Classifications

• • E—FIXED CONSTRUCTIONS
  • E04—BUILDING
  • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
  • E04D3/00—Roof covering by making use of flat or curved slabs or stiff sheets
  • E04D3/24—Roof covering by making use of flat or curved slabs or stiff sheets with special cross-section, e.g. with corrugations on both sides, with ribs, flanges, or the like
  • E04D3/32—Roof covering by making use of flat or curved slabs or stiff sheets with special cross-section, e.g. with corrugations on both sides, with ribs, flanges, or the like of plastics, fibrous materials, or asbestos cement
• • B—PERFORMING OPERATIONS; TRANSPORTING
  • B44—DECORATIVE ARTS
  • B44F—SPECIAL DESIGNS OR PICTURES
  • B44F9/00—Designs imitating natural patterns
  • B44F9/04—Designs imitating natural patterns of stone surfaces, e.g. marble
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/19—Sheets or webs edge spliced or joined
  • Y10T428/192—Sheets or webs coplanar
  • Y10T428/197—Sheets or webs coplanar with noncoplanar reinforcement
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
  • Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
  • Y10T428/24802—Discontinuous or differential coating, impregnation or bond [e.g., artwork, printing, retouched photograph, etc.]
  • Y10T428/24826—Spot bonds connect components
• • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
  • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
  • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
  • Y10T428/00—Stock material or miscellaneous articles
  • Y10T428/249921—Web or sheet containing structurally defined element or component
  • Y10T428/249924—Noninterengaged fiber-containing paper-free web or sheet which is not of specified porosity
  • Y10T428/24994—Fiber embedded in or on the surface of a polymeric matrix
  • Y10T428/24995—Two or more layers
  • Y10T428/249952—At least one thermosetting synthetic polymeric material layer

