Method for manufacturing roofing materials and method for connecting roofing materials formed by this manufacturing method

Abstract

To provide a method of manufacturing a roofing material such that the roofing material can be connected without installing a connection plate at a joint in a gradient direction of a roof.SOLUTION: A long-sized metal plate is bent and deformed stepwise by a roll molding machine 100 to form a roofing material 1A which comprises a main body 1a, a first fitting part 2a formed at one side end along a length direction of the main body, a mounting part 3a arranged at a side end edge of the first fitting part, and a second fitting part 4a formed at the other side end along the length direction of the main body. Then, a cover plate material 1C which is in the same cross-sectional shape as the roofing material and has a length corresponding to the part of the roofing material that is superposed in a gradient direction is superposed on a top surface of one length-directional end of the roofing material, and bent and deformed stepwise by the roll molding machine under the same condition as the formation of the roofing material, and the main body is expanded in a width direction to form a join part 5a. The cover plate material is superposed on the roofing material, and then bent and deformed by the roll molding machine, so that the roofing material can be connected without any gap when superposed in the gradient direction.SELECTED DRAWING: Figure 6

Description

Technical Field

[0001] The present invention relates to a roofing material for roofing by connecting a plurality of elongated metal roofing materials in the longitudinal direction and the lateral direction, and particularly to a method for manufacturing a roofing material that forms a connection structure for connecting the roofing materials in the slope direction of a roof and method for connecting roofing materials formed by this manufacturing method .

Background Art

[0002] Patent Document 1 describes a connection structure for uneven roof materials, in which the joint between a first uneven roof material and a second uneven roof material is covered with a connection plate, and the gaps between the connection plate and the first uneven roof material as well as between the connection plate and the second uneven roof material are covered with a sealing material.

Prior Art Literature

Patent Literature

[0003]

Patent Document 1

Summary of the Invention

Problem to be Solved by the Invention

[0004] However, in the connection structure described in the above Patent Document 1, since a connection plate must be installed at each joint of the roofing materials in the slope direction of the roof, the connection plate is required in addition to the roofing materials. Further, when roofing a roof, it is necessary to transport and install the connection plate onto the roof, which poses a problem that the work becomes complicated.

[0005] Accordingly, the present invention was created in view of the conventional circumstances as described above, and provides a method for manufacturing a roofing material that can connect roofing materials without installing a connection plate at the joint in the slope direction of the roof and method for connecting roofing materials formed by this manufacturing method .

Means for Solving the Problem

[0006] The invention of claim 1 according to the present invention comprises a body formed by progressively bending a long metal plate with a roll forming machine, and comprising a body, a first fitting portion formed on one side end along the longitudinal direction of the body, a mounting portion disposed on the side edge of the first fitting portion, and a second fitting portion formed on the other side end along the longitudinal direction of the body. multiple The process of forming the roofing material, The process of cutting at least one of the formed plurality of roofing materials to a length corresponding to the joint portion that overlaps in the slope direction of the roofing materials, removing the mounting portion to form a backing plate material, and the remaining of the formed plurality of roofing materials One end of the roofing material in the longitudinal direction The upper surface of the backing plate Repeatedly, The process involves using the roll forming machine to deform the first and second fitting portions so as to narrow them while restricting the expansion in the width direction at both ends of the short side of the roofing material, and forming a joint portion at one end of the long side of the roofing material that has a shape in which the main body is lowered by one step and is expanded in the width direction, The above-mentioned problems were solved by including a step of removing the backing plate from the roofing material.

[0007] According to the roofing material of claim 1, the main body can be widened in the width direction without changing the positions of the first and second fitting portions in the overlapping portions in the slope direction. As a result, when overlapping the roofing materials in the slope direction, the widened portion of the main body can be used to connect them without gaps, without installing a connecting plate.

[0009] Moreover, Since backing plates can be formed using existing roofing materials, there is no need to form new backing plates, thus reducing manufacturing complexity and cost increases. Furthermore, because there is no need to transport or install connecting plates on the roof, the roofing process is simplified. The invention of claim 2 according to the present invention solves the above-mentioned problems by having a head portion that constitutes a male portion in the first fitting portion and a receiving groove portion that constitutes a female portion in the second fitting portion. According to the roofing material of claim 2, adjacent roofing materials in the shorter direction can be connected with a single touch by overlapping and stepping on the head portion that constitutes the male part and the receiving groove portion that constitutes the female part.

