JP2011524441A - Composite material roof structure - Google Patents

Abstract

The present invention is a composition for producing high-quality building products that are waterproof and waterproof. The composition from which these products are formed may impair the integrity of the product in combination with recycled rubber products such as ethylene propylene-diene monomer and styrene-butadiene rubber, or fillers that may include inorganic fillers. Rather, it is a mixture of various polyethylene or polypropylene materials that give the formulation various feel and texture. This is accomplished by changing the amount and amount of high and / or low density polyethylene or polypropylene melts in the mixture, resulting in proper material integrity. Prior to final shaping, a colorant may additionally be added to the mixture. This composition allows the product to be similar to a traditional building product but has a higher level of performance and is reusable throughout the product.

Description

  The present invention relates to a building component such as a roofing element, and more particularly formed from a specific combination of synthetic materials to mimic building members formed from natural materials and enhance desirable properties of building members. Related to the building material.

  In the art of building members such as roofing with tiles made of natural materials, roof tiles with natural slate have been known for many years. Such slate obtained from the quarry can be cut to a certain size and punched or punched and stretched on the roof in a conventional manner. However, such natural slate is generally very much like the order of about 2,000 pounds per 10 feet x 10 feet area of the roof while providing roofs for many years, often 50-100 years. Requires a basic roof support structure that can withstand large weights.

  Synthetic products have been developed that mimic building elements of natural appearance for use in floors, roofs such as slate roofs, and other building structures. However, these composite building components are very heavy or configured thinner than natural slate or other natural roof tiles to reduce the required weight when weight is a consideration. When it is done, it is either thinned.

  For the purpose of reducing weight to address these problems, other synthetic building components have been developed, such as those from molded concrete containing appropriate lightweight fillers, sometimes with partial recesses. It was.

  However, such prior art synthetic products do not adequately mimic natural materials either in appearance or desirable impact, wear and fire resistance properties, or such materials It is either not constructed in a way that makes it possible to produce building components with recycled materials that will become increasingly popular with continued use of. Most of the synthetic materials used to form building components have large amounts of carbon dioxide emissions, for example, due to the extra energy used to form the material and in processing into building components. Yes. In addition, because the reuse of materials results in significant degradation of material properties, the prior art building components are formed entirely from unused materials, so that any form of recycled materials cannot be used. The formation of technical composite building components is not environmentally friendly.

  Furthermore, the properties of the particular materials used to form these materials require that the processing of the materials be carefully controlled to form useful products. Due to the properties of polypropylene that affect how the material flows and cools, the molding process is undesirable, such as limited impact resistance, such as in compression molding processes where articles molded from polypropylene are It must be strictly controlled in order not to have properties.

As a result, when a building component formed by the composition in a particular process is optionally used to form a roof in various building structures, such as when forming a roofing material. Can be modified as desired to ensure that it has sufficient durability and desired appearance for use without the need for additional parts,
It is desirable to develop a lightweight synthetic building material composition. In addition, the building component composition should be able to increase ease of manufacture so that the building component can be formed with the desired appearance in any suitable molding process. In addition, if building components are to be removed and replaced, the building components can be reused to form additional building components as opposed to simply disposing of those building components. It would be desirable to be able to

  According to one aspect of the present invention, there is provided a one-piece building member such as a roofing element formed from a molded synthetic material to mimic an element of natural appearance, and the building member composition may vary in the building member. Contains a variety of materials selected to provide benefits. The composition for the building member is formed from a polymer resin combined with a binder. The presence of the binder, especially in the case of recycled polymer resins, and the ability to process building resins by using various molding techniques to manipulate the properties of the polymer resins and the resulting building components. To make it possible. Advantages of these properties include increased fender resistance, flame retardancy, increased wind resistance, increased impact resistance and appearance.

  According to another aspect of the present invention, the binder used in the composition of the roofing element allows the composition for building components to be formed by synthetic components that can be obtained from waste or other recycled materials. To do. Also, the use of these materials and binders makes the roofing member itself fully reusable for the formation of further building components. The primary material used to form the roof tiles includes various types of polymeric resins or plastics such as polypropylene that gives the composition great flexibility when the composition is processed into the desired roofing element. Is mentioned. Then, the additional components of the composition are added to this initial starting material and subsequently formed into a building component having the desired shape, color and size.

  Many other aspects, features and advantages of the present invention will become readily apparent from the following detailed description of the preferred embodiments and from the appended claims.

