FR2697202A1 - In-line mfr. of profiled composite with metal film and anti-condensation fabric - by unrolling metal strip and fabric strip at same time and same speed and bonding under pressure - Google Patents

Abstract

In mfr. of a profiled composite material with a metal film covered with an anti-condensation fabric, by mechanically unrolling a strip of the metal on a profiling line, the novelty is that a sheet of anti-condensation fabric is unroleld at the same time and at the same speed and is applied by bonding under pressure to one of the faces of the metal strip, to cause in-line profiling of the composite. USE/ADVANTAGE - The composite is used internally in buildings, e.g. against roofing to prevent condensation. The process is quick.

Description

PROCESS FOR MANUFACTURING A PROFILE COMPOSITE MATERIAL, AND
INSTALLATION FOR ITS IMPLEMENTATION
The present invention relates to an improved method for manufacturing, on-line, a profiled composite material, intended for example to integrate with the internal faces of building structures, such as roofs, so as to prevent condensation. This profiled composite material consists of a metal sheet lined with a fabric whose role is to allow the absorption or retention of moisture and the desorption of this humidity under the usual conditions of use. The invention also relates to an installation for implementing this method.

 In European patent EP-B-31 701, there is described a process for preparing a laminated article comprising a metal sheet and a film of thermoplastic resin. This method includes heating the sheet and the film with an adhesive disposed therebetween at a temperature above the melting temperature of the adhesive, and cooling the laminated article between a chill roll and a pressure roll. elastic, at the temperature of heat deformation of the adhesive or at a temperature higher than this. The adhesive is chosen from polyolefins containing carboxyl groups and polyolefin-based resins prepared by hot mixing such a polyolefin and a metallic compound. A composite article is obtained which, among other things, can be used as a construction and having no lack of uniformity in adhesion, or frowns.

 American patent US-A-4 656 082 describes a laminated material, usable in place of an expanded expanded metal mattress, used in the construction of roofs. This laminate has at least one inner layer comprising a fibrous material, woven or nonwoven, adhesively bonded to each of the adjacent adjacent layers formed of paper or a metallic sheet. This laminate has at least one layer of paper, and at least one outer layer of said laminate is formed of a metal sheet.

 British patent GB-B-707,293 relates to the manufacture of building materials, in particular, thermal insulation coatings and resistant to flame propagation for roofs, walls and other surfaces.

The construction element described comprises a sheet of a relatively rigid thermal insulation plate, having little or no flame resistance properties, and one or more sheets of relatively flexible asbestos felt, linked to one or more two sides of the plate by an adhesive with sodium silicate, whereby the qualities of flame spread resistance of the building material are enhanced, a sheet of metal being bonded to the composite sheet by means of bitumen applied to the liquid or plastic state. In a particular embodiment, the metal sheet is corrugated or grooved and only the edges of the corrugations or grooves thereof are linked to the aforementioned composite sheet.

 In German patent DE-C-1 621 323, a composite is described having a steel core for example, bonded by molten metal to layers of fibrous materials. The composite can then be caused to pass into an impregnation bath with a resin or with bitumen.

 Also known, from Dutch patent application NL-A-83/02772, is a method of covering an external surface which may be made of aluminum, by a wetting product, a nonwoven and a paint.

 These documents do not offer any interesting indication in the context of the application intended according to the invention, in particular for carrying out a simple and reliable method of manufacturing a profiled composite as defined above.

 The Depositing Company had the idea of integrating the step of gluing an anti-condensation fabric against a metal sheet on the profiling chain of the latter, so that this gluing operation takes place in masked time, with the resulting advantages of speed and ease in terms of industrial manufacturing.

 The present invention therefore firstly relates to a process for manufacturing a profiled composite material, consisting of a metal sheet coated with an anti-condensation fabric, a process in which a strip of metallic material is mechanically unwound on a profiling chain , characterized in that, simultaneously, a strip of anticondensation fabric is unrolled at the same speed by applying it by gluing, and under the action of a pressure, against one of the faces of the strip of metallic material, in order to subject the composite to the in-line profiling operation.