[0010] Furthermore, the invention of claim 3 according to the present invention is made by the manufacturing method described in claim 1. After forming the roofing material, The above-mentioned problems were solved by connecting the upper surface of the side of the main body that has been expanded in the width direction by installing the aforementioned backing plate to the lower surface of the side of the roofing material that is adjacent to it in the upward direction of the roof slope and does not have the backing plate installed.

[0011] According to the roofing material of claim 3, the portion of the roofing material that has been extended in the width direction can be overlapped with the main body of the roofing material and connected without any gaps.

[0012] Furthermore, the invention according to claim 4 of the present invention solves the above-mentioned problem likewise by connecting via a water-stopping material interposed between the upper surface on the side where the main body is expanded in the width direction and the lower surface on the side where the backing plate is not provided.

[0013] According to the roofing material according to claim 4, waterproof performance can be improved by interposing a water-stopping material in the overlapping portion between the portion where the main body of the roofing material is expanded in the width direction and the main body of the roofing material.

[0016] In addition, the invention according to claim 5 of the present invention is characterized in that the second fitting portion of adjacently arranged roofing materials Groove is pushed into the head of the first fitting portion of the roofing material adjacent in the width direction, thereby being expanded and fitted, which likewise solves the above-mentioned problem.

[0017] According to the roofing material according to claim 5 , capillary action can be prevented at the fitting portion, and waterproof performance can be improved.

[0018] In addition, the invention according to claim 6 of the present invention further comprises a water-stopping material interposed between the Groove of the second fitting portion and the head of the first fitting portion, which likewise solves the above-mentioned problem.

[0019] According to the roofing material according to claim 6 , by interposing the water-stopping material, the waterproof performance between the groove of the second fitting portion and the head of the first fitting portion can be further improved. Effects of the Invention

[0020] According to the present invention, there can be provided a method for manufacturing a roofing material and method for connecting roofing materials formed by this manufacturing method that enables connecting roofing materials without arranging a connecting plate at the joint in the slope direction of the roof. Brief Description of the Drawings

[0021] [Figure 1] It is a perspective view of a roofing material according to an embodiment of the present invention and a cross-sectional view thereof in the width direction. [Figure 2]It is a perspective view for explaining the step of overlapping the roofing materials shown in Figure 1 in the slope direction of a roof. [Figure 3] It is a perspective view for explaining the first step in the method for manufacturing a roofing material according to an embodiment of the present invention and a cross-sectional view in the width direction thereof. [Figure 4] It is a perspective view for explaining the second step in the method for manufacturing a roofing material according to an embodiment of the present invention and a cross-sectional view in the width direction thereof. [Figure 5] It is a perspective view for explaining the third step in the method for manufacturing a roofing material according to an embodiment of the present invention and a cross-sectional view in the width direction thereof. [Figure 6] It is a perspective view for explaining the fourth step in the method for manufacturing a roofing material according to an embodiment of the present invention and a cross-sectional view in the width direction thereof. [Figure 7] It is a perspective view for explaining the fifth step in the method for manufacturing a roofing material according to an embodiment of the present invention and a cross-sectional view in the width direction thereof. Description of Embodiments

[0022] An embodiment of the present invention will be described below with reference to the drawings. Figure 1(a) is a perspective view of a roofing material according to an embodiment of the present invention, and Figure 1(b) is a cross-sectional view taken along line A-A' of Figure 1(a). As shown in Figure 1(a), a main body 1a of a (metal) roofing material 1A is formed in an elongated shape. A first fitting portion 2a is formed at one side end along the longitudinal direction of the main body 1a, and a mounting portion 3a is formed at a side edge of the first fitting portion 2a. A second fitting portion 4a is formed at the other side end along the longitudinal direction of the main body 1a. A joining portion 5a obtained by expanding the main body 1a in the width direction is formed at one end of the roofing material 1A in the longitudinal direction. The width of the upper surface of this joining portion 5a is equal to the width of the lower surface of one end of the roofing material 1A in the longitudinal direction.

