Customized manufacturing of single roof components

Abstract

1. A method for manufacturing a single piece roof for sealing a roof element, the method comprising the steps of: (a) Providing and / or obtaining a digital model of the roof element to be sealed; (b) Using this digital model, additively manufacture a single roof component that fits the contours of the roof element.

Description

[Technical Field]

[0001] The present invention relates to a method for manufacturing a single piece for a roof for sealing a roof element, and to a method for sealing a roof element. [Background technology]

[0002] Especially for flat roofs, sealing roof areas is very important as a precaution to keep the roof weatherproof, so it is common to use prefabricated or customized single roof components for specific roof elements or areas, such as penetrations, parapets, corners, ducts, etc.

[0003] The customized single roof components can be, for example, shaped tubing, corner pieces, etc., which, when watertightly joined with a sealing material, such as a membrane, in the main roof area, provide a reliable and durable seal across the entire roof area.

[0004] The variety of roofing applications requires many individually designed individual roof components. Therefore, so-called "universal shapes" that can be adapted to multiple shapes can be used, or custom-made components must be designed that are individually adapted to each situation. Universal shapes have the disadvantage that they usually do not fit perfectly to the actual geometric situation and often have to be squeezed or bent, creating a potential risk regarding watertightness. Therefore, great care must be taken to ensure the correct installation and fit of these components.

[0005] On the other hand, custom parts must be manufactured by hand, which makes them very expensive. Another drawback is that handmade parts are typically welded together from a basic shape, which introduces the risk of additional weld lines that can become weak points, especially when considering repeated seasonal heat cycles that induce thermal stresses.

[0006] As an alternative to pre-fabricated components, so-called "liquid-applied coatings" can be used. However, the joints with other sealants on the roof, such as membranes, are potential weak points in terms of watertightness, as application is critically dependent on proper workmanship.

[0007] Therefore, there is a need to provide an improved solution that overcomes the above-mentioned drawbacks. Summary of the Invention [Problem to be solved by the invention]

[0008] It is an object of the present invention to provide a method for providing a single customized roof component that can be produced in a fast and cost-effective manner, regardless of the number of components required. [Means for solving the problem]

[0009] Surprisingly, it has been found that these objects can be achieved by the features of patent claim 1. The core of the invention is therefore a method for manufacturing a single piece for sealing roof elements, which method comprises the following steps: (a) Providing and / or obtaining a digital model of the roof element to be sealed; (b) Using this digital model, additively manufacture a single roof component that fits the contours of the roof element.

[0010] As expected, the combination of obtaining a digital model of the roof element to be sealed and additive manufacturing makes it possible to manufacture a single roof component that fits perfectly to the roof element and at the same time can be produced in a cost-effective and cost-efficient manner.Since the manufacturing is based on a digital model of the actual roof element, all the properties of that roof element are captured in the single roof component.

[0011] In particular, the method of the present invention allows single roof components, even those with very complex shapes, to be manufactured in one piece, and these single roof components do not include welds or adhesive joints, so that watertightness is not an issue.

[0012] Overall, the method of the present invention provides an efficient method for manufacturing individualized single roofing components that can be produced just in time by anyone with basic expertise, therefore no special technical training is required.

[0013] Furthermore, additive manufacturing of single-piece roofing components allows for very low-cost production of a single component, particularly since the cost per component is essentially independent of rod size, and the single-piece roofing component can reliably provide the same quality as the types of membranes typically used to seal large roof areas.

[0014] Further aspects of the invention are the subject of further independent claims. Particularly preferred embodiments are outlined throughout the description and the dependent claims.

[0015] Methods for carrying out the invention A first aspect of the invention relates to a method for manufacturing a single piece roof for sealing roof elements, the method comprising the following steps: (a) Providing and / or obtaining a digital model of the roof element to be sealed; (b) Using this digital model, additively manufacture a single roof component that fits the contours of the roof element.

[0016] Preferably, the roof element is a building roof element.

[0017] The term "additive manufacturing" refers to a method in which three-dimensional objects or shapes are produced by selectively depositing, applying, and / or solidifying material in three dimensions. In this process, the deposition, application, and / or solidification of material is performed, in particular layer by layer, based on a data model of the object to be produced. In additive manufacturing, each object is typically produced from one or more layers. Objects are usually produced using amorphous materials (e.g., liquids, powders, granules, pastes, etc.) and / or materials in intermediate forms (e.g., bands, wires), which are subjected, in particular, to chemical and / or physical processes (e.g., melting, polymerizing, sintering, hardening, quenching).

