Roof resin patch and method for manufacturing the same

Abstract

This invention provides a highly versatile waterproofing resin patch that offers excellent adhesion to ethylene propylene-based elastomers that make up roof structures. [Solution] The resin patch 1 uses a TPO raw material produced by extrusion as the starting material. A flat, disc-shaped sheet material 5 punched out from the raw material is used as the direct material, which is heated to a temperature below its melting point to soften it, and then plastically deformed into a three-dimensional shape by a press device 14. Unlike injection molded products, no release agent is used, so it has excellent adhesion to the TPO layer that makes up the roof. In addition, since the resin patch 1 is made from an extruded product similar to the TPO layer of the roofing material, it also has excellent affinity with the TPO layer of the roof.

Description

Technical Field

[0001] The present invention relates to a resin patch for heat-sealing a joint portion by heat-sealing to a corner portion of a roof composed of a roofing material coated with an ethylene-propylene elastomer film.

Background Art

[0002] As buildings such as warehouses and various facilities whose bodies are made of steel frames or reinforced concrete, there is a type in which the roof is formed flat. This type of roof often has a structure in which a roofing material is attached to a steel deck plate or a concrete slab via a heat insulating material. There is a structure in which a resin film is coated on a metal plate (steel plate) as a roofing material. In this case, a high waterproof function and weather resistance are exhibited by the resin film.

[0003] And, it is normal for a parapet surrounding the periphery to rise from the roof surface, and it is also often the case that columnar portions protrude in an island shape from the roof surface. Therefore, there are corner portions such as outer corners and inner corners at the roof portion. In this case, both the parapet and the columnar portion are composed of metal plates coated with a resin film on their surfaces. However, there may be a joint between the metal plates at the corner portion, or the edge of the resin protection film arranged for sealing may be located at the corner portion, and a joint portion where rainwater or the like can penetrate may appear at the corner portion of the roof.

[0004] Therefore, the corners of the building are blocked (covered) with resin patches. As an example, Patent Document 1 discloses a type of resin patch that is adhered with an adhesive, and Patent Document 2 discloses a type of resin patch that is heated and fused. FIG. 1 of Patent Document 1 discloses a form in which six concavities and convexities are continuous in the circumferential direction, and it is described that this is a molded product. The same applies to Patent Document 2, which is formed in a three-dimensional shape as a molded product.

[0005] Products that are heat-sealed in a form similar to Figure 1 of Patent Document 1 are commercially available, and these include those made of polyvinyl chloride (PVC) and ethylene propylene elastomer (TPO), but both are molded products. [Prior art documents] [Patent Documents]

[0006] [Patent Document 1] CD-ROM of Japanese Utility Model Publication No. 06-71736 [Patent Document 2] Japanese Patent Application Publication No. 61-294046 [Overview of the project] [Problems that the invention aims to solve]

[0007] Disc-shaped heat-sealable resin patches are also commercially available for use in outer and inner corners. With these patches, the worker holds the resin patch against the wall or roof surface with one hand while inserting the flat nozzle of a heat gun between the patch and the surface to heat it. Once the patch is melted, the worker switches to a roller and presses the resin patch against the wall or roof surface to fix it in place. However, this method is cumbersome because it requires heating the resin patch with the heat gun while it is peeled back, resulting in very poor work efficiency.

[0008] In contrast, if the resin patch is pre-formed into a three-dimensional shape as described in Patent Document 1, the resin patch can be aligned to external and internal corners with a single touch, and the work of peeling off the resin patch becomes unnecessary, making it easier to blow hot air with a heat gun, thus improving work efficiency.

[0009] However, existing three-dimensional resin patches, even those made of TPO, had poor adhesion to the TPO film layer that makes up the roofing material. Even after heating them to their melting point with a heat gun and pressing them with a roller, adhesion failures (low adhesive strength and uneven adhesion) frequently occurred, making it difficult to achieve the desired sealing performance. Consequently, it was necessary to use flat, disc-shaped resin patches for the work, resulting in poor workability.

