NZ732088B2 - A roofing, cladding or siding product - Google Patents
A roofing, cladding or siding product Download PDFInfo
- Publication number
- NZ732088B2 NZ732088B2 NZ732088A NZ73208815A NZ732088B2 NZ 732088 B2 NZ732088 B2 NZ 732088B2 NZ 732088 A NZ732088 A NZ 732088A NZ 73208815 A NZ73208815 A NZ 73208815A NZ 732088 B2 NZ732088 B2 NZ 732088B2
- Authority
- NZ
- New Zealand
- Prior art keywords
- module
- layer
- another embodiment
- reinforcement
- layers
- Prior art date
Links
- 238000005253 cladding Methods 0.000 title claims abstract description 72
- 239000000463 material Substances 0.000 claims abstract description 212
- 230000002787 reinforcement Effects 0.000 claims abstract description 122
- 239000000945 filler Substances 0.000 claims abstract description 94
- 229920000642 polymer Polymers 0.000 claims abstract description 91
- 229920002994 synthetic fiber Polymers 0.000 claims abstract description 12
- 238000004040 coloring Methods 0.000 claims description 22
- 229920002725 Thermoplastic elastomer Polymers 0.000 claims description 20
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 20
- 229920001577 copolymer Polymers 0.000 claims description 18
- 239000010454 slate Substances 0.000 claims description 16
- 239000003365 glass fiber Substances 0.000 claims description 13
- 239000004575 stone Substances 0.000 claims description 13
- 239000000126 substance Substances 0.000 claims description 13
- VTYYLEPIZMXCLO-UHFFFAOYSA-L calcium carbonate Chemical compound [Ca+2].[O-]C([O-])=O VTYYLEPIZMXCLO-UHFFFAOYSA-L 0.000 claims description 12
- 229920001519 homopolymer Polymers 0.000 claims description 12
- 239000010426 asphalt Substances 0.000 claims description 11
- 239000011521 glass Substances 0.000 claims description 11
- 238000001746 injection moulding Methods 0.000 claims description 11
- 238000010030 laminating Methods 0.000 claims description 11
- OSGAYBCDTDRGGQ-UHFFFAOYSA-L Calcium sulfate Chemical compound [Ca+2].[O-]S([O-])(=O)=O OSGAYBCDTDRGGQ-UHFFFAOYSA-L 0.000 claims description 10
- 229920000840 ETFE Polymers 0.000 claims description 10
- 229920003020 cross-linked polyethylene Polymers 0.000 claims description 10
- 239000004703 cross-linked polyethylene Substances 0.000 claims description 10
- 229920005669 high impact polystyrene Polymers 0.000 claims description 10
- 239000004797 high-impact polystyrene Substances 0.000 claims description 10
- 229920001684 low density polyethylene Polymers 0.000 claims description 10
- 239000004702 low-density polyethylene Substances 0.000 claims description 10
- 229920003229 poly(methyl methacrylate) Polymers 0.000 claims description 10
- 229920000139 polyethylene terephthalate Polymers 0.000 claims description 10
- 239000005020 polyethylene terephthalate Substances 0.000 claims description 10
- 229920000098 polyolefin Polymers 0.000 claims description 10
- 229920001155 polypropylene Polymers 0.000 claims description 10
- 239000004814 polyurethane Substances 0.000 claims description 10
- 229920002635 polyurethane Polymers 0.000 claims description 10
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 claims description 10
- 239000011145 styrene acrylonitrile resin Substances 0.000 claims description 10
- 229920001169 thermoplastic Polymers 0.000 claims description 10
- 239000004416 thermosoftening plastic Substances 0.000 claims description 10
- VTHJTEIRLNZDEV-UHFFFAOYSA-L Magnesium hydroxide Chemical compound [OH-].[OH-].[Mg+2] VTHJTEIRLNZDEV-UHFFFAOYSA-L 0.000 claims description 9
- 238000001125 extrusion Methods 0.000 claims description 9
- 239000000347 magnesium hydroxide Substances 0.000 claims description 9
- 229910001862 magnesium hydroxide Inorganic materials 0.000 claims description 9
- 239000003381 stabilizer Substances 0.000 claims description 9
- 239000011248 coating agent Substances 0.000 claims description 8
- 238000000576 coating method Methods 0.000 claims description 8
- -1 polyethylene terephthalate Polymers 0.000 claims description 8
- 238000004381 surface treatment Methods 0.000 claims description 8
- 229960003563 Calcium Carbonate Drugs 0.000 claims description 6
- 239000004698 Polyethylene (PE) Substances 0.000 claims description 6
- 229910000019 calcium carbonate Inorganic materials 0.000 claims description 6
- 239000000919 ceramic Substances 0.000 claims description 6
- 229910052751 metal Inorganic materials 0.000 claims description 6
- 239000002184 metal Substances 0.000 claims description 6
- 229920000728 polyester Polymers 0.000 claims description 6
- 229920000573 polyethylene Polymers 0.000 claims description 6
- 239000004800 polyvinyl chloride Substances 0.000 claims description 6
- 229920000915 polyvinyl chloride Polymers 0.000 claims description 6
- 238000007493 shaping process Methods 0.000 claims description 6
- 239000004577 thatch Substances 0.000 claims description 6
- PZZYQPZGQPZBDN-UHFFFAOYSA-N Aluminium silicate Chemical compound O=[Al]O[Si](=O)O[Al]=O PZZYQPZGQPZBDN-UHFFFAOYSA-N 0.000 claims description 5
- 239000005995 Aluminium silicate Substances 0.000 claims description 5
- 229920000742 Cotton Polymers 0.000 claims description 5
- 241000208202 Linaceae Species 0.000 claims description 5
- 235000004431 Linum usitatissimum Nutrition 0.000 claims description 5
- 239000004677 Nylon Substances 0.000 claims description 5
- 239000004793 Polystyrene Substances 0.000 claims description 5
- 229920002522 Wood fibre Polymers 0.000 claims description 5
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 claims description 5
- 239000004676 acrylonitrile butadiene styrene Substances 0.000 claims description 5
- 235000012211 aluminium silicate Nutrition 0.000 claims description 5
- 229920003235 aromatic polyamide Polymers 0.000 claims description 5
- 239000011324 bead Substances 0.000 claims description 5
- 229920001400 block copolymer Polymers 0.000 claims description 5
- 239000001175 calcium sulphate Substances 0.000 claims description 5
- 235000011132 calcium sulphate Nutrition 0.000 claims description 5
- 229920002678 cellulose Polymers 0.000 claims description 5
- 239000001913 cellulose Substances 0.000 claims description 5
- 239000010459 dolomite Substances 0.000 claims description 5
- 229910000514 dolomite Inorganic materials 0.000 claims description 5
- QHSJIZLJUFMIFP-UHFFFAOYSA-N ethene;1,1,2,2-tetrafluoroethene Chemical group C=C.FC(F)=C(F)F QHSJIZLJUFMIFP-UHFFFAOYSA-N 0.000 claims description 5
- 235000013312 flour Nutrition 0.000 claims description 5
- 239000004700 high-density polyethylene Substances 0.000 claims description 5
- 239000004707 linear low-density polyethylene Substances 0.000 claims description 5
- 239000004701 medium-density polyethylene Substances 0.000 claims description 5
- CERQOIWHTDAKMF-UHFFFAOYSA-M methacrylate Chemical compound CC(=C)C([O-])=O CERQOIWHTDAKMF-UHFFFAOYSA-M 0.000 claims description 5
- 239000010445 mica Substances 0.000 claims description 5
- 229910052618 mica group Inorganic materials 0.000 claims description 5
- 229920001778 nylon Polymers 0.000 claims description 5
- 229920001707 polybutylene terephthalate Polymers 0.000 claims description 5
- 239000004626 polylactic acid Substances 0.000 claims description 5
- 239000004926 polymethyl methacrylate Substances 0.000 claims description 5
- 229920002223 polystyrene Polymers 0.000 claims description 5
- 239000000377 silicon dioxide Substances 0.000 claims description 5
- 229920000638 styrene acrylonitrile Polymers 0.000 claims description 5
- 239000000454 talc Substances 0.000 claims description 5
- 229910052623 talc Inorganic materials 0.000 claims description 5
- 229920001897 terpolymer Polymers 0.000 claims description 5
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 claims description 5
- 239000002023 wood Substances 0.000 claims description 5
- 238000010521 absorption reaction Methods 0.000 claims description 4
- 230000000813 microbial Effects 0.000 claims description 4
- 238000002310 reflectometry Methods 0.000 claims description 4
- 239000010410 layer Substances 0.000 description 619
- 210000000614 Ribs Anatomy 0.000 description 70
- 238000000034 method Methods 0.000 description 52
- OZAIFHULBGXAKX-UHFFFAOYSA-N precursor Substances N#CC(C)(C)N=NC(C)(C)C#N OZAIFHULBGXAKX-UHFFFAOYSA-N 0.000 description 51
- 239000000047 product Substances 0.000 description 30
- 230000003014 reinforcing Effects 0.000 description 26
- 238000000465 moulding Methods 0.000 description 23
- 239000002245 particle Substances 0.000 description 20
- 239000000853 adhesive Substances 0.000 description 18
- 230000001070 adhesive Effects 0.000 description 18
- 239000000789 fastener Substances 0.000 description 14
- 238000005304 joining Methods 0.000 description 14
- 238000004519 manufacturing process Methods 0.000 description 13
- 238000009434 installation Methods 0.000 description 12
- 239000012528 membrane Substances 0.000 description 10
- 239000004088 foaming agent Substances 0.000 description 8
- 239000004611 light stabiliser Substances 0.000 description 8
- 239000007788 liquid Substances 0.000 description 8
- BQCADISMDOOEFD-UHFFFAOYSA-N silver Chemical compound [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 description 8
- 229910052709 silver Inorganic materials 0.000 description 8
- 239000004332 silver Substances 0.000 description 8
- 230000003746 surface roughness Effects 0.000 description 8
- GWEVSGVZZGPLCZ-UHFFFAOYSA-N titan oxide Chemical compound O=[Ti]=O GWEVSGVZZGPLCZ-UHFFFAOYSA-N 0.000 description 8
- 238000003825 pressing Methods 0.000 description 7
- 238000003856 thermoforming Methods 0.000 description 7
- 230000000007 visual effect Effects 0.000 description 7
- 230000003115 biocidal Effects 0.000 description 5
- 239000003139 biocide Substances 0.000 description 5
- 230000000875 corresponding Effects 0.000 description 5
- 239000003063 flame retardant Substances 0.000 description 5
- 238000007789 sealing Methods 0.000 description 5
- 210000001624 Hip Anatomy 0.000 description 4
- MXRIRQGCELJRSN-UHFFFAOYSA-N O.O.O.[Al] Chemical compound O.O.O.[Al] MXRIRQGCELJRSN-UHFFFAOYSA-N 0.000 description 4
- 239000000654 additive Substances 0.000 description 4
- 238000004026 adhesive bonding Methods 0.000 description 4
- 150000001412 amines Chemical class 0.000 description 4
- 239000011230 binding agent Substances 0.000 description 4
- OKTJSMMVPCPJKN-UHFFFAOYSA-N carbon Chemical compound [C] OKTJSMMVPCPJKN-UHFFFAOYSA-N 0.000 description 4
- 239000006229 carbon black Substances 0.000 description 4
- 239000003086 colorant Substances 0.000 description 4
- RYGMFSIKBFXOCR-UHFFFAOYSA-N copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 4
- 229910052802 copper Inorganic materials 0.000 description 4
- 239000010949 copper Substances 0.000 description 4
- 238000000151 deposition Methods 0.000 description 4
- 238000003475 lamination Methods 0.000 description 4
- 239000000314 lubricant Substances 0.000 description 4
- 239000000155 melt Substances 0.000 description 4
- 239000002105 nanoparticle Substances 0.000 description 4
- 238000000059 patterning Methods 0.000 description 4
- 230000000149 penetrating Effects 0.000 description 4
- 235000013824 polyphenols Nutrition 0.000 description 4
- 230000001681 protective Effects 0.000 description 4
- 239000002356 single layer Substances 0.000 description 4
- 239000003017 thermal stabilizer Substances 0.000 description 4
- 239000004408 titanium dioxide Substances 0.000 description 4
- 238000004078 waterproofing Methods 0.000 description 4
- 210000001138 Tears Anatomy 0.000 description 3
- 230000006750 UV protection Effects 0.000 description 3
- 230000001680 brushing Effects 0.000 description 3
- 238000005266 casting Methods 0.000 description 3
- 239000002537 cosmetic Substances 0.000 description 3
- 238000005336 cracking Methods 0.000 description 3
- 238000005034 decoration Methods 0.000 description 3
- 230000032798 delamination Effects 0.000 description 3
- 238000007598 dipping method Methods 0.000 description 3
- 238000004049 embossing Methods 0.000 description 3
- 239000004744 fabric Substances 0.000 description 3
- 239000000835 fiber Substances 0.000 description 3
- 239000012467 final product Substances 0.000 description 3
- 239000012530 fluid Substances 0.000 description 3
- 238000002347 injection Methods 0.000 description 3
- 239000007924 injection Substances 0.000 description 3
- 235000012254 magnesium hydroxide Nutrition 0.000 description 3
- 238000002844 melting Methods 0.000 description 3
- 239000000203 mixture Substances 0.000 description 3
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- 230000002265 prevention Effects 0.000 description 3
- 238000005096 rolling process Methods 0.000 description 3
- 239000007787 solid Substances 0.000 description 3
- 238000005507 spraying Methods 0.000 description 3
- 210000000282 Nails Anatomy 0.000 description 2
- 239000003795 chemical substances by application Substances 0.000 description 2
- 238000001816 cooling Methods 0.000 description 2
- 239000000975 dye Substances 0.000 description 2
- 238000011068 load Methods 0.000 description 2
- 230000000704 physical effect Effects 0.000 description 2
- 239000000049 pigment Substances 0.000 description 2
- 229920002959 polymer blend Polymers 0.000 description 2
- 239000002994 raw material Substances 0.000 description 2
- 229920002943 EPDM rubber Polymers 0.000 description 1
- 240000004006 Gomphocarpus physocarpus Species 0.000 description 1
- 230000000996 additive Effects 0.000 description 1
- 239000000956 alloy Substances 0.000 description 1
- 229910045601 alloy Inorganic materials 0.000 description 1
- 230000000712 assembly Effects 0.000 description 1
- 230000015572 biosynthetic process Effects 0.000 description 1
- 150000001875 compounds Chemical class 0.000 description 1
- 238000000748 compression moulding Methods 0.000 description 1
- 239000000470 constituent Substances 0.000 description 1
- 238000010924 continuous production Methods 0.000 description 1
- 230000001276 controlling effect Effects 0.000 description 1
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- 230000004048 modification Effects 0.000 description 1
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- 239000002365 multiple layer Substances 0.000 description 1
- 239000011120 plywood Substances 0.000 description 1
- 229920005606 polypropylene copolymer Polymers 0.000 description 1
- 230000004224 protection Effects 0.000 description 1
- 239000011241 protective layer Substances 0.000 description 1
- 239000011227 reinforcement additive Substances 0.000 description 1
- 238000000518 rheometry Methods 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 238000004642 transportation engineering Methods 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
- B29C41/24—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of indefinite length
- B29C41/28—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of indefinite length by depositing flowable material on an endless belt
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C41/00—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor
- B29C41/24—Shaping by coating a mould, core or other substrate, i.e. by depositing material and stripping-off the shaped article; Apparatus therefor for making articles of indefinite length
- B29C41/32—Making multilayered or multicoloured articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/001—Combinations of extrusion moulding with other shaping operations
- B29C48/0013—Extrusion moulding in several steps, i.e. components merging outside the die
- B29C48/0014—Extrusion moulding in several steps, i.e. components merging outside the die producing flat articles having components brought in contact outside the extrusion die
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
- B29C48/07—Flat, e.g. panels
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
- B29C48/12—Articles with an irregular circumference when viewed in cross-section, e.g. window profiles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
- B29C48/13—Articles with a cross-section varying in the longitudinal direction, e.g. corrugated pipes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/16—Articles comprising two or more components, e.g. co-extruded layers
- B29C48/18—Articles comprising two or more components, e.g. co-extruded layers the components being layers
- B29C48/21—Articles comprising two or more components, e.g. co-extruded layers the components being layers the layers being joined at their surfaces
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
- B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
- B29C48/25—Component parts, details or accessories; Auxiliary operations
- B29C48/30—Extrusion nozzles or dies
- B29C48/303—Extrusion nozzles or dies using dies or die parts movable in a closed circuit, e.g. mounted on movable endless support
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/10—Building elements, e.g. bricks, blocks, tiles, panels, posts, beams
- B29L2031/104—Tiles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
- B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
