METHOD FOR MANUFACTURING A HYDROPHOBIC ELEMENT

Abstract

A method of manufacturing an embossed hydrophobic covering element for construction or decoration for protecting the surface from humidity or inclement weather. This method includes preparing a mixture of water and at least one organic material in a tank in which the organic material is insoluble in water, stirring the mixture so as to disperse the organic material in suspension in water, molding the prepared and stored mixture by immersing a forming mold under vacuum inside the tank in order to form a molded element, drying and densifying the molded element under vacuum so as to obtained a dried and densified element, and fully impregnating the dried and densified element in the binder so as to form the hydrophobic covering element. The binder is of an organic material. The organic material originates from a sustainably renewable resource.

Claims

1. A method of manufacturing an embossed hydrophobic covering element for construction or decoration for protecting a support surface from humidity or inclement weather, the method comprising: preparing a mixture of water and at least one organic material in a tank, the at least one organic material being insoluble in water; stirring the mixture so as to disperse the at least one organic material in suspension in water, the at least one organic material originating from a sustainably renewable resource; molding the prepared and stirred mixture by immersing a forming mold under vacuum inside the tank in order to form a molded element; drying and densifying the molded element under vacuum so as to obtain a dried and densified element; and fully impregnating the dried and densified element in a binder so as to form the hydrophobic covering element, the binder being an organic material having a softening temperature of between 50° C. and 80° C.

2. The method of claim 1, wherein the step of drying and densifying is carried out in a pressing system, the pressing system having at least one pressing mold and counter-mold pair.

3. The method of claim 2, wherein the at least one pressing mold and counter-mold pair is placed under a depression while being heated and are pressed against one another.

4. The method of claim 2, wherein the at least one pressing mold and counter-mold comprises a plurality of pressing mold and counter-mold pairs, the plurality of pressing mold and counter-mold pairs being disposed in a circle and moved by rotation of the circle.

5. The method of claim 1, wherein the step of drying and densifying comprising: additional drying in a hot air oven.

6. The method of claim 1, wherein the step of drying and densifying comprising: additional drying in an infrared oven.

7. The method of claim 1, wherein the step of drying and densifying comprising: additional drying in a microwave oven.

8. The method of claim 1, wherein the step of drying and densifying comprising: additional drying in a high-frequency oven.

9. The method of claim 1, wherein the organic material of the binder is in liquid form at between 20° C. and 150° C.

10. The method of claim 1, wherein the binder is from a mixture of organic materials, the mixture being in liquid form at between 20° C. and 150° C.

11. The method of claim 1, wherein the organic material of the binder is a derivative of tall-oil.

12. The method of claim 1, further comprising: coating the hydrophobic covering element with a coating.

13. The method of claim 12, wherein the coating is at least one layer of a finishing material, the finishing material selected from the group consisting of mineral pigments, mineral fillers, biosourced organic pigments from sustainably renewable resources, materials containing plant resins from biomass, and materials containing synthetic resins.

14. The method of claim 12, further comprising: fireproofing the hydrophobic covering element.

15. The method of claim 12, further comprising: hydrophobically treating the coated hydrophobic covering element.

16. The method of claim 1, further comprising: partially covering a roof with the hydrophobic covering element.

17. The method of claim 1, further comprising: partially covering a cladding with the hydrophobic covering element.

18. The method of claim 1, further comprising: forming the hydrophobic covering element into a decorative object, the decorative object selected from the group consisting of a frieze, a molding and a decorative panel.

19. The method of claim 1, the step of molding comprising: applying a molding cloth onto the portion of the mixture for a time of between 0.5 seconds and 10 seconds, the molding cloth carrying out a horizontal translation in a direction of the forming mold.

20. A method of manufacturing an embossed hydrophobic covering element for construction or decoration for protecting a support surface from humidity or inclement weather, the method comprising: preparing a mixture of water and at least one organic material in a tank, the at least one organic material being insoluble in water; stirring the mixture so as to disperse the at least one organic material in suspension in water, the at least one organic material originating from a sustainably renewable resource; molding the prepared and stirred mixture by immersing a forming mold under vacuum inside the tank in order to form a molded element, the step of molding comprising: applying a molding cloth onto the portion of the mixture for a time of between 0.5 seconds and 10 seconds, the molding cloth carrying out a horizontal translation in a direction of the forming mold; drying and densifying the molded element under vacuum so as to obtain a dried and densified element; and fully impregnating the dried and densified element in a binder so as to form the hydrophobic covering element, the binder being an organic material having a softening temperature of between 50° C. and 80° C.

Description

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

[0044] FIG. 1 is a schematic front view illustrating steps (1) and (2) of the method of the present invention.

[0045] FIG. 2 is a schematic front view of a forming mold used in step (2) of the method of the present invention.

[0046] FIGS. 3 and 4 are diagrams illustrating alternatives of step (2) of the method of the present invention.

[0047] FIG. 5 is a diagram illustrating step (3) of the method of the present invention.

[0048] FIG. 6a is a schematic front view of a pressing mold used during step (3) of the method of the present invention.