 As the metallic material, any metal which cannot be oxidized in air or protected against oxidation by an appropriate coating, such as aluminum foil, or in particular a sheet of galvanized steel, or else a strip of metal, may be used. steel. In the latter case, the side opposite to that receiving the anti-condensation fabric will have been coated with a layer of lacquer or a protective paint and the face receiving the anti-condensation fabric will have been coated, if necessary. 'a protective primer, on which the adhesive must ensure the connection of said fabric with the metal sheet.

 As anti-condensation fabric, use is made in particular of a fabric capable of ensuring absorption of moisture and desorption thereof under the usual conditions of use, said fabric preferably being chosen from non-woven fabrics. or veils, with multidirectional weft, based on fibers or combination of polyester, acrylic and cellulosic fibers.

 As glue, a hot-melt glue is essentially used, preferably having an open time of the order of 5-30 seconds, which is applied, in line, by coating, fiberizing or in beads, at a temperature preferably between 1200C and 16000 approximately, on the strip of anti-condensation fabric, before its application against the strip of metallic material, the latter being, at this point, preheated to a temperature sufficient to prevent the liquid adhesive applied from undergoing a thermal shock preventing its implementation. This preheating temperature is generally between 20 and 50 "C. The coating represents the preferred mode of application.

 By way of examples of hot-melt adhesive, mention may be made of those based on vinyl polymers, such as vinyl acetate-ethylene copolymers or polyvinyl alcohol, these adhesives generally additionally comprising at least one tackifying resin, at least one wax. and at least one plasticizer.

 In accordance with other embodiments of the sizing in the process of the invention, an anti-condensation fabric is used which is prepreg or else by a hot-melt adhesive, reactivable by heat, applied to the strip of metallic material or else by cold adhesive.

In the case of the use of a hot-melt adhesive, the metal strip must be heated, in the bonding zone, within the temperature range indicated for the previous embodiment, namely approximately 120-160 C. As reactivable hotmelt adhesives, there may be mentioned the same as above. As cold adhesives, mention may be made, on the one hand, of sealants based on polyurethane or polybutadiene, on the other hand, aqueous emulsions of vinyl or vinyl / acrylic (co) polymers or else adhesives in solvent medium based on rubber. natural or synthetic.

 Also, in a particular embodiment of the method according to the invention, a section is cut to the desired length of the strip of composite material before it passes through the profiling station.

 According to another characteristic of the process of the present invention, a strip of fabric is used which has a width less than that of the strip of metal foil, and it is applied so as to leave on one of the longitudinal edges, a reserve zone. not coated with the anti-condensation fabric, and on one of the transverse edges of each element of cut composite material, on the anti-condensation fabric side, a reserve zone is also created by neutralizing the absorbent action of the fabric, for example by applying end of line, along this border, a neutralizing varnish, or even by removing a strip of fabric along said border.These reserves make it possible to avoid a wicking effect in the anti-condensation structure mounted under- face of a metal roof for example and constituted by an assembly of different adjacent elements, overlapping along the longitudinal edges and placed end to end along the edges ures transverses.

The invention also relates to an installation for implementing the method as defined above, characterized in that it comprises - means for unwinding a strip of material
metallic and a strip of anti-condensation fabric to
from their respective spools - a gluing station by compressing the strip of fabric
anti-condensation against the strip of material
metallic, means being further provided for
preheating the strip of material
metallic in the bonding area if the glue is a
hot-melt adhesive applied hot, or to ensure
heating of said strip if the adhesive is an adhesive
heat reactivable hot melt - means of continuous traction of the composite as well
formed - a cutting station to the length of said composite - a profiling station thereof - if necessary, a station for applying a varnish to
one of the transverse borders of each element of
cut composite material, anti fabric side
condensation; - if necessary, width guide means for
get a bonding of the anti fabric strip
condensation across the full width of the sheet strip
metallic, except along a longitudinal zone of
Reserve.

 To better illustrate the object of the present invention, we will now describe a particular embodiment, with reference to the accompanying drawing.

