Patent Description:
Underroof collars of the kind mentioned above are known for example from <CIT>, <CIT>, and <CIT>, and since they are made from soft textile-like materials they can been packaged in many ways. Focus have primarily been on making the packed underroof collar as compact as possible in order to reduce the space needed for storage and transportation, but in later years focus has shifted towards making the installation of roof window related products, such as underroof collars, easier in order to avoid errors in mounting. One example is found in the applicants' own prior patent application <CIT>, where the underroof collar was provided with an engagement zone adapted for engagement with a window frame or the like.

It, however, remains a problem that as underroof collars are difficult to handle during packaging as they are relatively large and made from light and soft materials.

With this background, it is an object of the invention to provide an improved method for packaging an underroof collar.

This and further objects are achieved with a method as described above, and comprising the features of claim <NUM>, where the underroof collar is folded along two or more primary folding lines extending substantially in parallel to the length of the collar members of the first set using a folding tool comprising two or more elongate tool members, which are moveable in relation to each other, each of said tool members having a length extending in parallel to the length of the collar members of the first set when in use and defining a length direction, and where the underroof collar is lifted and/or displaced by the tool members thereby moving the collar members of the second set in relation to the collar members of the first set, so that at least a part of the centre sections of the collar members of the second set are arranged on top of at least one of the collar member of the first set.

The elongate tool members act as carriers engaging with and moving the material of the underroof collar so that it folds over each tool member along a folding line extending in parallel to the length of the tool member. When the tool members are subsequently retracted from the underroof collar or the underroof collar taken off the folding tool, the folds will remain, leaving the underroof collar in a folded state.

One or more tool members may be stationary, but at present it is considered advantageous that all tool members are individually moveable.

One or more tool members may remain idle during some uses, for example during folding of small underroof collars.

The length of tool members used is preferably longer than the length of the collar members of the first set so that one fold extending over the entire underroof collar is created by one tool member. It is, however, also possible to use tool members each engaging only with one of the collar members of the second set, i.e. using one set of tool members at one side of the underroof collar and another set of tool members at the other side of the underroof collar.

In addition to the pattern of movement of the tool members, the surface properties of the tool members may influence on the resulting configuration of the folded underroof collar. If the tool members have a smooth surface, the material of the underroof collar may slide over their surfaces, whereas a rough or profiled surface may result in friction against the material of the underroof, whereby it may be retained. All tool members do not have to be identical, and differences in surface properties may contribute to controlling the folding of the underroof collar. It is even possible to provide conveyors, such as belts, cables, or rollers, on the surface of one or more tool members. By activating such conveyors, the underroof collar may be forced to move in relation to the tool member in question. A similar effect may be achieved by rotating a tool member with rough or profiled surface about its length direction.

It is presently considered advantageous to release the underroof collar from the folding tool by arranging at least a part of the underroof collar so that it rests on a support surface and then retracting the tool members by moving them in their length directions, but it is also possible to for example pull the underroof collar off the folding tool, to change the angle of the tool members so that the underroof collar slides off the folding tool, or to use a combination of steps resulting in the underroof collar coming off the folding tool.

All tool members should preferably remain parallel to each other at all stages of the folding process to ensure that the folds are parallel, but a slight mutual angling of tool members may be advantageous when releasing the underroof collar from the folding tool to reduce friction between the tool members and the underroof collar.

In one embodiment the method for folding of the underroof collar further comprises the steps of:.

where the movement of the tool members is continued until the tool member engaging the interior side of the underroof collar has passed a plane defined by the exterior side in the hanging position in step A), and/or the tool member engaging the exterior side of the underroof collar has passed a plane defined by the interior side of the underroof collar in the hanging position in step A).

In other words, the tool members move in on the hanging underroof collar from opposite sides and push the underroof collar in front of them so that each tool member creates a fold and the underroof collar is forced into a zig-zag configuration where sections of the underroof collar extend from one tool member to another. The angle of these sections of the underroof collar relative to each other and to the initial vertical orientation of the underroof collar will depend on the mutual distance between the tool members in the vertical direction and on how far across the tool members are moved. Another factor influencing on the resulting configuration of the underroof collar is the cross-sectional shape and size of the tool members. It is presently considered advantageous that the tool members have a circular cross-section with a diameter of at least <NUM> so that the primary folds created on the underroof collar are not sharply defined and the underroof collar may slide over the tool members as they move across.

