Roofing material manufacturing method

Abstract

To provide a method for manufacturing a roofing material that can prevent curvature at overlapping portions while employing roll forming processing of transported metal sheets. [Solution] A method for manufacturing a roofing material that has two protrusions and a flat portion formed between the two protrusions, comprising: an overlapping process in which one end side of a first metal plate MP1 is overlapped with the other end side of a second metal plate MP2 to form an overlapping portion D; a temporary fixing process in which a temporary fixing portion TF is formed by temporarily fixing the overlapping portion D formed in the overlapping process in a releasable manner; a processing process in which the first metal plate MP1 and the second metal plate MP2 having the overlapping portion D temporarily fixed in the temporary fixing process are transported and subjected to roll forming processing; and a release process in which the temporary fixing portion TF is released after the processing process.

Description

[Technical Field]

[0001] The present disclosure relates to a method for manufacturing a roofing material. [Background technology]

[0002] Previously, roofing materials have been proposed that have, for example, two ridges on both sides and a flat section between the two ridges (see, for example, Patent Document 1). Such roofing materials are smaller than the upper area of ​​the building. For this reason, multiple roofing materials are installed on the upper part of the building. In this case, the ends of each roofing material are installed overlapping each other to prevent rainwater from seeping in through the gaps between the roofing materials. More specifically, with respect to the slope direction of the roof, the downstream end of the roofing material on the upward slope is overlapped on the upstream end of the roofing material on the downward slope, thereby preventing rainwater flowing down the roofing materials from seeping in and causing leaks. [Prior art documents] [Patent documents]

[0003] [Patent Document 1] Japanese Patent Publication No. 2020-176405 Summary of the Invention [Problem to be solved by the invention]

[0004] Here, typical roofing materials are manufactured by roll-forming a transported metal sheet and then cutting it. All roofing materials manufactured in this way have the same cross-sectional shape perpendicular to the transport direction.

[0005] FIG. 8 is a perspective view showing the overlapping portion of roofing materials according to a comparative example. As shown in FIG. 8, when roofing materials 201 with the same cross-sectional shape are stacked, the upper roofing material 201a is pushed in the width direction by the lower roofing material 201b, causing the flat surface 220 of the roofing material 201a to bend upward. If the upper roofing material 201a bends, wind and rain will enter the gap between the roofing materials 201a and 201b, increasing the possibility of water leakage. Therefore, the roofing material of Patent Document 1 has a cross-sectional shape of the short side portion facing above water that is different from the cross-sectional shape of the other portions. This prevents wind and rain from entering the gap.

[0006] However, because the roofing material described in Patent Document 1 requires only the overlapping portions to be reshaped, processing the metal sheet is not simple. For example, after roll forming, the overlapping portions must be reshaped in a separate process. In particular, such roofing materials are generally formed by roll forming, in which the metal sheet is processed while being transported. Therefore, a manufacturing method that employs roll forming but does not require a separate process and can prevent curvature in the overlapping portions OL is desired. Note that this issue is not limited to plate-shaped roofing materials, but is also common to sandwich panels and hollow bodies with a certain thickness or more in which plate portions overlap.

[0007] An object of the present disclosure is to provide a method for manufacturing a roofing material that employs roll forming processing while preventing curvature at overlapping portions. [Means for solving the problem]

[0008] The method for manufacturing a roofing material according to the present disclosure is a method for manufacturing a roofing material that uses roll-forming processing on a metal plate to produce a roofing material having two parallel protrusions and a flat portion formed between the two protrusions, and includes an overlapping process in which one end of a first metal plate is overlapped with the other end of a second metal plate to form an overlapping portion, a temporary fixing process in which a temporary fixing portion is formed that temporarily fixes the overlapping portion formed in the overlapping process in a releasable manner, a processing process in which the first metal plate and the second metal plate having the overlapping portion temporarily fixed in the temporary fixing process are transported and subjected to the roll-forming processing, and a release process in which the temporary fixing portion is released after the processing process. [Effects of the Invention]

[0009] According to the present disclosure, it is possible to provide a method for manufacturing a roofing material that employs roll forming processing of transported metal sheets while preventing curvature in overlapping portions. [Brief explanation of the drawings]