[0049] FIG. 6b is a schematic top view of the mold of FIG. 6a.

[0050] FIG. 7 is a schematic perspective top view of a hydrophobic element for a roof covering.

[0051] FIG. 8 is a schematic front view of an alternative to that shown in FIG. 7.

[0052] FIG. 9 is an example of a hydrophobic element for covering a wall viewed from above.

[0053] FIG. 10 shows a wall covered by hydrophobic elements of FIG. 9.

DETAILED DESCRIPTION OF THE INVENTION

[0054] As used hereinafter, the terms “horizontal”, “vertical”, “transverse” and “longitudinal” should be understood as qualifying elements resting in a fixed manner in parallel to the ground. The method of the present invention is the following steps: (1) preparation of a mixture of water and of organic material coming from resources that are sustainably renewable; (2) molding the mixture prepared in step (1) in order to obtain a molded element; (3) drying and densifying the molded element obtained in step (2) in order to obtain a dried and densified element; and (4) fully impregnating the dried and densified element obtained in step (3) in a binder composed of organic materials coming from resources that are sustainably renewable. In particular, this step (1) involves preparing a mixture of water and at least one organic material in a tank in which the one organic material is insoluble in water. This mixture is stirred so as to disperse the organic material in suspension in water. The organic material originates from the sustainably renewable resource. The step (2) of molding the prepared and stirred mixture occurs by immersing a forming mold under vacuum inside the tank in order to form a molded element. The step (3) of drying and densifying involves drying and densifying in the molded element under vacuum so obtained a dried and densified element. The step (4) of fully impregnating involves fully impregnating the dried and densified element of the binder so as to form the hydrophobic covering element. The binder is an organic material having a softening temperature of between 50° and 80° C. Importantly, the step of molding includes applying a molding cloth onto the portion of the mixture for a time of between one-half second and ten seconds. This increases the effect of suction in the mold and obtains the molded element. The cloth carries out a horizontal translation in the direction of the forming mold. This method allows one to obtain a hydrophobic element.

[0055] In particular, the steps (1) and (2) of preparing a mixture M of water and of cellulose fibers and of molding this mixture are illustrated in FIG. 1. The mixture M of water and of 1 to 20% cellulose fibers is prepared in a tank 1 at a temperature between 10° C. and 75° C. and preferably between 35° C. and 45° C. The forming mold 2 is shown in more detail in FIG. 2. This forming mold 2 is immersed, under vacuum, in the tank 1 containing the mixture M so that a portion P of the mixture M is transferred onto the forming mold 2. The forming mold 2 is disposed on a drum or shaft 3 having four faces 3A, 3B, 3C, 3D in which each comprises the forming mold 2. The drum 3 successively carries out rotations of 90° about a central axis X in such a way that each forming mold 2 of each face 3A, 3B, 3C and 3D is immersed in the tank 1 containing the mixture M. The speed of rotation of the drum 3 is approximately 1.5 to 30 r.p.m. The portion P of the mixture M transferred onto the surface of each forming mold 2 is thus molded under vacuum in such a way as to obtain a molded element E. The molded element E is then transferred onto the surface of a transfer counter-mold 4, under vacuum, and disposed on a plate 40 above the drum 30. The step of transfer of the molded element E is possible via the creation of an overpressure (stoppage of the vacuum) in the forming mold 2 comprising the molded element E and of a depression (i.e. vacuum) in the transfer counter-mold 4.

[0056] More particularly, the molding step involves: (a) immersing the face 3A of the drum 3 comprising the forming mold 2 in the tank 1 comprising the mixture M in such a way as to transfer a portion P of the mixture M onto the surface of the forming mold 2 via a first rotation of the drum 3 by 90° in the clockwise direction according to the arrow F1; (b) after a time of between 0.5 and 10 seconds, carrying out a second rotation of the drum 3 by 90° in the clockwise direction according to the arrow F1 so that the face 3A is located perpendicularly to the tank exterior of the tank; (c) applying a molding cloth 5 onto the portion P of the mixture M for a time of between 0.5 and 10 seconds in order to increase the effect of suction in the forming mold 2 and to obtain the molded element E. The cloth carries out a movement of horizontal translation in the direction of the forming mold 2 in the direction of the arrow f; (d) carrying out a third rotation of the drum 3 by 90° in the clockwise direction according to the arrow F1 in such a way that the face 3A and the molded element E are located in parallel to the transfer counter-mold 4; (e) lowering the transfer counter-mold 4 onto the molded element E according to arrow F2; and (f) creating a depression in the mold 2 and raising the transfer counter-mold 4 so that the molded element 3 is disposed on the surface of the counter-mold. According to this method, the forming mold 2 of the face 3A is empty.

[0057] A fourth rotation of the drum 3 by 90° in the clockwise direction allows the positioning of the face 3A perpendicularly to the tank 1. Then, the steps described above are repeated in such a way as to mold a plurality of molded elements E. The vacuum created inside the forming mold 2 maintains the portion P of the mixture M on the surface of the forming mold 2. When the transfer counter-mold 4 is lowered against the forming mold 2, the molded element E is smooth and densified.