If the location of fixation of the fixated collar member of the first set is stationary, the distance between the free hanging collar member of the first set and the folding tool will gradually decrease as the tool members move across and sections of the underroof collar come to extend between them. It is also possible to move the location of fixation, the free hanging collar member, the folding tool, and/or individual tool members in relation to each other in the vertical direction to control the folding.

The fixation of the underroof collar may for example be achieved by clamping the underroof collar between two rail member of the folding tool, thus providing a linear support for the underroof collar, but it is also possible to use two or more local fixations, such as clips.

The folding method may further comprise the subsequent step C) of moving at least one of the tool members in a direction, which is substantially parallel to the plane defined by the exterior side in the hanging position in step A) so that a mutual angle between two sections of the underroof collar located on different sides of a tool member following step B) becomes smaller, said sections of the underroof collar preferably becoming substantially parallel. In this way the underroof collar is moved further towards its intended folded state, thereby increasing the precision of the folding compared to methods where the underroof collar is released in position, where the tool members are further from each other.

Due to the fixation of the underroof collar, it is considered advantageous that the underroof collar slides over at least one of the tool members during at least a part of the steps B) and C). To facilitate this, the tool members used in this embodiment of the invention preferably have a rounded and smooth surface as described above.

In another embodiment, the method, instead of steps A) and B), comprises the steps of:.

As the initial position of the underroof collar, when it rests on the support surface, is now substantially horizontal there is no need for a fixation of the underroof collar. The continuous support provided by the support surface may also be advantageous if the skirt part of some of the collar members are made with a surplus of material, for example being pleated, as a surplus of material may be more difficult to manage in a hanging position.

In this embodiment the members used preferably have a rough or profiled surface so that the tendency of the underroof collar to slide over the tool members due the folding steps is kept low as described above.

To move the underroof collar further towards its intended folded state, it is presently considered advantageous that step F) results in at least two tool members becoming arranged closely above each other when seen in a direction perpendicular to the support surface. As described above this will increase the precision of the folding compared to methods where the underroof collar is released in position, where the tool members are further from each other.

Regardless how the folding tool is embodied, the method may further comprise one or more of the following steps:.

This will result in the folded or packed underroof collar becoming more compact, and potentially in that only a single collar member is exposed in the packed state. It is presently preferred that the underroof collar is folded along two secondary folding line, each coinciding substantially with the inner rim of a collar member of the second set. The folding along a tertiary folding can be performed before or after the folding along one or more secondary folding lines, or the underroof collar may be folded along two or more tertiary folding lines, possibly both before and after a folding one or more secondary folding lines. The folding along secondary and/or tertiary folding lines may be performed by hand or using a folding tool.

To facilitate the mounting of the underroof collar around a rectangular window frame mounted in an inclined roof structure the first set of collar members are top and bottom collar members configured for extending along top and bottom frame member of the rectangular window frame, where the underroof collar is folded so that at least a part of the centre section of each side collar member is arranged on top of or underneath the top collar member, the bottom collar member, and/or a section of the side collar member located in continuation of the top collar member or the bottom collar member when seen in the length direction of said top collar member or bottom collar member, and so that the top collar member and the bottom collar member are arranged one on top of the other. This allows the packed underroof collar to be arranged at the top frame member of the window frame and to be then unfolded in the direction of the inclination of the roof so that the side collar members become arranged along the side member of the window frame and the bottom collar member is lastly arranged along the bottom frame member.

The inner rim parts of the underroof collar will typically be configured for abutting on outer sides of the top, bottom and side members of the window frame in the mounted state, said outer sides facing away from the opening defined by the frame and extending substantially perpendicular to the plane of the roof, i.e. being substantially vertical. This means that in the mounted state the inner rim parts will extend at an angle with respect to the skirt parts, which extend over the roof structure, away from the window frame. During the folding of the underroof collar, however, the inner rim parts are preferably arranged so that they lay flat in the same plane as the outer skirt parts. This makes it easier to fold the underroof collar.