[0010] [Figure 1] 1 is a perspective view showing a roofing material manufactured by a roofing material manufacturing method according to an embodiment of the present invention. [Figure 2] FIG. 2 is a front view of the roofing material shown in FIG. 1 as viewed along the tilt direction. [Figure 3] FIG. 10 is an enlarged view of the main part when the roofing materials according to this embodiment are stacked in the inclined direction. [Figure 4] This is a process diagram showing the manufacturing method of the upper panel of the roofing material in this embodiment, where (a) is the unwinding process, (b) is the cutting process, (c) is the overlapping process, (d) is the temporary fixing process, and (e) is the processing process. [Figure 5] This is a process diagram showing the manufacturing method of the lower panel of the roofing material in this embodiment, where (a) is the second unwinding process, (b) is the second cutting process, (c) is the second overlapping process, (d) is the second temporary fixing process, and (e) is the second processing process. [Figure 6] 5 is a perspective view showing a part of a manufacturing apparatus for manufacturing an upper plate by carrying out the steps shown in FIG. 4. FIG. [Figure 7]6 is a process diagram showing the manufacturing process of a roofing material using the upper and lower plates manufactured in the manufacturing process shown in Figures 4 and 5, where (a) is the pipe installation process, (b) is the installation process, (c) is the insertion process and wire cutting process, and (d) is the release process. [Figure 8] FIG. 10 is a perspective view showing an overlapping portion of a roofing material according to a comparative example. DETAILED DESCRIPTION OF THE INVENTION

[0011] The present disclosure will be described below in accordance with preferred embodiments. Note that the present disclosure is not limited to the embodiments shown below and can be modified as appropriate without departing from the spirit of the present disclosure. In addition, in the embodiments shown below, some configurations are omitted from illustration and description, but it goes without saying that publicly known or well-known technologies are applied as appropriate to the details of the omitted technologies within the scope of the content described below.

[0012] Fig. 1 is a perspective view showing a roofing material manufactured by a roofing material manufacturing method according to this embodiment, and Fig. 2 is a front view of the roofing material shown in Fig. 1 as viewed along the slope direction. As shown in Figs. 1 and 2, the roofing material 1 is intended to be installed, for example, in a sloped structure at the top of a building, and is configured as a so-called sandwich panel comprising an upper plate UB, a lower plate LB, and a thermal insulating material I. In other words, the roofing material 1 has a structure of a predetermined thickness, with the thermal insulating material I sandwiched between the upper plate UB and the lower plate LB.

[0013] Such a roofing material 1 has two parallel ridges 10 on the upper plate UB and a flat portion 20 formed between the two ridges. The two ridges 10 are portions that protrude upward from the roofing material 1. When the roofing material 1 is used in a sloped structure at the top of a building, the two ridges 10 are arranged along the slope direction as shown in Figure 1. The two ridges 10 ensure the rigidity of the roofing material 1. When viewed from the front as shown in Figure 2, the two ridges 10 are roughly trapezoidal in shape, tapering upward.

[0014] As shown in Figure 2, the roofing material 1 has two ridges 10, one of which, ridge 10a, is filled with insulating material I, and the other ridge 10b is not filled with insulating material I. As shown in Figure 1, the roofing material 1 is arranged so that the other ridge 10b overlaps one of the ridges 10a of the adjacent roofing material 1 in the width direction, which is perpendicular to the tilt direction. In this arranged state, the roofing materials 1 are firmly connected by inserting a rod-shaped member R, such as a piece of tex, into one of the ridges 10a from above the other ridge 10b.

[0015] As shown in Fig. 1, some of the rod-shaped members R, namely, rod-shaped members Ra, are long enough to extend to the building frame F. Therefore, the roofing material 1 is firmly fixed to the building itself by the rod-shaped members Ra.

[0016] As shown in FIG. 2, the lower plate LB has four ridges 10. The first and second ridges 10c, 10d are provided adjacent to each other on one side of the lower plate LB in the width direction, and the third and fourth ridges 10e, 10f are provided adjacent to each other on the other side of the width direction. The spaces between these adjacent ridges 10c-10f function as water catchers in case rainwater seeps in through the upper plate UB and the thermal insulation material I. Furthermore, a flat surface 20 is formed between the relatively wide second ridge 10d and third ridge 10e, which functions as, for example, a storage space for heat storage material or a water catcher. While no flat surface 20 exists between the first and second ridges 10c, 10d and between the third and fourth ridges 10e, 10f in FIG. 2, this is not a limitation, and flat surfaces 20 may be formed.

