JPS5810227B2 - Roofing material manufacturing method - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to a method for producing a dog roofing material that is effective in preventing condensation and is heat resistant.

BACKGROUND ART Conventionally, as roofing materials, there have been known materials obtained by pressing thin metal plates such as galvanized iron plates and paint-baked iron plates into shapes such as long folded plates and corrugated shapes.

This roofing material has the advantages of being easy to construct, having a good appearance, and being lightweight, but on the other hand, it has poor heat insulation and soundproofing properties, and is thin and has a hollow space under the roofing material, so it is difficult to prevent rain. There were many problems, such as sound resonance and condensation.

In order to improve the above-mentioned problems, it has been proposed to laminate foams such as polyethylene, polyurethane, polystyrene, etc. on the metal plate, but since the above-mentioned resins do not have moisture absorption ability, they may cause dew condensation or are flammable. However, it has the disadvantage of emitting toxic gas when burned.

Gypsum sheets or foamed gypsum sheets are flame retardant and have moisture absorption ability, so if a foam is laminated between a metal plate and a gypsum sheet or foamed gypsum sheet to form a laminate with a three-layer structure, this The laminate is a roofing material that is flame retardant, has excellent heat insulation properties, has a dew condensation prevention effect, and has excellent sound insulation properties.

However, the above-mentioned gypsum sheet or foamed gypsum sheet has a drawback in that it cannot be deformed into a suitable shape as a roofing material because of its low flexibility.

The purpose of the present invention is to produce a roofing material that has a large heat insulation effect, a dew condensation prevention effect, excellent soundproofing properties, and is flame retardant by deforming the above-mentioned less flexible gypsum sheet or foamed gypsum sheet. Our goal is to provide the following.

That is, the gist of the present invention is to provide a gypsum sheet or a foamed gypsum sheet, which is a composite sheet in which an elastic porous material layer is adhered to a metal plate, and a gypsum sheet or a foamed gypsum sheet is adhered to the other side of the material layer. The method of manufacturing a roofing material comprises spraying or applying water on the composite sheet and then applying an external force to shape the surface of the composite sheet into an uneven shape.

The elastic porous material used in the present invention only needs to have enough elasticity to adhere tightly to the metal plate without any voids, such as soft polyurethane foam, polyethylene foam, rubber foam, etc. , glass fiber web, etc., and polyethylene foam having closed cells is preferably used.

More preferably, the foam is crosslinked to improve heat resistance.

Further, the material layer may be a laminate of two or more types of materials, such as a laminate of a flexible polyurethane foam having open cells and a polyethylene foam having closed cells,
The polyurethane foam may then be closely bonded to the metal plate.

The metal plates used in the present invention are metal plates generally used for roofing materials, such as galvanized iron plates,
An iron plate or the like is used for baking the paint, and its shape is not limited in any way, and any shape that can be used as a roofing material can be applied.

The gypsum sheet used in the present invention is a sheet mainly composed of gypsum bound by a water-soluble binder such as polyvinyl alcohol, and the foamed gypsum sheet is obtained by foaming the above-mentioned gypsum sheet.

The above-mentioned water-soluble binder is flammable, so if a large amount is added, the above-mentioned gypsum sheet becomes flammable. Therefore, in order to keep the sheet flame-retardant, the amount of the above-mentioned water-soluble binder added is generally 5% by weight or less. It is.

Further, the thickness of the sheet is not limited in any way, but a thickness of 8.5 to 10 mm is generally suitably used.

In the present invention, the elastic porous material is adhered to the metal plate, and the gypsum sheet or foamed gypsum sheet is adhered to the other side of the material to produce a composite sheet having a three-layer structure. Water is sprinkled or applied to the gypsum sheet or foamed gypsum sheet to give it flexibility, and then an external force is applied to the composite sheet to shape it into the shape of the roofing material.

Any known method may be used to bond the metal plate and the elastic porous material and the elastic porous material and the gypsum sheet or foamed gypsum sheet. For example, bonding with an adhesive, A method of heat-melting and fusing, a method of adhering with double-sided adhesive tape, etc. may be adopted.

The amount of water to be sprayed or applied is not limited in any way; if the forming angle is small, a small amount may be added, and if the forming angle is large, a large amount may be added. It is generally added in an amount of 0.1 to 50 parts by weight per 100 parts by weight of the gypsum sheet.

