GB2070517A - Laminated covering elements and processes for making the same - Google Patents

Laminated covering elements and processes for making the same Download PDF

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Publication number
GB2070517A
GB2070517A GB8105380A GB8105380A GB2070517A GB 2070517 A GB2070517 A GB 2070517A GB 8105380 A GB8105380 A GB 8105380A GB 8105380 A GB8105380 A GB 8105380A GB 2070517 A GB2070517 A GB 2070517A
Authority
GB
United Kingdom
Prior art keywords
element according
layer
face
web
resin
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.)
Withdrawn
Application number
GB8105380A
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.)
TECHENET R
Original Assignee
TECHENET R
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 TECHENET R filed Critical TECHENET R
Publication of GB2070517A publication Critical patent/GB2070517A/en
Withdrawn legal-status Critical Current

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered 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
    • B32B5/02—Layered 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 structural features of a fibrous or filamentary layer
    • B32B5/022—Non-woven fabric
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered 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
    • B32B5/18—Layered 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered 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
    • B32B5/22—Layered 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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
    • B32B5/24—Layered 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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
    • B32B5/245—Layered 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 the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it being a foam layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/02—Synthetic macromolecular fibres
    • B32B2262/0276—Polyester fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2266/00—Composition of foam
    • B32B2266/02—Organic
    • B32B2266/0214—Materials belonging to B32B27/00
    • B32B2266/0285—Condensation resins of aldehydes, e.g. with phenols, ureas, melamines
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/304—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/714—Inert, i.e. inert to chemical degradation, corrosion
    • B32B2307/7145—Rot proof, resistant to bacteria, mildew, mould, fungi
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2607/00—Walls, panels
    • B32B2607/02—Wall papers, wall coverings

Landscapes

  • Engineering & Computer Science (AREA)
  • Textile Engineering (AREA)
  • Laminated Bodies (AREA)
  • Casting Or Compression Moulding Of Plastics Or The Like (AREA)

Abstract

The present invention relates to laminated covering elements and to processes for manufacturing same. A laminated covering element in the form of a rigid three-dimensional structure which comprises an inner layer of rot-proof non-woven web covered on one face by a polyvinyl chloride water-tight layer and on the opposite face by a layer of hardened resin in which mineral aggregates are anchored, said water-tight layer and said resin layer adhering to said web. Such elements are suitable for covering either horizontal or inclined surfaces and for covering vertical surfaces; in other words, the elements constitute roof or wall coverings or possibly constitute the roofs and walls themselves. <IMAGE>