[0017] In this embodiment, the roofing material 1 is not limited to that shown in Figures 1 and 2. For example, the roofing material 1 may not include the insulating material I and may be composed only of the upper plate UB. The roofing material 1 may also have three or more protrusions 10 on the upper plate UB. In addition, the roofing material 1 may be installed so that it is layered on top of another roofing material already installed on the top of a building. In this case, it is sufficient that some of the rod-shaped members Ra have a length that reaches at least the other roofing material. In addition, the lower plate LB may be made of a flat plate and may not have the overlapping portion OL described below.

[0018] Figure 3 is an enlarged view of the main part when roofing materials 1 according to this embodiment are stacked in the tilt direction. As shown in Figure 3, the upper plate UB of roofing material 1 has an end portion in the downward water direction, which is lower in the tilt direction, that protrudes in the downward water direction beyond the insulating material I. The upper plate UB of roofing material 1a facing the above water direction is arranged so as to be stacked on the upper plate UB of roofing material 1b facing the below water direction. The overlapping portion between the upper plates UB of roofing materials 1a and 1b in this way is called the overlapping portion OL.

[0019] Furthermore, the lower plate LB of roofing material 1b facing downward in the water direction has its end facing upward in the water direction, which is the upper end in the tilting direction, protruding further in the water direction than the insulating material I. The lower plate LB of roofing material 1b facing downward in the water direction is arranged so that it overlaps under the lower plate LB of roofing material 1a facing upward in the water direction. The overlapping portion between the lower plate LB of roofing material 1b and the lower plate LB of roofing material 1a in this manner is also referred to as the overlapping portion OL.

[0020] Next, a method for manufacturing the upper plate UB and lower plate LB of the roofing material 1 according to this embodiment will be described. Figure 4 is a process diagram showing a method for manufacturing the upper plate UB of the roofing material 1 according to this embodiment, where (a) is the unwinding process, (b) is the cutting process, (c) is the overlapping process, (d) is the temporary fixing process, and (e) is the processing process.

[0021] First, in this embodiment, the metal sheet M constituting the upper plate UB is wound in a coil shape, and the metal sheet M is fed in a feeding step as shown in Fig. 4(a), whereby the flat metal sheet M is transported.

[0022] Next, as shown in FIG. 4(b), in the cutting process, the conveyed flat metal plate M is cut in a direction (thickness direction) that intersects with the conveyance direction. In this process, for example, the metal plate M is cut by being sandwiched between cutting members CM provided above and below the metal plate M. The cut piece that precedes the conveyance direction becomes the first metal plate MP1, and the cut piece that follows the conveyance direction becomes the second metal plate MP2. Furthermore, in this cutting process, the first metal plate MP1 is shifted in the height direction relative to the second metal plate MP2.

[0023] Then, as shown in FIG. 4(c), in the overlapping step, one end of the first metal plate MP1 and the other end of the second metal plate MP2 are overlapped by a length corresponding to the overlapping portion OL (see FIG. 3). During this process, the manufacturing equipment transports the trailing second metal plate MP2 at a speed faster than that of the preceding first metal plate MP1. This allows the second metal plate MP2 to catch up with the first metal plate MP1, which has shifted in the height direction during the cutting step, forming an overlapping portion D where the two are overlapped. Note that, although the overlapping portion D is formed by the first metal plate MP1 and the second metal plate MP2 being in contact with each other in FIG. 4(c), they may not be in contact with each other and may have a certain degree of clearance as long as it does not interfere with the subsequent temporary fixing step.

[0024] Next, as shown in FIG. 4(d), in a temporary fixing process, the overlapping portion D is temporarily fixed in a releasable manner to form a temporary fixed portion TF. At this time, the overlapping portion D is temporarily fixed, for example, by a spot clincher. As an example, the manufacturing device includes a punch unit PP that punches the overlapping portion D in the plate thickness direction without penetrating the first metal plate MP1 and the second metal plate MP2. The manufacturing device then temporarily fixes both the first metal plate MP1 and the second metal plate MP2 by utilizing the shape deformation that occurs when punched by the punch unit PP.

[0025] Thereafter, as shown in Fig. 4(e), the first metal plate MP1 and the second metal plate MP2 are processed in a processing step. In this step, the manufacturing device transports the first metal plate MP1 and the second metal plate MP2 with the overlapping portion D temporarily fixed, and performs roll forming in the roll forming unit RF. In this processing step, the upper plate UB having the two ridges 10 and the flat portion 20 shown in Fig. 1 is produced.