[0010] The present invention was made against this backdrop, and aims to provide a highly versatile resin patch for roofs that offers excellent heat-sealing properties. [Means for solving the problem]

[0011] The reason why existing three-dimensional resin patches have poor adhesion to resin-coated roofing materials is not clear, but two reasons can be considered. One reason is the presence of a release agent, which is presumably used to improve mold release during injection molding using a mold device. It is speculated that the release agent acts as a thin film between the resin patch and the roofing material, thereby hindering adhesion.

[0012] Furthermore, the molding of the resin patch is carried out using a mold device equipped with a fixed mold (cavity) and a movable mold (core). After molding, the product is separated from the fixed mold while still attached to the movable mold, and the product is detached from the movable mold by ejector pins or the like during the movable mold's retraction. It is presumed that a release agent is applied to the fixed mold to improve cavity separation, and also presumed that a release agent is applied to the movable mold to prevent deformation of the resin patch when ejected from the movable mold. It is presumed that the release agent is transferred to the resin patch as a product and functions as a barrier that inhibits adhesion during fusion to the roofing material.

[0013] Another possible reason for the poor adhesion of resin patch molded products to resin-coated roofing materials is subtle differences in the composition of the resin itself. Specifically, the resin film used in roofing materials is manufactured by extrusion, where molten resin extruded from a T-die is cooled and aligned to a predetermined thickness by rollers, and the rolled film is fused or bonded to a metal plate. In contrast, resin patches as molded products are manufactured by melting resin pellets and injecting and solidifying them under high pressure into the space of a mold. Subtle differences in the composition of the raw materials (pellets), or subtle differences in molecular orientation and cross-linking structure, may result in the resin patch becoming difficult to adhere to the TPO film of the roofing material even after it has softened.

[0014] The inventor of the present invention completed the present invention based on this analysis of the existing product. The present invention includes many components, the typical components of which are specified in each claim.

[0015] Of these, the invention described in claim 1 constitutes a higher-level concept of the manufacturing method. "A method for manufacturing waterproof resin patches that are heat-sealed to the corners of roofs made of roofing material coated with ethylene propylene elastomer film." It is targeted at, "A process of preparing a flat material sheet of ethylene propylene-based elastomer formed to a predetermined size and shape, A step of heating the sheet material to a temperature below its melting point and at which it can be plastically deformed to soften it, The process involves pressing the softened sheet material from both sides using a press device to plastically deform it into a three-dimensional shape, It contains It has the following characteristics.

[0016] The invention of claim 2 is characterized by a method for softening a sheet material. That is, the invention of claim 2 is, in claim 1, "The process of softening the sheet material is carried out by placing the sheet material on a rotating table in a horizontal position and blowing hot air onto it from above while rotating it horizontally." It has the following characteristics.

[0017] The invention of claim 3 limits the use of the resin patch. In claim 1 or 2, "On the opposing surfaces of the upper and lower dies constituting the press device, wave-shaped concavities and convexities that mesh with each other are continuously formed in the circumferential direction, and the resin patch is formed in a concavo-convex shape that undulates in the circumferential direction." It has the following characteristics.

[0018] The invention of claim 4 is an expansion example of claim 1 or 2. "When the sheet material is sandwiched and plastically deformed by the upper and lower dies of the press device, by making the distance between the upper and lower dies larger than the distances between the inclined surface parts of the concavities and convexities, the ridge line parts, and the valley line parts, elongation deformation of the sheet material is allowed." It has the following characteristics.

[0019] The invention of claim 5 also embodies claim 1 or 2. "On the lower die constituting the press device, a positioning member made of a soft material for centering the sheet material is arranged so as to surround the sheet material from the outside. When the sheet material is sandwiched between the lower die and the upper die arranged thereon, part or all of the stopper is allowed to undergo compressive deformation." It has the following characteristics.

[0020] The invention of claim 6 specifies the resin patch as a product. That is, the invention of claim 6 "There are a right-angle type used at the corner where the wall surface and the horizontal plane are perpendicular, and an inclined type used at the corner where the wall surface and the horizontal plane intersect at an obtuse angle. The vertical height of the concavities and convexities of the inclined type is lower than the vertical height of the concavities and convexities of the right-angle type." It has the following characteristics.