- B29L2031/00—Other particular articles
- B29L2031/10—Building elements, e.g. bricks, blocks, tiles, panels, posts, beams
- B29L2031/108—Roofs
-
- 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
-
- 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
- B32B2419/00—Buildings or parts thereof
- B32B2419/06—Roofs, roof membranes
-
- 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
- B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different 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
- B32B5/18—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
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D1/00—Roof covering by making use of tiles, slates, shingles, or other small roofing elements
- E04D1/12—Roofing elements shaped as plain tiles or shingles, i.e. with flat outer surface
- E04D1/22—Roofing elements shaped as plain tiles or shingles, i.e. with flat outer surface of specified materials not covered by any one of groups E04D1/14 - E04D1/205, or of combinations of materials, where at least one is not covered by any one of groups E04D1/14 - E04D1/205
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D1/00—Roof covering by making use of tiles, slates, shingles, or other small roofing elements
- E04D1/26—Strip-shaped roofing elements simulating a repetitive pattern, e.g. appearing as a row of shingles
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D1/00—Roof covering by making use of tiles, slates, shingles, or other small roofing elements
- E04D1/28—Roofing elements comprising two or more layers, e.g. for insulation
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F13/00—Coverings or linings, e.g. for walls or ceilings
- E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
- E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
- E04F13/0864—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements composed of superposed elements which overlap each other and of which the flat outer surface includes an acute angle with the surface to cover
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F13/00—Coverings or linings, e.g. for walls or ceilings
- E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
- E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
- E04F13/0866—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements composed of several layers, e.g. sandwich panels or layered panels
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F13/00—Coverings or linings, e.g. for walls or ceilings
- E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
- E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
- E04F13/16—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements of fibres or chips, e.g. bonded with synthetic resins, or with an outer layer of fibres or chips
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04F—FINISHING WORK ON BUILDINGS, e.g. STAIRS, FLOORS
- E04F13/00—Coverings or linings, e.g. for walls or ceilings
- E04F13/07—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor
- E04F13/08—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements
- E04F13/16—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements of fibres or chips, e.g. bonded with synthetic resins, or with an outer layer of fibres or chips
- E04F13/165—Coverings or linings, e.g. for walls or ceilings composed of covering or lining elements; Sub-structures therefor; Fastening means therefor composed of a plurality of similar covering or lining elements of fibres or chips, e.g. bonded with synthetic resins, or with an outer layer of fibres or chips with an outer layer imitating natural stone, brick work, tiled surface or the like
Abstract
This invention relates to a roofing, cladding, or siding module 1, comprising an underlapping region 2 extending from a head edge 4 of the module 1 and an exposed region 3 extending from a foot edge 5 of the module 1. The length of the foot edge 5 defining the length of the module 1. The underlapping region 2 is adapted to be substantially covered by the exposed region of an adjacent or overlapping module when installed on a building surface. The module is formed of at least one layer of extruded material. The layer so formed comprises at least 40% w/w filler and/or reinforcement, and one or more polymer(s). The reinforcement comprises one or more non-conductive natural or synthetic fibres. The layer comprises at least 6% w/w of the one or more non-conductive natural or synthetic fibres, and the fibres are aligned along the length of the module. The module comprises a plurality of formed surfaces molded along the length of the module, each of the formed surfaces comprising at least one three-dimensional surface feature. The module is capable of being industrially produced in suitable quantities. g region 2 is adapted to be substantially covered by the exposed region of an adjacent or overlapping module when installed on a building surface. The module is formed of at least one layer of extruded material. The layer so formed comprises at least 40% w/w filler and/or reinforcement, and one or more polymer(s). The reinforcement comprises one or more non-conductive natural or synthetic fibres. The layer comprises at least 6% w/w of the one or more non-conductive natural or synthetic fibres, and the fibres are aligned along the length of the module. The module comprises a plurality of formed surfaces molded along the length of the module, each of the formed surfaces comprising at least one three-dimensional surface feature. The module is capable of being industrially produced in suitable quantities.
Description
A ROOFING, CLADDING OR SIDING PRODUCT
FIELD OF THE INVENTION
The present invention relates to roofing, cladding, and/or siding products and assemblies
of such products, for installation onto a building surface. Described herein are also
systems and methods of manufacture of roofing, cladding, and/or siding products.
BACKGROUND TO THE INVENTION
There are a variety of known roofing, cladding and/or siding products, each of which
have particular appearance and performance characteristics for installing onto building
surfaces according to a user's preference. Well-known products include asphalt shingles,
slate, tiles, concrete tiles, corrugated profiles, etc.
It would be advantageous to provide an alternative roofing, cladding and/or siding
product which provides the same or similar appearance as those products which have
been used traditionally, yet which also provide for performance characteristics. In
particular, to provide for such alternatives which are capable of being industrially
produced in suitable quantities, and/or from alternative materials.
It is an object of the present invention to provide an alternative or a substitute roofing,
cladding and/or siding module.
It is an alternative or additional object of the present invention to provide an alternative
method of manufacturing roofing, cladding, and/or siding products in a more productive
and/or efficient and/or cost-effective manner.
In this specification where reference has been made to patent specifications, other
external documents, or other sources of information, this is generally for the purpose of
providing a context for discussing the features of the invention. Unless specifically stated
otherwise, reference to such external documents is not to be construed as an admission
that such documents, or such sources of information, in any jurisdiction, are prior art, or
form part of the common general knowledge in the art.
SUMMARY OF THE INVENTION
In a first aspect, the present invention provides a roofing, cladding, or siding module,
comprising:
an underlapping region extending from a head edge of the module and an
exposed region extending from a foot edge of the module, the length of the foot edge
defining the length of the module,
wherein the underlapping region is adapted to be substantially covered by the
exposed region of an adjacent or overlapping module when installed on a building
surface,
wherein the module is formed of at least one layer of extruded material, wherein
the layer so formed comprises:
at least 40% w/w filler and reinforcement or at least 40% w/w reinforcement, and
one or more polymer(s),
wherein the reinforcement comprises one or more non-conductive natural or
synthetic fibres, and wherein the layer so formed comprises at least 6% w/w of said one
or more non-conductive natural or synthetic fibres, and wherein the fibres are aligned
along the length of the module; and
wherein the module comprises a plurality of formed surfaces molded along the
length of the module, each of the formed surfaces comprising at least one three-
dimensional surface feature.
In a first described aspect, there is provided a roofing, cladding, or siding module,
comprising:
an underlapping region extending from a head edge of the module and an
exposed region extending from a foot edge of the module, the length of the foot edge
defining the length of the module,
wherein the underlapping region is adapted to be substantially covered by the
exposed region of an adjacent or overlapping module when installed on a building
surface,
wherein the module is formed of at least one layer of extruded material, wherein
the layer so formed comprises:
a) at least 40% w/w filler and/or reinforcement,
b) one or more polymer(s).
In one embodiment, the module comprises a plurality of formed surfaces molded along
the length of the module.
In another embodiment, the layer so formed comprises at least 60% w/w filler and/or
reinforcement.
In another embodiment, the layer comprises about 60% to about 95% w/w filler and/or
reinforcement.
In another embodiment, the layer comprises at least about 5% w/w reinforcement.
In another embodiment, the layer comprises about 5% to about 30% w/w reinforcement.
In another embodiment, the layer comprises at least about 80% filler and at least about
% reinforcement.
In one embodiment, the layer comprises one or more of the following polymers:
a) polystyrene (GPPS),
b) polyethylene terephthalate (PET),
c) polyester methacrylate (PEM),
d) high impact polystyrene (HIPS),
e) acrylonitrile butadiene styrene (ABS),
f) polyvinyl chloride (PVC),
g) polyurethanes (PU),
h) polyethylene (PE), including homopolymer, copolymer, block copolymer and
terpolymer forms,
i) polylactic acid (PLA),
j) nylon (PA),
k) acrylics (PMMA),
l) high density polyethylene (HDPE),
m) low density polyethylene (LDPE),
n) linear low density polyethylene (LLDPE),
o) medium density polyethylene (MDPE),
p) cross linked polyethylene (PEX),
q) thermoplastic elastomer (TPE),
r) thermoplastic polyolefin (TPO),
s) thermoplastic rubber (TPR),
t) polypropylene (PP), including homopolymer and copolymer forms,
u) polybutylene terephthalate (PBT),
v) styrene-acrylonitrile resin (SAN),
w) ethylene tetrafluoroethylene (ETFE),
x) vinyl,
y) methacrylate copolymers
z) foamed polymer.
In another embodiment, the filler comprises one or more of the following:
a) talc,
b) calcium carbonate,
c) mica,
d) silica,
e) kaolin,
f) calcium sulphate,
g) magnesium hydroxide
h) stabilizers
i) dolomite.
In another embodiment, the reinforcement comprises one or more non-conductive
natural or synthetic fibres.
In another embodiment, the reinforcement comprises one or more of the following:
a) glass fibres,
b) glass beads,
c) glass flakes,
d) flax,
e) cellulose,
f) wood fibres,
g) wood flour,
h) cotton,
i) sawdust,
j) inorganic fibres,
k) polymer fibres,
l) polymer scrim,
m) polymer knit,
n) polymer weave,
o) aramids,
p) ceramics.
In another embodiment, the layer further comprises one or more of the following:
a) colorants (including but not limited to carbon black, titanium dioxide)
b) flame retardants (including but not limited to magnesium hydroxide, aluminum
trihydrate)
e) stabilizers (including but not limited to UV light stabilizers such as hindered
amine light stabilizers (HALS), and thermal stabilizers such as phenolics),
f) foaming agents (including but not limited to exothermic, endothermic or gas
foaming agents),
g) lubricants
h) biocides (including but not limited to particles of silver, including nano-sized
silver particles).
In another embodiment, as a percentage of the total weight of the layer so formed, the
filler and/or reinforcement is about 40%, 41%, 42%, 43%, 44%, 45%, 46%, 47%, 48%,
49%, 50%, 51%, 52%, 53%, 54%, 55%, 56%, 57%, 58%, 59%, 60%, 61%, 62%,
63%, 64%, 65%, 66%, 67%, 68%, 69%, 70%, 71%, 72%, 73%, 74%, 75%, 76%,
77%, 78%, 79%, 80%, 81%, 82%, 83%, 84%, 85%, 86%, 87%, 88%, 89%, 90%,
91%, 92%, 93%, 94%, 95 % or may be numerical values between each of these.
In another embodiment, the layer comprises at least about 65% w/w filler and/or
reinforcement, or at least about 70%, or at least about 75%, or at least about 80%, or
at least about 85%, or at least about 90% w/w filler and/or reinforcement.
In another embodiment, the layer comprises about 5% to about 25% w/w reinforcement,
or about 5% to about 20%, or about 2% to about 15%, or about 2% to about 12%, or
about 2% to about 10%, 2% to about 8%, or about 2% to about 5%.
In another embodiment, as a percentage of the total weight of the layer so formed, the
reinforcement is about 1%, 2%, 3%, 4%, 5%, 6%, 7%, 8%, 9%, 10%, 11%, 12%,
13%, 14%, 15%, 16%, 17%, 18%, 19%, 20%, 21%, 22%, 23%, 24%, 25%, 26%,
27%, 28%, 29%, 30% or may be numerical values between each of these.
In another embodiment, the layer comprises at least about 10%, or at least about 15%
or at least about 20%, or at least about 25% w/w reinforcement.
In another embodiment, the layer comprises up to about 30%, or up to about 25%, or
up to about 20%, or up to about 15%, or up to about 10% w/w reinforcement.
In another embodiment, the layer comprises at least about 55% filler and at least about
% reinforcement, or at least about 60% filler and at least about 5% reinforcement, or
at least about 65% filler and at least about 5% reinforcement, or at least about 70%
filler and at least about 5% reinforcement, or at least about 75% filler and at least about
5% reinforcement, or at least about 80% filler and at least about 5% reinforcement, or
at least about 85% filler and at least about 5% reinforcement, or at least about 90%
filler and at least about 5% reinforcement, or may be numerical values between each of
these.
In another embodiment, the layer comprises at least about 55% filler and at least about
10% reinforcement, or at least about 60% filler and at least about 10% reinforcement, or
at least about 65% filler and at least about 10% reinforcement, or at least about 70%
filler and at least about 10% reinforcement, or at least about 75% filler and at least
about 10% reinforcement, or at least about 80% filler and at least about 10%
reinforcement, or at least about 85% filler and at least about 10% reinforcement, or may
be numerical values between each of these.
In another embodiment, the layer comprises at least about 55% filler and at least about
% reinforcement, or at least about 65% filler and at least about 15% reinforcement, or
at least about 70% filler and at least about 15% reinforcement, or at least about 75%
filler and at least about 15%reinforcement, or at least 80% filler and at least about 15%
reinforcement, or may be numerical values between each of these.
In another embodiment, the layer comprises at least about 61% filler and at least about
% reinforcement, or at least about 65% filler and at least about 20% reinforcement, or
at least about 70% filler and at least about 20% reinforcement, or at least about 75%
filler and at least about 20% reinforcement, or may be numerical values between each of
these.
In another embodiment, the layer comprises at least about 61% filler and at least about
% reinforcement, or at least about 65% filler and at least about 25% reinforcement, or
at least about 70% filler and at least about 25% reinforcement, or may be numerical
values between each of these.
In another embodiment, the filler comprises calcium carbonate.
In another embodiment, the reinforcement comprises or consists of glass fibres.
In another embodiment, at least a portion of a top surface of the exposed region
comprise(s) three dimensional surface features, whether as surface relief or surface
texturing.
In another embodiment, said portion comprises surface features resembling one of:
a) asphalt shingle,
b) slate,
c) shingles,
d) shakes,
e) concrete tiles,
f) stone chips,
g) weatherboard,
h) thatch,
i) stone,
j) woodgrain,
k) metal (including but not limited to copper tiles or roofing shingles).
In another embodiment, the surface features are, at least in part, due to coloring,
patterning, surface cracking or polymer fracturing or other two-dimensional or three-
dimensional ornamentation of said portion.
In another embodiment, the surface features further comprise three-dimensional
features including one or more of:
a) surface texturing,
b) surface relief,
c) other three-dimensional pattern or ornamentation configured or arranged to
simulate a natural or manufactured material.
In another embodiment, each of the formed surfaces comprises said surface features.