  In accordance with the present invention, a synthetic roofing element comprises a body constructed from a material shaped to closely resemble the appearance of natural building materials such as slate, ceramic, wood, and stone, among others. In addition, the composite building components of the present invention are not limited to, but not limited to, roofing applications in general, including but not limited to use in building construction applications and, inter alia, exterior wall materials, foundations, flooring, and decorative applications. Can be manufactured to be realistically similar to other natural materials, such as in any molding, extrusion, or similar process suitable for composite plastic materials. By way of example only, such natural materials that are mimicked according to the present invention include stone, clay, cedar, and other finishes that are intended to mimic the appearance and texture of stone and wood materials. Thus, the composite building component of the present invention when imitating stone or ceramic finish is formed to reproduce the shape, size, structure and texture of clay, terracotta, Spanish tile / mission tile, cylindrical tile and ceramic tile. obtain. When mimicking a wood finish, composite building components should reproduce the shape, size, structure, texture and grain of any of a variety of hard and soft materials such as cedar, oak, mahogany, etc. Can be formed.

  The building component of the present invention is a plastic comprising one or more plastic materials selected from polyester, polyolefin, polyethylene including high density, medium density and low density polyethylene, polystyrene, polyamide, polypropylene, and equivalents and combinations thereof. It is formed from a composition containing a material material or a polymer resin material as a main component or component. The plastic or resin component of the roofing element composition is present in the range of about 10% to 90% by weight of the roofing element composition.

The plastic material component of the building member of the present invention imparts mechanical properties of hardness, rigidity, infusibility and insolubility (ie waterproof) to the building member, and optionally has a wide range of crosslinks. By way of example, the plastic material or polymeric resin material may be obtained as a virgin thermoplastic polymer material or may be obtained from a recycled material stream formed essentially from the above-described polymers.

  In a preferred embodiment of the building member, the plastic component is at least partially formed from a polypropylene material. Polypropylene has long been used to construct building components, but its use has been limited to unused polypropylene. The use of pure virgin polypropylene alone has resulted in building components with limited desirable properties such as fire resistance and impact resistance, due to the processing of virgin polypropylene in the injection molding process.

  Another essential component of the building component composition is one or more binders, preferably present in an amount up to about 90% by weight of the total composition, more preferably from about 1% to about 75% by weight. The binder effectively alters the properties of the polymeric resin used to form the building component to provide the building member with the desired fire resistance, impact resistance and wear resistance, while at the same time It is also possible for the member to be formed using multiple molding processes. Specifically, the presence of the binder changes the melt index of the polymer resin, so that the resin and binder are used in different molding processes such as injection molding, compression molding, and extrusion to form building components. Make it possible to do. In addition, the binder modifies the physical properties, including impact resistance, of the resulting building component without degrading the inherent properties of the main component, such as its fire resistance.

The binder itself takes the form of another polymer resin different from that used as the main component of the building component, but may be similar to those resins used as the main component. For example, the polyethylene resins discussed above can also be used or function in the composition as a binder to other resins present in the composition. In addition to polyethylene, other suitable plastics or polymeric resins that can be used as binders include ethylene / vinyl acetate polymers that can be used alone or in combination with very low density polyethylene to form the binder, For example, EVAC-ethylene-vinyl acetate copolymer and LLDPE-linear low density polyethylene, LDPE-low density polyethylene, metallocine, EAA-ethylene / acrylic acid copolymer, very low density polypropylene, EEA-poly (ethylene -Ethyl acrylate), EAA-ethylene / acrylic acid copolymer, PVB-poly (vinyl butyral), EMAC-poly (ethylene methyl acrylate), TPO-thermoplastic polyolefin (often attached to elastomers), T Examples include PU-Thermoplastic Polyurethene (often attached to elastomers) or similar materials.

This allows the formation of building components from recycled materials as there are a wide range of components that can be used in combination with each other as either the primary polymeric resin component or binder for the building component composition. To some extent, the use of binders in combination with various polymer resins as the main component is in contrast to prior art synthetic building materials that require the use of unused materials based on the specific conditions under which they are formed. Based on the type and amount of binder used, it essentially allows the composition to be modified as needed to provide the desired properties to the building component. Specifically, when the properties of the selected main component cannot cause the component to properly form or function with respect to the desired building component, the binder may have a specific The process can be used to form a desired building component and is selected to form a composition having the desired impact, wear, and heat or fire resistance characteristics. Therefore, when using a recycled polymer resin material as a main component that may not have the desired initial characteristics, the binder should have the desired characteristics and be effectively used to form a building member. Can be selected to provide a composition that can be added to the recycled resin. Furthermore, since each of the resin components used in the composition can be provided by recycled material, the entire building component formed from the composition can itself be completely reused.