Advantages of the Invention

[0021] In the present invention, since the resin patch is made by plastically forming a sheet material using a press device, a release agent is not required, and therefore, adhesion defects caused by the release agent do not occur. Thus, while ensuring the effect of improving workability by forming the resin patch into a three-dimensional shape in advance, the range in which the resin patch can be used can be expanded, greatly contributing to improved workability.

[0022] Furthermore, since the sheet material of the present invention can be made by extruding, similar to the film used in roofing materials, an improvement in adhesion due to the commonality of materials can be expected. In addition, while extruded products may be subjected to stretching when their thickness is standardized with rollers, if they are softened and pressed as in the present invention, the stretching effect is released by the softening and pressing processes, and it is expected that the fusion properties will be improved. In other words, it can be expected that softening and pressing will have a modifying effect on the sheet material that enhances its adhesion.

[0023] Injection molding dies are expensive, and since molding machines are necessary for manufacturing, molded products tend to be costly. However, the press device of the present invention is less expensive than injection molding dies, and the applied pressure is minimal, allowing for manual bending, thus contributing to cost reduction.

[0024] While methods for softening the sheet material include placing it on a heated metal plate or using a heating furnace, employing a rotary table and a hot air device as described in claim 2 allows for uniform heating and softening of the sheet material with a simple structure. Therefore, high-quality resin patches with consistent dimensional accuracy can be manufactured at a low cost.

[0025] Furthermore, the sheet material used for the resin patch can be made from a sheet roll produced by extrusion, and then cut (punched out) from it. This ensures the improved adhesion effect achieved by standardizing the materials as described above. The resin patch of claim 4 has the same appearance as Figure 1 of Patent Document 1 and is suitable for use on corners.

[0026] While it is possible to form a constant distance between the upper and lower dies that make up the press device, the resin elastomer sheet material has far lower strength than a metal plate. Therefore, if the gap between the upper and lower dies is constant throughout, there is a concern that excessive compressive force will act on the sloping parts of the uneven surface, making it prone to breakage.

[0027] In this regard, by adopting the configuration of claim 4 of this application, the sheet material can be plastically deformed into an uneven surface without causing fracture, as it stretches and deforms smoothly. In order to allow the stretching deformation of the sheet material, it is preferable to set the gap in the inclined portion to be slightly larger than the thickness of the sheet material (thickness before processing).

[0028] The sheet material to be used as the material needs to be positioned so that its center aligns with the center of the upper and lower dies before being set in the press machine. One possible way to achieve this is to form a line-like mark on the peak of the lower die, but in this case, the sheet material is not forcibly positioned, and therefore it has the problem of not being able to prevent it from being pressed in a misaligned state.

[0029] In contrast, by adopting the configuration of claim 5, the sheet material is forcibly positioned by a soft stopper, allowing the sheet material to be accurately formed into a three-dimensional shape without requiring skilled personnel. Furthermore, even if the upper die hits the stopper, the stopper undergoes elastic deformation and does not affect the clamping action of the sheet material, thus not hindering the processing of the sheet material.

[0030] The resin patch of claim 4 is suitably applicable to outside corners, but can also be applied to sealing the ends of trapezoidal cross-section solar frames as disclosed in Japanese Patent No. 7401712. In this case, since the longitudinal side of the solar frame is inclined with respect to the horizontal, if a resin patch used for a normal outside corner where the wall surface rises perpendicularly from the roof surface is used, the deformation may be too great, potentially causing wrinkles after installation.

[0031] In this regard, by making the height of the inclined type unevenness smaller than that of the right-angle type unevenness, as in claim 6, when applied to sealing the ends of trapezoidal frames such as the solar frame in Japanese Patent Publication No. 7401712, wrinkle formation can be prevented and the sealing function can be ensured. Since the presser die of the press device is less expensive than the injection molding die, the overall cost can be reduced when manufacturing multiple types of resin patches with different unevenness heights (even if the unevenness heights differ, the softening device is common, which contributes to reducing the overall cost of the product group). [Brief explanation of the drawing]