The method may be performed using a folding tool for folding the underroof collar along two or more primary folding lines, said folding tool comprising two or more elongate tool members, each having a length defining a length direction, and an activation mechanism configured for moving the elongate tool members in relation to each other in directions, which are substantially perpendicular to the length directions of the tool members, where said tool members are configured for individually engaging the underroof collar and for lifting and/or displacing it into a folded state. In other words, the tool members serve as carriers by being configured for engaging with and moving the material of the underroof collar so that the underroof collar folds over each tool member along a folding line extending in parallel to the length of the tool member.

While the invention has primarily been described with reference to embodiments where all tool members are individually moveable in relation to each other, it is to be understood that one or more tool members may be stationary, as long as the mutual movement between tool members and the underroof collar results in a folding of the underroof collar.

The activation mechanism may for example comprise pneumatic cylinders adapted for moving each tool member and may be controlled by a computer. As another example, a mechanical activation mechanism driven by a motor may be used.

It is presently preferred that the activation mechanism is configured for moving each of the elongate tool members independently of each other to change their mutual positions.

The activation mechanism may also or alternatively be configured for rotating one or more tool members about its own length direction and/ or for activating one or more conveyors on the surface of one or more tool members.

In one embodiment the activation mechanism is also configured for moving the tool members in their length directions, which may facilitate removal of the underroof collar from the folding tool.

The folding tool may further comprise a fixation mechanism for fixation the underroof collar in a hanging position and/or a support surface for supporting the underroof collar in a substantially horizontal position and/or a release mechanism for facilitating the removal of the underroof collar from the tool members. The fixation mechanism may for example comprise a pair of rail members configured for clamping the underroof collar between them. The support surface may comprise a table and/or a belt conveyor on which the underroof collar may rest. The release mechanism may for example comprise clamps for holding on to the underroof collar during a retraction of the tool members and/or for pulling on the underroof collar.

Referring initially to <FIG>, the mounting of an underroof collar <NUM> around a window frame <NUM> installed in an inclined roof structure <NUM> including an underroof <NUM> is shown. The packed underroof collar is arranged with a top collar member <NUM> at the top frame member <NUM> of the window frame and unfolded as shown by the arrows. In this way, side collar members <NUM> of the underroof collar come to extend alongside frame members <NUM> of the window frame and the bottom collar member <NUM> is eventually arranged along the bottom frame member <NUM>. The top and bottom collar members <NUM>, <NUM> here constitute a first set of collar members and the side collar members <NUM> constitute a second set of collar members extending perpendicular to the first set of collar members. Each collar member <NUM>, <NUM>, <NUM> includes an inner rim part <NUM>, <NUM> and an outer skirt part <NUM>, <NUM>, <NUM>. The inner parts delimit a collar opening <NUM> and are oriented so that they stand upright at an angle with respect to the skirt parts and will thus be parallel with and abut on the vertical exterior parts of the top, bottom and side members of the window frame <NUM> in the mounted state. An interior side of the outer skirt parts comes into engagement with the underroof <NUM> and laths <NUM> of the roof structure, while the exterior side <NUM>, which is coloured grey in <FIG>, faces the exterior and diverts any precipitation, e.g. rain or snow, from the joint between the roof structure <NUM> and the window frame <NUM>.

To facilitate mounting of the underroof collar <NUM>, it is delivered in a packed state, where is it folded several times.

One method for folding an underroof collar in an automated manner is illustrated <FIG>.

In <FIG> the underroof collar <NUM> is hanging under the influence of gravity from a fixation mechanism <NUM> of a folding tool. The underroof collar is shown simply as a line, as it is preferably arranged in a flattened state before being folded, but it will be understood that the presence of for example inner rim parts <NUM>, <NUM>, which are intended to project upwards along outer sides of the window frame in the mounted state as shown in <FIG>, may result in some sections of the underroof collar appearing slight thicker than others. Likewise, the presences of pleating on the side collar members <NUM> may result in them being slightly thicker than the top and bottom collar members <NUM>, <NUM>. The invention is not limited to the folding of an underroof collar having the exact features shown in <FIG> but is defined by the claims.