[0018] Additive manufacturing is also referred to by terms such as "generative manufacturing," "additive manufacturing," or "3D printing." Compared to traditional technologies based on creating objects through molding / casting or cutting / machining material from raw objects, additive manufacturing or 3D printing technology takes a fundamentally different approach to manufacturing. The process used in additive manufacturing was originally inspired by inkjet printing technology, which has been extended to three dimensions with other materials. The design of each object can be varied without increasing production costs, providing tailor-made solutions for a wide range of products.

[0019] "Digital model" means a digital representation of a real object, i.e., a roof element, that accurately replicates the shape of that object. Typically, the digital model is stored in a computer-readable data storage, in particular in a data file. The data file format can be, for example, a computer-aided design (CAD) file format, a G-code (also called RS-274) file format, and / or an STL file format. In particular, the digital model is a digital representation of at least the outer shape of the roof element.

[0020] In particular, the roof element may be a roof curb, a roof drain, a roof edge, a roof expansion joint, a roof parapet, a roof penetration, a roof sleeper, a roof joint, a roof corner, a roof tie-in, and / or a roof wall.

[0021] In particular, a roofing detail part is a cover, hood, cap, or revetment for a roof element, in particular a roof curb, a roof drain, a roof edge, a roof expansion joint, a roof parapet wall, a roof penetration, a roof sleeper, a roof transition, a roof corner, a roof tie-in, and / or a roof wall.

[0022] In step (b), a control system can be used to generate control data from the digital model for controlling the additive manufacturing process. Control systems of this kind are well known and commercially available. The control system can be part of the additive manufacturing equipment, e.g., a 3D printer, or can be part of a separate data processing unit, e.g., a computer system.

[0023] When manufacturing the single roof component in step (b) of the method of the present invention, the digital model is used as the basis for manufacturing the single roof component by additive manufacturing, in particular the single roof component is manufactured such that its internal shape corresponds to the negative of the digital model.

[0024] In particular, in step (b), a separate digital model of the roof element to be manufactured is generated, which separate digital model is calculated based on the digital model of the roof element. The separate digital model can be obtained, for example, by taking the outer surface of the digital model of the roof element and generating a surface with a negative form as the inner surface of the separate digital model of the roof element. The outer surface of the separate model of the roof element can be generated, for example, by adding a specific wall thickness to the area behind the inner surface of the separate digital model.

[0025] Preferably, in step (a), the digital model of the roof element is obtained by 3D scanning of the roof element. 3D scanning is a process in which a real-world object, e.g., a roof element, is analyzed to collect data about its shape. The collected data can then be used to construct a digital model of the object. A control system can then be used to generate the digital model from the collected data. The control system can be part of the 3D scanner or part of a separate data processing unit, e.g., a computer system.

[0026] With 3D scanning, the actual roof elements can be scanned directly on the roof, which ensures that the digital model is an accurate representation of the actual roof elements that will be sealed. Overall, the combination of 3D scanning and additive manufacturing, especially 3D printers, offers an efficient method for producing individual single roof components with high precision.

[0027] However, in principle it is also possible to obtain a digital model by manually measuring all of the lengths and angles of the roof elements and manually generating the digital model in modeling software, which would still be time consuming and more prone to error.

[0028] Various 3D scanners that can be used for 3D printing are commercially available. Preferably, the scanning of the roof element is performed using a handheld and / or portable 3D scanner. A handheld and / or portable 3D scanner does not require complex equipment and allows for quick and easy scanning of the roof element to be sealed.

[0029] Preferably, the 3D scanner is designed to capture objects with a length between 1 cm and 20 m, in particular between 20 cm and 10 m.

[0030] In particular, the 3D scanner is a non-contact 3D scanner, which probes an object by emitting some type of radiation, such as light, ultrasound, or X-rays, and detecting the radiation reflected or transmitted through the object being scanned.

[0031] For example, the 3D scanner is a "Calibri 3D Scanner" type scanner by Thor3d, Varshavskoe Sh. 33, Moscow, Russia.

[0032] Preferably, additive manufacturing is performed by 3D printing, in particular by FDM (fused deposition modeling) or FPF (fused particle fabrication). FDM is a process that typically uses continuous filaments of thermoplastic material. FPF is similar to FDM, but it uses particles, e.g., granules, as feed material rather than continuous filaments. FPF is also called FGF (fused granular fabrication).