[0032] [Figure 1] The figure shows the resin patch of the embodiment, where (A) is a perspective view, (B) is a plan view, and (C) is a CC front view of (B). [Figure 2] This is a front view of the softening device. [Figure 3] The diagram shows a press device, where (A) is a front view of the separation before pressurization, (B) is a cross-sectional view of the press device under pressurization as seen from the IIB-IIB direction in Figure 1(B), and (C) is a cross-sectional view of the press device under pressurization as seen from the IIC-IIC direction in Figure 1(B). [Figure 4] These are schematic perspective views of a site where the resin patch of the embodiment can be applied, with (A) mainly showing an external corner, (B) showing an internal corner, and (C) a perspective view of a site equipped with a trapezoidal frame material. [Figure 5] This figure shows other aspects of the construction site. [Figure 6] This figure shows another form of the resin patch. [Modes for carrying out the invention]

[0033] (1) Structure and manufacturing method of resin patch Next, embodiments of the present invention will be described based on the drawings. Figure 1 shows one form of the resin patch. The resin patch 1 of this embodiment is made from a sheet material (extruded product) of ethylene propylene elastomer (TPO), and has an uneven shape with six peaks 2 and valleys 3 that alternately continue in the circumferential direction. However, since the resin patch 1 does not have a front or back direction, the identification of peaks 2 and valleys 3 is for convenience only, and when flipped over, the relationship between peaks 2 and valleys 3 is reversed. The peaks 2 and valleys 3 are curved and smoothly continuous. Therefore, when viewed from the outer circumference, it forms a corrugated shape in the circumferential direction.

[0034] The peaks 2 and valleys 3 converge towards the center. Therefore, the height H of the unevenness decreases from the outer perimeter towards the center 4. This type of resin patch 1 often has an outer diameter of about 150 mm, but for corner applications, the maximum height H of the unevenness is set to about 20 mm. The thickness is about 1.5 mm, but can be arbitrarily selected as needed.

[0035] In this embodiment, the resin patch 1 uses a flat, circular sheet material 5 as its material, as shown in Figure 2. The sheet material 5 is made from an extruded roll of raw material and is cut (punched) from the roll to a predetermined size and dimensions.

[0036] The melting temperature of ethylene propylene elastomer is approximately 160°C. The sheet material 5 is heated to a softening temperature lower than the melting temperature, at which point it undergoes plastic deformation. Then, the heated sheet material 5 is pressed and plastically deformed using a press device as shown in Figure 3 to obtain a three-dimensional product.

[0037] An example of a softening device 6 is shown in Figure 2. In this example, the softening device 6 comprises a rotary table 7 on which the sheet material 5 is placed, a base unit 8 that drives the rotary table 7, a heater 9 positioned above the rotary table 7, a fan 10 positioned above the heater 9, and a funnel-shaped umbrella member 11 that diffuses hot air and blows it towards the sheet material 5. A motor is built into the base unit 8. By turning on the fan 10 and the heater 9 and driving the rotary table 7, hot air is blown evenly onto the sheet material 5, allowing the sheet material 5 to be softened uniformly.

[0038] As shown in Figure 3, the press device 14 comprises a lower die 15 and an upper die 16. The lower die 15 has six upward-facing peaks 17 and downward-facing valleys 18 formed alternately in the circumferential direction, corresponding to the irregularities of the resin patch 1. The upper die 16 has six downward-facing peaks 19 and upward-facing valleys 20 formed alternately in the circumferential direction, corresponding to the irregularities of the resin patch 1. In this embodiment, the outer diameter of the lower die 15 is larger than the outer diameter of the upper die 16, but the upper and lower dies 15 and 16 may have the same diameter.

[0039] The lower mold 15 is fixed, while the upper mold 16 is movable up and down. Therefore, by placing the sheet material 5 on the lower mold 15 and then lowering the upper mold 16 to clamp the sheet material 5, the sheet material 5 can be plastically deformed into a three-dimensional shape to obtain the resin patch 1. In order to enable the sheet material 5 to be placed on the lower mold 15, the sheet material 5 is held in a state that, although softened, has enough rigidity to maintain a flat state even when held by hand (even with both ends supported).