In this embodiment the fixation mechanism <NUM> comprises two rail members, each having a triangular cross-sectional shape and extending into the plane of the drawing, and the underroof collar <NUM> is fixated by a collar member of the first set being clamped between them, in this case it is the bottom collar member <NUM> as shown in <FIG>. The fixation may, however, also be achieved in a different way as long as the underroof collar hangs safely.

Three tool members <NUM> are arranged below the fixation mechanism <NUM>, one of one side of the underroof <NUM> collar and two on the opposite side. Each tool member is a rod, having a circular cross-sectional shape and extending into the plane of the drawing, and each is connected to an activation mechanism (not shown) of the folding tool configured for moving the tool member in directions substantially perpendicular to its length direction, i.e. in the plane of the drawing.

For initiating the folding of the underroof collar <NUM>, the tool members <NUM> are moved as indicated by the arrows in <FIG> into contact with the underroof collar. In this case one tool member engages the interior side <NUM> of the underroof collar and two tool members engage the exterior side <NUM> of the underroof collar. As may be seen, the tool member <NUM> engaging the interior side <NUM> is located approximately at the centre of the underroof collar, i.e. at the centre sections of side collar members <NUM> extending between the top and bottom collar members <NUM>, <NUM> along the collar opening <NUM> as shown in <FIG>. To be able to engage with both side collar members <NUM> it is preferred that the tool members <NUM> have a length in the direction extending into the drawing in <FIG>, which is longer than the length of the top and bottom collar members <NUM>, <NUM>, i.e. the collar members of the first set. It is, however, also possible to use two sets of tool members each engaging one of the collar members of the second set, i.e. the side collar members in this embodiment.

Turning now to <FIG>, it is seen that the movement of the tool members <NUM> continues until the tool member engaging the interior side <NUM> of the underroof collar <NUM> has passed a plane defined by the exterior side <NUM> in the hanging position in <FIG>, and the tool members engaging the exterior side <NUM> have passed a plane defined by the interior side <NUM> in the hanging position. In this way the underroof collar is displaced by the tool members and brought into a zig-zag configuration with a soft fold at each tool member, the tool members thus defining three primary folding lines extending substantially in parallel to the length of the collar members of the first set. As may be seen, the distances between the tool members <NUM> is larger in <FIG> than in <FIG>. This means that the underroof collar <NUM> is forced to slide over the tool members during their movement and that the free hanging section <NUM> of the underroof collar hanging below the lowermost tool member is thus shortened.

The tool members <NUM> are then moved upwards in a direction, which is substantially parallel to the plane defined by the exterior side <NUM> in the hanging position in <FIG> as illustrated by the arrows in <FIG> to the position illustrated in <FIG>. This results in that the mutual angles between the sections of the underroof collar <NUM> located on different sides of a tool member becomes smaller and in that the free hanging section <NUM> becomes slightly longer again due to the underroof collar sliding over the tool members. It is, however, also possible to initially arrange the tool members closer to each other in the direction parallel to the plane defined by the exterior side <NUM> in the hanging position, thereby eliminating or reducing the need for the movements illustrated by the arrows in <FIG>.

The distance covered by the tool members <NUM> during their movement may depend on the size of the underroof collar <NUM>. A longer movement will allow the folding of a longer underroof collar. It is also possible to increase the number of tool members, for example adding one or more additional tool members below those shown in <FIG>, and to use some of them only for the folding of underroof collars, which are longer than the one shown. Such additional tool members (not shown) may be kept idle when folding shorter underroof collars or simply move without engaging the shorter underroof collar.

To continue the folding, the tool members <NUM> are moved downwards and sideways as illustrated by the arrows in the <FIG> to the positions in <FIG>. By this movement the free hanging section <NUM> of the underroof collar comes into contact with a support surface <NUM> and is pulled to the side by the friction between the material of the underroof collar and the support surface. It is, however, also possible to apply a simpler pattern of movement, for example only moving the tool members <NUM> straight downwards towards the support surface.

At the same time, or thereafter, the fixation mechanism releases its grip so that the section <NUM> of the underroof collar previously extending between the uppermost tool member <NUM> and the fixation mechanism <NUM> falls down over the neighbouring section extending between the two uppermost tool members. In <FIG> all four sections of the underroof collar are shown as extending substantially in parallel, but it is to be understood that the previously fixated section <NUM> will usually be resting on the neighbouring section underneath it. It is also to be understood that if applying more tool members, the number of folds and hence the number of sections arranged on top of each other will be higher.