[0033] The filament is thereby fed through a moving, heated printer extrusion head and deposited onto the object being manufactured. The printer extrusion head is moved under computer control to define the shape to be printed. Typically, the head is moved in two dimensions to deposit at least one horizontal plane, or layer, at a time. The object and / or printer extrusion head are then moved vertically by a small amount to begin a new layer.

[0034] A variety of 3D printers are commercially available that can be used in the methods of the present invention.

[0035] Preferably, the roofing unit is manufactured from a plastic material, in particular from a thermoplastic material, in particular from a plastic material having a melting point between 120°C and 300°C, preferably between 140°C and 250°C.

[0036] In particular, the plastic material is selected from thermoplastic polyolefins (TPO), polyvinyl chloride (PVC) and / or ketone ethylene esters (KEE).

[0037] These materials may be formulated with antioxidants, fillers, pigments, reinforcing materials, and / or further thermoplastic polymers. The reinforcing materials may be selected from fibers, such as carbon fibers, polyethylene fibers, and / or glass fibers. The further thermoplastic polymers preferably have a melting point between 50°C and 300°C, preferably between 80°C and 250°C.

[0038] Plastic, and particularly thermoplastic, roofing units are best suited to typical roof sealing materials, such as membranes. In particular, roofing units made from thermoplastic materials can be easily welded to thermoplastic membranes to provide a watertight joint.

[0039] In particular, the single roof component is manufactured in a single-ply structure, which is physically stable and can be produced in a reliable manner using additive manufacturing.

[0040] More preferably, the single roof component is a monolithic component, which does not have the risk of leaks caused by weld seams etc. Therefore, a monolithic component is much more reliable than a component made up of multiple parts joined together.

[0041] In particular, the wall thickness of the roofing unit components produced is 0.1 to 10 mm, especially 1 to 5 mm. Such components have been found to be physically stable and watertight, while still being flexible enough for installation. However, in particular applications, roofing unit components with wall thicknesses other than these may also be suitable.

[0042] A further aspect of the present invention relates to a method of sealing a roof element comprising the steps of: (i) carrying out the method of the present invention as described above to obtain a single roof component that fits onto the roof element; (ii) attaching a single roofing component to a roof element; (iii) Optionally, joining the attached single roof component to another sealing element of the roof, in particular by heat welding.

[0043] In step (iii), the separate sealing element may for example be a separate roof unitary piece and / or sealing material for the main area of ​​the roof, such as a membrane and / or a waterproofing sheet.

[0044] In this way, the entire roof area can be sealed with a single roofing piece and sealing material that is interconnected in a watertight manner.

[0045] Preferably, the material of the single roofing piece is selected so that it can be heat welded to the separate sealing element, in particular both the single roofing piece and the separate sealing element are made from a thermoplastic material, preferably a material as described above.

[0046] However, other combinations may also be suitable for specific applications.Alternative bonding methods may be used instead of or in addition to heat welding, such as adhesive bonding and / or clamping.

[0047] Further advantageous configurations of the invention emerge from the exemplary embodiments.

[0048] The drawings used to explain the embodiments are as follows: [Brief explanation of the drawings]

[0049] [Figure 1] Schematic diagram of a section of a flat roof having a duct running through a membrane, where the duct is scanned with a 3D scanner to obtain a digital model of the duct. [Figure 2] FIG. 2 is a schematic diagram of the 3D printing process for a single roof piece based on the digital model of FIG. 1. [Figure 3]3 is a schematic diagram of the flat roof section of FIG. 1 after the roofing unitary piece of FIG. 2 has been attached to the duct and the roofing unitary piece has been heat welded to the membrane to create a watertight joint. [Figure 4] This is a prior art sealing method for a model of a complex corner shape of a flat roof using many roofing membrane pieces. [Figure 5] This is a 3D scan of the model corner in Figure 4. DETAILED DESCRIPTION OF THE INVENTION

[0050] In the drawings, like components are marked with like reference symbols. [Example]

[0051] Exemplary Embodiments A portion of a flat roof is shown on the left side of Figure 1. Specifically, a thermoplastic membrane 2 is placed on top of the flat roof with a roof element in the form of a vertically extending cylindrical duct 1. In the situation of Figure 1, the duct 1 extends through a circular opening 2.1 in the membrane 2.

[0052] Using a portable 3D scanner 3, the duct 1 is scanned with a laser beam 4 to collect data about the shape of the duct 1. The collected data is processed in a control unit of the scanner 3 and stored as a digital model 6 of the duct 1 in a data file 5. For example, the file format of the data file 5 is a CAD file format.

