GB2456423A - Purlin with pre-formed coating film - Google Patents

Purlin with pre-formed coating film Download PDF

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Publication number
GB2456423A
GB2456423A GB0900736A GB0900736A GB2456423A GB 2456423 A GB2456423 A GB 2456423A GB 0900736 A GB0900736 A GB 0900736A GB 0900736 A GB0900736 A GB 0900736A GB 2456423 A GB2456423 A GB 2456423A
Authority
GB
United Kingdom
Prior art keywords
film
purlin
sheet
reel
applying
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Granted
Application number
GB0900736A
Other versions
GB2456423B (en
GB0900736D0 (en
Inventor
James Carolan
Gregory Flynn
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Kingspan Research and Developments Ltd
Original Assignee
Kingspan Research and Developments Ltd
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Kingspan Research and Developments Ltd filed Critical Kingspan Research and Developments Ltd
Publication of GB0900736D0 publication Critical patent/GB0900736D0/en
Publication of GB2456423A publication Critical patent/GB2456423A/en
Application granted granted Critical
Publication of GB2456423B publication Critical patent/GB2456423B/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

Links

Classifications

    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/18Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material
    • B32B5/20Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by features of a layer of foamed material foamed in situ
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B15/00Layered products comprising a layer of metal
    • B32B15/04Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B15/08Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/18Structures comprising elongated load-supporting parts, e.g. columns, girders, skeletons
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B5/00Floors; Floor construction with regard to insulation; Connections specially adapted therefor
    • E04B5/16Load-carrying floor structures wholly or partly cast or similarly formed in situ
    • E04B5/32Floor structures wholly cast in situ with or without form units or reinforcements
    • E04B5/36Floor structures wholly cast in situ with or without form units or reinforcements with form units as part of the floor
    • E04B5/38Floor structures wholly cast in situ with or without form units or reinforcements with form units as part of the floor with slab-shaped form units acting simultaneously as reinforcement; Form slabs with reinforcements extending laterally outside the element
    • E04B5/40Floor structures wholly cast in situ with or without form units or reinforcements with form units as part of the floor with slab-shaped form units acting simultaneously as reinforcement; Form slabs with reinforcements extending laterally outside the element with metal form-slabs
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04BGENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B7/00Roofs; Roof construction with regard to insulation
    • E04B7/02Roofs; Roof construction with regard to insulation with plane sloping surfaces, e.g. saddle roofs
    • E04B7/022Roofs; Roof construction with regard to insulation with plane sloping surfaces, e.g. saddle roofs consisting of a plurality of parallel similar trusses or portal frames
    • E04B7/024Roofs; Roof construction with regard to insulation with plane sloping surfaces, e.g. saddle roofs consisting of a plurality of parallel similar trusses or portal frames the trusses or frames supporting load-bearing purlins, e.g. braced purlins
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04CSTRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/284Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • E04C2/292Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and sheet metal
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04CSTRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/30Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure
    • E04C2/32Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure formed of corrugated or otherwise indented sheet-like material; composed of such layers with or without layers of flat sheet-like material
    • E04C2/322Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by the shape or structure formed of corrugated or otherwise indented sheet-like material; composed of such layers with or without layers of flat sheet-like material with parallel corrugations
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00Properties of the layers or laminate
    • B32B2307/30Properties of the layers or laminate having particular thermal properties
    • B32B2307/304Insulating
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2311/00Metals, their alloys or their compounds
    • B32B2311/30Iron, e.g. steel
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2419/00Buildings or parts thereof
    • B32B2419/06Roofs, roof membranes
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2607/00Walls, panels
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B32LAYERED PRODUCTS
    • B32BLAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B37/00Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
    • B32B37/12Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
    • B32B37/1207Heat-activated adhesive

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Physics & Mathematics (AREA)
  • Electromagnetism (AREA)
  • Laminated Bodies (AREA)
  • Lining Or Joining Of Plastics Or The Like (AREA)
  • Bulkheads Adapted To Foundation Construction (AREA)

Abstract

A purlin with a pre-formed coating film. The film may be pre-bonded to the purlin and this may be done before the purlin is profiled. The film may be of a plastic material and may be adhesively bonded to the purlin. The bonding may also be activated by pressure and/or heat. Also described is the method of manufacturing the purlin, providing a film, a metal sheet, applying the film to the metal sheet on-line and then profiling the film coated purlin. The metal may be provided in the form of a reel which is unwound before applying the film, which may be fixed by bonding and may use an adhesive or glue. The bonding process may involve the use of heat and/or pressure. The film may also be provided in the form of a reel. The sheet and or film may be treated before applying the film.