[0058] FIG. 2 shows that each forming mold 2 comprises orifices 20 that are lined with a bottom mesh 21. The orifices 20 have a have a thickness of between three and ten millimeters. The bottom mesh 21 is a mesh having a size smaller than the orifices 20.

[0059] In a second embodiment, illustrated in FIG. 3, a forming mold 2 is immersed, under vacuum, in the tank 1 having the mixture M. The forming mold 2 having a portion P of the mixture M carries out a movement of vertical translation according to the arrow F′1 in order to remove the forming mold 2 from the tank 1. Then, the forming mold 2 carries out a movement of horizontal translation in the direction of a belt contact conveyor (not shown) according to arrow F′2 until a molded element E is obtained. The molded element E is then deposited on the belt conveyor (not shown) after creation of an overpressure (stoppage of the vacuum) in the forming mold 2. The forming mold 2 is suspended from a plate 40′ by elements that allow its vertical and horizontal movement. The belt conveyor allows movement of the molded element E in the direction of a pressing system 6 as shown in FIG. 5.

[0060] A third embodiment is illustrated in FIG. 4 in which the forming mold 2 is immersed, under vacuum, in the tank 1 having the mixture M. The forming mold 2 carries out a movement of vertical translation according to the arrow F″1 and a movement of rotation of 180° according to the arrow F″2 in such a way as to present the molded element E opposite a transfer counter-mold 4 as described in relation to FIG. 1. The transfer of the molded element E from the forming mold 2 to the transfer counter-mold 4 takes place in the same way as above in the accordance with the first embodiment.

[0061] FIG. 5 shows that the molded element E is transferred to a carousel pressing system 6. The carousel pressing system 6 comprises four pressing molds 70 (shown in FIGS. 6a and 6b) and counter-mold pairs 7A, 7B, 7C and 7D. More precisely, the molded element E is transferred into a first pressing mold and a counter-mold pair 7A in which the mold and counter-mold are pressed against one another, under vacuum. The mold and counter-mold are heated to a temperature of between 160 to 280° C. The carousel pressing system 6 then carries out a succession of rotation by 90° in the counter-clockwise direction in accordance with arrows R1, R2, R3 and R4, in such a way that each pair 7A, 7B, 7C and 7D can receive a molded element E. When the pair 7A has carried out three rotations of 90°, a dried and densified element S is obtained. The mold and counter-mold of the pair 7A move apart from one another and the dried and densified element S is transferred to the step of impregnation.

[0062] As shown in FIGS. 6a and 6b, each pressing mold 70 has orifices 72 having a size of preferably between three and ten millimeters. These orifices 72 are closed by nozzle 73 with slots or holes. Each counter-mold also has orifices and nozzles.

[0063] In the context of construction, the present invention is more particularly described with regard to a hydrophobic covering element for roofing or a hydrophobic element for covering roofing without being limited such a use. The term “covering element for roofing” means an element capable of covering at least a portion of the surface of a roof. The term “element for covering roofing” designates both the main covering elements for roofing, such as the plates or tiles, and the accessories, such as ridge tile, flashing or bargeboard.

[0064] FIG. 7 shows an example of a hydrophobic element H obtained after the step of impregnating. The hydrophobic element H is intended for use in roofing. It is in the form of a corrugated plate with a visible front 11 and an opposite back. The plate is substantially parallelepipedic with a length “L” equal to 1020 millimeters, a width “W” equal to 665 millimeters, a thickness “T” equal to 2.5 millimeters and a non-developable shape. Along the length “L”, there are six rows of five tiles 8. The tiles 8 are parallel to each other. The longitudinal direction of a tile 8 is identical to the longitudinal direction of the hydrophobic element H. Each row of tile 8 is separated by an offset 9. The tiles 8 of the same row are connected to each other by a groove 10. Each tile 8 has a length “L” of 160 millimeters.

[0065] FIG. 8 shows an alternative H′ of the hydrophobic element H of FIG. 7. In this alternative embodiment, the hydrophobic element H′ is intended be used as a ridge tile or ridge accessory. The hydrophobic element H′ has four tiles 8 longitudinally fitted together in the longitudinal direction.

[0066] FIG. 9 shows another example of a hydrophobic element H″ with the width “W″”, length “L″” and thickness “T″” viewed from above. The hydrophobic element H″ comprises a visible front 11 having a relief 12 with a spindle shape repeated six times.

[0067] FIG. 10 shows the placement of hydrophobic elements H″ on a surface 13 formed by a wall. The hydrophobic elements H″ are those shown in FIG. 9. A plurality of hydrophobic elements H″ are already placed on the wall 13 by using glue. The arrows p1 and p2 in FIG. 10 indicate the direction of placement in order to finish completely covering the wall 13.

[0068] The foregoing disclosure and description of the invention is illustrative and explanatory thereof. Various changes in the details of the steps of the present method can be made in accordance with the present claims without departing from the true spirit of the invention. The present invention should only be limited by the following claims and their legal equivalents.