In this drawing - Figure 1 is a schematic view of an installation
for the implementation of this process, involving a
application of adhesive by coating - Figure 2 is, on a larger scale, a view
diagram of the installation bonding station
of Figure 1, produced according to a variant - Figure 3 shows, in perspective, an element of
profiled composite material obtained by the
the invention, with application, at the end of the operation of
profiling, on one of its transverse edges, of a
anti fabric layer covering varnish
condensation; and - Figure 4 illustrates, in a partial view in
perspective, a longitudinal connection between two elements
of composite material in a structure
insulation and protection from the conden
in the mounting position.

 If one refers to Figure 1, one can see that one illustrated the manufacture, in a line of profiling, of a profiled composite material 1, comprising a metallic sheet 2, on a face of which is glued an anti-condensation fabric 3. The metal sheet 2, the thickness of which can range from approximately 600 to 800 μm, is made up, for example, of a steel strip whose face faces upwards if one looks at it the figure is provided with a prepainting, and the opposite face is provided with a protective primer, in particular based on silicone or polyester.

 The sheet 2 is unwound from a reel 4, being pulled continuously at a speed of the order of 40 to 80 m / min., Then brought to pass in a dressing station 5, in which it is guided between rollers 6 and, simultaneously, heated using devices 7 of the infrared ramp type (FIG. 2), at a temperature of approximately 30-40 C.

Simultaneously, an anti-condensation veil is unwound from a reel 8, at the same speed as the sheet 2, and is brought to come to apply on the latter, with the interposition of a layer of hot-melt adhesive, coated in continuous from a gluing machine 9, comprising a row of coating nozzles 10, like. this is shown diagrammatically in Figure 1. The hot-melt adhesive chosen may, among other things, be the adhesive marketed by the company BOSTIK under the designation
THERMORESOL AF 103/8, which has an open time of approximately 15 seconds.

 In Figure 2, there is shown, on a larger scale, a gluing station 9 # a, constituted by a ramp also carrying nozzles 10a for applying glue, while the sheet 3 is guided successively between a roller 11, a roller 12, the glue applicator nozzles 10a and a roller 13. This represents another possibility of arrangement of the gluing station, with a pit for access to the coil 8 and to the station 9a.

 Preheating the metal sheet 2 to 30-40 avoids causing a thermal shock when the fabric 3 glued with liquid glue at approximately 130-1400C comes into contact with the sheet 2. An undesired phenomenon of "frosting" is therefore prevented. glue. The open time being, as indicated, of the order of 15 seconds, immediately after the application of the sheets 2 and 3 against each other and their passage between pressure rollers 14-15, the composite is formed, and it is caused to pass over guide rollers 16, to be directed into a station 17 for cutting to length. The composite 1 is, at the entrance to this cutting station 17, pinched between two pairs of rollers 18-19. Upstream of the cutting station 17, a pit 20 is provided, in which the loop 21 which forms during this cut-to-length operation can be placed. The guide rollers 16 are arranged in an inclined manner on either side of this loop 21, to allow its formation.

 At the exit from the cutting station 17, the composite 1 passes over guide rollers 22 in order to be then guided through a profiling station 23, in which polished rollers give it the desired profiled shape, the anti-condensation fabric 3 conforming to the shape given to the metal sheet 2.

 One of these forms is shown in Figure 3, which shows a profiled composite element 1 leaving the production line which has just been described. We can see that we applied, at the outlet, on a transverse border of the element, a varnish 24, anti-condensation fabric side 3. In this way, during assembly, when adjacent elements will be brought to be placed end to end, there will be no wicking effect at the junction of these adjacent elements.

 To avoid this same difficulty on the longitudinal connections between two adjacent elements, the sheet 2 is not coated with the fabric 3 along one of its longitudinal edges, so that when laying, when the two longitudinal edges overlap as shown in Figure 4, the wicking effect is also removed. A width guide, not shown, ensures bonding of the strip 3 with a reserve area 25, for example 5 cm for a sheet width of the order of 1 m-1.5 m.

 The arrangement of the anti-condensation fabric 3, the regulation of its tension, its positioning, are, in this process, ensured by a system of rollers synchronized with the rotation of the coils 4, 8, this system having been shown only so schematic.