[0026] As described above, in the manufacturing method of the roofing material 1 according to this embodiment, roll forming is performed while the overlapping portion D is temporarily fixed, so the cross-sectional shapes of the upper plates UB do not completely match at the overlapping portion OL. In other words, the width of the flat portion 20 of the upper plate UB overlapping above is smaller than the width of the flat portion 20 of the upper plate UB overlapping below. Therefore, the curvature at the overlapping portion OL of the roofing material 1 is eliminated. Note that, particularly when the roofing material 1 is composed of a single plate without the insulating material I, the upper plate UB may be used as the roofing material 1 as is.

[0027] Next, a method for manufacturing the lower plate LB will be described. Figure 5 is a process diagram showing the method for manufacturing the lower plate LB of the roofing material 1 according to this embodiment, where (a) is the second feeding step, (b) is the second cutting step, (c) is the second overlapping step, (d) is the second temporary fixing step, and (e) is the second processing step.

[0028] First, as shown in FIG. 5(a), the metal plate M constituting the lower plate LB is wound in a coil shape, and the metal plate M is fed in a second feeding process. This causes the flat metal plate M to be transported. Next, like the upper plate UB, the lower plate LB is cut in a second cutting process (see FIG. 5(b)). At this time, the cut piece that precedes the conveyance direction becomes the third metal plate MP3, and the cut piece that follows in the conveyance direction becomes the fourth metal plate MP4. Furthermore, in this second cutting process, the third metal plate MP3 is shifted in the height direction relative to the fourth metal plate MP4.

[0029] Next, as shown in FIG. 5(c), in the second overlapping step, one end of the third metal plate MP3 and the other end of the fourth metal plate MP4 are overlapped by a length corresponding to the overlapping portion OL (see FIG. 3), forming a second overlapping portion D2. During this process, the manufacturing equipment transports the succeeding fourth metal plate MP4 at a speed faster than that of the preceding third metal plate MP3. This allows the fourth metal plate MP4 to catch up with the third metal plate MP3, which is displaced in the height direction in the cutting direction, thereby forming the second overlapping portion D2 where the two are overlapped. Note that the third metal plate MP3 and the fourth metal plate MP4 may be spaced apart from each other at the second overlapping portion D2 as long as this does not interfere with the subsequent second temporary fixing step.

[0030] 5(d), in a second temporary fixing step, the second overlapping portion D2 is temporarily fixed in a releasable manner to form a second temporary fixed portion TF2. At this time, the second overlapping portion D2 is temporarily fixed by, for example, a spot clincher in the same manner as described above.

[0031] 5(e), the third metal plate MP3 and the fourth metal plate MP4 are processed in the second processing step. In this step, the manufacturing device transports the third metal plate MP3 and the fourth metal plate MP4 with the second overlapping portion D2 temporarily fixed, and performs roll forming. In this second processing step, a lower plate LB having a predetermined shape is produced.

[0032] This makes it possible to prevent the lower plate LB from curving at the overlapping portion OL in the same manner as the upper plate UB.

[0033] Fig. 6 is a perspective view showing a part of a manufacturing apparatus for manufacturing the upper plate UB by carrying out the steps shown in Fig. 4. Note that Fig. 6 shows a part of the manufacturing apparatus for manufacturing the upper plate UB, but the manufacturing apparatus for manufacturing the lower plate LB is similar.

[0034] As shown in FIG. 6, the manufacturing apparatus 100 includes conveying rollers 110 and 120, a traveling cutting shear 130, and a traveling spot clincher 140.

[0035] The first conveying rollers 110 convey the metal sheet M conveyed from upstream to the traveling cutting shear 130. The second conveying rollers 120 convey the metal sheet M downstream to the roll forming section RF (see FIG. 4(e)).

[0036] The traveling cutting shear 130 has a cutting member CM as shown in Figures 4(b) and 6 and is movable along the conveyance direction. The traveling cutting shear 130 cuts the metal sheet M by operating the cutting member CM while moving in accordance with the conveyance speed of the metal sheet M. As a result of cutting by this traveling cutting shear 130, a first metal sheet MP1 leading in the conveyance direction and a second metal sheet MP2 following in the conveyance direction are formed.