In another embodiment, the roofing, cladding, or siding module further comprises a
plurality of formed surfaces, wherein each of the formed surfaces comprises said surface
features, and wherein the formed surfaces are joined without weld lines, attachments or
injection molding points.
In another embodiment, each formed surface is a molded segment along the length of
the module.
In another embodiment, each formed surface comprises an underlapping region and an
exposed region, wherein the underlapping region is adapted to be substantially covered
by the exposed region of an adjacent or overlapping module when installed on a building
surface.
In another embodiment, each formed surface resembles an individual tile or shingle or
slate or shake within the module.
In another embodiment, each formed surface resembles a set of tiles or shingles or
slates or shakes within the module.
In another embodiment, the module is subsequently sectioned (or divided or partitioned)
to provide a plurality of smaller module sections for installation onto a building surface.
In another embodiment, each smaller module section resembles an individual tile or
shingle or slate or shake.
In another embodiment, each smaller module section resembles a set, or one or more of,
said tiles or shingles or slates or shakes within the section.
In another embodiment, said underlapping region is formed of at least one of said layers
so formed of a said extruded material.
In another embodiment, the module comprises a single layer so formed of a said
extruded material.
In another embodiment, said layer so formed of a said extruded material is provided as a
base or bottom layer of the module, and the module further comprises one or more
additional upper layers provided as further layers upon said base or bottom layer.
In another embodiment, said one or more upper layer(s) is formed of an extruded
material, said one or more upper layer(s) comprising a different weight percentage of
filler and/or reinforcement relative to the base or bottom layer.
In another embodiment, the module comprises of at least three layers, at least one of
said layers formed of said extruded material, alternatively two or more of said layers so
formed are of a said extruded material, alternatively three or more of said layers so
formed are of a said extruded material, alternatively all of the layers of said module are
so formed of a said extruded material, whether the layers of the same or different make-
up of filler and/or reinforcement, and said one or more polymers.
In another embodiment, the module comprises a base layer, an intermediate layer and a
top layer, the intermediate layer and the top layer being upper layers to a base or
bottom layer of the module.
In another embodiment, layers are co-extruded to form the or at least a part of said
module.
In another embodiment, layers are joined together in a continuous forming process to
form the or at least a part of said module.
In another embodiment, the substantially an entire module is formed by arrangement
together of said layer(s) of extruded material.
In another embodiment, the module is at least about 0.5 m long.
In another embodiment, the module is at least about 36 inches long.
In another embodiment, the module is at least about 1 m long, or at least about 1.5 m
long, or at least about 2 m long, or at least about 2.5 m long, or at least 3 m long.
In another embodiment, the module is about 0.3 mm or about 12 inches wide.
In another embodiment, the module is about 0.5 m wide, or is about 0.8 m wide, or is
about 1 m wide.
In another embodiment, at least one layer, such as a base or bottom layer of said
module, has a coefficient of thermal expansion of less than about 30 · 10 m/(m K).
In another embodiment, the coefficient of thermal expansion of the module is less than
about 30 · 10 m/(m K).
In another embodiment, at least a portion of the module comprises a top layer (or an
upper layer or a plurality of upper layers forming a said top layer), a base or bottom
layer (or a lower layer or a plurality of lower layers forming a said base or bottom layer),
and an intermediate layer (or a plurality of layers forming a said intermediate layer)
between the top and base or bottom layers.
In another embodiment, one or more property/properties of one or more of said top
layer, intermediate layer and base or bottom layer varies along the length and/or width
of the layer.
In another embodiment, one or more property/properties of said top layer is/are different
from corresponding one or more property/properties of said intermediate layer and/or
base or bottom layer(s).
In another embodiment, one or more property/properties said intermediate layer is/are
different from corresponding one or more property/properties of said top layer and/or
base or bottom layer(s).
In another embodiment, one or more property/properties said base or bottom layer
is/are different from corresponding one or more property/properties of said top layer
and/or intermediate layer(s).
In another embodiment, said property/properties comprise(s) one or more of:
a) thickness,
b) surface area
c) tensile strength
d) shear strength
e) resilience
f) elasticity
g) flexibility
h) toughness
i) fire resistance
j) water resistance
k) continuity or uniformity
l) impact resistance
m) resistance to pull through
n) fixing capability
o) chemical resistance
p) puncture resistance
q) content of filler and/or reinforcement
r) concentration of filler and/or reinforcement,
s) color
t) microbial resistance
u) temperature resistance
v) light/heat absorption/reflectivity,
w) thermal transfer.
In another embodiment, a layer extends across at least a part of the width and/or at
least a part of the length of the module to provide for a variation to one or more
properties to the module so formed by the at least one layer, the properties selected
from one or more of those properties listed above.
In another embodiment, the intermediate layer is a reinforcing layer.
In another embodiment, the intermediate layer is one or more of:
a) a film,
b) a sheet,
c) a mesh,
d) a scrim,
e) a weave,
f) a fibre,
g) a fabric,
h) a wire,
i) a string,
j) a web.
In another embodiment, the intermediate reinforcing layer provides for one or more of:
a) resistance against shrinkage,
b) resistance against warping,
c) resistance against tearing,
d) increased toughness,
e) prevention against unwanted deflections of the module,
f) weather resistance,
g) resistance against delamination of the layers,
h) reduced flammability,
i) water resistance,
j) impact resistance,
k) resistance to pull through,
l) fixing capability,
m) chemical resistance,
n) puncture resistance,
o) sealing
p) shape memory
q) adhesive/gluing/bonding capability.
In another embodiment, the intermediate layer is chemically and/or mechanically
bonded, welded, fused, co-extruded and/or connected to the top layer and/or the base or
bottom layer.
In another embodiment, the intermediate layer comprises one or more surface
treatment(s).
In another embodiment, the intermediate layer is both chemically and mechanically
bonded, welded, fused, co-extruded and/or connected to the top layer and/or the base or
bottom layer.
In another embodiment, the intermediate layer comprises one or more of the following
three-dimensional surface features to increase or improve the mechanical bond or
connection with the top and/or base or bottom layers:
a) surface texturing,
b) surface roughness,
c) projections,
d) corrugations,
e) reinforcements,
f) chemical coating(s),
g) protrusions,
h) apertures,
i) perforations.
In another embodiment, the intermediate layer, when being joined to the top and base or
bottom layers, is in a molten or semi-molten or cold but pliable state.
In another embodiment, the module is shaped and/or contoured during the joining or
lamination process, while the intermediate layer is in a molten or semi-molten or cold but
pliable state or a formable or moldable condition.
In another embodiment, the top and base or bottom layers substantially thermally
insulate the intermediate layer, so that the intermediate layer remains, or maintains the
condition of being, molten or semi-molten or pliable during the forming process.
In another embodiment, the module is shaped and/or contoured via a casting,
thermoforming, pressing or other forming process, whether continuous or discontinuous.
In another embodiment, the property/properties of the intermediate layer is/are varied
by deforming the layer when in said molten or semi-molten or cold but pliable state or
formable or moldable condition.
In another embodiment, all three layers are in a molten or semi-molten or cold but
pliable state or formable or moldable condition when joined together.
In another embodiment, the material for each of the layers is chosen to have a melt flow
index and/or heat capacity sufficiently high such that the layers remain molten or semi-
molten or pliable while the module is formed.
In another embodiment, the layers are processed at a sufficiently high temperature such
that the layers remain molten or semi-molten or pliable while the module is formed.
In another embodiment, the intermediate layer provides a substantially water or liquid
resistant barrier, or a water or liquid impermeable barrier between the top and base or
bottom layers.
In another embodiment, the top layer and/or base or bottom layer is porous.
In another embodiment, the top layer and/or base or bottom layer is porous due to
fracturing of said layer to provide surface ornamentation.
In another embodiment, at least the top layer comprises sections of non-homogenous
and/or non-compatible materials, and wherein the intermediate layer provides a binder
layer for binding said non-homogenous and/or non-compatible sections to the
intermediate layer.
In another embodiment, the top layer comprises a plurality of discontinuous sections
formed of different materials, the materials being non-homogenous or non-compatible
with each other, and wherein the discontinuous sections are bound to each other via the
intermediate layer.
In another embodiment, at least the top layer has a relatively high UV resistance.
In another embodiment, the module is configured to withstand cyclical variations in
temperature of about -40 to about 100 degrees Celsius.
In another embodiment, the layers are joined together to form the module in a batch or
continuous forming process.
In another embodiment, the layers are formed and joined together in a batch or
continuous forming process.
In another embodiment, the layers are extruded in series from two or more (or
preferably three) serially arranged extruders.
In another embodiment, one or more of the top, intermediate and base or bottom layers
is/are molded by thermoforming, pressing or other method of forming.
In another embodiment, said one or more property/properties of the intermediate layer
is/are optimized preferentially along the direction of the length of the module.
In another embodiment, said one or more property/properties of the intermediate layer
is/are optimized preferentially along the direction of the width of the module.
In another embodiment, said portion of the module, comprising the top layer,
intermediate layer and base or bottom layer, corresponds to the exposed region.
In another embodiment, said portion of the module, comprising the top layer,
intermediate layer and base bottom layer, corresponds to the underlapping region.
In another embodiment, the intermediate layer extends from at or adjacent the foot
edge, to at or adjacent the underlapping region of the module.
In another embodiment, the roofing, cladding, or siding module further comprises a
fastening region adapted to receive one or more fasteners for fixing the module to the or
a building surface, preferably the fastening region including a visual guide or boundary
markers to allow visual identification of said fastening region.
In another embodiment, the fastening region is substantially adjacent the exposed region
and within the underlapping region.
In another embodiment, said portion of the module, comprising the top layer,
intermediate layer and base or bottom layer, corresponds to the fastening region.
In another embodiment, said portion of the module, comprising the top layer,
intermediate layer and base or bottom layer, corresponds to the exposed region and the
fastening region.
In another embodiment, the intermediate layer extends from at or adjacent the foot
edge, to within or beyond the fastening region of the module.
In another embodiment, said one or more property/properties of the intermediate layer
is/are optimized preferentially within the fastening region.
In another embodiment, the intermediate layer is thicker or comprises thickened regions
or other 3-dimensional qualities within the fastening region of the module, preferably the
thicker or thickened or other 3-dimensional qualities of the intermediate layer provide for
a fastening region capable of retaining a fastener penetrating or pulling through the
fastening region or resisting tear of the module by shear force applied to the module or
each of the said layers by the fastener.
In another embodiment, the pull through force is at least about 90 N, preferably at least
about 100 N.
In another embodiment, said one or more property/properties of the intermediate layer
is/are optimized preferentially within the exposed region and fastening region.
In another embodiment, the roofing, cladding, or siding module comprises more than one
intermediate layer.
In another embodiment, the roofing, cladding, or siding module comprises discrete
intermediate layers in different regions of the module.
In another embodiment, the roofing, cladding, or siding module comprises different
intermediate layers in different regions of the module.
In another embodiment, the roofing, cladding, or siding module comprises multiple
intermediate layers in one or more regions of the module.
In another embodiment, the top layer is about 0.1 mm to about 50 mm thick.
In another embodiment, the top layer is about 0.1 mm to about 10 mm thick.
Preferably, the top layer is about 0.05, 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9 mm
thick, or may be numerical values between each of these.
In another embodiment, the intermediate layer is about 0.01 mm to about 10 mm thick.
Preferably, the intermediate layer is about 0.05, 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8,
0.9, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5, 8, 8.5, 9, or 9.5 mm thick, or
may be numerical values between each of these.
In another embodiment, the bottom layer is about 0.1 mm to about 50 mm thick.
In another embodiment, the bottom layer is about 0.1 mm to about 10 mm thick.
Preferably, the bottom layer is about 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9 mm thick, or may be
numerical values between each of these.
In another embodiment, each or all of the layers comprise(s) one or more crystalline
polymer(s).
In another embodiment, each or all of the layers comprise(s) one or more amorphous
polymer(s).
In another embodiment, the top and bottom layers are made of, or comprise, one or
more polymer(s) having a higher degree of crystallinity compared to one or more
polymer(s) of the intermediate layer.
In another embodiment, the top and bottom layers are made of, or comprise, one or
more polymer(s) having a lower degree of crystallinity compared to one or more
polymer(s) of the intermediate layer.
In another embodiment, the top and/or bottom layer is made of, or comprises,
thermoplastic polyolefin (TPO).
In another embodiment, the intermediate layer is made of, or comprises, homopolymer
or copolymer polypropylene (PP).
In another embodiment, the bottom layer and/or intermediate layer is/are foamed.
In another embodiment, the module is post-treated after being formed.
In another embodiment, the post-treatment may comprise one or more of:
a) shaping,
b) folding,
c) coloring,
d) corrugating,
e) adding surface treatment(s),
f) perforating,
g) laminating,
h) coating.
In another embodiment, the module, once formed, is shaped and/or cut and/or folded
into:
a) a ridge tile,
b) a hip tile,
c) a barge tile,
d) an apex tile,
e) other shape such as a corrugated tile.
In another embodiment, the under surface (e.g. a surface of the module to be placed
substantially adjacent to or facing of the building surface upon which the module is to be
fastened) of the module is substantially flat.
In another embodiment, the under surface of at least the exposed region of the module
comprises a plurality of projections.
In another embodiment, the projections provide surfaces for adhering the exposed region
of the module to the top surface of the underlapping region of an adjacent or overlapping
module when installed.
In another embodiment, the projections provide reinforcement for the module.
In another embodiment, the projections are pre-formed or post-formed from the same
material as the under surface of the module.
In another embodiment, the projections are formed from a different material compared
to the under surface of the module and incorporated into the module before, during or
after forming the module.
In another embodiment, the projections comprise surface features on a bottom surface.
In another embodiment, the surface features are one or more of:
a) corrugations,
b) serrations,
c) projections,
d) ribs,
e) nodes,
f) surface roughness.
In another embodiment, the projections comprise one or more continuous or
discontinuous longitudinal ribs extending along the length of the module.
In another embodiment, the projections comprise one or more continuous or
discontinuous transverse ribs extending substantially perpendicular to the length of the
module.
In another embodiment, the roofing, cladding, or siding module comprises a plurality of
longitudinal ribs spaced between 1 and 1000 mm apart from each other.
In another embodiment, the roofing, cladding, or siding module comprises a plurality of
longitudinal ribs spaced about 1 mm to about 50 mm apart from each other and
extending substantially parallel to each other.
In another embodiment, the height of the, or each, longitudinal rib is about 1 mm to
about 100 mm.
In another embodiment, the height of the, or each, longitudinal rib is about 1 mm to
about 10 mm.
In another embodiment, the width of the, or each, longitudinal rib is about 1 to about
1000 mm.
In another embodiment, the width of the, or each, longitudinal rib is about 1mm to
about 10 mm.
In another embodiment, the transverse ribs extend from at, or adjacent, the foot edge
to, at, or adjacent, the underlapping region.
In another embodiment, the transverse ribs are spaced about 1 mm to about 100 mm
apart from each other.
In another embodiment, the transverse ribs are spaced about 1 mm to about 10 mm
apart from each other and extend substantially parallel to each other.
In another embodiment, the height of the transverse ribs tapers from at or adjacent the
foot edge to, at, or adjacent, the underlapping region.
In another embodiment, the width of each transverse rib is about 1 mm to about about
1000 mm.
In another embodiment, the width of each transverse rib is about 1 mm to about 10 mm.
In another embodiment, the projections comprise a plurality of longitudinal ribs and a
plurality of transverse ribs extending substantially perpendicular to the ribs.