Next, an example of the manufacturing method of the present invention and a roofing material manufactured by the manufacturing method will be explained with reference to the drawings.

FIG. 1 is a sectional view showing an example of a roof material manufactured by the manufacturing method of the present invention, and FIG. 2 is an example of the manufacturing method of the present invention.

In FIG. 1, 4 is a galvanized iron plate, 2 is a closed-cell foam made of polyethylene, and 1 is a foamed gypsum sheet.
The three members are laminated to form the roof material 6.

In Figure 2, 1 is the foaming ratio of 1.5 made into a roll.
2 is a foamed gypsum sheet with a thickness of 1 mm, and 2 is a foamed polyethylene sheet with a foaming ratio of 40 times and a thickness of 3 mm wound into a roll.

The above-mentioned foamed gypsum sheet and foamed polyethylene sheet are supplied to the pressure bonding roll 21 and pressed together. Immediately before the pressure bonding, molten polyethylene at about 300° C. is supplied between the two sheets from the adhesive supply device 11, and then the sheets are pressure bonded to form a composite sheet. 3.

While the composite sheet 3 is fed by guide rolls 22°25,
It is crimped with a pressure roll 23 and cooled with a cooling roll 24 to achieve more complete adhesion.

4 is a galvanized iron plate with a thickness of 0.8 mm that has been wound into a roll, and is supplied to a level roll 26 to remove curls, and then a neoprene adhesive is supplied from an adhesive supply device 12 and applied to the surface. The surface of the iron plate was heated to 10
Pressure roll 27 after being heated to 0 to 110°C
supplied to

The composite sheet 3 and the iron plate 4 coated with adhesive are fed to a pressure roll 27 and pressed together so that the foamed polyethylene sheet 2 of the composite sheet is laminated on the iron plate 4 to form a three-layer sheet 5.

Next, water is sprinkled on the foamed gypsum sheet 1 of the three-layer sheet 5 by a water sprinkler 14, and the sheet is supplied to a molding machine 15 and molded to obtain a roofing material 6.

The method for manufacturing the roofing material of the present invention is as described above, and since the gypsum sheet or foamed gypsum sheet becomes very flexible when a small amount of water is added, it can be molded into any shape.

Further, if manufactured as shown in FIG. 2, continuous manufacturing is possible.

Furthermore, the obtained roofing material has the above-mentioned structure, and since the elastic porous material layer is laminated between the metal plate and the difficult gypsum sheet, it is suitable for areas exposed to high heat. It is safe and combustible even in the event of a fire.

In addition, both the material layer and the gypsum sheet are porous, have low thermal conductivity, and have an excellent heat insulating effect, so that the difference in temperature between the front and back of the metal plate is small, making it difficult for dew condensation to occur.

In addition, gypsum sheets or foamed gypsum sheets are inherently hygroscopic;
It holds a large amount of water and prevents condensation by absorbing moisture that would otherwise condense. It also repeatedly absorbs and releases moisture depending on the indoor humidity, making it effective in regulating indoor humidity.

Furthermore, since both the material layer and the gypsum sheet are porous, they have sound absorbing properties and are effective in significantly reducing noise such as the sound of rain.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a sectional view showing an example of a roof material manufactured by the manufacturing method of the present invention, and FIG. 2 is an example of the manufacturing method of the present invention. 1... Foamed gypsum sheet, 2... Polyethylene foam, 3... Laminate of foamed gypsum sheet and polyethylene foam, 4... Galvanized iron plate ,
5... Three-layer laminate of foamed gypsum sheet, polyethylene foam, and galvanized metal plate, 6... Roofing material,
11, 12... Adhesive supply device, 13...
... Heating furnace, 14 ... Water sprinkler roll, 22.25 ... Guide roll, 24.
...Cooling roll, 26...Level roll.

Claims (1)

[Claims] 1. A gypsum sheet or foamed gypsum of a composite sheet in which an elastic porous material layer is adhered to a metal plate, and a gypsum sheet or a foamed gypsum sheet is adhered to the other side of the material layer. A method for producing a roofing material, which comprises spraying or applying water on a sheet, and then applying an external force to shape the surface of the composite sheet into an uneven shape. 2. The manufacturing method according to claim 1, wherein the material layer is a foam having closed cells. 3. The manufacturing method according to claim 2, wherein the foam having closed cells is made of polyethylene.