Description

• ••• • • •
• ♦ t • •
• •••
• « • ••• • •
• • 41 %
2456423
1
"A purlin"
Introduction
5 This invention relates to purlins
Purlins arc generally formed by roll forming a sheet of metal such as steel to a desired profile or shape. There are two conventional ways in which to provide a purlin with a decorative coating.
10
In one method after the sheet metal is manufactured it is passed through a painting process which applies a coating to the sheet which is then rolled up onto a supply reel. A manufacturer unrolls the coated steel from the supply reel and then forms the sheet metal into a desired shape. One of the problems with this method is that such 15 reels of coated steel are expensive. Another problem is that a single reel of such painted sheet metal is very long to cater for production runs If only a short run is required with a particular finish only part of the reel is used, leading to problems in downtime in changing reels and storage of partially used reels and consequent risk of damage/wastage as well as inventory and control costs.
20
In a second method a raw metal sheet is formed to a desired purlin shape/profile by a manufacturer and the purlins are painted on site. This is also expensive and difficult because the profiles are often complex and therefore difficult to pamt. In addition, the purlins are often difficult and/or dangerous to access when erected.
25
This invention is directed to addressing at least some of these problems.
Statements of Invention
30
2
According to the invention there is provided a purlin having a pre-formed coating film applied thereto.
In one embodiment the film is pre-bonded to the purlin
5
In one case the purlin is profiled and the film is applied to the sheet in advance of profiling.
The film may be of a plastics material.
10
Preferably the film is bonded to the purlin. The film may be adhesively bonded to purlin. Alternatively or additionally the bonding between the film and purlin is activated by pressure and/or heat
15 In one case the purlin has at least one exposed face and the film is applied to the exposed face
The invention also provides a method for manufacturing a purlin of the invention comprising the steps of:-
20
providing a film;
• • • •
> I
• • • •
providing a metal sheet;
25 applying the film to the metal sheet on line; and subsequently profiling the film coated sheet to form a purlin.
In one embodiment the metal sheet is provided on a reel and the method comprises 30 drawing the metal sheet from the reel and applying the film to the unreeled sheet.
3
The method may comprise bonding the film to the sheet. The film may be adhesively bonded to the sheet. Alternatively or additionally, the film is bonded to the sheet by heat and/or pressure.
5 The film may be provided on a film reel and the method comprises drawing the film from the reel so that the film and sheet are in alignment for applying the film to the sheet.
In one case the sheet to which film is applied is profiled by roll forming.
10
In one embodiment the method comprises treating the sheet and/or film in advance of applying the film to the sheet.
15 Brief Description of the Drawings
The invention will be more clearly understood from the following description of some embodiments thereof, given by way of example only, with reference to the accompanying drawings, in which:-
20
Fig. 1 is an isometric view of a purlin according to the invention;
Fig. 2 is an end view of the purlin of Fig. 1;
• • • •
• • •
• • •
• •••
25 Fig. 3 is a cross sectional view of part of the purlin of Fig. 1;
Fig. 4 is a schematic side view of equipment used in the manufacture of the purlin of Figs 1 and 2;
Fig. 5 is an isometric view of part of the equipment illustrated in Fig.4; and
4
Figs. 6 and 7 are views similar to Figs. 1 and 2 of another purlin according to the invention.
5 Detailed Description
In the invention, a purlin of metal has a pre-formed coating film 20 applied thereto on-line. The purlin is formed by profiling, for example by roll forming, a sheet 25 of metal to a desired shape The coating film 20 is applied to the sheet 25 on-line in 10 advance of on-line roll forming Referring to Figs 4 and 5, in this case the metal sheet 25 is provided on a supply reel 26 and the coating film is also on supply reels 27. The reels 26, 27 are set up as illustrated so that the film 20 is aligned with the sheet 25 In this case the film 20 is applied to both faces of the metal sheet 25 but it may, if desired only be applied to one of the metal sheet faces. The film may be 15 applied across the full width or only part of the width of the metal sheet.
To bond the film 20 to the sheet 25 the film 20 may be passed under a pressure/nipping roller 28. The bonding may be activated for example, by passing under pressure and/or heating plate(s) 29. Further nipping rollers 30 may be provided 20 downstream of the plate(s) 29. Edge trim knives 30 may also be provided. The metal sheet 25 with coating film 20 applied to both faces is shown in Fig. 3.
The coating film is preferably of a weather resistant plastics material such as polyethylene terephthalate (PET), ethylene tetrafluorethylene (ETFE) (which has a 25 high corrosion resistance), PVC (polyvinylchlonde) or polyolefin (PO), or mixtures thereof. The film may be adhesively bonded to the metal sheet using a compatible adhesive such as a polyurethane based adhesive. The bonding of the film to the metal sheet may be activated and/or cured by heat, pressure, UV, ultrasonics, or any combination thereof. The coating film may be provided on the exposed face of one 30 or both sheets of the panel. In the case where both sheets have coating films, the same film or different films may be applied to the sheets.
5
The film may be provided with any desired decorative finish or indicia such as to mimic wood gram, brick, or a slate-like finish.
5 The coated metal sheet is then profiled into a desired purlin shape, for example by roll forming The profiling may result in any desired shape/profile One example of a purlin 1 according to the invention is illustrated in Figs. 1 and 2.
The purlin 1 in this case comprises a first flange 2, a second flange 3, and a web 4 10 extending between the first flange 2 and the second flange 3. The first flange 2 and the second flange 3 extend from the web 4 in the same direction l"he purlin 1 also comprises a first lip 8, a second lip 9, a first lip return 10 and a second lip return 11. The first lip 8 extends from the first flange 2 and the second lip 9 extends from the second flange 3. The first lip return 10 extends from the first lip 8 and the second lip 15 return 11 extends from the second lip 9.
The web in this case 4 has a non-straight, indented section 21 between the first flange 2 and the second flange 3. In this case the purlin 1 has a "sigma" shape.
20 The purlin 1 may be manufactured from any suitable metal 1, for example steel. The flanges 2, 3, the web 4, the lips 8, 9 and the lip returns 10, 11 are integrally formed by profiling, typically by roll forming the film - coated metal sheet.
Thus, the invention provides a purlin with a film coating which can present any 25 desired decorative finish, when installed.
In Figs. 6 and 7 there is illustrated another purlin 30 according to the invention, which is similar to the purlin 1 of Figs. 1 to 3, and similar elements in Figs 6 and 7 are assigned the same reference numerals. In this case the web 4 extends from the 30 first flange 2 to the second flange 3 in a straight section 31. The purlin 30 is provided in the form of a channel.
6
The invention is not limited to the embodiments hereinbefore described which may be varied in construction and detail.