In another embodiment, the roofing, cladding, or siding module further comprises one or
more continuous or discontinuous strips of adhesive on the top surface of the
underlapping region of the module (optionally which may be exposed upon removal of a
release sheet), configured to contact projections on the under surface of the exposed
region of an adjacent or overlapping module when installed.
In another embodiment, the roofing, cladding, or siding module further comprises one or
more continuous or discontinuous strips of adhesive on a bottom surface of the
projections (optionally which may be exposed upon removal of a release sheet),
configured to contact a top surface of an adjacent or underlapping module when
installed.
In another embodiment, the module is formed with a convex precamber perpendicular to
the length of the module, such that the exposed region is curved downwardly of the
underlapping region.
In another embodiment, the convex precamber applies a preload to said exposed region
of the module.
In another embodiment, the module is manufactured via a continuous forming process,
wherein each of the formed surfaces comprises three dimensional surface features,
wherein the formed surfaces are molded, discretely or otherwise, along the
length of the module,
wherein the process comprises providing to a continuous forming machine a feed
material able to assume and retain a form after being molded between a first forming
surface and a second forming surface,
wherein at least the first forming surface comprises a plurality of die faces
provided in sequence and configured to mold the three dimensional surface features,
wherein each of said formed surfaces is molded by a die face, and
wherein the number of die faces is offset from the number of formed surfaces in
said module.
In another embodiment, there is a greater number of die faces compared to the number
of formed surfaces in said module.
In another embodiment, there are fewer die faces compared to the number of formed
surfaces in said module.
In another embodiment, there is one excess die face provided along said first forming
surface compared to the number of formed surfaces in said module.
In another embodiment, said one excess die face molds the first formed surface of a next
module in the continuous forming process.
In another embodiment, each formed surface has three dimensional surface features
which are different from the surface features of adjacent formed surfaces.
In another embodiment, each of the formed surfaces within the module has three
dimensional surface features which are different from the surface features of any other
formed surface within the module.
In another embodiment, the offset number of die faces provides for the module to be
formed with a series of formed surfaces which are arranged in a non-identical manner to
the series of formed surfaces on at least a previously formed module and/or on a module
to be subsequently formed in the continuous forming process.
In another embodiment, the offset number of die faces provides for each module to be
formed with a series of formed surfaces which are arranged in a non-identical manner to
the series of formed surfaces on a plurality of previously formed modules and on a
plurality of modules to be subsequently formed.
In another embodiment, the module comprises seven formed surfaces, and said first
forming surface comprises eight die faces.
In another embodiment, each die face may be rotated in place to provide for a different
orientation of three dimensional surface features on the formed surface to be molded.
In another embodiment, each die face may be swapped with another die face along said
first forming surface.
In another embodiment, at least the or a portion of the top surface of the exposed region
is colored or treated in a manner so as to yield a visually observable color, by applying a
colored material onto at least a portion of the top surface of the top layer before joining
the layers together.
In another embodiment, at least the or a portion of the top surface of the exposed region
is colored by applying a colored material onto at least a portion of the top surface of the
top layer while the layers are being joined together.
In another embodiment, at least the or a portion of the top surface of the exposed region
is colored by applying a colored material onto at least a portion of the top surface of the
top layer after the layers have been joined together.
In another embodiment, the colored material once applied to at least a portion of the top
surface may form at least a further additional layer of material upon the module. In some
examples, the colored material comprises a polymer (or a polymer comprises a colored
material) which is then applied to a surface of a layer so formed as a part of the module,
and forms an additional layer of the module. For example, the colored material may
comprise of a material which may melt when put into contact with the top surface (or
may be melted by application of heat or by a thermal transfer process), and the colored
material becomes an additional layer of the module. The colored material may become
fused or melted into the top surface of the layer to which the colored material is applied,
thereby forming a part of the layer to which it was applied.
In another embodiment, the module is formed by molding, and at least a portion of a top
surface of the module is a colored and/or decorated and/or textured by applying a
colored material onto at least a portion of the top surface of a precursor of the module,
wherein the colored material is applied before and/or during and/or after the molding
process.
In another embodiment, the precursor is molded between a first forming surface and a
second forming surface to form the module, and the colored material is applied to at
least a portion of the first forming surface, wherein the colored material is transferred to
said portion of the precursor during the molding step.
In another embodiment, the first forming surface comprises at least one die face
configured to mold surface features onto at least a portion of a top surface of the
module, wherein the colored material is applied to at least a portion of said die face prior
to the molding step.
In another embodiment, the colored material is applied directly or indirectly to the
precursor and/or the forming surface by one or more of:
a) stamping,
b) injecting,
c) embossing,
d) spraying,
e) rolling,
f) feeding,
g) brushing,
h) melting,
i) immersing,
j) dipping,
k) sprinkling,
l) depositing,
m) by drawing or suctioning the colored material onto the precursor and/or forming
surface using a vacuum system.
In another embodiment, at least a portion of the module comprises a plurality of layers,
and the colored material is applied to at least a portion of the top surface of the top-most
layer prior to or during a step of joining of the layers to form the module.
In another embodiment, at least the top-most layer is extruded, and the colored material
is applied to said portion of the upper surface of the layer as the layer emerges from the
extrusion die or an extruder.
In another embodiment, the colored material comprises a powder and/or a fluid capable
of being dispersed upon at least the or a portion of the top surface of the exposed region,
whether the application is direct or indirect to the surface or whether a die face is used to
convey the colored material to the surface.
In another embodiment, the colored material comprises charged particles configured to
be attracted to said portion of the top surface of said precursor and/or said first forming
surface and/or said second forming surface.
In another embodiment, the colored material comprises charged particles configured to
be ejected from a source of such charged particles onto the top surface of the precursor
and/or said first forming surface and/or said second forming surface.
In another embodiment, the colored material comprises an adhesive for attaching to said
portion of the top surface of said precursor and/or said first forming surface and/or said
second forming surface.
In another embodiment, the colored material is applied through a stencil and/or mask, to
selectively color one or more portions of said top surface of the precursor and/or said
first forming surface and/or said second forming surface.
In another embodiment, the colored material is applied to the module in multiple
application steps, being one or more of:
a) applying a different colored material to said portion of the precursor,
b) applying a colored material to a different portion of said precursor
c) applying a colored material through a different stencil or mask.
In another embodiment, the colored material comprises a plurality of components, the
components having different melt flow indices.
In another embodiment, the module has at least one surface colored and/or decorated
and/or textured by the colored material to resemble one of:
a) asphalt shingles,
b) slate,
c) shingles,
d) shakes,
e) concrete tiles,
f) stone chips,
g) weatherboard,
h) thatch,
i) stone,
j) woodgrain,
k) metal.
In another embodiment, at least a portion of a top surface of the module is a colored
and/or decorated and/or textured by applying a colored material onto at least a portion
of the top surface of the module after the module has been formed by a
molding/joining/laminating process.
In another embodiment, the module may comprise further features as described in any
one of the following described aspects or embodiments.
In a second described aspect, there is provided a roofing, cladding, or siding module,
comprising:
an underlapping region extending from a head edge of the module and an
exposed region extending from a foot edge of the module, the length of the foot edge
defining the length of the module,
wherein the underlapping region is adapted to be substantially covered by the
exposed region of an adjacent or overlapping module when installed on a building
surface, and
wherein at least a portion of the module comprises a top layer (or an upper layer
or a plurality of upper layers forming a said top layer), a bottom layer (or a lower layer
or a plurality of lower layers forming a said bottom layer), and an intermediate layer (or
a plurality of layers forming a said intermediate layer) between the top and bottom
layers, and
wherein one or more property/properties of the intermediate layer varies along
the length and/or width of the layer.
In one embodiment, said property/properties comprise(s) one or more of:
a) thickness,
b) surface area
c) tensile strength
d) shear strength
e) resilience
f) elasticity
g) flexibility
h) toughness
i) fire resistance
j) water resistance
k) continuity or uniformity
l) impact resistance
m) resistance to pull through
n) fixing capability
o) chemical resistance
p) puncture resistance
q) content of filler and/or reinforcement
r) concentration of filler and/or reinforcement
s) color
t) microbial resistance
u) temperature resistance
v) light/heat absorption/reflectivity,
w) thermal transfer
x) shape memory.
In another embodiment, the intermediate layer is a reinforcing layer.
In another embodiment, the intermediate layer is one or more of:
k) a film,
l) a sheet,
m) a mesh,
n) a scrim,
o) a weave,
p) a fibre,
q) a fabric,
r) a wire,
s) a string,
t) a web.
In another embodiment, the intermediate reinforcing layer provides for one or more of:
a) resistance against shrinkage,
b) resistance against warping,
c) resistance against tearing,
d) increased toughness,
e) prevention against unwanted deflections of the module,
f) weather resistance,
g) resistance against delamination of the layers,
h) reduced flammability,
i) water resistance,
j) impact resistance,
k) resistance to pull through,
l) fixing capability,
m) chemical resistance,
n) puncture resistance,
o) sealing
p) shape memory
q) adhesive/gluing/bonding capability.
In another embodiment, the intermediate layer is chemically and/or mechanically
bonded, welded, fused, co-extruded and/or connected to the top layer and/or the bottom
layer.
In another embodiment, the intermediate layer comprises one or more surface
treatment(s), optionally to increase one or more physical properties of the layer (e.g.,
adhesive capability).
In another embodiment, the intermediate layer is both chemically and mechanically
bonded, welded, fused, co-extruded and/or connected to the top layer and/or the bottom
layer.
In another embodiment, the intermediate layer comprises one or more of the following
three-dimensional surface features to increase the mechanical bond or connection with
the top and/or bottom layers:
a) surface texturing,
b) surface roughness,
c) projections,
d) corrugations,
e) reinforcements,
f) chemical coating(s),
g) protrusions,
h) apertures,
i) perforations.
In another embodiment, the intermediate layer, when being joined to the top and bottom
layers, is in a molten or semi-molten or cold but pliable state.
In another embodiment, the module is shaped and/or contoured during the joining or
lamination process, while the intermediate layer is in a molten or semi-molten or cold but
pliable state or a formable or moldable condition.
In another embodiment, the module is shaped and/or contoured via a casting,
thermoforming, pressing or other forming process, whether continuous or discontinuous.
In another embodiment, the property/properties of the intermediate layer is/are varied
by deforming the layer when in said molten or semi-molten or cold but pliable state or
formable or moldable condition.
In another embodiment, all three layers are in a molten or semi-molten or cold but
pliable state or formable or moldable condition when joined together.
In another embodiment, the material for each of the layers is chosen to have a melt flow
index and/or heat capacity sufficiently high such that the layers remain molten or semi-
molten or pliable while the module is formed.
In another embodiment, the layers are processed at a sufficiently high temperature such
that the layers remain molten or semi-molten or pliable while the module is formed.
In another embodiment, the layers are joined together to form the module in a batch or
continuous forming process.
In another embodiment, the layers are formed and joined together in a batch or
continuous forming process.
In another embodiment, one or more of the top, intermediate and bottom layers is/are
extruded.
In another embodiment, the layers are co-extruded.
In another embodiment, the layers are extruded in series from two or more (or
preferably three) serially arranged extruders.
In another embodiment, one or more of the top, intermediate and bottom layers is/are
molded by thermoforming, pressing or other method of forming.
In another embodiment, said one or more property/properties of the intermediate layer
is/are optimized preferentially along the direction of the length of the module.
In another embodiment, said one or more property/properties of the intermediate layer
is/are optimized preferentially along the direction of the width of the module.
In another embodiment, said portion of the module, comprising the top layer,
intermediate layer and bottom layer, corresponds to the exposed region.
In another embodiment, said portion of the module, comprising the top layer,
intermediate layer and bottom layer, corresponds to the underlapping region.
In another embodiment, the intermediate layer extends from at or adjacent the foot
edge, to at or adjacent the underlapping region of the module.
In another embodiment, the roofing, cladding, or siding module further comprises a
fastening region adapted to receive one or more fasteners for fixing the module to the
building surface, preferably the fastening region including a visual guide or boundary
markers to allow visual identification of said fastening region.
In another embodiment, the fastening region is substantially adjacent the exposed region
and within the underlapping region.
In another embodiment, said portion of the module, comprising the top layer,
intermediate layer and bottom layer, corresponds to the fastening region.
In another embodiment, said portion of the module, comprising the top layer,
intermediate layer and bottom layer, corresponds to the exposed region and the
fastening region.
In another embodiment, the intermediate layer extends from at or adjacent the foot
edge, to within or beyond the fastening region of the module.
In another embodiment, said one or more property/properties of the intermediate layer
is/are optimized preferentially within the fastening region.
In another embodiment, the intermediate layer is thicker or comprises thickened regions
or other 3-dimensional qualities within the fastening region of the module, preferably the
thicker or thickened or other 3-dimensional qualities of the intermediate layer provide for
a fastening region capable of retaining a fastener penetrating or pulling through the
fastening region or resisting tear of the module by shear force applied to the module or
each of the said layers by the fastener.
In another embodiment, the pull through force is at least about 90 N, preferably at least
about 100 N.
In another embodiment, said one or more property/properties of the intermediate layer
is/are optimized preferentially within the exposed region and fastening region.
In another embodiment, the roofing, cladding, or siding module comprises more than one
intermediate layer.
In another embodiment, the roofing, cladding, or siding module comprises discrete
intermediate layers in different regions of the module.
In another embodiment, the roofing, cladding, or siding module comprises different
intermediate layers in different regions of the module.
In another embodiment, the roofing, cladding, or siding module comprises multiple
intermediate layers in one or more regions of the module.
In another embodiment, the top layer is about 0.1 to about 50 mm thick. In another
embodiment, the top layer is about 0.1 to about 10 mm thick. Preferably, the top layer is
about 0.05, 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8, 0.9 mm thick, or may be numerical
values between each of these.
In another embodiment, the intermediate layer is about 0.01 to about 10 mm thick.
Preferably, the intermediate layer is about 0.05, 0.1, 0.2, 0.3, 0.4, 0.5, 0.6, 0.7, 0.8,
0.9, 1, 1.5, 2, 2.5, 3, 3.5, 4, 4.5, 5, 5.5, 6, 6.5, 7, 7.5, 8, 8.5, 9, or 9.5 mm thick, or
may be numerical values between each of these.
In another embodiment, the bottom layer is about 0.1 to about 50 mm thick In another
embodiment, the bottom layer is about 0.1 to about 10 mm thick. Preferably, the bottom
layer is about 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9 mm thick, or may be numerical values between
each of these.
In another embodiment, each or all of the layers comprise(s) one or more crystalline
polymer(s).
In another embodiment, each or all of the layers comprise(s) one or more amorphous
polymer(s).
In another embodiment, the top and bottom layers are made of, or comprise, one or
more polymer(s) having a higher degree of crystallinity compared to one or more
polymer(s) of the intermediate layer.
In another embodiment, the top and bottom layers are made of, or comprise, one or
more polymer(s) having a lower degree of crystallinity compared to one or more
polymer(s) of the intermediate layer.
In another embodiment, one or more of the top layer, intermediate layer and bottom
layer is/are made of, or comprise, one or more of the following:
a) polystyrene (GPPS),
b) polyethylene terephthalate (PET),
c) polyester methacrylate (PEM),
d) high impact polystyrene (HIPS),
e) acrylonitrile butadiene styrene (ABS),
f) polyvinyl chloride (PVC),
g) polyurethanes (PU),
h) polyethylene (PE) including homopolymer, copolymer, block copolymer and
terpolymer forms,
i) polylactic acid (PLA),
j) nylon (PA),
k) acrylics (PMMA),
l) high density polyethylene (HDPE),
m) low density polyethylene (LDPE),
n) linear low density polyethylene (LLDPE),
o) medium density polyethylene (MDPE),
p) cross linked polyethylene (PEX),
q) thermoplastic elastomer (TPE),
r) thermoplastic polyolefin (TPO),
s) thermoplastic rubber (TPR),
t) polypropylene (PP), including homopolymer and copolymer forms,
u) polybutylene terephthalate (PBT),
v) styrene-acrylonitrile resin (SAN),
w) ethylene tetrafluoroethylene (ETFE),
x) vinyl,
y) methacrylate copolymers
z) foamed polymer.