  In addition to the main resin component and binder, the building component of the present invention may preferably include other components in the composition. One of these components is a filler compound. Compounds that can be used as fillers for the building component compositions of the present invention include a composition matrix that exhibits considerable stiffness and rigidity compared to that of pure thermoplastic or polymeric resin components. The chemical component which is an inactive compound which acts as a reinforcing material to be given to the above. The filler compound for a building member composition of the present invention is used to increase the modulus and strength of the composition forming the building member. In addition, this thermoplastic or polymeric resin component and filler compound combination was used to produce a composite building component that was less brittle and more resistant to impact stress and was formed at the same time. Maintain appropriate compressive strength, tensile strength, bending strength, and shear strength for building components. Filler compounds that can be used in the composition for roofing elements include calcium oxide; calcium carbonate; cement; fly ash; glass fiber fiber; metal shavings; metal oxides such as zinc oxide; Fiber; Aluminum oxide; Mica; Perlite; Zeolite; Vermiculite; Silica; Silicate; Silica, # 12 sand; # 30 sand, # 60 sand; Stone, rock, marble, gravel, glass, clay and talc aggregate Examples include filler compounds selected from among particles / pebbles and their equivalents and combinations.

  One additional filler compound most preferably used in the building component composition of the present invention comprises a polymeric compound and a reclaimed tire piece. Both ethylene propylene-diamine monomer copolymers and styrene-butadiene rubbers obtained from shredded vehicle tires are excellent fillers in the moldings of the present invention, typically already already in other cases. It is obtained by reusing waste that would go to a full landfill. Since such fillers are already “vulcanized”, they are also flame retardant materials, which provides further advantages to the roofing element of the present invention. The fillers are relatively low cost, water repellency and high temperature heat resistant, so that the fillers are among other items roofing materials (roofboards), floor finishing materials (tile and sheet materials) and Particularly suitable for use on building components such as other construction materials. If alternative filler compounds have the properties required for building components, especially water and heat resistance, then other filler compounds such as those described above may be used with all or some of the preferred copolymers and rubber materials. It can also be replaced.

  In addition to the main resin component, binder and filler compound, the composition used to form the building component of the present invention preferably also contains various additional additives. Such additives include thermal stabilizers, ultraviolet (UV) light stabilizers, pigments or colorants, compatibilizers, processing aids, flame retardant additives, and building materials formed from materials processing and compositions. Mention may be made of compounds such as other functional chemicals that can improve performance.

  With respect to the colorant, the colorant is preferably present in an amount up to 15% by weight of the total composition, more preferably up to about 10% by weight, with the preferred colorant being natural iron oxide. However, other suitable natural or synthetic colorants may be used to provide the desired appearance to the building component.

With respect to the flame retardant that can be used in the building component composition, the component is preferably present in an amount of up to 60% by weight of the total composition, more preferably from about 1% to about 50% by weight. Preferred said components are aluminum trihydrate and magnesium hydroxide. Other flame retardants may be used in place of either aluminum trihydrate or magnesium hydroxide. These include Platisan B from 3V Corp., Georgetown, South Carolina, Phos-check available from Solutia Corp., St. Louis, MO, and Dover-phos-9228 from Dover Chemical, Dover, Ohio. In addition, the other components of the roofing element composition, like the preferred fillers, include recycled tire rubber that already has flammable properties as a result of being vulcanized in addition to the actual flame retardant. This can contribute to the flame retardancy of the member.

The UV component may be present in the composition in an amount up to about 20% by weight of the total composition, more preferably from about 0.1% to about 16% by weight. Examples of UV components include UV inhibitors and UV stabilizers. UV stabilizers may include Tinuvin® 783FDL or Univol 5050H from Ciba®, Basel, Switzerland. Each of the UV stabilizers makes a significant contribution to long-term thermal stability to the composite element and helps keep the material from chalking on the surface over time. UV inhibitors include Chimassorb (R) 81 or Univol 3008 from Ciba (R), Basel, Switzerland, each a solid UV absorber of the 2-hydroxy-benzophenone class. Can be. The absorbance spectrum for the inhibitor (in the UVB range only) and the relatively low photopermanence absorb ultraviolet light that can cause premature degradation of the material for the composition where the inhibitor otherwise forms a building component. Making the inhibitor useful in the present application.