[0040] With the upper mold 16 fully lowered, there is a gap between the upper and lower molds for the sheet material 5 to fit into. As exaggeratedly shown in Figure 3(C), the gap in the slope area 21 is set to be larger than the gap in the ridge and valley areas. Specifically, the gap in the ridge and valley areas is set to be the same as or slightly smaller than the thickness of the sheet material 5 (for example, 90-95% of the thickness), while the gap in the slope area 21 is set to be slightly larger than the thickness (for example, 104-110% of the thickness). This allows the sheet material 5 to stretch and deform freely without breaking, preventing the occurrence of defective products.

[0041] As shown in Figure 3(A), stoppers 50 for centering the sheet material 5 are attached or otherwise positioned on the ridges of each upward-facing peak 17 that make up the lower mold 15. Therefore, the sheet material 5 is precisely positioned so that its center coincides with the center of the upper and lower molds 15 and 16. The stoppers 50 are made of a soft material such as felt and are thinner than the sheet material 5.

[0042] The upper die 16 is formed to have a diameter slightly larger than the outer diameter of the sheet material 5 so that the sheet material 5 can be evenly clamped. Therefore, in a plan view, some or all of the stoppers 50 may overlap with the upper die 16. However, since the stoppers 50 are made of a soft material, even if they are clamped by the upper and lower dies 15 and 16, they will undergo compressive deformation (elastic deformation) and will not hinder the plastic deformation of the sheet material 5. Therefore, without compromising the reliability of the processing of the sheet material 5, the sheet material 5 can be accurately positioned and a resin patch 1 with excellent quality can be manufactured.

[0043] (2) Construction of outer and inner corners Figure 4 briefly illustrates the site configuration and the usage of resin patch 1. Figure 4(A) shows a configuration in which the parapet and columnar parts rise from the roof surface. The structure has two wall surfaces 23 and 24 that intersect at right angles in plan view, a horizontal roof surface 25 that is continuous with the lower edges of the two wall surfaces 23 and 24, and a horizontal upper surface 26 that is continuous with the upper edges of the two wall surfaces 23 and 24. Therefore, the structure has an outer corner 22, which has a lower outer corner 22a and an upper outer corner 22b.

[0044] The walls and roof are made of a roofing material having insulation material 27, steel plates 28, and a TPO resin layer (surface layer) 29, and the roof is supported by a deck plate or concrete slab (not shown). A protective sheet 30 is wrapped from one wall surface 23 to the other wall surface 24, and the protective sheet 30 has a lower flange 30a that overlaps the roof surface 25 and an upper flange 30b that overlaps the upper end surface, however, there is a risk that a pinhole-like area will appear at the lower corner of the lower corner portion 22a that is not covered by the protective sheet 30, and there is also a risk that a pinhole-like area will appear at the upper corner portion 22b that is not covered by the protective sheet 30.

[0045] Therefore, the lower corner 22a and the upper corner 22b are covered from the outside with the resin patch 1 shown in Figures 1-3. For the lower corner 22a, the resin patch 1 is folded in half while maintaining the state in which one of its peaks 2 overlaps with the ridge line 31, thereby overlapping the entire resin patch 1 with the wall surfaces 23, 24 and the roof surface 25. Then, hot air is blown in from the peak 2 using a heat gun (not shown) to partially soften the resin patch 1 to near its melting temperature, and then the resin patch 1 is pressed against the application surface with a roller or spatula. This procedure is repeated to adhere the resin patch 1 to the wall surfaces 23, 24 and the roof surface 25.

[0046] For the ridges 31, the resin patch 1 is pressed using a roller with an annular groove formed on its outer circumference, as in the conventional method. For the inner corners where the roof surface 25 and wall surfaces 23 and 24 intersect, the resin patch 1 can be pressed in using a roller shaped like an abacus bead or a wedge-shaped pressing member. In any case, the peaks of the resin patch 1 are flattened by the pressure of the roller, resulting in the state shown in Figure 4(A).

[0047] A step will form at the edge of the protective sheet 30, but in this case, the resin patch 1 can be bent into an L shape, pressed against it, softened, and bonded. Since the resin patch 1 has six alternating peaks 2 and valleys 3, it can be easily folded in half.