Definitions

• the present invention relates to a prefabricated roofing element in the form of a laminate.
• a roof covering element composed of its internal face towards its external face exposed to the weather of at least one first continuous layer constituting the core of said element and formed of a mixture of at least one binder and of reinforcing materials, of a second continuous layer of an ultraviolet and weather protection product called gelcoat, consisting of the mixture of at least one synthetic resin, preferably thermosetting, such as a polyester resin, of a constituent mass dyeing said resin and a catalyst.
• Interlocking tiles have been widely used in multiple ways for roofing dwellings. These tiles generally made of baked clay make it possible to obtain very waterproof and resistant but heavy covers and very exposed to breakage, in particular in the event of hail. So we saw appear on the market, for roofing, synthetic sheets which have been printed in the shape of interlocking tiles. These light, weather resistant plates, however, did not achieve the expected commercial success essentially for two reasons. On the one hand, the use of asbestos-based materials, such as fiber cement (registered trademark), poses risks to the health of users. On the other hand, these plates offer a poor imitation of the natural appearance of traditional products, such as tiles and slates, this poor imitation is further accompanied by a rapid degradation over time of this aspect.
• Patent FR-A-2,522,348 recommends, to imitate the appearance of traditional products, the use of aggregates which pose problems of homogenization of the mixture and distribution of the aggregates on the surface of the finished product.
• Patent FR-A-2,451,429 recommends, for its part, the use of a tinted gelcoat having a rough appearance capable of causing a certain number of drawbacks such as the retention of dust and, the development of foams in the level of roughness.
• An object of the present invention is to overcome the aforementioned drawbacks by proposing a prefab roofing element with a very similar appearance.
• traditional products such as tiles and slates, which age well over time and with water and which can be manufactured using an industrial process.
• Another object of the present invention is to provide a method of manufacturing a prefabricated roofing element which is easy to implement and which enables the finished product to be obtained quickly.
• the subject of the invention is a prefabricated roofing element in the form of a laminate composed of its internal face towards its external face exposed to the weather, of at least one first continuous layer constituting the core of said element and formed from a mixture of at least one thermosetting binder and reinforcing materials, from a second continuous layer of a protective coating to ultraviolet and weathering called gelcoat consisting of the mixture of at least one synthetic resin, preferably thermosetting, such as a polyester resin, of a tinting component in the mass of said resin and of a catalyst, this element being characterized in that it also comprises, at least a third discontinuous layer of a paint irregularly distributed on the surface of the second layer and composed of materials immiscible with the constituents of the second layer to form on the surface of the second layer of tasks giving, in cooperation with the second layer of said element, an appearance imitating the appearance of traditional materials such as slates or tiles.
• the third layer of the covering element consists of a paint based essentially on a thermoplastic resin chosen from the group of polyurethane, acrylic resins or two-component resins acrylic-urethane, a catalyst capable of promoting the polymerization of said resin and pigments.
• the subject of the invention is also a method of manufacturing a prefabricated roofing element characterized in that, by spraying, it is deposited in the form of irregular droplets on the surface of the molding cavity of a mold of corresponding shape.
• a paint based on a thermoplastic resin to form the so-called upper layer of a laminated roofing covering element in that this layer is covered after hardening a second continuous layer of a mixture based on a tinted thermosetting resin immiscible with the paint of the upper layer and in that, after hardening of this second layer, a layer capable of forming the core of said element is applied , this layer consisting of at least one reinforcing material and a binder.
• the roof covering element is in the form of a part whose conformation depends on the traditional material to be imitated. This conformation is generally obtained by molding.
• the shaped part imitates by imprints several successive rows of elements such as tiles, the edges of this part being shaped to allow assembly by covering of said edges during the side by side positioning of two identical parts on a roof frame.
• This roofing element is in the form of a laminate composed of at least three layers.
• the first layer also called the core of said element and constituting the internal face of said element is formed of a mixture of at least one thermosetting binder and reinforcing materials. Mention may be made, as thermosetting binder, of polyester, phenolic resins, furanic, epoxy or other. However, in a preferred embodiment of this core, it consists of a mixture of at least one thermosetting resin tinted in the mass, such as a tinted polyester resin, and glass fibers, the fibers of glasses being present in said mixture in a proportion in the range [20-30%] by weight.
• an unsaturated polyester resin diluted with styrene and methyl methacrylate can be used.
• This resin is accelerated by means of an accelerator, such as a 6% solution of cobalt octoate, then hardened by means of a catalyst, such as a peroxide of either methyl ethyl ketone or acetyl acetone ( 2-4- pentanedione).
• a catalyst such as a peroxide of either methyl ethyl ketone or acetyl acetone ( 2-4- pentanedione).
• a catalyst such as a peroxide of either methyl ethyl ketone or acetyl acetone ( 2-4- pentanedione).
• a catalyst such as a peroxide of either methyl ethyl ketone or acetyl acetone ( 2-4- pentanedione.
• the second layer of this element is a continuous layer of a protective coating, called gelcoat, consisting of the mixture of at least one synthetic resin, preferably thermosetting, such as a polyester resin, of a tinting component in the mass. said resin, and a catalyst.
• the thickness of this second layer is generally in the range [0.3-0.5 mm].
• the constituents of the first and second layers used for dyeing said layers are chosen such that the shade of the first layer is identical to that of the second layer.
• rutile titanium treated with chlorine mention may be made of rutile titanium treated with chlorine.
• the colors of the core and of the second layer are obtained from bases of white, blue, or black for a covering element imitating slate and from bases of yellow, red, orange for a cover element imitating the tile.
• the final colors of the core and the second layer may be for a cover element imitating slate type RAL 7015, 7016 or 7021 and for a cover element imitating tile type RAL 2001 to 2010.
• This laminate further comprises at least a third layer constituting the external face exposed to the weather of said element.
• This third layer is a discontinuous layer of a paint distributed unevenly on the surface of the second layer.
• This third layer is composed of materials immiscible with the constituents of the second layer to form on the surface of the second layer tasks conferring on said element, in cooperation with the second layer, an appearance imitating that of traditional materials such as slates or tiles.
• This third layer is preferably made of a paint, essentially based on a resin chosen from the group of polyurethane, acrylic, acrylic-urethane resins, a catalyst capable of promoting the polymerization of said resin and color pigments. black.
• the resin of this third layer consists of a base preferably belonging to the family of hydroxylated acrylic compounds and / or compounds based on urethane and of a diluent consisting of an organic solvent, such as acetate. of 2-butoxyethyl, ethyl acetate or the like.
• the catalyst generally belongs to the family of polyisocyanates.
• a diluent one can use the diluent D807 S0741 from PPG Industries SA and as a catalyst the hardener D802 STP of this same company.
• the color of the paint varies according to the desired aging aspect.
• a typical composition of a roofing element can be defined as follows:
• Mi-Dion FR 7722.00 (Reichhold) 75-85% by weight
• M4-Viapam VUP 4754 Bemt (Vianova Resins) 65.75% by weight
• pigments rutile titanium treated with chlorine
• Pigments rutile titanium treated with chlorine
• a mold is produced, generally made of synthetic material to allow obtaining shapes conforming to those of a traditional cover part.
• a spray-on in the form of irregular droplets, deposits a polyurethane or acrylic paint or two-component acrylic-urethane to form the so-called upper layer of the covering element laminate roofing.
• This projection is carried out by means of pneumatic gravity guns. We choose a large flow of paint and a low air pressure to obtain during the fall by gravity of the paint irregular projections.
• At least one mold release agent is applied to the surface of the molding cavity.
• At least one of the release agents is constituted by polyvinyl alcohol to give a matt appearance to the covering element once it has been produced.
• polyvinyl alcohol it is possible to use a release agent chosen from the following compounds:
• This release agent (s) are generally also applied with a pneumatic gravity gun.
• the catalyst capable of promoting the drying of the paint, is sprayed simultaneously with the paint, the catalyst / paint mixture having been produced beforehand. This spraying operation is carried out inside a heated tunnel so as to activate the polymerization. Hot air is blown through nozzles in the tunnel. These hot air inlets participate in obtaining irregular projections of the paint.
• the mold is brought to the gelcoat application station.
• This application is again made with a spray gun.
• the mold continues to move inside the heated tunnel to receive a layer intended to constitute the core of said covering element.
• This layer consists of glass fibers and a mass-dyed polymerizable resin. This is also applied by spray gun. The presence of glass fibers requires a subsequent boiling of this layer.
• This debubbling can be carried out by means, for example, of a load of steel balls placed inside a polyethylene envelope, the assembly being applied to the surface to be debubbed.
• the part is extracted from the production installation and can be stored for mounting on a frame. During its manufacture, it is preferable that this part is exposed to a temperature of the order of 30 ° C-60 ° C to accelerate all polymerizations.
• the mold is during the first stage of projection of a paint kept inclined to give the spots obtained from the projection of paint a casting appearance, better imitating the slate.