While the method has here been described with reference to an embodiment where all tool members <NUM> are moved in relation to the support surface <NUM> it is to be understood that the it may also be the other way around, and/or that one or more tool members may be stationary. What is important, is the mutual movement, and similar considerations apply to the other movements of tool members described, also with reference to the other embodiments of the invention.

The underroof collar <NUM> is now folded along three primary folding lines and the folding tool can be retracted either in a direction into or out of the plane of the drawing, or the underroof collar can be pulled off the tool members. The underroof collar is thereby left in the state shown in <FIG>, where the primary folding lines I-I are indicated by the dash-dotted lines, and where the top collar member <NUM> and the bottom collar <NUM> member are arranged one on top of the other.

The actual folds on the underroof collar <NUM> may not be exactly linear due to the soft nature of the material typically used for underroof collars and the relatively large diameter of the tool members <NUM>. If sharper folds are needed or desired, tool members with a smaller diameter may be used and/or both ends of the underroof collar may be fixated so that the underroof collar may be pressed against the tool members. A fixation of the section <NUM> hanging free in <FIG> may replace the support surface <NUM> in <FIG>, but it is presently considered advantageous that at least a part of the underroof collar <NUM> rests on a support surface during the release from the tool members <NUM>, as this provides a good control of the relatively soft folded material.

To make the packed underroof collar more compact, it may be folded further along secondary and/or tertiary folding lines, which are indicated by the broken lines II-II and III-III and shown by the arrows a and b, respectively, in <FIG>.

If folded only along the primary folding lines I and the secondary folding lines II, which extend substantially perpendicular to the primary folding lines and along the inner rim parts of the side collar members <NUM>, i.e. the second set of collar members, the underroof collar <NUM> get into the configuration in <FIG>. Here, the corner sections of the underroof collar <NUM>, where the side collar members <NUM> meet the top and bottom collar members, are arranged on top of the bottom collar member <NUM>.

In some embodiments of the underroof collar the top and bottom collar members extend over the entire width of the underroof collar, in other embodiments the side collar members extend over the entire height of the underroof collar, and in still further embodiments the collar members are interconnected in bevelled joints. In the embodiment in <FIG> the top collar member <NUM> extend over the entire width of the underroof collar, while the side and bottom collar members <NUM>, <NUM> are interconnected in bevelled joints, but other combinations of different joint types are also possible.

If the underroof collar is folded only along the primary folding lines I and the tertiary folding line III, which extends substantially in parallel to the primary folding lines, the underroof collar <NUM> get into the configuration in <FIG>. Here, the centre sections of the side collar members <NUM> are arranged on top of the bottom collar member <NUM>.

It is also within the scope of the invention, in addition to the features of claim <NUM>, to fold the corner sections or side collar members onto the top collar member <NUM> and/or to fold along all of the primary I, secondary II, and tertiary III folding lines. Likewise, the underroof collar <NUM> may be folded along further folding lines, which will particularly be advantageous when packaging large underroof collars intended for large roof windows or like roof penetrating structures.

While the secondary and tertiary folding lines II, III are shown as extending along edges of collar members it is to be understood that they may be located differently, depending for example on the overall size of the underroof collar <NUM> and the desired shape of the packed underroof collar.

Another method for folding an underroof collar <NUM> is shown in <FIG>. In this embodiment the underroof collar is arranged on a support surface <NUM> in a substantially horizontal orientation and tool members <NUM> corresponding to those described above with reference to <FIG> are arranged in grooves <NUM> in the support surface. When the tool members are moved upwards as indicated by the arrows in <FIG>, the underroof collar <NUM> is lifted to the position shown in <FIG>. As the soft underroof collar is now hanging from the tool members <NUM>, a primary folding line is created above each tool member and a third, but less well-defined primary folding line extends at the position marked c.

The tool members <NUM> are then moved sideways and downwards as indicated by the arrows in <FIG> to the positions in <FIG>. As described with reference to the free hanging section <NUM> in <FIG>, the right-hand end-section <NUM> is kept back by friction when coming into contact with the support surface <NUM> and thus comes to lie underneath the other sections of the underroof collar.