[0037] The first metal plate MP1 cut by the traveling cutting shear 130 is transported by the second transport rollers 120, and the second metal plate MP2 is transported by the first transport rollers 110. Here, the rotation speed of the first transport rollers 110 is set higher than the rotation speed of the second transport rollers 120. As a result, the second metal plate MP2 is transported so as to catch up with the first metal plate MP1, and an overlapping portion D (see FIG. 4(c)) corresponding to the length of the overlapping portion OL (see FIG. 3) is formed.

[0038] The traveling spot clincher 140 has a punch portion PP as shown in Figure 4(d) and is movable along the conveying direction. The traveling spot clincher 140 operates the punch portion PP while moving in accordance with the conveying speed of the overlapping portion D, thereby temporarily fixing the first metal plate MP1 and the second metal plate MP2 together. As shown in Figure 6, the traveling spot clincher 140 is configured to temporarily fix the first metal plate MP1 and the second metal plate MP2 near their widthwise ends.

[0039] Figure 7 is a process diagram showing the manufacturing process of roofing material 1 using the upper plate UB and lower plate LB manufactured in the manufacturing process shown in Figures 4 and 5, where (a) is the pipe installation process, (b) is the installation process, (c) is the insertion process and wire cutting process, and (d) is the release process. Note that the cutting process is made up of the pipe installation process shown in Figure 7(a) and the insertion process and wire cutting process shown in Figure 7(c). Also, for ease of explanation, the protrusions 10 are omitted from Figure 7.

[0040] First, in the manufacturing process shown in Figure 4, an upper plate UB (first metal plate MP1 and second metal plate MP2) in a temporarily fixed state and a lower plate LB (third metal plate MP3 and fourth metal plate MP4) in a temporarily fixed state are manufactured.

[0041] When the upper plate UB and lower plate LB are transported, a pipe (pipe member) P is installed between them, as shown in FIG. 7(a). This pipe P is a member through which the wire used in the wire cutting process of FIG. 7(c) can be inserted. This pipe P is made of a straw-like resin material that is rigid enough not to be crushed by the insulating material I in the installation process shown in FIG. 7(b). In particular, considering the movement of the metal plates MP1 to MP4 in the transport direction and gravity, it is preferable that the pipe P be installed at the tip position of the fourth metal plate MP4, which will become the lower plate LB. Note that the pipe P is not limited to a circular cylinder, and may also be a rectangular cylinder.

[0042] Next, as shown in Fig. 7(b), an installation process of the heat insulating material I is performed. In this installation process, the heat insulating material I is provided on one side of the first metal plate MP1 and the second metal plate MP2 and on the other side of the third metal plate MP3 and the fourth metal plate MP4, i.e., between the two. In this case, it is preferable that the heat insulating material I be formed by foaming, for example.

[0043] Thereafter, as shown in Fig. 7(c), an insertion step is carried out to insert the filament into the pipe P. The filament may be a band saw made of metal or resin, a heating wire that generates heat when supplied with current, or may have other configurations.

[0044] After the wire has been inserted, a wire cutting step is carried out, and the manufacturing apparatus 100 (an apparatus including the configuration of FIG. 6) uses the wire to cut the insulating material I together with the pipe P. At this time, the wire cuts the insulating material I without cutting the first to fourth metal plates MP1 to MP4.

[0045] As shown by the dashed arrows in FIG. 7(c), the wire cuts the insulating material I while moving in the normal direction of the first to fourth metal plates MP1 to MP4. This prevents the cut surface from becoming oblique. Since the cutting actually occurs while the first to fourth metal plates MP1 to MP4 are being conveyed, the wire is moved in the conveying direction in accordance with the conveying speed while also moving in the normal direction of the first to fourth metal plates MP1 to MP4 to prevent the cut surface from becoming oblique. To achieve this cutting, the leading edge of the second metal plate MP2 is conveyed in a state where it precedes the leading edge of the fourth metal plate MP4 in the conveying direction. Specifically, the first to fourth metal plates MP1 to MP4 are conveyed with the rear end position of the first metal plate MP1 and the leading edge position of the fourth metal plate MP4 aligned. The conveyance is not limited to the above, and may be performed in other states, such as when the rear ends of the first metal plate MP1 and the third metal plate MP3 are aligned. In particular, when the rear end position of the first metal plate MP1 and the front end position of the fourth metal plate MP4 are transported with a misalignment in the transport direction, the filament may operate so that the cut surface is oblique (in the direction connecting the rear end position of the first metal plate MP1 and the front end position of the fourth metal plate MP4).