Claims (1)

  1. A purlin having a pre-formed coating film applied thereto.
    A purlin as claimed in claim 1 wherein the film is pre-bonded to the purlin.
    A purlin as claimed m claim 1 or 2 wherein the purlin is profiled and the film is applied to the purlin in advance of profiling.
    A purlin as claimed in any of claims 1 to 3 wherein the film is of a plastics material
    A purlin as claimed in any of claims 1 to 4 wherein the film is bonded to the purlin.
    A purlin as claimed in claim 5 wherein the film is adhesively bonded to purlin.
    A purlin as claimed in claim 5 or 6 wherein the bonding between the film and the purlin is activated by pressure and/or heat.
    A purlin as claimed m any of the claims 1 to 7 wherein the purlin has at least one exposed face and the film is applied to the exposed face.
    A purlin substantially as therein before descnbed with reference to the accompanying drawings.
    A method for manufacturing a purlin as claimed in any of claims 1 to 11 comprising the steps of.-
    8
    providing a film;
    providing a metal sheet;
    5
    applying the film to the metal sheet on-line; and subsequently profiling the film coated sheet to form a purlin.
    10 11 A method as claimed in claim 10 wherein the metal sheet is provided on a reel and the method comprises drawing the metal sheet from the reel and applying the film to the unreeled sheet.
    12 A method as claimed in claim 10 or 11 comprising bonding the film to 15 sheet
    13. A method as claimed in claim 12 wherein the film is adhesively bonded to the sheet.
    20 14. A method as claimed in claim 12 or 13 wherein the film is bonded to the sheet by heat and/or pressure.
    15. A method as claimed in any of claims 11 to 14 wherein the film is
    * provided on a film reel and the method comprises drawing the film from
    25 the reel so that the film and sheet are in alignment for applying the film to
    > the sheet.
    16.
    A method as claimed in any of claims 10 to 15 wherein the sheet to which film is applied is profiled by roll forming.
    A method as claimed in any of claims 10 to 16 composing treating the sheet and/or film in advance of applying the film to the sheet
    A method substantially as herein before descnbed with reference to the accompanying drawings.
GB0900736.0A 2008-01-16 2009-01-16 A purlin Active GB2456423B (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
IE20080031 2008-01-16

Publications (3)

Publication Number Publication Date
GB0900736D0 GB0900736D0 (en) 2009-03-04
GB2456423A true GB2456423A (en) 2009-07-22
GB2456423B GB2456423B (en) 2012-06-06