[0048] Figure 4(B) shows the configuration of the inner corner 32. The inner corner 32 has a lower inner corner 32a and an upper inner corner 32b. In either case, pinhole-like areas may occur that cannot be covered even when using the protective sheet 30, so they can be sealed using the resin patch 1. If the resin patch 1 in Figure 1 is used on the lower inner corner 32a, the area must be made considerably smaller, which may cause wrinkles. Therefore, it is preferable to use a specially formed triangular pyramidal resin patch 1 for sealing the lower inner corner 32a, rather than using the one in Figure 1. The resin patch 1 in Figure 1 can be used for the lower inner corner 32a.

[0049] In Figures 4(A) and 4(B), the inner corner 33a and outer corner 33b where the two surfaces intersect are also covered with resin patches 1 at the edges of the protective sheet 30. In this case, the resin patch 1 is bent into an L shape, but it is also possible to use the wave-shaped product shown in Figure 1, or a specially made L-shaped product.

[0050] (3) Example of application to trapezoidal frame material Figure 4(C) shows an example of on-site construction where a trapezoidal frame 34 for mounting solar panels, etc., is fixed to the roof surface 25. The trapezoidal frame 34 has a trapezoidal cross-section, and its longitudinal wall surface 35 intersects the roof surface 25 and the upper end surface 36 at an obtuse angle. The trapezoidal frame 34 has a flange 37 that is continuous with the lower end of the longitudinal wall surface 35, and the flange 37 is fixed to the roofing material or deck plate by fasteners (not shown).

[0051] The trapezoidal frame 34 has open ends, but these openings are closed by end plates (not shown). The end plates intersect the roof surface 25 and the upper end surface 36 at right angles. The end plates, the ends of the longitudinal wall surface 35, the ends of the upper end surface 36, and the portion of the roof surface 25 located outside the end plates are covered by end protection sheets 38, and the flange 37 is covered by a longitudinal protection sheet 39 that straddles the roof surface 25.

[0052] The edge protection sheet 38 covers the longitudinal wall surface 35, etc., by folding its outer periphery, but at the corners where the three surfaces intersect at the upper and lower corners 22a and 22b, there are pinhole-like areas that are not covered by the edge protection sheet 38. Therefore, the upper and lower corners 22a and 22b are covered with the resin patch 1 shown in Figure 1.

[0053] Since the longitudinal wall surface 35 of the trapezoidal frame 34 is inclined with respect to the roof surface 25 and the upper end surface 36, the amount of stretching of the resin patch 1 is less than that of an upright corner. Therefore, as shown by the dotted line in Figure 1(C), the height H of the unevenness of the resin patch 1 is lower than when used for a right-angle type corner. Specifically, the height H of the unevenness was set to about 20 mm for the right-angle type as described above, but for the trapezoidal frame 34 where the intersection angle between the longitudinal wall surface 35 and the roof surface 25 is, for example, about 120 degrees, it is set to about 13 mm.

[0054] Thus, in the case of a site with a trapezoidal frame 34, by reducing the height H of the unevenness and minimizing the deformation of the resin patch 1, wrinkles can be prevented and a proper seal can be achieved.

[0055] Figure 5(A) shows another sealing configuration for the inner corner 32. In this example, the parapet 41 and the roof surface 25 are covered with base protective sheets 42 and 43, while the lower corner and vertical corner are covered with horizontal protective sheet 44 and vertical protective sheet 45. The area where one end of the horizontal protective sheet 44 meets the lower end of the vertical protective sheet 45 is covered with a resin patch 1, and the upper inner corner 32b is also covered with a resin patch 1. In other words, the area where there is no overlap between the protective sheets 42-45 is covered with a resin patch 1.

[0056] The example shown in Figure 5(B) illustrates the sealing method when a rectangular stepped portion 46 exists on the roof surface 25. In this example, when the top and sides of the stepped portion 46, the roof surface 25, the wall surface 47, etc. are covered with multiple protective sheets 48, areas not covered by the protective sheets 48, such as the upper outer corner portion 22b formed by the stepped portion 46 and the wall surface 47, and the inner corner portion 33a formed by two surfaces, are covered with resin patches 1.

[0057] Figure 6 shows another example of resin patch 1. Figure 6(A) shows an example of resin patch 1 used for the lower corner 22a, in which, when press-forming it into a shape having three elements 1a, 1b, and 1c, each element 1a, 1b, and 1c is formed in a state where it bulges outwards, thereby facilitating the blowing of hot air with a heat gun.

