19) then shapes a profiled sheet metal (20) which is then cut by the cutting system (21).

2. Method according to claim 1, characterized in that the cuts of the cutting system (21) are made inside or at the end of the sections of sheet metal without anti-condensation coating (18).

3. Method according to any one of claims 1 to 2, characterized in that a box in which the anti-condensation coating (12) passes is placed so as to allow the positioning of a standard anti-condensation coating coil unwinder (10) upstream of a standard steel sheet coil unwinder (11).

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