In another embodiment, the top and/or bottom layer is made of, or comprises,
thermoplastic polyolefin (TPO).
In another embodiment, the intermediate layer is made of, or comprises, homopolymer
or copolymer polypropylene (PP).
In another embodiment, the bottom layer and/or intermediate layer is/are foamed.
In another embodiment, one or more of the top, intermediate and bottom layers
comprise(s) three dimensional surface features, whether as surface relief or surface
texturing.
In another embodiment, at least the exposed region of the top layer comprises surface
features resembling one of:
a) asphalt shingle,
b) slate,
c) shingles,
d) shakes,
e) concrete tiles,
f) stone chips,
g) weatherboard,
h) thatch,
i) stone,
j) woodgrain,
k) metal.
In another embodiment, the surface features are, at least in part, due to coloring,
patterning, surface cracking or polymer fracturing or other two-dimensional or three-
dimensional ornamentation of said region.
In another embodiment, the surface features further comprise three-dimensional
features including one or more of:
a) surface texturing,
b) surface relief,
c) other three-dimensional pattern or ornamentation configured or arranged to
simulate a natural or manufactured material.
In another embodiment, the roofing, cladding, or siding module further comprises a
plurality of formed surfaces, wherein each of the formed surfaces comprises said surface
features, and wherein the formed surfaces are joined without weld lines, attachments or
injection molding points.
In another embodiment, each formed surface is a molded segment along the length of
the module.
In another embodiment, each formed surface comprises an underlapping region and an
exposed region, wherein the underlapping region is adapted to be substantially covered
by the exposed region of an adjacent or overlapping module when installed on a building
surface.
In another embodiment, each formed surface resembles an individual tile or shingle or
slate or shake within the module.
In another embodiment, each formed surface resembles a set of tiles or shingles or
slates or shakes within the module.
In another embodiment, the module is subsequently sectioned (or divided or partitioned)
to provide a plurality of smaller module sections for installation onto a building surface.
In another embodiment, each smaller module section resembles an individual tile or
shingle or slate or shake.
In another embodiment, each smaller module section resembles a set of tiles or shingles
or slates or shakes within the section.
In another embodiment, the module is post-treated after being formed.
In another embodiment, the post-treatment may comprise one or more of:
a) shaping,
b) folding,
c) coloring,
d) corrugating,
e) adding surface treatment(s),
f) perforating,
g) laminating,
h) coating.
In another embodiment, the module, once formed, is shaped and/or cut and/or folded
into:
a) a ridge tile,
b) a hip tile,
c) a barge tile,
d) an apex tile,
e) other shape such as a corrugated tile.
In another embodiment, the under surface of the module is substantially flat.
In another embodiment, the under surface of at least the exposed region of the module
comprises a plurality of projections.
In another embodiment, the projections provide surfaces for adhering the exposed region
of the module to the top surface of the underlapping region of an adjacent or overlapping
module when installed.
In another embodiment, the projections provide reinforcement for the module.
In another embodiment, the projections comprise one or more continuous or
discontinuous longitudinal ribs extending along the length of the module.
In another embodiment, the projections comprise one or more continuous or
discontinuous transverse ribs extending substantially perpendicular to the length of the
module.
In another embodiment, the projections are pre-formed or post-formed from the same
material as the under surface of the module.
In another embodiment, the projections are formed from a different material compared
to the under surface of the module and incorporated into the module before, during or
after forming the module.
In another embodiment, the projections comprise surface features on a bottom surface.
In another embodiment, the surface features are one or more of:
a) corrugations,
b) serrations,
c) projections,
d) ribs,
e) nodes,
f) surface roughness.
In another embodiment, the intermediate layer provides a substantially water or liquid
resistant barrier, or a water or liquid impermeable barrier between the top and bottom
layers.
In another embodiment, at least the top layer comprises sections of non-homogenous
and/or non-compatible materials, and wherein the intermediate layer provides a binder
layer for binding said non-homogenous and/or non-compatible sections to the
intermediate layer.
In another embodiment, the top layer comprises a plurality of discontinuous sections
formed of different materials, the materials being non-homogenous or non-compatible
with each other, and wherein the discontinuous sections are bound to each other via the
intermediate layer.
In another embodiment, one or more of the layers further comprises one or more
additives, such as, but not limited to, one or more of the following:
a) fillers (including but not limited to talc, calcium carbonate, mica, silica, kaolin,
calcium sulphate, magnesium hydroxide, stabilizers, dolomite)
b) colorants (including but not limited to carbon black, titanium dioxide)
c) reinforcements (including but not limited to glass fibres, glass beads, glass
flakes, natural fibres such as flax, cellulose, wood fibres, wood flour, cotton,
sawdust, and inorganic or polymer fibres, scrim, knits, weave, non-woven, aramids,
ceramics)
d) flame retardants (including but not limited to magnesium hydroxide, aluminum
trihydrate)
e) stabilizers (including but not limited to UV light stabilizers such as hindered
amine light stabilizers (HALS), and thermal stabilizers such as phenolics),
f) foaming agents (including but not limited to exothermic, endothermic or gas
foaming agents),
g) lubricants,
h) biocides (including but not limited to particles of silver, including nano-sized
silver particles).
In another embodiment, at least the top layer has a high UV resistance.
In another embodiment, the module is configured to withstand cyclical variations in
temperature between -40 and 100 degrees Celsius.
In another embodiment, at least the or a portion of the top surface of the exposed region
is colored or treated in a manner so as to yield a visually observable color, by applying a
colored material onto at least a portion of the top surface of the top layer before joining
the layers together.
In another embodiment, at least the or a portion of the top surface of the exposed region
is colored by applying a colored material onto at least a portion of the top surface of the
top layer while the layers are being joined together.
In another embodiment, at least the or a portion of the top surface of the exposed region
is colored by applying a colored material onto at least a portion of the top surface of the
top layer after the layers have been joined together.
In another embodiment, the module may comprise a layer of extruded material as
described in the first described aspect or associated embodiments.
In a third described aspect, there is provided a roofing, cladding, or siding module,
comprising:
an underlapping region extending from a head edge of the module and an exposed
region extending from a foot edge of the module,
wherein the underlapping region is adapted to be substantially covered by the
exposed region of an adjacent or overlapping module when installed on a building
surface,
wherein at least a portion of the module comprises a top layer, a bottom layer, and
an intermediate layer between the top and bottom layers, and
wherein the intermediate layer provides a substantially water or liquid resistant
barrier, or a water or liquid impermeable barrier between the top and bottom
layers.
In one embodiment, the top layer and/or bottom layer is porous.
In another embodiment, the top layer and/or bottom layer is porous due to fracturing of
said layer to provide surface ornamentation.
In another embodiment, the intermediate layer extends from at or adjacent the foot
edge, to at or adjacent the underlapping region of the module.
In another embodiment, the roofing, cladding, or siding module further comprises a
fastening region adapted to receive one or more fasteners for fixing the module to the
building surface.
In another embodiment, the fastening region is adjacent the exposed region and within
the underlapping region.
In another embodiment, the intermediate layer extends from at or adjacent the foot
edge, to beyond the fastening region of the module.
In another embodiment, the intermediate layer extends through and along at least the
exposed region of the module.
In another embodiment, the module may comprise further features as described in any
one of the preceding or following described aspects or embodiments.
In another embodiment, the module may comprise a layer of extruded material as
described in the first described aspect or associated embodiments.
In a fourth described aspect, there is provided a method of manufacture of a roofing,
cladding or siding module comprising a plurality of formed surfaces molded, discretely or
otherwise, along the length of the module, wherein each of the formed surfaces
comprises three dimensional surface features, the method comprising
providing to a continuous forming machine a feed material able to assume and
retain a form after being molded between a first forming surface and a second forming
surface,
wherein at least the first forming surface comprises a plurality of die faces
provided in sequence and configured to mold the three dimensional surface features,
each of said formed surfaces to be molded by a die face, and
wherein the number of die faces is either:
- offset from the number of formed surfaces in each module to be formed, or
- matches the number of formed surfaces in each module to be formed (for
example where the formed surfaces are to be of repeating or matching
surfaces).
In one embodiment, there is a greater number of die faces compared to the number of
formed surfaces in each module to be formed.
In another embodiment, there are fewer die faces compared to the number of formed
surfaces in each module to be formed.
In another embodiment, there is one excess die face provided along said first forming
surface compared to the number of formed surfaces in each module to be formed.
In another embodiment, said one excess die face molds the first formed surface of the
next module in a continuous forming process.
In another embodiment, each formed surface has three dimensional surface features
which are different from the surface features of adjacent formed surfaces.
In another embodiment, each of the formed surfaces within the module has three
dimensional surface features which are different from the surface features of any other
formed surface within the module.
In another embodiment, the offset number of die faces provides for each module to be
formed with a series of formed surfaces which are arranged in a non-identical manner to
the series of formed surfaces on at least the previously formed module and/or on the
next or a module to be subsequently formed.
In another embodiment, the offset number of die faces provides for each module to be
formed with a series of formed surfaces which are arranged in a non-identical manner to
the series of formed surfaces on a plurality of previously formed modules and on a
plurality of modules to be subsequently formed.
In another embodiment, there are eight die faces along said first forming surface, to
mold seven formed surfaces in each module.
In another embodiment, each die face may be rotated in place to provide for a different
orientation of three dimensional surface features on the formed surface to be molded.
In another embodiment, each die face may be swapped with another die face along said
first forming surface.
In another embodiment, each formed surface resembles an individual tile or shingle or
slate or shake within the module.
In another embodiment, the method further comprises a step of sectioning the module
once formed, to provide a plurality of smaller module sections for installation onto a
building surface.
In another embodiment, the method further comprises post-treating the module once
formed.
In another embodiment, the post-treatment may comprise one or more of:
a) shaping,
b) folding,
c) coloring,
d) corrugating,
e) adding surface treatment(s),
f) perforating,
g) laminating,
h) coating.
In another embodiment, the method further comprises shaping and/or cutting and/or
folding the module, once formed, into:
a) a ridge tile,
b) a hip tile,
c) a barge tile,
d) an apex tile,
e) other shape such as a corrugated tile.
In another embodiment, the module may comprise further features as described in any
one of the preceding or following described aspects or embodiments.
In another embodiment, the module may comprise a layer of extruded material as
described in the first described aspect or associated embodiments.
In a fifth described aspect, there is a provided a roofing, cladding, or siding module,
wherein at least a portion of the module comprises a top layer, a bottom layer and an
intermediate layer between the top and bottom layers,
wherein the top and bottom layers are made of, or comprise, one or more
polymer(s),
wherein the intermediate layer is made of, or comprise, one or more polymer(s),
wherein said one or more polymer(s) of the top and bottom layers has/have a
lower degree of crystallinity compared to said one or more polymer(s) of the
intermediate layer, and
wherein each layer is in a molten or semi-molten or pliable state when joined to
the adjacent layer to form the module.
In one embodiment, the top and bottom layers are made of, or comprise, one or more
amorphous or semi-crystalline polymer(s),
wherein the intermediate layer is made of, or comprise, one or more crystalline
or semi-crystalline polymer(s).
In another embodiment, the temperature of the forming process is monitored to control
the rheology of each layer such that the layers remain molten or semi-molten or pliable
while the module is formed.
In another embodiment, the top and bottom layers substantially thermally insulate the
intermediate layer, so that the intermediate layer remains, or maintains the condition of
being, molten or semi-molten or pliable during the forming process.
In another embodiment, the intermediate layer is a reinforcing film or sheet.
In another embodiment, one or more of the top, intermediate and bottom layers is/are
extruded.
In another embodiment, the layers are co-extruded.
In another embodiment, the layers are extruded in series from an array of serially
arranged extruders.
In another embodiment, one or more of the top, intermediate and bottom layers is/are
molded by thermoforming, pressing or other method of forming.
In another embodiment, the layers are formed and/or joined together in a continuous
forming process.
In another embodiment, the top and/or bottom layers comprise(s) thermoplastic
polyolefin (TPO).
In another embodiment, the intermediate layer comprises polypropylene (PP).
In another embodiment, the module may comprise further features as described in any
one of the preceding or following described aspects or embodiments.
In another embodiment, the module may comprise a layer of extruded material as
described in the first described aspect or associated embodiments.
In a sixth described aspect, there is provided a roofing, cladding, or siding module,
comprising:
an underlapping region extending from a head edge of the module and an
exposed region extending from a foot edge of the module, the length of the foot edge
defining the length of the module,
wherein the exposed region is adapted to substantially cover an underlapping
region of an adjacent or overlapping module when installed on a building surface, and
wherein the under surface of the exposed region comprises a plurality of
projections, the projections providing surfaces upon which the exposed region of the
module may be adhered to the top surface of the underlapping region of an adjacent or
overlapping module when installed.
In one embodiment, said module comprises a plurality of formed surfaces molded along
the depth of the module, and wherein said module is formed via a continuous forming
process such that said formed surfaces are connected to each other without weld lines or
attachment points.
In another embodiment, said module comprises one or more layers formed of an
extruded material.
In another embodiment, the projections comprise one or more longitudinal ribs extending
along the length of the module.
In another embodiment, the roofing, cladding, or siding module comprises a plurality of
longitudinal ribs spaced between 1 and 1000 mm apart from each other.
In another embodiment, the roofing, cladding, or siding module comprises a plurality of
longitudinal ribs spaced between 1 and 50 mm apart from each other and extending
substantially parallel to each other.
In another embodiment, the height of the, or each, longitudinal rib is between 1 and 100
In another embodiment, the height of the, or each, longitudinal rib is between 1 and 10
In another embodiment, the width of the, or each, longitudinal rib is between 1 and 1000
mm.
In another embodiment, the width of the, or each, longitudinal rib is between 1 and 10
In another embodiment, the projections further comprise a plurality of transverse ribs
extending substantially perpendicular to the or each longitudinal rib.
In another embodiment, the transverse ribs extend from at, or adjacent, the foot edge
to, at, or adjacent, the underlapping region.
In another embodiment, the transverse ribs are spaced between 1 and 100 mm apart
from each other.
In another embodiment, the transverse ribs are spaced between 1 and 10 mm apart
from each other and extend substantially parallel to each other.
In another embodiment, the height of the transverse ribs tapers from at or adjacent the
foot edge to, at, or adjacent, the underlapping region.
In another embodiment, the width of each transverse rib is between 1 and 1000 mm.
In another embodiment, the width of each transverse rib is between 1 and 10 mm.
In another embodiment, the ribs may be continuous or discontinuous or discrete sections
or portions of projections, each of the projected portions providing one or more surfaces
upon which the exposed region of the module may be adhered to the top surface of the
underlapping region of an adjacent or overlapping module when installed.
In another embodiment, the projections are molded into said under surface of the
exposed region of the module.
In another embodiment, the projections are pre-formed or post-formed from the same
material as the under surface of the module.
In another embodiment, the projections are formed from a different material compared
to the under surface of the module and incorporated into the module before, during or
after forming the module.
In another embodiment, the projections comprise surface features on a bottom surface.