[0046] Furthermore, as shown in Figure 2, in the roofing material 1, the protrusions 10 of the upper plate UB are filled with insulating material I. The insulating material I is also filled between the protrusions 10c to 10f of the lower plate LB. Since this filled insulating material I cannot be cut by the wire, it is preferable to scrape it out with a hook-shaped member or the like.

[0047] Thereafter, as shown in Fig. 7(d), a release step is performed to release the temporary fixation. At this time, for example, the temporary fixation portion TF (see Fig. 4(d)) and the second temporary fixation portion TF2 (see Fig. 5(d)) may be punched and cut off with a cylindrical blade, or the temporary fixation portion TF and the second temporary fixation portion TF2 may be cut off with a turning machine or the like. Furthermore, the temporary fixation portion TF and the second temporary fixation portion TF2 may be released by punching again from the opposite direction to the punching direction with the punch portion PP (see Fig. 6).

[0048] As a result of the above, the roofing material 1 shown in Figs. 1 and 2 is manufactured.

[0049] In this way, according to the manufacturing method of the roofing material 1 of this embodiment, the first metal plate MP1 and the second metal plate MP2 having the temporarily fixed overlapping portion D are transported and roll-formed. As a result, the cross-sectional shapes of one end of the first metal plate MP1 and the other end of the second metal plate MP2 do not completely match, as occurs when they are roll-formed separately, and the width of the planar portion 20 on the overlapping upper side becomes smaller than the width of the planar portion 20 on the overlapping lower side. Therefore, it is possible to provide a manufacturing method of the roofing material 1 that can prevent curvature at the overlapping portion OL while employing roll-forming.

[0050] In particular, the method for manufacturing the roofing material 1 according to this embodiment allows the metal sheet M to be manufactured while being transported. Furthermore, it is possible to provide a method for manufacturing the roofing material 1 that does not require re-roll forming or performing another process to suppress the curvature shown in FIG. 8 after roll forming.

[0051] Furthermore, in the manufacturing method of the roofing material 1 according to this embodiment, the insulating material I is provided before the release step in which the temporary fixation is released, so there is no need to cut off a portion of the insulating material I before overlapping it later, as is the case when the insulating material I is provided after the release step, and the generation of wasted portions due to cutting can be reduced. Therefore, by providing the insulating material I before the release step, the generation of wasted portions of the insulating material I can be reduced when overlapping it later.

[0052] Furthermore, the manufacturing method of the roofing material 1 according to this embodiment can produce sandwich panels having overlapping portions OL not only for the first and second metal plates MP1, MP2 which become the upper plate UB, but also for the third and fourth metal plates MP3, MP4 which become, for example, the lower plate LB located on the other side of the insulating material I.

[0053] Furthermore, in the method for manufacturing the roofing material 1 according to this embodiment, the insulating material I is cut using a wire. Therefore, there is no need to insert a long blade or a chainsaw from the side. This makes it possible to prevent a situation in which the first to fourth metal plates MP1 to MP4 are damaged due to, for example, a long blade not being inserted properly.

[0054] Furthermore, in the manufacturing method of the roofing material 1 according to this embodiment, the metal sheet M is cut during transportation, and then the transportation speed is adjusted to form the overlapping portion D. Therefore, roll forming can be performed while the sheet is being transported, and processing to prevent curvature can be performed while the sheet is being transported.

[0055] The present disclosure has been described above based on the embodiments, but the present disclosure is not limited to the above embodiments, and modifications may be made within the scope of the spirit of the present disclosure, and publicly known or well-known technologies may be combined to the extent possible.

[0056] For example, the roofing material 1 is not limited to the above and can be modified in various ways. That is, the roofing material 1 may be composed of only the upper plate UB shown in Figures 1 and 2, or may also have three or more protrusions 10a, 10b. Furthermore, the roofing material 1 may have a structure in which the flat surface portion 20 has two or more stages of different heights.