 It is understood that the embodiment of the present invention which has just been described has been given by way of non-limiting indication and that numerous modifications and variants may be made without departing from the framework. of the present invention.

Claims (10)

 1 - Method for manufacturing a profiled composite material (1), consisting of a metal sheet (2) coated with an anti-condensation fabric (3), method according to which a strip of metallic material (2) is mechanically unwound on a profiling chain (23), characterized in that, simultaneously, a strip of an anti-condensation fabric (3) is unrolled at the same speed by applying it by gluing, and under the action of a pressure, against one of the faces of the strip of metallic material (2), in order to subject the composite to the in-line profiling operation.  2 - Method according to claim 1, characterized in that one uses, as metallic material (2), any metal not oxidizable in air or protected against oxidation by an appropriate coating, said metallic material being in particular a galvanized steel sheet, steel strip or aluminum foil.  3 - Method according to one of claims 1 and 2, characterized in that one uses, as anti-condensation fabric (3), a fabric capable of ensuring absorption of moisture and desorption thereof in the usual conditions of use, said fabric being chosen in particular from nonwoven fabrics or veils, with multidirectional weft, based on fibers or a combination of polyester, acrylic and cellulosic fibers.  4 - Method according to one of claims 1 and 3, characterized in that one uses a hot melt adhesive, having an open time of 5-30 seconds, which is applied, in line, by coating, fiberizing or in cords, at a temperature generally between 120 and 160 C, on the strip of anti-condensation fabric (3), before its application against the strip of metallic material (2), the latter being, at this point, preheated to a sufficient temperature to prevent the applied liquid adhesive from undergoing a thermal shock preventing its implementation.  5 - Method according to one of claims 1 to 3, characterized in that one uses an anti-condensation fabric (3) prepreg with a hot-melt adhesive, reactivable by the heat applied to the strip of metallic material (2).  6 - Method according to one of claims 4 and 5, characterized in that one uses a hot melt adhesive based on vinyl polymers, such as vinyl acetate-ethylene copolymers or polyvinyl alcohol, these adhesives can further comprising at least one tackifying resin, at least one wax and at least one plasticizer.  7 - Method according to one of claims 1 to 3, characterized in that one uses an anti-condensation fabric prepreg with a cold adhesive, chosen in particular from sealants based on polyurethane or polybutadiene; aqueous emulsions of vinyl or vinyl / acrylic (co) polymers; and solvent-based adhesives based on natural or synthetic rubber.  8 - Method according to one of claims 1 to 7, characterized in that one conducts a cut to the desired length (in 17) of the strip of composite material (1) before its passage through the profiling station ( 23).  9 - Method according to claim 8, characterized in that a strip of fabric (3) of width less than that of the strip of metal foil (2) is used, and that it is applied so as to leave on one of the longitudinal edges, a reserve area (25) not coated with the anti-condensation fabric (3), and that, on one of the transverse edges of each element of composite material (1), anti-condensation side condensation (3), a reserve area is also created by neutralizing the absorbent action of the fabric, in particular by applying at the end of the line, along this border, a neutralizing varnish (24).  10 - Installation for the implementation of the method as defined in one of claims 1 to 9, characterized in that ~ it comprises means for unwinding a strip of material  metallic (2) and a strip of anti-condensation fabric  sation (3) from their respective coils (4-8) ;; a bonding station by compression of the fabric strip  anti-condensation (3) against the strip of material  metallic (2), means being further provided for  preheating the strip of material  metallic (2) in the bonding area if the adhesive is  hot melt adhesive, or for  heating said strip if the adhesive is  hot-melt adhesive reactivated by the heat of the continuous traction means of the composite (1) as well  formed a station (17) for cutting to length of said composite (1) i a station (23) for profiling the latter if necessary, a station for applying a varnish (24)  on one of the transverse borders of each element  of cut composite material, anti-condensation fabric side  if necessary, width guide means for  obtain a bonding of the anti-conden fabric strip  sation (3) over the entire width of the sheet strip  metallic (2), except along a longitudinal area  reserve (25).