[0023] As shown in Figure 1(b), the first fitting portion 2a has a head portion that constitutes the male part, and the second fitting portion 4a has a receiving groove portion that constitutes the female part. In addition, the mounting portion 3a is bent upward. This roofing material 1A has, for example, a thickness of 0.35 to 0.4 mm, a width of 455 to 500 mm or 515 to 620 mm, and a length of 1.0 to 10 m.

[0024] Then, as shown in Figures 2(a) and (b), the lower surface of the other end of roofing material 1B, which has a similar structure to roofing material 1A and is positioned adjacent to the roofing material 1B in the upward direction of the roof slope, is placed on the upper surface of the joint 5a of roofing material 1A and overlapped, thereby connecting and attaching roofing material 1A and roofing material 1B. Alternatively, the lower surface of the other end of roofing material positioned adjacent to the roofing material in the upward direction of the roof slope is placed on the upper surface of this joint 5a with a waterproofing material interposed therebetween, thereby connecting and attaching roofing material 1A and roofing material 1B. For example, a highly elastic synthetic rubber called hot melt can be used as this waterproofing material.

[0025] When installing the roofing material, the mounting parts 3a and 3b at one end of each connected roofing material (for example, roofing material 1A and 1B connected together) are attached to the roof decking, such as plywood, with mounting screws or nails. The adjacent connected roofing material (similarly made by connecting roofing material 1A and 1B) is then aligned in the upward direction of the roof slope, and the mounting parts 3a and 3b at one end of each connected roofing material are attached to the roof decking, such as plywood, with mounting screws or nails.

[0026] Next, the grooves of the second fitting portions 4a and 4b of adjacent connecting roofing materials in the shorter direction are placed on top of the heads of the first fitting portions 2a and 2b of the adjacent connecting roofing materials and pressed down, expanding and fitting them together by pushing them onto the heads of the first fitting portions 2a and 2b. Then, the roofing materials are connected and installed sequentially using the same procedure to lay the roof. At this time, a waterproofing material may be interposed between the grooves of the second fitting portions 4a and 4b and the heads of the first fitting portions 2a and 2b. For this waterproofing material, for example, a highly elastic synthetic rubber called hot melt can be used.

[0027] Next, the manufacturing method of the roofing material described above will be explained with reference to Figures 3 to 7. Figure 3(a) is a perspective view, Figure 3(b) is a cross-sectional view of the backing plate shown in Figure 3(a) along the line B-B', and Figure 3(c) is a cross-sectional view of the roofing material 1A shown in Figure 3(a) along the line C-C'. First, prepare the roofing material 1A and the backing plate material 1C, as shown in Figure 3(a).

[0028] The roofing material 1A is formed by gradually bending a long metal sheet using a roll forming machine (bending machine) 100. Along the longitudinal direction of the main body 1a, a first fitting portion 2a is formed at one side end of the roofing material 1A, and an attachment portion 3a is formed at the side edge of the first fitting portion 2a, and a second fitting portion 4a is formed at the other side end along the longitudinal direction of the main body 1a.

[0029] Furthermore, the backing plate 1C is made by cutting the roofing material 1A shorter in the longitudinal direction (to a length corresponding to the joint portion 5a that overlaps in the slope direction of the roofing material 1A) and removing the mounting portion 3a. Therefore, as shown in Figure 3(b), this backing plate 1C has a cross-sectional shape that is almost the same as that of the roofing material 1A.

[0030] Next, as shown in Figures 4(a) and 4(b), the backing plate 1C is placed over one end of the roofing material 1A in the longitudinal direction. Since the width of the main body 1c of the backing plate 1C is equal to the width ΔL1 of the main body 1a of the roofing material 1A, the main body 1c of the backing plate 1C bends upward (this is exaggerated in Figure 4(b)).