In another embodiment, the surface features are one or more of:
a) corrugations,
b) serrations,
c) projections,
d) ribs,
e) nodes,
f) surface roughness.
In another embodiment, the projections further reinforce the exposed region of the
module.
In another embodiment, the roofing, cladding, or siding module further comprises one or
more continuous or discontinuous strips of adhesive on the top surface of the
underlapping region of the module (optionally which may be exposed upon removal of a
release sheet), configured to contact projections on the under surface of the exposed
region of an adjacent or overlapping module when installed.
In another embodiment, the roofing, cladding, or siding module further comprises one or
more continuous or discontinuous strips of adhesive on a bottom surface of the
projections (optionally which may be exposed upon removal of a release sheet),
configured to contact a top surface of an adjacent or underlapping module when
installed.
In another embodiment, the module is formed with a convex precamber perpendicular to
the length of the module, such that the exposed region is curved downwardly of the
underlapping region.
In another embodiment, the convex precamber applies a preload to said exposed region
of the module.
In another embodiment, the module may comprise further features as described in any
one of the preceding or following described aspects or embodiments.
In another embodiment, the module may comprise a layer of extruded material as
described in the first described aspect or associated embodiments.
In a seventh described aspect, there is a method of coloring or decorating at least a
portion of a top surface of a molded roofing, cladding, or siding module, comprising
applying a colored material onto at least a portion of the top surface of a
precursor of the module to be molded, wherein the colored material is applied before
and/or during the molding process.
In one embodiment, the method further comprises a step of molding the precursor
between a first forming surface and a second forming surface to form the module,
wherein the colored material is applied to at least a portion of the first forming surface,
and wherein the colored material is transferred to said portion of the precursor during the
molding step.
In another embodiment, the first forming surface comprises at least one die face
configured to mold surface features onto at least a portion of a top surface of the
module, wherein the colored material is applied to at least a portion of said die face prior
to the molding step.
In another embodiment, the colored material is applied directly or indirectly to the
precursor and/or the forming surface by one or more of:
a) stamping,
b) injecting,
c) embossing,
d) spraying,
e) rolling,
f) feeding,
g) brushing,
h) melting,
i) immersing,
j) dipping,
k) sprinkling,
l) depositing,
m) by drawing or suctioning the colored material onto the precursor and/or forming
surface using a vacuum system.
In another embodiment, at least a portion of the module comprises a plurality of layers,
and wherein the colored material is applied to at least a portion of the upper surface of
the top-most layer prior to or during a step of joining of the layers to form the module.In
another embodiment, at least the top-most layer is extruded, and the colored material is
applied to said portion of the upper surface of the layer as the layer emerges from the
extrusion die or an extruder.
In another embodiment, the colored material comprises a powder and/or a fluid capable
of being dispersed upon at least the or a portion of the top surface of the exposed region,
whether the application is direct or indirect to the surface or whether a die face is used to
convey the colored material to the surface.
In another embodiment, the colored material comprises charged particles configured to
be attracted to said portion of the top surface of said precursor and/or said first forming
surface and/or said second forming surface.
In another embodiment, the colored material comprises charged particles configured to
be ejected from a source of such charged particles onto the top surface of the precursor
and/or said first forming surface and/or said second forming surface.
In another embodiment, the colored material comprises an adhesive for attaching to said
portion of the top surface of said precursor and/or said first forming surface and/or said
second forming surface.
In another embodiment, the colored material is applied through a stencil and/or mask, to
selectively color one or more portions of said top surface of the precursor and/or said
first forming surface and/or said second forming surface.
In another embodiment, the method further comprises multiple colored material
application steps, being one or more of:
a) applying a different colored material to said portion of the precursor,
b) applying a colored material to a different portion of said precursor
c) applying a colored material through a different stencil or mask.
In another embodiment, the colored material comprises a plurality of components, the
components having different melt flow indices.
In another embodiment, the output is a roofing, cladding, or siding module having at
least one surface colored to resemble one of:
a) asphalt shingles,
b) slate,
c) shingles,
d) shakes,
e) concrete tiles,
f) stone chips,
g) weatherboard,
h) thatch,
i) stone,
j) woodgrain,
k) metal.
In another embodiment, the module comprises an underlapping region extending from a
head edge of the module and an exposed region extending from a foot edge of the
module,
wherein the underlapping region is adapted to be substantially covered by the
exposed region of an adjacent or overlapping module when installed on a building
surface, and
wherein the method comprises coloring the top surface of at least the exposed
region of the module.
In another embodiment, the module may comprise further features as described in any
one of the preceding or following described aspects or embodiments.
In another embodiment, the module may comprise a layer of extruded material as
described in the first described aspect or associated embodiments.
In an eighth described aspect, there is provided a method of coloring at least a portion of
a top surface of a molded roofing, cladding, or siding module, comprising
applying a colored material onto at least a portion of the top surface of the
module after the module has been formed by a molding/joining/laminating process.
In another embodiment, the method may further comprise one or more features as
described in the preceding embodiments.
In another embodiment, the module may comprise further features as described in any
one of the preceding described aspects or embodiments. In another embodiment, the
module may comprise a layer of extruded material as described in the first described
aspect or associated embodiments.
In another described aspect, there is provided a layer of extruded material, wherein the
layer so formed comprises:
a) at least 40% w/w filler and/or reinforcement,
b) one or more polymer(s).
In one embodiment, the layer may be formed (optionally with additional layers) into a
roofing, cladding, or siding module. In further embodiments, the layer so formed may be
a layer according to any one of the above described aspects.
In another described aspect, there is provided a roofing, cladding, or siding module,
comprising:
an underlapping region extending from a head edge of the module and an
exposed region extending from a foot edge of the module, the length of the foot edge
defining the length of the module,
wherein the underlapping region is adapted to be substantially covered by the
exposed region of an adjacent or overlapping module when installed on a building
surface, and
wherein at least a portion of the module comprises a top layer (or an upper layer
or a plurality of upper layers forming a said top layer), a bottom layer (or a lower layer
or a plurality of lower layers forming a said bottom layer), and an intermediate layer (or
a plurality of layers forming a said intermediate layer) between the top and bottom
layers,
and wherein at least one or more of said top layer or said intermediate layer or
said base or bottom layer comprises a foamed polymer.
In another described aspect, there is provided an assembly for installation on a building
surface comprising a plurality of the roofing, cladding, or siding modules of any one of
the preceding clauses.
In another described aspect, there is provided a building surface clad by a plurality of the
roofing, cladding, or siding modules of any one of the preceding clauses.
In another described aspect, there is provided a building comprising a surface clad by a
plurality of the roofing, cladding, or siding modules of any one of the preceding clauses.
This invention may also be said broadly to consist in the parts, elements and features
referred to or indicated in the specification of the application, individually or collectively,
and any or all combinations of any two or more said parts, elements or features, and
where specific integers are mentioned herein which have known equivalents in the art to
which this invention relates, such known equivalents are deemed to be incorporated
herein as if individually set forth.
The term “comprising” as used in this specification and claims means “consisting at least
in part of”. When interpreting each statement in this specification and claims again that
includes the term “comprising”, features other than that or those prefaced by the term
may also be present. Related terms such as “comprise” and “comprises” are to be
interpreted in the same manner.
The present technology is described herein using several definitions, as set forth
throughout the specification. Unless otherwise stated, the singular forms “a,” “an,” and
“the” include the plural reference. For example, a reference to “a device” includes a
plurality of devices.
As used herein the term “and/or” means “and” or “or”, or both.
As used herein “(s)” following a noun means the plural and/or singular forms of the
noun.
Relative terms, such as "lower" or "bottom", "upper" or "top," and "front" or "back" may
be used herein to describe one element's relationship to another element as illustrated in
the Figures. It will be understood that relative terms are intended to encompass different
orientations of the device in addition to the orientation depicted in the Figures. For
example, if the device in one of the figures is turned over, elements described as being
on the "lower" side of other elements would then be oriented on "upper" sides of the
other elements. The exemplary term "lower", therefore, encompasses both an orientation
of "lower" and "upper," depending of the particular orientation of the figure. Similarly, if
the device in one of the figures is turned over, elements described as "below" or
"beneath" other elements would then be oriented "above" the other elements. The
exemplary terms "below" or "beneath" can, therefore, encompass both an orientation of
above and below.
As used herein, the term “formed surface” refers to a molded segment of a polymeric
material corresponding to an individual die or mold of a continuous forming machine.
As used herein, the term "building surface" refers to a wall surface or a top surface, etc.
of a building, e.g. an exterior wall, a roof, a ceiling, etc., unless otherwise specified. In
the context of a roof, the building surface typically comprises a waterproof roofing
product attached to the roof deck adjacent an eave of the roof for preventing water
damage to the roof deck and an interior of a building from wind-blown rain or water
buildup on the roof. The roof deck is typically made of an underlying material, such as
plywood. The waterproof membrane may be any of a number of waterproof roofing
membranes or underlay known in the art such as but not limited to bituminous
waterproof membranes, modified bituminous roofing membranes, self-adhering roofing
membranes, or single ply waterproofing roofing membranes (e.g. EPDM waterproof
roofing membranes, PVC waterproof roofing membranes, TPO waterproof roofing
membranes, synthetic underlay). One exemplary membrane sheet is Deck-Armor™ Roof
Protection, manufactured by GAF Corp., Wayne, New Jersey.
As used herein, the term “roofing” means the provision of a protective covering on the
roof surface of a building. Without limitation, such a protective covering might take the
form of shingles, tiles, panels, shakes, planks, boards, modules, moldings or sheets.
As used herein, the terms “cladding” and/or “siding” mean the provision of a protective
covering on a side or other surface of a building. Without limitation, such a protective
covering might take the form of shingles, tiles, panels, shakes, planks, boards, modules,
moldings or sheets.
As used herein, the terms “profiled” and/or “contoured” mean having a region, or regions
which extend above or below a notional planar surface lying along the longitudinal axis of
the product. This includes profiling or contouring of only one upper or lower surface,
and/or profiling or contouring of an entire thickness of material such that the upper and
lower surfaces have the same relative degree of extension above or below the notional
planar surface.
As used herein, the term “polymer” (and associated terms such as “polymeric”) includes
polymers, polymer blends, polymer alloys, polymer compounds and polymers with or
without additive inclusions.
As used herein, the term "mechanical bond" means a bond between surfaces which have
physical features to create more bonding surface area. For example, the surfaces may
have surface textures or other three-dimensional features which allow keying,
interlocking, increased friction fit, etc., between the surfaces bonded.
As used herein, the term "w/w" when referring to a component of a layer, refers to the
weight of the constituents or components making up the total weight of a layer so
formed.
As used herein, the term "colored material" refers to one or more dyes or pigments or
colored particles which may be used to add surface color and/or decoration and/or
texture to the module. The colored material may be transparent, translucent or opaque,
and may comprise multiple components of different types of coloring or colored agents.
The colored material may be applied to a precursor or module that has already been
colored during the forming process.
This invention may also be said broadly to consist in the parts, elements and features
referred to or indicated in the specification of the application, individually or collectively,
and any or all combinations of any two or more said parts, elements or features, and
where specific integers are mentioned herein which have known equivalents in the art to
which this invention relates, such known equivalents are deemed to be incorporated
herein as if individually set forth.
The invention consists in the foregoing and also envisages constructions of which the
following gives examples only.
In the description in this specification reference may be made to subject matter that is
not within the scope of the claims of the current application. That subject matter should
be readily identifiable by a person skilled in the art and may assist in putting into practice
the invention as defined in the claims of this application.
BRIEF DESCRIPTION OF THE DRAWINGS
Preferred embodiments of the invention will be described by way of example only and
with reference to the drawings, in which:
Figure 1 is a plan view of one preferred embodiment of the roofing, cladding, or siding
module of the present invention,
Figure 2 is a bottom view of the roofing, cladding, or siding module of Figure 1,
Figure 3 is a bottom perspective view of a section of the roofing, cladding, or siding
module of Figure 1,
Figure 4a is a cross-sectional view across the width of one embodiment of the roofing,
cladding, or siding module,
Figure 4b is a cross-sectional view across the width of a second embodiment of the
roofing, cladding, or siding module,
Figure 4c is a cross-sectional view across the width of a third embodiment of the roofing,
cladding, or siding module,
Figure 5 is a top perspective view of an assembly comprising a plurality of roofing,
cladding, or siding modules according to a second embodiment of the present invention,
Figure 6a and 6b are top and partial cross-sectional views respectively of a third
embodiment of the roofing, cladding, or siding module of the present invention,
Figures 7 and 8 are close-up views of contoured portions of the roofing, cladding, or
siding module of the present invention,
Figure 9 shows a continuous forming system of one preferred embodiment described
herein, which may be used to manufacture a roofing, cladding, or siding module of the
present invention,
Figure 10 shows a system for coloring a roofing, cladding, or siding module according to
one preferred embodiment of the present invention,
Figure 11 shows a second embodiment of a system for coloring a roofing, cladding, or
siding module,
Figure 12 shows a third embodiment of a system for coloring a roofing, cladding, or
siding module,
Figure 13a-13h show various arrangements of a three-layered roofing, cladding, or siding
module,
Figure 14 is a schematic showing a detailed view of a further embodiment of the roofing,
cladding, or siding module,
Figure 15 shows examples of modules shaped after forming into ridge and barge tiles,
Figure 16 shows an embodiment of the roofing, cladding, or siding modules, comprising
adhesive and release sheets, arranged in a stack.
DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS
The present invention relates to a roofing, cladding, or siding module, for installing onto
a building surface.
Roofing, cladding and siding products for installation onto building surfaces need to be
lightweight, easy to install, weatherproof, resistant to environmental wear, aesthetically
pleasing and preferably economical and efficient to manufacture. Polymeric materials are
suitable candidates for roofing, cladding and siding products due to their weight,
durability and cost-effectiveness.
However, consumers typically prefer the appearance of more traditional roofing, cladding
or siding products, such as asphalt shingles, shingles, slates or shakes, concrete tiles,
etc. Accordingly, polymeric products need to be cosmetically treated to simulate the
appearance of these more traditional products. Systems and methods for manufacturing
these polymeric products need to be suitably flexible, in order to be able to simulate a
variety of materials.
In particular embodiments of the present invention, the roofing, cladding and/or siding
module has improved weather resistance (e.g., water resistance, hail-proofing),
durability, fire resistance, flame retardant qualities and/or aesthetic qualities.
Other embodiments described herein relate to improved methods and systems for
manufacturing and coloring a roofing, cladding or siding module out of a polymeric
material, such that the module resembles tiles, shingles, etc., made of another type of
material.
Preferred embodiments described herein relate to improved methods and systems for
manufacturing a roofing, cladding or siding module in a high speed and/or cost-effective
and/or efficient process.
For example, preferred embodiments described herein relate to continuous forming
processes, and to modules manufactured using such processes. Larger areas and lengths
of the module may be produced over a shorter duration of time compared to prior art
methods such as injection or pressure molding. It is envisaged that the continuous
forming system described herein can produce approximately 5 to 60 m of product per
minute. In one embodiment, the continuous forming system produces approximately 20
m of product per minute.
In one particular example, a single moulding machine (e.g. may be continuous) may be
utilised having a plurality (e.g. 2 or more) output tracks or lanes of as-molded products
exiting from the machine. In this manner, a plurality of as-moulded products may be
simultaneously formed.