[0058] Figure 6(B) shows an example applied to the upper corner 22b, where, during press forming into a triangular pyramidal shape, the three elements 1a to 1c are given an outward-bulging shape. Figure 6(C) shows an example applied to the lower corner 32a, where, while forming the basic triangular pyramidal shape, the three elements 1a to 1c are given an outward-bulging shape. (B) and (C) are similar, but the direction of the bulge of each element 1a to 1c is different. In both cases, the apex 1d is bulged outward in a nipple-like shape so that a hole cannot be made even if pressed with a spatula or the like.

[0059] Figure 6(D) shows an example of a resin patch 1 applied to the inner corner 33a where two surfaces intersect, and Figure 6(E) shows an example of a resin patch 1 applied to the outer corner 33b where two surfaces intersect, both of which have two elements 1a and 1b that bulge outwards. In each example in Figure 6, it is preferable to set up a pocket-like space between each element 1a to 1c and the application surface so that the hot air from the heat gun is trapped in between.

[0060] Although embodiments of the present invention have been described above, the present invention can be implemented in various other ways. For example, in each embodiment, the resin patch is basically formed in a circular shape, but it is also possible to form it in a polygon such as a triangle. [Industrial applicability]

[0061] The present invention can be embodied in the technology of resin patches for roofs. Therefore, it can be used industrially. [Explanation of symbols]

[0062] 1. Resin patch 2 Yamabe 3 Tanibe 4 center 5. Sheet material (intermediate material) 6 Softening device 7 Rotating Table 8 Base section 9 Heater 10 Fans 11 Umbrella parts 14 Pressing device 15 Lower mold 16 Upper mold 17 Upward-facing mountain section 18 Downward valley 19 Downward-facing mountain section 20 Upward valley 21 Sloping section 22, 22a, 22b Corner section 23, 24 Wall surfaces 25 Roof surface 26 Upper end surface 32, 32a, 32b Inside corner 33a Interior corner 33b Outer corner 34 Trapezoidal Frame 35 Long wall surface

Claims

1. A method for manufacturing waterproof resin patches that are heat-sealed to the corners of roofs made of roofing material coated with ethylene propylene elastomer film, A step of preparing a flat material sheet of ethylene propylene-based elastomer formed to a predetermined size and shape, A step of heating the sheet material to a temperature below its melting point and at which it can be plastically deformed to soften it, The process involves pressing the softened sheet material from both sides using a press device to plastically deform it into a three-dimensional shape, Includes, A method for manufacturing resin patches for roofs.

2. The process of softening the sheet material is carried out by placing the sheet material on a rotating table and rotating it horizontally while blowing hot air from above. A method for manufacturing a resin patch for roofs as described in claim 1.

3. The opposing surfaces of the upper and lower molds constituting the press device have interlocking, wave-shaped irregularities formed continuously in the circumferential direction, and the resin patch is formed in a circumferentially undulating irregular shape. A method for manufacturing a resin patch for roofs as described in claim 1 or 2.

4. In the process of compressing the sheet material between the upper and lower dies of the press device to cause plastic deformation, the distance between the upper and lower dies is set such that the distance between the sloping surfaces of the unevenness is greater than the distance between the ridges and valleys, thereby allowing for elongation deformation of the sheet material. A method for manufacturing a resin patch for roofs as described in claim 1 or 2.

5. A positioning member made of a soft material is positioned in the lower die of the press device so as to surround the sheet material from the outside and to center the sheet material, and when the sheet material is pressed between the lower die and the upper die positioned above it, it is permissible for part or all of the stopper to be compressed and deformed. A method for manufacturing a resin patch for roofs as described in claim 1 or 2.

6. A resin patch manufactured by the method of claim 4, which is used at an external corner where two intersecting wall surfaces in a plan view intersect with a horizontal plane that is continuous with their lower or upper edge, There is a right-angle type used for corners where the wall surface and the horizontal plane intersect perpendicularly, and an inclined type used for corners where the wall surface and the horizontal plane intersect at an obtuse angle, wherein the vertical height of the protrusions in the inclined type is lower than the vertical height of the protrusions in the right-angle type. Resin patches for roofs.

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