In this embodiment is may be advantageous that the tool members <NUM> are less smooth than in the embodiment in <FIG>, as the underroof collar <NUM> only needs to slide over them when it is taken off the folding tool, either by retraction of the tool members, by pulling on the underroof collar or by a combination of the two.

The size distribution of the four sections of the underroof collar <NUM> in <FIG> is slightly more equal than in <FIG>, but this is only intended to illustrate the possibility for variation. The size distribution may be changed by changing the initial distance between the tool members <NUM> or by changing the pattern of movement of the tool members, and the surface properties of the tool members, which define the friction against the underroof collar, will also play a role.

A still further method for folding an underroof collar is shown in <FIG>. In this embodiment the underroof collar <NUM> is initially arranged in a horizontal position on a conveyor <NUM>, here illustrated as a roller conveyor, and then passes over the edge of the conveyor at the right-hand side in <FIG>. By this movement the underroof collar passes between two tool members <NUM>, which are moved sideways as shown by the arrows in substantially the same way as described with reference to <FIG>. In this case, however, the third and lowermost tool member engages later than the first two as shown in <FIG>, waiting until the free hanging end of the underroof collar has reached down to it. Finally, the trailing end of the underroof collar <NUM> comes off the conveyor as shown in <FIG> and falls down onto the neighbouring section of the underroof collar as shown by the arrow, thereby ending up in the final position shown in <FIG>, where the underroof collar is ready for being released from the folding tool. In this embodiment there are only two primary folding lines, but a third may be added by adding an additional tool member or by engaging a support surface as described above.

The forward movement of the underroof collar <NUM> is here described as being driven by the conveyor <NUM>, but it is also possible to use one or more of the tool members as drive members. This may for example be done by making them rotatable and having a high coefficient of friction in contact with the underroof collar or by making a belt conveyor pass over them. In this way the tool members may pull the underroof collar off the conveyor, which may then be passive or only active during an initial phase of the folding process. The conveyor may then also be replaced with an entirely passive support surface as described with reference to <FIG>.

Claim 1:
A method for packaging an underroof collar (<NUM>) for use in water-proofing a joint between a roof structure (<NUM>) and a window frame (<NUM>), said underroof collar comprising a first set of collar members (<NUM>, <NUM>, <NUM>) and a second set of collar members (<NUM>, <NUM>, <NUM>) extending perpendicular to the first set of collar members, said collar members being configured for extending along frame members (<NUM>, <NUM>, <NUM>) of a rectangular window frame (<NUM>) in a mounted state, each collar member (<NUM>, <NUM>, <NUM>) including an inner rim part (<NUM>, <NUM>, <NUM>) and an outer skirt part (<NUM>, <NUM>, <NUM>) intended for coming into engagement with the roof structure (<NUM>), and said inner rim parts together delimiting a collar opening (<NUM>), where each collar member (<NUM>, <NUM>, <NUM>) has a length extending in parallel with the inner rim part, where each collar member (<NUM>, <NUM>, <NUM>) comprises a centre section extending between the collar members of the other set of collar members along the collar opening, where the underroof collar (<NUM>) has an interior side (<NUM>) adapted for facing the roof structure (<NUM>) and window frame (<NUM>) in a mounted state and an opposite exterior side (<NUM>) adapted for facing away from the roof structure (<NUM>) and the window frame (<NUM>) in a mounted state, said method including the step of folding the underroof collar along two or more folding lines, characterised in that the underroof collar (<NUM>) is folded along two or more primary folding lines (I) extending substantially in parallel to the length of the collar members (<NUM>, <NUM>, <NUM>) of the first set using a folding tool (<NUM>) comprising two or more elongate tool members (<NUM>), which are moveable in relation to each other, each of said tool members (<NUM>) having a length extending in parallel to the length of the collar members (<NUM>, <NUM>, <NUM>) of the first set when in use and defining a length direction, and that the underroof collar (<NUM>) is lifted and/or displaced by the tool members (<NUM>) thereby moving the collar members (<NUM>, <NUM>, <NUM>) of the second set in relation to the collar members of the first set, so that at least a part of the centre sections of the collar members of the second set are arranged on top of at least one of the collar member of the first set.