Description

SPECIFICATION Laminated covering elements and processes for making the same The present invention relates to laminated covering elements and to processes for manufacturing same.
Such elements are suitable for covering either horizontal or inclined surfaces and for covering vertical surfaces; in other words, the elements constitute roof or wall coverings or possibly constitute the roof and walls themselves.
It is known to use polymeric material for making synthetic tiles but it is very difficult to manufacture at low cost laminated elements comprising a watertight polymeric layer and other layers having a shape similar to conventional roofing tiles.
The invention aims at providing such laminated elements.
The element according to the present invention is a rigid three-dimensional element which comprises an inner layer of a rot-proof non-woven web covered on one face by a polyvinyl chloride water-tight layer and on the opposite face by a layer of hardened resin in which mineral aggregates are anchored, said water-tight layer and said resin layer adhering to said web.
The resin layer protects the polyvinyl chloride layer against infra-red and ultra-violet radiation, and against thermal shocks; consequently, it is possible to use so-called recovery polyvinyl chloride, which is inexpensive but which offers low resistance to bad weather.
The element is a three-dimensional element, that is to say that the element is not a sheet-like flat element.
The element preferably has, on the free face of the water-tight layer, a second adherent layer of a rot-proof non-woven web for receiving a coating, for instance, a heat-insulating coating which adheres to the underface of said other sheet.
The webs are advantageously made of polyester filaments.
The heat-insulating coating may for example be a phenolic The invention will now be described in greater detail by way of example with reference to the accompanying drawings, in which: figure 1 is a schematic vertical section through an element according to a first embodiment of the invention; figure 2 is a schematic section through a device used for making the element of figure 1, and figure 3 is a schematic vertical section through several embodiments of an element according to the invention.
Referring now to the drawings, figure 1 shows the element according to the invention which is a roofing element intended to imitate a set of several half-round tiles of a conventional roof.
Only a part of the element has been shown, in order to simplify the figure.
The element is a rigid shaped element made of: - a sheet of polyvinyl chloride (PVC) 1, for example 0.30 to 1 mm thick, sandwiched between two webs 2, 3 of non-woven polyester filaments of which the filaments are mechanical bonded (for example the product sold under the registered trademark BIDIM by the French company Rhone Poulenc Textiie) having a density of 200 to 500 grams per m2; - a top layer 4 of resin in which mineral aggregates are anchored, - a bottom layer 5 of heat-insulating foam, for example a phenolic foam.
To make the element, a sheet 1 of PVC, in the flexible state, is lined with webs 2 and 3 of BIDIM by any known process, for example by means of an adhesive or by applying the webs to the sheet at the exit of an extruding device. The composite element thus obtained is placed between two moulding jaws 6, 7 having the desired shapes. A hardenable resin, for example a thermosetting resin (such as, for example, a phenolic, polyester or epoxy resin) is applied on the top face of the composite element, mineral aggregates, for example fragments of slate, brick, sand or gravel, are deposited or projected onto the resin. The application of the resin and the deposit of the aggregates are effected before or after the positioning of the complex between the jaws 6, 7.
The resin is hardened by means of the appropriate agent according to the type of resin, the jaws 6, 7 being pressed towards each other during the hardening of the resin. The operation may be carried out at room temperature and with moderate pressure. For speeding the polymerisation of the resin, moderate heating may be applied preferably below 1 000C, for instance 60 to 800 C. Such a low temperature and low pressure are convenient for shaping PVC without injuring the qualities of PVC.
The resin has a triple role: anchoring the aggregates; rigidifying the sheet of PVC which was initially flexible; and protecting the PVC.
In the embodiment of figure 1 where the element further comprises a heat-insulating foam coating, the compositions necessary for preparing the foam are poured in the jaw 6 and, by means of the other jaw 7, the element is pressed on the foam during foaming.
Jaws 6 and 7 constitute a mould: jaw 6 is the cavity of the mould whereas jaw 7 is the shaping part of the mould. In the example, jaw 7 has a section representing concave portions alternating with convex portions. At the boundaries between concave and convex portions, the PVC sheet make round plies which contribute to make the element rigid.
It is to be emphasized that the moulding operation may be carried on at will neat the place where the element is to be used.
If it is desired to improve the mechanical strength of the element further, one of the following means is used preferably, as exemplified on figure 3: - incorporation in the element of stretched bands or cords 8 which prestress the element (figure 3A) - incorporation in the element of small beams 9 (figure 3B) - gluing of a sheet 10 (fabric, paper, plastics material) on the underface of the element (figure 3C) - deposition of a stiffening coating 11 on the non-woven fabric located on the underface (figure 3D).
The invention is applicable to all shapes and all dimensions of roofing elements, but specially to shapes comprising curved zones alternating with zones curved in opposite direction (e.g. concave zones and convex zones as shown on figure 1) or alternating with flat zones as shown on figure 3C for instance.

Claims (16)