  The composition is also preferably a phenolic anti-oxidant that prevents heat-induced polymer oxidation in high temperature applications as a component present in an amount up to 10% by weight of the total composition, more preferably from about 1% to about 8% by weight. Antioxidants, such as Irganox® B225 or Annox B8011, from Ciba®, Basel, Switzerland, can be included as oxidizing agents. Antioxidants function to stabilize the surface color and appearance of the composite material used to form the building component. The stabilizing function of the antioxidants does not allow high processing temperatures to adversely affect the color and surface appearance of building components, but effectively improves the appearance of building components across all of the various temperatures of material processing. To control.

The following are some examples of building members formed using the polymer resin and binder composition of the present invention.
Example 1
Spanish-style imitated tile roofing elements can be formed by the following components in a preferred embodiment of the composition of the present invention.

1. Waste from ethylene propylene-diene monomer and styrene-butadiene rubber products in amounts up to about 50% by weight (of the total composition) as fillers,
2. As binder, ethylene vinyl acetate and ultra-low density polyethylene in an amount of about 10 to 40% by weight, more preferably about 15% by weight;
3. flame retardant in an amount of 10 to 35% by weight (ie aluminum trihydrate or magnesium hydroxide),
4). Iron oxide in an amount of about 1-10% by weight;
5. As the main resin component, high density polyethylene in an amount of about 5 to 50% by weight;
6). U.S. in an amount of about 1-8% by weight. V. Stabilizer,
7). U.S. in an amount of about 1-8% by weight. V. Inhibitors,
8). An antioxidant in an amount of about 1-8% by weight.

The above materials are added together in the form of a dry powder into a suitable mixing device and stirred for a sufficient time in the mixing device to obtain a uniform and homogeneous building component composition. During agitation of the composition in the device, the desired colorant for the desired specific building component is added to the composition in the mixing device to provide a uniform and homogeneous distribution of the colorant throughout the composition. I do. The homogeneous mixture composition is then used in various forms to introduce the composition into a suitably formed mold and form a building component within the mold under sufficient temperature and pressure, A desired roofing element can be formed. By way of example only, specific methods that can be used to process the composition into building elements having the desired shape include extrusion, compression molding, injection molding and thermoforming.

  In addition, the homogeneous composition can be used to build the composition so that the composition can be stored for later use, or to form the composition, eg, to form the composition into multiple pellets. To increase the ease of use of the composition in other processes for forming parts, to maximize the quality of the composition and roofing elements formed from the composition, and to reduce dust resulting from the use of the composition By doing so, it can be further processed, such as to help create a less harmful production environment.

One additional advantage of the building component composition of the present invention is that there is no need for any preheating step in the processing of the composition. In some other similar processes using similar materials, the unused polymer composition is preheated or chemically cured while the composition is being processed prior to forming the building component. It is necessary to make it. Unfortunately, this necessary process has the disadvantage of reducing the properties of the unused material during processing, which results in building components having degraded properties. There is no preheating or chemical curing step in the process of forming the roofing member of the composition of the present invention. The ingredients or components of the composition are simply mixed together in the form of a dry powder and then immediately heated to form a building part or cooled and pelletized, the pellets being Can be heated and shaped into a final product, either stored or transported for later use. This reduces energy consumption and stress on the material by reducing the number of thermal cycles. Furthermore, since no additional heat needs to be applied to the composition, the amount of fossil fuel used in the processing of building components can be reduced.
(Example 2)
The roofing sheet material is similar to that used in Example 1 but is made with a formulation that does not contain styrene-butadiene rubber and mineral filler.

1. Up to about 50% by weight of TPO thermoplastic polyolefin (of total composition) as binder,
2. As binder, ethylene vinyl acetate and ultra-low density polyethylene in an amount of about 10 to 40% by weight, more preferably about 15% by weight;
3. flame retardant in an amount of 10 to 35% by weight (ie aluminum trihydrate or magnesium hydroxide),
4). Polypropylene in an amount of about 5 to 50% by weight as the main component.

Polypropylene is used to make the product slightly flexible but still sufficiently hard to be used as a desired component, such as for flooring, due to the presence of a binder. The binder alters the inherent properties of polypropylene to achieve these properties even when in a regenerated form. In addition, since the component is designed for use under other building materials, no colorant is added to the composition. The material composition provides a strongly non-corrosive material that seals and / or engages the fastener to prevent water ingress. The product formed from this composition is impact resistant and has a much longer service life than the natural product it replaces, so that this particular application of the building component composition is over time. The need for degrading underlayments can be eliminated. The baseboard can also be manufactured to standard dimensions without losing the composition in the manufacturing process. This material composition is also completely reusable.
(Example 3)
In order to achieve the highest fire rating and hail rating hail ratings, the following formulation is used to form the roofing element.