Further, the continuous forming method described herein produces a module that lacks
weld lines, attachments or injection moulding points along the entire length of the
module. Weld lines are formed during injection molding processes when two or more
molten polymer flows meet. This can occur when a polymer flow splits to go around an
interruption (e.g., a post that forms a hole) and then rejoins, or when polymer melt
fronts meet, from multiple injection points. This can also occur when molten polymer
meets a non molten polymer. Consequently, a visible weld line is observed and the
adhesion/bond in this weld line at the interface is weaker than the balance of the polymer
within the product.
Injection moulding points are the area of a product where the heated material was fed
into the mold cavity. It is also difficult to make a product comprising more than one
layer of material using injection moulding, and injection moulding is slow and may
produce color differences or variations that affect the aesthetics of the final product. In
one embodiment, as shown in Figure 1, the module 1 preferably comprises an
underlapping region 2 extending from a head edge 4 of the module and an exposed
region 3 extending from a foot edge 5 of the module. The underlapping region 2 is
adapted to be substantially covered by the exposed region of an adjacent or overlapping
module when installed on a building surface, as shown in Figure 5. The module may take
a variety of forms, for example, several variations 1, 1a, 1b, 1c, 1d, 1e are shown in
Figures 1, 3, 5, 6, 14 and 15.
The module preferably has at least one layer which is formed of an extruded material
comprising one or more polymers and at least 40% filler and/or reinforcement.
Figure 4a shows a cross-sectional view of one embodiment of the module 1. The module
comprises a single layer along a section of the module or along the entire length of the
module. In the preferred embodiment, the layer is formed of an extruded material
comprising at least about 40% w/w/ filler and/or reinforcement, more preferably at least
about 60% w/w filler and/or reinforcement.
In an embodiment, at least a portion of the underlapping region 2 of the module is
formed of the extruded material comprising at least about 40% w/w filler and/or
reinforcement, more preferably at least about 60% w/w filler and/or reinforcement.
The extruded material comprises one or more of the following polymers: polystyrene
(GPPS), polyethylene terephthalate (PET), polyester methacrylate (PEM), high impact
polystyrene (HIPS), acrylonitrile butadiene styrene (ABS), polyvinyl chloride (PVC),
polyurethanes (PU), polyethylene (PE) including homopolymer, copolymer, block
copolymer and terpolymer forms, polylactic acid (PLA), nylon (PA), acrylics (PMMA), high
density polyethylene (HDPE), low density polyethylene (LDPE), linear low density
polyethylene (LLDPE), medium density polyethylene (MDPE), cross linked polyethylene
(PEX), thermoplastic elastomer (TPE), thermoplastic polyolefin (TPO), thermoplastic
rubber (TPR), polypropylene (PP) including homopolymer and copolymer forms,
polybutylene terephthalate (PBT), styrene-acrylonitrile resin (SAN), ethylene
tetrafluoroethylene (ETFE), vinyl, methacrylate copolymers, etc. Any of these polymers
may be foamed if suitable.
Examples of suitable fillers include any one or more of talc, calcium carbonate, mica,
silica, kaolin, calcium sulphate, magnesium hydroxide, stabilizers, dolomite, etc.
Examples of suitable reinforcements include any one or more of glass fibres, glass beads,
glass flakes, natural fibres such as flax, cellulose, wood fibres, wood flour, cotton and
sawdust, inorganic fibres, polymer fibres, polymer scrim, polymer knit, polymer weave,
aramids, ceramics, etc.
Fillers are added to the extruded material to reduce the amount of the more expensive
polymer component, hence reducing the material cost. However, increasing the filler
content tends to negatively affect the physical properties of the extruded material. For
example, prior art injection moulded products typically require relatively low filler
content, otherwise the material does not flow to fill the dies and/or becomes too hard to
be mouldable and/or the moulded product is unstable (e.g., may be poor melt flow or
may be due to thermal expansion) or brittle. Prior art products compensate by adding a
reinforcing scrim layer between layers of polymer; however, these are typically difficult
and expensive to manufacture. In particular, it is challenging to obtain a consistent
positioning of the scrim layer between the polymer layers, and may be difficult to form a
3-D molded product or desired shape of the scrim itself, and even more so when there is
a scrim layer needing to be encapsulated between layers of polymer
In contrast, the extruded material described herein comprises at least about 40% w/w
filler and/or reinforcement, and preferably at least about 60% w/w filler and/or
reinforcement. In some embodiments, the percentage of filler and/or reinforcement is
between about 60% and 95% by weight of the extruded material.
Provision of filler and/or reinforcement into a layer can provide for an increased weight or
density or bulk (e.g. volume) of a layer so formed and thereby of a module made by at
least one of such a layer.
In one embodiment, the extruded material comprises both filler and reinforcement. That
is at least 40% w/w of the extruded material comprises filler and reinforcement.
In some embodiment, the extruded material does not contain reinforcement. In some
embodiments, the extruded material comprises at least about 5% w/w reinforcement
(i.e., in this embodiment, the extruded material comprises at least about 55% w/w filler
and at least about 5% w/w reinforcement). In some embodiments, the extruded material
comprises between about 5% and 20% w/w reinforcement, preferably about 10%
reinforcement.
In preferred embodiments, the reinforcement comprises glass fibres. In an example,
typical dimensions of the glass fibre prior to processing (e.g., prior to the extrusion
process) may be between about 0.5 and 5 mm in length (or may be about 1-5 mm, or
about 2-5 mm, or about 3-5 mm in length) and about 0.015 to about 0.018 mm in
diameter.
In addition to toughening the module, the reinforcement may also reduce thermal
expansion of the module, hence improving stability and durability of the module when
exposed to cyclical variations in heat. In an embodiment, the glass fibres align along the
length of the module during the forming process. As a result, the module is particularly
stable along its length (i.e., the longest dimension of the module, which typically
undergoes greatest change in length due to thermal expansion).
Table 1 compares the thermal expansion coefficient of three test samples: a) polymer
(TPO) with no filler and no reinforcement, b) exemplary prior art product comprising a
layer of reinforcing (polyester) scrim encapsulated between top and bottom TPO layers,
the TPO layers comprising 40% w/w filler, and c) one embodiment of the present
invention comprising polymer (TPO) with 80% w/w filler and 10% w/w reinforcement. In
each case, heat was applied to the test sample to raise the temperature of the sample by
about 80°C from ambient temperature. The dimensions of each sample were measured
at initial (ambient) temperature of about 14°C and again at the final elevated
temperature of about 94°C to determine the thermal expansion.
The embodiment of the present invention demonstrates much less thermal expansion,
compared to pure polymer. The present embodiment instead undergoes minimal thermal
expansion that is comparable to polymer reinforced with a scrim layer, but does not
suffer from the manufacturing challenges associated with the prior art product.
Table 1: Thermal expansion coefficient of test samples with differing levels of
filler.
Thermal
expansion
Polymer % filler % reinforcement
coefficient
(10 m/(m K))
TPO 0 0 165
TPO with reinforcing scrim 40 0 10
TPO 80 10 22
Due to the specific content of the extruded material, the layer of the module is tough,
heat-stable and low cost (in particular due to the high filler content).
The entire length of the module is preferably manufactured in a single continuous
forming process (described in more detail below). It is envisaged that module may be
formed in lengths of at least about 0.5 m. Alternatively, the module may be formed in
lengths of about 36 inches long. Alternatively, the module may be formed in lengths of at
least about 1 m, 1,5 m, 2 m, 2.5 m, 3 m, or any numerical value in between.
In addition to the increase in productivity and reduction in cost, moulding the entire
length of the module in a continuous process eliminates any weld lines. This increases
the durability and weather resistance of the modules, and improves the appearance of
the final product.
In other embodiments, the extruded material may further comprise one or more of the
following additives: colorants (including but not limited to carbon black, titanium
dioxide), flame retardants (including but not limited to magnesium hydroxide, aluminum
trihydrate), stabilizers (including but not limited to UV light stabilizers such as hindered
amine light stabilizers (HALS), and thermal stabilizers such as phenolics), foaming agents
(including but not limited to exothermic, endothermic or gas foaming agents), lubricants,
and/or biocides (including but not limited to particles of silver, including nano-sized silver
particles).
Figure 4b shows a cross-sectional view of a second embodiment of the module 1. The
module comprises two layers along a section of the module or along the entire length of
the module. In one embodiment, the base or bottom layer 8 is formed of an extruded
material comprising at least 60% filler and at least 5% reinforcement.
In other embodiments, the top layer 6 or both layers is/are formed of an extruded
material comprising at least 60% filler and at least 5% reinforcement. That is, the
percentages and/or material of the polymer(s) and/or filler and/or reinforcement may be
the same or different in each layer. The material content of each layer is preferably
selected to suit the function, appearance and/or exposure of the particular layer.
Figure 4c shows a cross-sectional view of a third embodiment of the module 1. The
module has at least one portion 10 which comprises at least three layers: a top layer 6, a
bottom layer 8, and an intermediate layer 7 between the top and bottom layers.
Alternatively, the module may be formed from more than three layers, for example if
more than one layer of material forms a precursor to the top layer, intermediate layer
and/or bottom layer.
In an embodiment, at least one layer is formed of an extruded material comprising at
least 40% filler and/or reinforcement, preferably at least 60% filler and/or reinforcement.
The module may further comprise one or more additional layers formed of material that
may comprise less than 40% filler and/or reinforcement.
In an embodiment, the at least one layer formed of an extruded material comprising at
least 40% filler and/or reinforcement is a base or bottom layer that substantially
contributes to the structure of the module. In some embodiments, this base or bottom
layer is formed of an extruded material comprising at least 60% filler and at least 5%
reinforcement.
In some embodiments, the base or bottom layer comprises about 80% to 85% w/w filler
and/or reinforcement, more specifically, about 70% to 75% filler and about 10% w/w
reinforcement. Optionally, such a base or bottom layer may have a thickness of about 1-
3mm. The resulting layer(s) may provide resistance against significant thermal
expansion of the module, which in turn may help reduce shear forces between layers
and/or other structures attached to the module that may be due to thermal expansion of
those other layers. In other embodiments, the structural layer(s) may be provided as one
or more intermediate and/or upper layer(s).
In some embodiments, the upper or top layer(s) 6 and/or the intermediate layer(s) 7
and/or two or more layers may also be formed of an extruded material comprising at
least 60% filler and/or reinforcement. In some embodiments, the extruded material
comprises at least 5% reinforcement. The material of the matrix and/or filler and/or
reinforcement may be the same or different in each layer.
In one example, the top layer 6 may comprise at least 65% filler, and no reinforcement.
The higher polymer content may be suitable for the top layer, e.g., to facilitate binding of
colored material (as described in more detail below). Optionally, such a top layer may
have a thickness of about 0.4mm.
In one example, the intermediate layer may comprise about 100% polymer (i.e., the
intermediate layer may not comprise filler or reinforcement), which may increase one or
more particular reinforcing properties of the layer, such as waterproofing. In one
example, the intermediate layer may comprise a polypropylene copolymer reinforced
with a copolymer polyethylene. The reinforcing polymer may comprise up to about 50%
w/w of the layer, preferably between 10% and 25% w/w of the layer. Optionally, such an
intermediate layer may have a thickness of about 0.5mm.
According to the above description, a multi-layered module may be formed using at least
the top layer, the intermediate layer and the base or bottom layer as described above.
Regardless of whether the module comprises one or more layers, in the preferred
embodiment, one or more of the layers may comprise(s) three-dimensional features such
as surface texturing, surface relief or other three-dimensional pattern or ornamentation.
For example, Figure 1 schematically shows surface texturing on the exposed regions 3 of
the module 1 (i.e., the surface is not smooth), to simulate asphalt shingles.
In the preferred embodiment, at least a portion of the exposed region 3 of the module
has three-dimensional surface features. Accordingly, in the multi-layered embodiments
shown in Figure 4b, at least a portion of the upper surface of the top layer, corresponding
to the exposed region in the finished module, may have three-dimensional surface
features.
The module may additionally or alternatively comprise two or three dimensional surface
features such as coloring, patterning, surface cracking or fracturing or other two- or
three-dimensional decoration or ornamentation.
These three dimensional and/or two dimensional (e.g. flat) surface features are
preferably provided on at least the exposed region 3 of the module, in order to simulate
another type of natural or manufactured material, including but not limited to asphalt
shingles, slate, timber shingles or shakes, concrete tiles, stone chips, weatherboard,
thatch, stone, woodgrain, metal (e.g., copper tiles), etc.
In one embodiment, as shown in Figure 4, the module comprises at least three layers at
the exposed and fastening regions. In this embodiment, the top layer 6 provides the
cosmetic finish on the exposed region of the module, and preferably includes surface
features on the top surface as described above. The intermediate layer 7 may provide
additional reinforcement, water or weather resistance and/or a binding layer between the
top and bottom layers. The bottom layer 8 forms the base structure of the module and
therefore preferably extends throughout the entire width and length of the module. In
one embodiment, the bottom surface of the bottom layer at the exposed region further
includes projections (e.g., ribs) that provide adhesion surfaces, as described in more
detail below.
The module may comprise three layers in any arrangement, and across any region of the
module. Exemplary embodiments are shown in Figures 13a-13h.
In another embodiment shown in Figure 4b, the module comprises at least two layers at
the exposed and/or fastening region(s). The top layer 6 may provide the cosmetic finish
on the exposed region of the module, and preferably includes surface features on the top
surface as described above. The base or bottom layer 8 may provide the base structure
for the module, and may be reinforced. In one embodiment, the bottom surface of the
base layer 8 may further includes projections (e.g., ribs) that provide adhesion surfaces,
as described in more detail below.
In the single-layered embodiment shown in Figure 4a, the layer may have a cosmetic
finish (e.g. surface color added) on the exposed region of the module, and preferably
includes surface features on the top surface as described above. The layer may also
provide structural support for the module, and may likewise be reinforced (e.g., with
reinforcement additives, surface treatment, surface features such as projections, etc.).
In one embodiment, where the module has at least one portion 10 which comprises more
than one layer, one or more of the layers may be extruded. If two or more layers are
extruded, they may be co-extruded.
Alternatively, the layers may be extruded in series from two or more serially arranged
extruders 20a, 20b, 20c, as shown in Figure 9. Preferably, a first extruded layer is
deposited onto an advancing support surface of a continuous forming machine 11, and
subsequently the other extruded layer(s) is/are deposited on top of the first layer. The
layers then proceed as a layered feed to be molded between the first forming surface 12
and second forming surface 13, preferably as described below.
Alternatively, one or more of the layers may be molded by thermoforming, compression
moulding, pressing or other method of forming. In any case, the layers are subsequently
joined together preferably by the continuous forming machine 11 as described below.
Preferably, the layers are joined or laminated together to form the module in a
continuous forming process (described in more detail below). The layers and/or their
content, such as the polymer(s) is/are selected to be compatible with each other, to
ensure adequate joining/fusing between each layer. The preferred forming process allows
for multiple layers in various configurations (e.g., varying continuity, material properties,
etc) to be joined together to form the finished module. Referring to the cross-sectional
view of one example of the module shown in Figure 4c, in a preferred embodiment of the
present invention, one or more properties of the intermediate layer 7 varies along the
length and/or width of this layer.
In one example, as shown in Figure 4, the thickness of the intermediate layer 7 varies
along its width. Specifically, the intermediate layer is thinner near the foot edge 5 of the
module, and increases in thickness towards the middle of the module. As will be
discussed in more detail below, this thicker portion preferably coincides with the
fastening region of the module.
In other examples, as shown in Figures 13b to 13d, and 13h, the reinforcing layer 7 may
be formed above or below the top or bottom layer of the module respectively. The
reinforcing layer may be present intermediate the head edge 4 and foot edge 5 of the
module, or may extend to one or both of the edges. The intermediate layer (where
present) may be between 0.01 and 10 mm thick, whether of a constant thickness
throughout, or whether the thickness varies as discussed above. Preferably, the
intermediate layer may be between 0.1 and 0.5 mm thick; or may be any numerical
value between 0.01 and 10 mm.