[0057] Furthermore, in the above embodiment, temporary fixing portions TF, TF2 are formed by traveling spot clincher 140. However, this is not limiting, and temporary fixing portions TF, TF2 may be formed by bonding with a thermoplastic adhesive and released by heating. Similarly, temporary fixing portions TF, TF2 may be formed by a fixture attached in a position that does not interfere with the roll forming process and released by removing the fixture. [Explanation of symbols]

[0058] 1, 1a, 1b: Roofing materials 10,10a~10f: Projection 20: Flat part D: Overlapping part D2: 2nd overlap part I: Insulation material LB: Lower board M: Metal plate MP1: 1st metal plate MP2: 2nd metal plate MP3: 3rd metal plate MP4: 4th metal plate OL: Overlapped area P: Pipe (pipe component) PP: Punch section RF: Roll forming section TF: Temporary fixing part TF2: Second temporary fixing part UB: Upper plate

Claims

1. A method for manufacturing a roofing material, comprising: rolling a metal plate to produce a roofing material having two parallel protrusions and a flat portion formed between the two protrusions; an overlapping step of overlapping one end side of the first metal plate and the other end side of the second metal plate to form an overlapping portion; a temporary fixing step of forming a temporary fixing portion by temporarily fixing the overlapping portion formed in the overlapping step in a releasable manner; a processing step of transporting the first metal plate and the second metal plate having the overlapping portion temporarily fixed in the temporary fixing step and performing the roll forming process to form the two protrusions; a releasing step of releasing the temporary fixing portion after the processing step; A method for manufacturing a roofing material, comprising:

2. A method for manufacturing a roofing material, which comprises roll-forming a metal plate to produce a roofing material having two parallel ridges and a flat portion formed between the two ridges, an overlapping step of overlapping one end side of the first metal plate and the other end side of the second metal plate to form an overlapping portion; a temporary fixing step of forming a temporary fixing portion by temporarily fixing the overlapping portion formed in the overlapping step in a releasable manner; a processing step of transporting the first metal plate and the second metal plate having the overlapping portion temporarily fixed in the temporary fixing step and performing the roll forming; a release step of releasing the temporary fixing portion after the processing step, The method further includes an installation step of installing a heat insulating material on one surface of the first metal plate and the second metal plate after the processing step and before the release step. A method for manufacturing a roofing material.

3. a second overlapping step of overlapping one end side of the third metal plate and the other end side of the fourth metal plate to form a second overlapping portion; a second temporary fixing step of forming a second temporary fixing portion by temporarily fixing the second overlapping portion formed in the second overlapping step in a releasable manner; a second processing step of transporting the third metal plate and the fourth metal plate having the second overlapping portion temporarily fixed in the second temporary fixing step and performing the roll forming process, In the installation step, the heat insulating material is installed between the first metal plate and the second metal plate after the processing step and the third metal plate and the fourth metal plate after the second processing step, The heat insulating material installed in the installation step is further provided with a cutting step of cutting the heat insulating material without cutting the first metal plate, the second metal plate, the third metal plate, and the fourth metal plate, In the releasing step, the temporary fixing portion and the second temporary fixing portion are released after the installing step. The method for manufacturing a roofing material according to claim 2 .

4. The cutting step includes, prior to the installing step, a pipe installing step of installing a pipe member through which a filament can be inserted between the first metal plate and the second metal plate after the processing step and the third metal plate and the fourth metal plate after the second temporary fixing step; an inserting step of inserting the filament into the pipe member installed in the pipe installing step; and a filament cutting step of cutting the heat insulating material together with the pipe member using the filament after the installing step. The method for manufacturing a roofing material according to claim 3 .

5. A method for manufacturing a roofing material, which comprises roll-forming a metal plate to produce a roofing material having two parallel ridges and a flat portion formed between the two ridges, an overlapping step of overlapping one end side of the first metal plate and the other end side of the second metal plate to form an overlapping portion; a temporary fixing step of forming a temporary fixing portion by temporarily fixing the overlapping portion formed in the overlapping step in a releasable manner; a processing step of transporting the first metal plate and the second metal plate having the overlapping portion temporarily fixed in the temporary fixing step and performing the roll forming; a releasing step of releasing the temporary fixing portion after the processing step; a cutting step of cutting the conveyed planar metal plate in a direction intersecting the conveying direction to form the first metal plate and the second metal plate, In the overlapping step, the conveying speed of the second metal plate, which is a subsequent cut metal plate in the conveying direction, is made higher than the conveying speed of the first metal plate, which is a preceding cut metal plate in the conveying direction, among the cut metal plates in the cutting step, so that the second metal plate and the first metal plate are overlapped along the conveying direction by a length corresponding to the overlapping portion, thereby forming the overlapping portion; In the processing step, the first metal plate and the second metal plate are transported in the transport direction, including the overlapping portion, to perform the roll forming. A method for manufacturing a roofing material.

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