1. A laminated covering element, made of a rigid three-dimensional element which comprises an inner layer of rot-proof non-woven web covered on one face with a polyvinyl chloride water-tight layer and on the opposite face with a layer of hardened resin in which mineral aggregates are anchored, said water-tight layer and said resin layer adhering to said web.
2. An element according to claim 1, wherein said web is made of polyester filaments.
3. An element according to claim 1 or claim 2, further comprising on the free face of the watertight layer a second adherent layer of a rot-proof non-woven web.
4. An element according to claim 3, further comprising a heat-insulating coating which adheres to the underface of said second web.
5. An element according to claim 4, wherein the heat-insulating coating is a phenolic foam of a cellular plaster.
6. An element according to claim 3, further comprising a stiffening coating deposited on said second web.
7. An element according to one of claims 1 to 6, further comprising stretched bands or cords which prestress the element.
8. An element according to one of claims 1 to 6, further comprising stiffening beams.
9. An element according to claim 8, wherein the stiffening beams are anchored in a heatinsulating foam on the underface of the element.
10. An element according to any of claims 1 to 9, further comprising a sheet of fabric, paper or plastics material under the water-tight layer.
11. An element according to any of claims 1 to 10, the shape of which comprises curved zones alternating with zones curved in opposite direction or with flat zones.
12. A process for manufacturing an element according to any of claims 1 to 11, which comprises the step of pressing between two moulding jaws, a flexible sheet of polyvinyl chloride lined on one face with an adherent rotproof non-woven web coated with a hardenable resin and on which mineral aggregates have been deposited, said pressing being carried on whilst the resin is hardening.
13. A process according to claim 12, wherein pressing is carried on at room temperature, or with moderate heating below 1000C, preferably between 60--800C.
14. A process according to claim 12 or 13 wherein the said sheet is lined on its face opposite to said one face with a second adherent rot-proof non-woven web, wherein the starting precursors of an insulating foam are poured in one of the two jaws and wherein said pressing is carried on during the foaming.
15. An element according to claim 1, substantially as described herein with reference to and as shown in Fig. 1 and/or any of Figs. 3a, 3b, 3cor3d.
16. A process according to claim 12 substantially as described herein with reference to Fig. 2 of the drawings.
GB8105380A 1980-02-20 1981-02-20 Laminated covering elements and processes for making the same Withdrawn GB2070517A (en)

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
FR8003702A FR2476184A1 (en) 1980-02-20 1980-02-20 RIGID ELEMENTS AND COVER LAMINATES AND METHODS OF MAKING SAME

Publications (1)

Publication Number Publication Date
GB2070517A true GB2070517A (en) 1981-09-09

Family

ID=9238763

Family Applications (1)

Application Number Title Priority Date Filing Date
GB8105380A Withdrawn GB2070517A (en) 1980-02-20 1981-02-20 Laminated covering elements and processes for making the same

Country Status (6)

Country Link
JP (1) JPS56133157A (en)
BE (1) BE887582A (en)
DE (1) DE3106151A1 (en)
FR (1) FR2476184A1 (en)
GB (1) GB2070517A (en)
NL (1) NL8100729A (en)

Cited By (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2166385A (en) * 1984-09-20 1986-05-08 William John White Wallboard
US4891084A (en) * 1986-03-11 1990-01-02 Raychem Limited Method of making a curved composite article
EP1227188A2 (en) * 2001-01-30 2002-07-31 Ruberoid Building Products Limited Waterproofing system
WO2008128967A1 (en) * 2007-04-24 2008-10-30 Freudenberg Politex S.R.L. A watertight composite support for bituminous membranes with limited thickness and weight and a process for the production thereof

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB2166385A (en) * 1984-09-20 1986-05-08 William John White Wallboard
US4891084A (en) * 1986-03-11 1990-01-02 Raychem Limited Method of making a curved composite article
EP1227188A2 (en) * 2001-01-30 2002-07-31 Ruberoid Building Products Limited Waterproofing system
EP1227188B1 (en) * 2001-01-30 2007-08-08 Iko Plc Waterproofing system
WO2008128967A1 (en) * 2007-04-24 2008-10-30 Freudenberg Politex S.R.L. A watertight composite support for bituminous membranes with limited thickness and weight and a process for the production thereof

Also Published As

Publication number Publication date
FR2476184B3 (en) 1982-12-03
NL8100729A (en) 1981-09-16
BE887582A (en) 1981-08-19
FR2476184A1 (en) 1981-08-21
DE3106151A1 (en) 1982-01-14
JPS56133157A (en) 1981-10-19

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Legal Events

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WAP Application withdrawn, taken to be withdrawn or refused ** after publication under section 16(1)