Landscapes

• Engineering & Computer Science (AREA)
• Architecture (AREA)
• Civil Engineering (AREA)
• Structural Engineering (AREA)
• Application Of Or Painting With Fluid Materials (AREA)
• Roof Covering Using Slabs Or Stiff Sheets (AREA)
• Laminated Bodies (AREA)
• Electric Double-Layer Capacitors Or The Like (AREA)
• Body Structure For Vehicles (AREA)
• Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)

Applications Claiming Priority (3)

Publications (2)

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ID=9512201

Family Applications (1)

Country Status (8)

Families Citing this family (1)

Family Cites Families (6)

• 1997
  • 1997-10-14 FR FR9712829A patent/FR2769653B1/fr not_active Expired - Fee Related
• 1998
  • 1998-10-13 DE DE69803086T patent/DE69803086T2/de not_active Expired - Fee Related
  • 1998-10-13 ES ES98949044T patent/ES2170527T3/es not_active Expired - Lifetime
  • 1998-10-13 AT AT98949044T patent/ATE211078T1/de not_active IP Right Cessation
  • 1998-10-13 WO PCT/FR1998/002187 patent/WO1999019154A1/fr active IP Right Grant
  • 1998-10-13 CA CA002304026A patent/CA2304026A1/fr not_active Abandoned
  • 1998-10-13 US US09/529,545 patent/US6251511B1/en not_active Expired - Fee Related
  • 1998-10-13 EP EP98949044A patent/EP1023189B1/de not_active Expired - Lifetime

Non-Patent Citations (1)

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