[0031] Next, as shown in Figures 5(a) and 5(b), the backing plate 1C is pressed against the roofing material 1A to temporarily fix it in place. In this state, as shown in Figures 6(a) and 6(b), the material is placed in the roll forming machine 100 under the same conditions as when the roofing material 1A was formed and bent in stages.

[0032] As a result, as shown in Figures 7(a) and (b), the width ΔL1 of the main body 1a of the roofing material 1A is expanded in the width direction to ΔL2. Since the width expansion at both ends of the roofing material 1A is restricted by the roll forming machine 100, the first and second fitting portions 2a and 4a are effectively deformed in such a way that they are narrowed. As a result, when the backing plate 1C is removed, a joint portion 5a is formed at one end of the roofing material 1A in the longitudinal direction, with the width of the main body 1a expanded.

[0033] Accordingly, according to the present invention, the main body 1a can be widened in the width direction without substantially changing the position or size of the first and second fitting portions 2a and 4a in the portion that overlaps in the direction of the roof slope. As a result, when overlapping roofing materials in the direction of the slope, the widened portion of the main body can be used to connect them without gaps, without installing a connecting plate. As a result, there is no need to form new backing plates, thus reducing the complexity of manufacturing and the increase in costs. Furthermore, since there is no need to transport or install connecting plates on the roof, the roofing process can be simplified.

[0034] Furthermore, the present invention is not limited to the embodiments described above, and can be implemented in various ways without departing from the spirit of the invention.

[0035] For example, I explained the case where roofing materials are connected in the longitudinal direction first, and then in the transverse direction, but it is also possible to connect roofing materials in the transverse direction first, and then in the longitudinal direction.

[0036] Furthermore, the structures of the first and second fitting and mounting parts are merely examples, and are not limited to the cross-sectional shapes described above. Naturally, various other configurations can be applied as long as adjacent roofing materials can be fitted together. [Explanation of symbols]

[0037] 1A, 1B…Roofing materials 1C... backing plate material 1a, 1b... Main unit 2a, 2b... First fitting part 3a,3b...Mounting part 4a, 4b... Second fitting part 5a,5b…Joint part 100... Roll forming machine

Claims

1. A process of forming a plurality of roofing materials, each comprising a main body, a first fitting portion formed on one side end along the longitudinal direction of the main body, a mounting portion positioned on the side edge of the first fitting portion, and a second fitting portion formed on the other side end along the longitudinal direction of the main body, The process involves cutting at least one of the formed plurality of roofing materials to a length corresponding to the joint portion that overlaps in the slope direction of the roofing materials, removing the mounting portion, and forming a backing plate material. The process involves placing the backing plate on the upper surface of one end in the longitudinal direction of the remaining roofing material of the formed plurality of roofing materials, and using the roll forming machine to deform the first and second fitting portions so as to narrow them while restricting the expansion in the width direction of both ends in the short direction of the roofing material, and forming a joint portion at one end in the longitudinal direction of the roofing material in which the main body is lowered by one step and the width direction is expanded, The process of removing the backing plate from the roofing material and A method for manufacturing roofing materials, characterized by comprising the following:

2. The method for manufacturing a roofing material according to claim 1, characterized in that the first fitting portion has a head portion constituting a male portion, and the second fitting portion has a receiving groove portion constituting a female portion.

3. A method for connecting roofing materials, characterized in that, after forming the roofing material by the manufacturing method described in claim 1, the backing plate material is installed on the upper surface of the roofing material on the side where the main body is expanded in the width direction, and the other end of the roofing material, which is adjacent to it in the upward direction of the roof slope, is connected to the upper surface of the roofing material on the other end where the backing plate material is not installed.

4. The method for connecting roofing materials according to claim 3, characterized in that a waterproofing material is interposed between the upper surface of the main body that is extended in the width direction and the lower surface of the side on which the backing plate material is not installed.

5. The method for connecting roofing materials according to claim 3, characterized in that the groove of the second fitting portion of an adjacent roofing material is pushed into the head of the first fitting portion of an adjacent roofing material in the shorter direction to widen and fit them together.

6. The method for connecting roofing materials according to claim 5, further comprising a water-stopping material interposed between the groove of the second fitting portion and the head of the first fitting portion.

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