[0053] As shown in Figure 2, a data file 5 containing a digital model 6 of the duct 1 is transferred to a 3D printer 7. In a control unit 8 of the 3D printer 7, a separate digital model 10 of a single roof component that fits onto the duct 1 is generated based on the digital model 6 of the duct 1 and stored in a separate data file 9. Thereby, a negative of the outer surface of the digital model 6 of the duct 1 corresponds to the inner surface of the separate digital model 10 of the single roof component.

[0054] Based on another digital model 10, the control unit 8 of the 3D printer 7 generates control data for a print head 11 that produces a single roof piece 12 that fits into the duct 1. The material used for printing is a thermoplastic polymer with a melting point of, for example, 160°C. As shown on the right side of Figure 2, the single roof piece 12 is a monolithic hollow cylinder that is closed at the top and open at the bottom.

[0055] Once the roofing unit 12 is prepared, it can be attached to the duct 1 as shown in Figure 3. Thereby, the roofing unit 12 is joined all around by heat welding to the membrane 2 in the area of ​​the opening 2.1, providing a watertight joint between the roofing unit 12 and the membrane 2.

[0056] Figure 4 shows a prior art sealing method for a model of a corner of a complex shape of a flat roof, where the corner is covered with several small pieces of roofing membrane, which are joined by heat welding. Therefore, this method results in a "patchwork" cover with several weak spots (weld lines) for watertightness.

[0057] Figure 5 shows a 3D scan of the model corner of Figure 4. Similar to the procedure shown in Figures 1-3, the collected data is used to synthesize a digital model of the corner, which is then fed into a 3D printing system, which produces a monolithic, singulated part using a suitable thermoplastic composition.

[0058] Thus, those skilled in the art will recognize that the present invention may be embodied in other specific forms without departing from its spirit or essential characteristics. The presently disclosed embodiments are, therefore, considered in all respects to be illustrative and not restrictive. The present disclosure includes the following inventive aspects: <Aspect 1> 1. A method for manufacturing a single (12) roof component for sealing a roof element (1), comprising the steps of: (a) providing and / or obtaining a digital model (6) of the roof element (1) to be sealed; (b) additively manufacturing a single roof part (12) that fits the contours of the roof element (1) based on the digital model (6). <Aspect 2> 2. The method of claim 1, wherein in step (a), the digital model (6) of the roof element (1) is obtained by 3D scanning of the roof element. <Aspect 3> 3. The method of any one of aspects 1 to 2, wherein the scanning of the roof element (1) is performed using a handheld and / or portable 3D scanner (3). <Aspect 4> 4. The method according to any one of aspects 1 to 3, wherein the additive manufacturing is carried out by 3D printing, in particular by fused deposition modelling (FDM) or fused particle fabrication (FPF). <Aspect 5> 5. The method according to any one of aspects 1 to 4, wherein the roofing unitary component (12) is made from a plastic material, in particular from a thermoplastic material, in particular from thermoplastic polyolefin (TPO), polyvinyl chloride (PVC), and / or ketone ethylene ester (KEE). <Aspect 6> Aspect 6. The method of any one of aspects 1 to 5, wherein the plastic material further comprises an antioxidant, a filler, a pigment, a reinforcing agent, and / or a further thermoplastic polymer. <Aspect 7> Aspect 7. The method of any one of aspects 1-6, wherein the unitary roofing component is manufactured with a single-ply construction. <Aspect 8> A method according to any one of aspects 1 to 7, wherein the wall thickness of the roofing unitary component (12) produced is between 0.1 and 10 mm, in particular between 1 and 5 mm. <Aspect 9> 9. The method according to any one of aspects 1 to 8, wherein in step (b), the single roof piece (12) is manufactured to have an inner surface shape that corresponds to a negative of the digital model (6) of the roof element (1). <Aspect 10> 10. The method according to any one of aspects 1 to 9, wherein the manufacturing of the roofing unit (12) is carried out so that the outer surface of the roofing unit (12) is similar to the outer surface of the roof element (1), in particular so that the outer surface of the roofing unit (12) assumes a uniformly scaled shape of the outer surface of the roof element (1). <Aspect 11> 11. The method according to any one of aspects 1 to 10, wherein in step (b) a further digital model (10) of the roof single piece (12) to be manufactured is generated based on the digital model (6) of the roof element (1). <Aspect 12> A method for sealing a roof element (1) comprising the steps of: (i) performing the method according to any one of aspects 1 to 11 to obtain a single roof piece (12) that fits onto the roof element (1); (ii) attaching the roof unitary piece (12) to the roof element (1); (iii) Optionally, joining said attached roof unitary piece (12) with another sealing element (2) of the roof, in particular by heat welding. <Aspect 13> 13. The method of any one of aspects 1 to 12, wherein the roof element (1) is a roof curb, a roof drain, a roof edge, a roof expansion joint, a roof parapet, a roof penetration, a roof sleeper, a roof joint, a roof corner, a roof tie-in, and / or a roof wall. <Aspect 14> 14. The method of any one of aspects 1 to 13, wherein the roof unitary piece (12) is a cover, hood, cap, or retaining wall for a roof element, in particular for a roof curb, a roof drain, a roof edge, a roof expansion joint, a roof parapet, a roof penetration, a roof sleeper, a roof joint, a roof corner, a roof tie-in, and / or a roof wall.