1. A flame retardant in an amount of 45% by weight (of the total composition),
2. As binder a very low density polyethylene and / or ethylene vinyl acetate in an amount of 25% by weight,
3. High density polyethylene in an amount of about 20% by weight as part of the main component,
4). Low density polyethylene in an amount of about 10% by weight as part of the main component,
5. A small amount of colorant, ie less than 10% by weight.
Example 4
Spanish imitation tiles that are very lightweight and rated to fire class A and fireproof class 4 can be molded from the following composition of the present invention formed in a manner similar to Example 1. it can.

1. Polypropylene main component in an amount up to about 75% by weight (of the total composition),
2. Calcium carbonate in an amount of about 10-50% by weight, more preferably about 35% by weight;
3. A flame retardant present in an amount of about 20-50% by weight;
4). Linear low density polyethylene present in an amount of about 1-20% by weight as a binder system,
5. U.S. present in an amount of about 0.1-8% by weight. V. Stabilizer,
Present in an amount of 6.01 to 8% by weight. V. Inhibitor.
(Example 5)
In another preferred embodiment of the composition of the present invention, a kraft or cedar simulated roofing board can be formed by the following components.

1. Polypropylene main component in an amount up to about 75% by weight of the total composition,
2. Calcium carbonate present in an amount of about 10-50% by weight, more preferably about 35% by weight;
3. A flame retardant present in an amount of about 20-50% by weight;
4). As a binder system, very low density polyethylene present in about 1 to 20% by weight,
5. U.S. present in an amount of about 0.1-8% by weight. V. Stabilizer,
7). U.S. present in an amount of about 0.1-8% by weight. V. Inhibitor.

  Although specific percentages of materials are disclosed herein, this specification includes all equivalents that would occur to one skilled in the art through appropriate laboratory work with the compounds and processes disclosed herein. Is intended.

Claims (20)

a) about 10-60% by weight filler,
b) about 10-40% by weight of a binder;
c) about 0 to 40% by weight of a flame retardant;
d) A building product comprising a composition with about 5 to 80% by weight of a polymeric resin.   The building product of claim 1, wherein the polymeric resin comprises low density polyethylene and high density polyethylene in an amount of about 5-50 wt%.   The building component of claim 1, wherein the polymeric resin comprises high density polyethylene in an amount of about 20% by weight and low density polyethylene in an amount of about 10% by weight.   The building product of claim 1, wherein the polymeric resin comprises polypropylene present in an amount up to about 75% by weight.   The building product according to claim 1, wherein the filler includes recycled vulcanized rubber.   6. The building product of claim 5, wherein the filler contains waste combinations from ethylene propylene-diene monomer and styrene-butadiene rubber products in an amount up to about 50% by weight.   The building product according to claim 1, wherein the filler includes a mineral filler.   The building product of claim 1, wherein the binder contains ethylene vinyl acetate in an amount of about 10-40 wt%.   The building product of claim 1, wherein the binder comprises ultra low density polyethylene in an amount of about 10-40 wt%.   The building product of claim 1, further comprising about 0.1-8 wt% antioxidant.   About 0.1 to 8 wt. V. The building product according to claim 1, further comprising an inhibitor.   About 0.1 to 8 wt. V. The building product of claim 1 further comprising a stabilizer.   The building product of claim 1, wherein the product is selected from roof tiles, field boards, exterior wall materials, handrails, floorboards, pallets, paving materials, and decorative building accessories.   Furthermore, the building member of Claim 1 containing a coloring material.   The building member of claim 1, wherein the entire building member is reusable.   The building member according to claim 1, wherein the entire composition is formed from a regenerated component. a) polypropylene in an amount up to about 75% by weight of the composition;
b) calcium carbonate in an amount of about 10-50% by weight;
c) a flame retardant present in an amount of about 20-50% by weight;
d) a binder system present in an amount of about 1-20% by weight;
e) U.I. present in an amount of about 0.1-8% by weight. V. A stabilizer,
f) U.I. present in an amount of about 0.1-8% by weight. V. A building product comprising a composition with an inhibitor. a) a flame retardant in an amount of 45% by weight of the total composition;
b) a binder in an amount of 25% by weight;
c) high density polyethylene in an amount of about 20% by weight;
d) A building component comprising a composition with low density polyethylene in an amount of about 10% by weight.   The building member according to claim 18, wherein the binder contains a combination of ethylene vinyl acetate and ultra-low density polyethylene.   The building member according to claim 18, further comprising a coloring material.