Family

ID=40445924

Family Applications (3)

Application Number Title Priority Date Filing Date
GB0900736.0A Active GB2456423B (en) 2008-01-16 2009-01-16 A purlin
GB0900734.5A Active GB2456422B (en) 2008-01-16 2009-01-16 Sheet decking
GB0900735.2A Active GB2458743B (en) 2008-01-16 2009-01-16 A composite panel

Family Applications After (2)

Application Number Title Priority Date Filing Date
GB0900734.5A Active GB2456422B (en) 2008-01-16 2009-01-16 Sheet decking
GB0900735.2A Active GB2458743B (en) 2008-01-16 2009-01-16 A composite panel

Country Status (2)

Country Link
GB (3) GB2456423B (en)
IE (2) IE20090041A1 (en)

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN102644357A (en) * 2012-05-02 2012-08-22 赵依健 Rock wool composite plate

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4128984A (en) * 1978-01-18 1978-12-12 Minnesota Mining And Manufacturing Company Method of constructing a sloped roof
JPH102057A (en) * 1996-06-19 1998-01-06 Ig Tech Res Inc Steel house member
GB2356584A (en) * 1999-08-06 2001-05-30 Carboline Europ Ltd Fire protective film
US6506466B1 (en) * 1999-10-06 2003-01-14 Silu Verwaltung Ag Adhesive vapor barrier tape for a ridge purlin
US20050155322A1 (en) * 1998-04-09 2005-07-21 Robert Kroie Building elements

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US3845593A (en) * 1972-09-12 1974-11-05 G Zen Lightweight concrete panel
US4238544A (en) * 1979-05-16 1980-12-09 Virginia Door Co. Door panel and manner of making
US4707401A (en) * 1986-12-12 1987-11-17 Whirlpool Corporation Refrigerator cabinet construction
US5118174A (en) * 1991-05-17 1992-06-02 Whirlpool Corporation Method to prevent chemical (HCFC) attack of plastic foodliner from foam insulation chemicals
JPH0596675A (en) * 1991-10-11 1993-04-20 Ig Tech Res Inc Sandwiched board
JP3169090B2 (en) * 1991-12-05 2001-05-21 株式会社アイジー技術研究所 Composite board
GB9815590D0 (en) * 1998-07-18 1998-09-16 Ward Building Components Limit Sheet decking
GB2340993B (en) * 1998-08-19 2003-10-29 British Steel Plc Integrated photovoltaic composite panel
GB9824696D0 (en) * 1998-11-11 1999-01-06 Kingspan Building Products Lim A panel
JP2003056090A (en) * 2001-08-20 2003-02-26 Dainippon Plastics Co Ltd Composite heat insulating material
GB2397074B (en) * 2003-01-07 2006-10-11 Corus Uk Ltd Profiled steel decking
JP2004257039A (en) * 2003-02-25 2004-09-16 Nisshin Steel Co Ltd Metal panel for exterior wall of building and manufacturing method therefor
US7972688B2 (en) * 2005-02-01 2011-07-05 Letts John B High density polyurethane and polyisocyanurate construction boards and composite boards
GB2425282A (en) * 2005-04-22 2006-10-25 Celotex Ltd A laminate structure for use in insulation boards
WO2007029220A1 (en) * 2005-09-06 2007-03-15 Kingspan Research And Developments Limited A roof system

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4128984A (en) * 1978-01-18 1978-12-12 Minnesota Mining And Manufacturing Company Method of constructing a sloped roof
JPH102057A (en) * 1996-06-19 1998-01-06 Ig Tech Res Inc Steel house member
US20050155322A1 (en) * 1998-04-09 2005-07-21 Robert Kroie Building elements
GB2356584A (en) * 1999-08-06 2001-05-30 Carboline Europ Ltd Fire protective film
US6506466B1 (en) * 1999-10-06 2003-01-14 Silu Verwaltung Ag Adhesive vapor barrier tape for a ridge purlin

Also Published As

Publication number Publication date
IE20090042A1 (en) 2009-08-19
GB2456422B (en) 2012-05-02
IE86154B1 (en) 2013-03-13
GB2456423B (en) 2012-06-06
GB2456422A (en) 2009-07-22
GB2458743A (en) 2009-10-07
IE20090041A1 (en) 2009-08-19
GB0900736D0 (en) 2009-03-04
GB0900734D0 (en) 2009-03-04
IE20090038A1 (en) 2009-08-19
GB2458743B (en) 2012-09-05
GB0900735D0 (en) 2009-03-04

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