Claims

1. A method for manufacturing a single roof piece (12) for sealing a roof element (1), comprising the steps of: (a) providing and / or obtaining a digital model (6) of the roof element (1) to be sealed; (b) additively manufacturing a single roof component (12) that fits the contour of the roof element (1) based on the digital model (6). wherein the wall thickness of the roofing unit (12) produced is between 0.1 and 10 mm, in particular between 1 and 5 mm.

2. A method for manufacturing a roof unitary component (12) for sealing a roof element (1), comprising the steps of: (a) providing and / or obtaining a digital model (6) of the roof element (1) to be sealed; (b) additively manufacturing a single roof component (12) that fits the contour of the roof element (1) based on the digital model (6). wherein in step (b) said single roof piece (12) is manufactured to have an internal shape corresponding to the negative of said digital model (6) of said roof element (1).

3. A method for manufacturing a roof unitary component (12) for sealing a roof element (1), comprising the steps of: (a) providing and / or obtaining a digital model (6) of the roof element (1) to be sealed; (b) additively manufacturing a single roof component (12) that fits the contour of the roof element (1) based on the digital model (6).

10. A method according to claim 9, wherein in step (b) a further digital model (10) of the roof single piece (12) to be manufactured is generated based on the digital model (6) of the roof element (1).

4. The method according to any one of claims 1 to 3, wherein in step (a) the digital model (6) of the roof element (1) is obtained by 3D scanning of the roof element.

5. 5. The method according to claim 4, wherein the scanning of the roof element (1) is performed using a handheld and / or portable 3D scanner (3).

6. The method according to any one of claims 1 to 5, wherein additive manufacturing is carried out by 3D printing, in particular by fused deposition modelling (FDM) or fused particle fabrication (FPF).

7. 7. The method according to any one of claims 1 to 6, wherein the roofing unit (12) is manufactured from a plastic material, in particular from a thermoplastic material, in particular from thermoplastic polyolefin (TPO), polyvinyl chloride (PVC) and / or ketone ethylene ester (KEE).

8. The method of claim 7 , wherein the plastic material further comprises antioxidants, fillers, pigments, reinforcing agents, and / or additional thermoplastic polymers.

9. A method according to any one of claims 1 to 8, wherein the single roofing component is manufactured in a single-ply construction.

10. 10. The method according to any one of claims 1 to 9, wherein the manufacturing of the roofing unit (12) is carried out so that the outer surface of the roofing unit (12) is similar to the outer surface of the roof element (1), in particular so that the outer surface of the roofing unit (12) assumes a uniformly scaled shape of the outer surface of the roof element (1).

11. A method for sealing a roof element (1) comprising the steps of: (i) carrying out the method according to any one of claims 1 to 10 to obtain a roof unitary piece (12) that fits onto said roof element (1); (ii) attaching said roof unitary piece (12) to said roof element (1); (iii) Optionally, joining said attached roof unitary piece (12) with another sealing element (2) of the roof.

12. The method according to any one of claims 1 to 11, wherein the roof element (1) is a roof curb, a roof drain, a roof edge, a roof expansion joint, a roof parapet, a roof penetration, a roof sleeper, a roof joint, a roof corner, a roof tie-in, and / or a roof wall.

13. 13. The method according to any one of claims 1 to 12, wherein the roof unitary piece (12) is a cover, hood, cap or retaining wall for a roof element, in particular for a roof curb, a roof drain, a roof edge, a roof expansion joint, a roof parapet, a roof penetration, a roof sleeper, a roof joint, a roof corner, a roof tie-in and / or a roof wall.

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