The top and bottom layers may each be between 0.1 and 50 mm thick, whether the
thickness is constant or varying across each layer. Preferably, the top layer is between
0.1 to about 10 mm thick. Preferably, the top layer is about 0.05, 0.1, 0.2, 0.3, 0.4, 0.5,
0.6, 0.7, 0.8, 0.9 mm thick, or may be numerical values between each of these.
Preferably, the bottom layer is about 0.1 to about 10 mm thick. Preferably, is the bottom
layer about 0.5, 1, 2, 3, 4, 5, 6, 7, 8, 9 mm thick, or may be numerical values between
each of these.
Additionally or alternatively, the varying property of the intermediate layer could be a
change in surface area of the intermediate layer, for example by corrugating (or
changing the degree of corrugations on) a portion of the intermediate layer.
Other additional or alternative properties of the intermediate layer which may be varied
along the length or width of the layer include tensile strength, shear strength, resilience,
elasticity, flexibility, toughness, fire resistance, water resistance, continuity or uniformity,
water-proofing, impact resistance, resistance to pull through, fixing capability, chemical
resistance, puncture resistance, content of filler and/or reinforcement, concentration of
filler and/or reinforcement, color, microbial resistance, temperature resistance, light/heat
absorption/reflectivity, thermal transfer, etc., of the layer. Regarding continuity and
uniformity, there may be areas where the intermediate layer is not present in the
module, such that the intermediate layer is discontinuous across the length and/or width
of the module.
In other embodiments, one or more property/properties of the other layers (i.e., the top
or bottom layer) may additionally or alternatively vary along the length and/or width of
the layer. In another example, the surface area of the intermediate layer may be varied
by changing the properties of three-dimensional surface features on the intermediate
layer. The intermediate layer may have three-dimensional surface texturing, or other
projections, corrugations, reinforcements, chemical coatings, protrusions, apertures,
perforations or surface roughness which increase the mechanical bonding of this layer to
the top and/or bottom layers.
Alternatively, any one of the layers, such as the intermediate layer, may be pre-formed
(e.g., by extrusion, or other type of forming process) and subsequently introduced to the
forming/lamination process to form the module. In another embodiment, the layer may
be heated or reheated so that it is in a molten or pliable state when fed to the
forming/laminating machine.
These variations in the property/properties of these surface features may be
implemented when forming the intermediate layer. For example, the height or width of
the surface features may vary along one or more directions of the layer, or in specific
areas of the layer. Additionally or alternatively, the number of surface features (i.e., the
concentration of surface features per unit length or width of the layer) may vary along
one or more directions of the layer, or in specific areas of the layer.
Additionally or alternatively, the variation in the property/properties of the intermediate
layer may be caused by deforming the intermediate layer before or during joining or
laminating to the top and/or bottom layers. For example, by stretching a localized portion
of the intermediate layer while it is still in a molten, semi-molten or pliable state, the
concentration of surface features within this region may be reduced. Accordingly, the
mechanical bond strength at this region would be weaker compared to other non-
deformed regions, or preferentially reduced to provide for desired mechanical properties
of the intermediate layer and its reinforcement of the associated upper and lower layers.
In the preferred embodiment, the intermediate layer is a reinforcing layer (e.g., a
reinforcing film, mesh, scrim, weave, fibre, fabric, wire, string, web or sheet) between
the top and bottom layers. Accordingly, the intermediate reinforcing layer preferably
provides for one or more of: resistance against shrinkage, resistance against warping,
resistance against tearing, increased toughness, prevention against unwanted deflections
of the module, weather or water resistance, reduced flammability, impact resistance,
resistance to pull through (e.g., of fasteners due to high winds), fixing capability,
chemical resistance, puncture resistance, sealing (e.g., self-sealing around fasteners),
shape memory and increased resistance against delamination of the layers,
adhesive/gluing/bonding capability, etc.
The pull through strength of the module is preferably at least as required in the standard
specification for asphalt shingles made from glass felt and surfaced with mineral granules
(ASTM D3462). The standard specifies that when pulling a nail head through the shingle
at 100mm/min, the pull through force is at least 90 N. Accordingly, the nail pull through
force demonstrated by the present module is at least about 90 N, more preferably at
least about 100 N, and may be more than 130 N.
To increase the weather resistance of the module, the intermediate layer may provide a
substantially water or liquid resistant barrier, or a water or liquid impermeable barrier
between the top and bottom layers. This is particularly advantageous where the top or
bottom layers are porous.
For example, the top layer of the module may be fractured or otherwise crazed to
provide surface ornamentation for simulating another type of material. Accordingly, the
intermediate layer preferably provides a substantially waterproof barrier below this top
surface, at least at the porous region(s).
The reinforcing properties of the intermediate layer may vary depending on the
requirements at different sections of the module. At zones of increased exposure or
under increased loading, for example, the reinforcing properties of the intermediate layer
may be increased, but at other sections, may be reduced to reduce the amount of
material used.
For example, the module may further comprise a fastening region 14 for receiving one or
more fasteners that fix the module to the building surface when installed. As shown in
Figure 1, the fastening region may be substantially adjacent the exposed region 3 and
within the underlapping region 2. The fastening region may include a visual guide or
boundary markers to allow visual identification of the region.
The fasteners may be nails, screws, etc, which puncture or penetrate the module when
installed. Accordingly, the intermediate layer may extend from at or adjacent the foot
edge 5 of the module to within or beyond the fastening region 14 of the module.
Alternatively, the intermediate layer may be present only along the fastening region 14
of the module.
Alternatively, if the module does not require penetrative fastenings, the intermediate
layer may extend from at or adjacent the foot edge, to at or adjacent the underlapping
region of the module. That is, the intermediate layer may provide for additional
reinforcement and/or weather resistance throughout the exposed region of the module.
Alternatively, the module may comprise more than one intermediate layer. The two or
more intermediate layers may comprise the same or different material and/or may
perform the same or different functions. The layers may be present as discrete
intermediate layers in different regions of the module or there may be multiple
intermediate layers in one or more regions of the module. For example, there may be
two intermediate layers in the fastening region, one providing a waterproofing function,
the other providing self-sealing properties around fasteners. Additionally, the reinforcing
property/properties of the intermediate layer may be optimized preferentially within this
fastening region 14, to increase the toughness and tear-resistance of the module at this
layer. Additionally, the reinforcing property/properties of the intermediate layer may
also be increased within the exposed region of the module.
For example, as shown in Figure 4C, the intermediate layer may be thicker along the
fastening region, compared to within the exposed region. The intermediate layer may
comprise thickened regions or other 3-dimensional qualities within the fastening region
14, which provide for a fastening region capable of retaining a fastener penetrating the
fastening region or resisting tear or pull through of the module by shear force applied to
the module or each of the said layers by the fastener.
Additionally, or alternatively, the reinforcing property/properties of the intermediate layer
may be optimized preferentially along the direction of the length of the module and/or
along the direction of the width of the module. It will be appreciated that the direction
and/or regions of optimizing or increasing the reinforcing properties of the intermediate
layer will depend on the structural requirements (e.g., the amount of loading, shear
force, tensile force, strain, etc., along that direction or within that region) of the module
when installed.
As discussed above, variations in these properties may be achieved when forming the
intermediate layer, whether by extrusion or other forming processes. These variations
may additionally or alternatively be achieved by deforming (e.g., stretching) the
intermediate layer when it is being joined to the top and/or bottom layers, and is in a
molten or semi-molten moldable state.
Accordingly, the intermediate layer, when being joined to the top and/or bottom layers,
is preferably in a molten or semi-molten state, or a cold but pliable, formable or moldable
condition. In this state, the intermediate layer is able to be deformed with little or no
localized areas of high stress.
Additionally, in the molten or semi-molten state, the intermediate layer may form
chemical bonds with compatible material(s) in the top and/or bottom layer. Alternatively,
if the intermediate layer may be inserted between molten or semi-molten top and bottom
layers, and may therefore form chemical bonds with these layers.
Further, the module may be shaped and/or contoured during the joining/laminating
process, while the intermediate layer is in the cold but pliable or molten or semi-molten
moldable state. This ensures that the intermediate layer remains substantially aligned
and/or substantially consistently positioned between the top and bottom layers through
the shape and/or contour. This is shown in the detailed views of Figures 7 and 8.
The module may be shaped and/or contoured via a casting, thermoforming, pressing or
other forming process, whether continuous or discontinuous, during or after the
joining/laminating process.
In another embodiment, all three layers of the module are in a molten, semi-molten, cold
but pliable, formable or moldable condition when being joined together. This may further
increase the strength of the chemical bond between compatible materials in each layer.
This may additionally reduce the occurrence of localized high stress points in the module,
whether or not the module is further shaped after joining the layers.
Accordingly, the material for each of the layers (or at least for the intermediate layer) is
preferably chosen to have a melt flow index and/or heat capacity sufficiently high such
that the layer(s) remain molten or semi-molten or pliable while the module is formed.
Additionally or alternatively, the layers are processed at a sufficiently high temperature
such that the layers remain molten or semi-molten or pliable while the module is formed.
Preferably, the layers are each made of, or comprise, one or more polymer(s). Materials
which may be used include (but are not limited to) general purpose polystyrene (GPPS),
polyethylene terephthalate (PET), polyester methacrylate (PEM), high impact polystyrene
(HIPS), acrylonitrile butadiene styrene (ABS), polyvinyl chloride (PVC), polyurethanes
(PU), polyethylene (PE) including homopolymer, copolymer, block copolymer and
terpolymer forms, polylactic acid (PLA), nylon (PA), acrylics (PMMA), high density
polyethylene (HDPE), low density polyethylene (LDPE), linear low density polyethylene
(LLDPE), medium density polyethylene (MDPE), cross linked polyethylene (PEX),
thermoplastic elastomer (TPE), thermoplastic polyolefin (TPO), thermoplastic rubber
(TPR), polypropylene (PP) including homopolymer and copolymer forms, Polybutylene
terephthalate (PBT), styrene-acrylonitrile resin (SAN), ethylene tetrafluoroethylene
(ETFE), vinyl, methacrylate copolymers, etc. The materials may be a blend of any or all
of these, and/or may be foamed.
Any one or more of the layers may further comprise one or more additives, such as, but
not limited to fillers (including but not limited to talc, calcium carbonate, mica, silica,
kaolin, calcium sulphate, magnesium hydroxide, stabilizers, dolomite), colorants
(including but not limited to carbon black, titanium dioxide), reinforcements (including
but not limited to glass fibres, glass beads, glass flakes, natural fibres such as flax,
cellulose, wood fibres, wood flour, cotton, sawdust, and inorganic or polymer fibres,
scrim, knits, weave, non-woven, aramids, ceramics), flame retardants (including but not
limited to magnesium hydroxide, aluminum trihydrate), stabilizers (including but not
limited to UV light stabilizers such as hindered amine light stabilizers (HALS), and
thermal stabilizers such as phenolics), foaming agents (including but not limited to
exothermic, endothermic or gas foaming agents), lubricants, or biocides (including but
not limited to particles of silver, including nano-sized silver particles).
In particular, at least the top layer preferably has a high UV resistance. Additionally, the
module is preferably configured and materials preferably chosen to withstand cyclical
variations in temperature, for example, about -40 to about 100 degrees Celsius.
In one embodiment, the polymer(s) of the top and bottom layers has/have a lower
degree of crystallinity compared to the polymer(s) of the intermediate layer. That is, the
intermediate layer comprises a tougher, more crystalline polymer or polymer blend
compared to the top and bottom layers. The top and bottom layers may comprise an
amorphous polymer or a polymer which is less crystalline compared to the intermediate
layer.
For example, the intermediate layer may comprise polypropylene (PP). The top and/or
bottom layers may comprise thermoplastic polyolefin (TPO), which is less crystalline or
has fewer crystalline regions compared to polypropylene (PP).
In alternative embodiments, the layers may each have any degree of crystallinity
compared to each other.
Additionally or alternatively to selecting different materials with different material
properties, the relative crystallinity of the layers may be achieved during manufacture of
each layer, for example by controlling the temperature, rate of cooling, rate of extrusion,
shear forces, or other factors as known in the art.
Preferably, the top and bottom layers may substantially thermally insulate or encapsulate
the intermediate layer, so that the intermediate layer remains molten or semi-molten or
pliable during the forming process. This controls the amount and/or rate of shrinkage of
the crystalline or semi-crystalline intermediate layer throughout the cooling process,
reducing warping in the module.
In other embodiments, the top and bottom layers may also substantially transfer or
provide heat to the intermediate layer, to promote or maintain its molten or semi-molten
or pliable state.
In addition to, or alternatively to reinforcing the module, the intermediate layer may
also provide a binder layer for binding materials in the top and/or bottom layer together
to form the module.
For example, the top layer may comprise sections of non-homogenous and/or non-
compatible materials in order to achieve a particular surface texture or appearance
simulating another type of material. The intermediate layer may be chosen to comprise a
material which is compatible with each of the materials in the top layer. The
intermediate layer therefore binds to each of the discontinuous sections of the top layer,
effectively acting as a binder for binding these sections together.
In order to reduce material costs, the module need not comprise three layers throughout
the entire unit of module. The module may comprise a single layer or double layers
throughout, or at specific regions, as described previously.
Additionally, to reduce the amount of raw material required for production, the top
and/or bottom layer may be foamed. This additionally reduces the weight of the module.
In the preferred embodiment, the bottom layer 8 is made of a foamed polymer, such as
foamed thermoplastic polyolefin (TPO).
The module may comprise one or more anti-scuff or protective layers on a top surface of
the module, to protect at least the exposed region of the module during storage,
transport and installation. The layer may be applied as an integral layer, or may be
removably provided as a release sheet (to be removed after installation). The anti-scuff
layer may be a layer of substantially virgin polymer, or a layer or coating comprising
polymer or other suitable materials.
In some embodiments, the module may comprise one or more side laps for lapping under
an adjacent module, to increase water resistance between adjacent modules. The side
lap may be thinner, and/or may comprise fewer layers than other portions of the module.
Side laps can provide for regions upon which adjacent modules may overlap with another
module.
Further, to reduce the amount of raw material for the bottom layer, the under surface of
the layer may comprise projections instead of being a solid, continuous surface.
The projections provide surfaces upon which the exposed region of the module may be
adhered to the top surface of the underlapping region of an adjacent and/or overlapping
module when installed. The projections provide sufficient adhesive surface area over
discrete regions of the base, instead of a solid continuous surface, which would be more
affected by shrinkage or thermal expansion/contraction, causing issues with adhesion.
The projections further provide the required strength and rigidity of the layer, while
reducing the weight of the layer.
In one embodiment, as shown in Figures 2 and 3, the projections comprise one or more
longitudinal ribs 15 or other formations extending along the length of the module.
Each longitudinal rib 15 may be continuous or discontinuous throughout its length, but
preferably provides sufficient coverage of the module to provide sufficient adhesion
surfaces. More preferably, the longitudinal rib extends through the entire length of the
module, in order to provide sufficient strength along the length, and prevent warping
along the length.
In one embodiment, the longitudinal ribs 15 extend substantially parallel to the foot edge
of the module. Alternatively, the longitudinal rib 15 may extend along a direction which
is not parallel to the foot edge (e.g., the rib(s) may extend(s) diagonally across the
module), but the rib preferably still extends along a substantial portion of the length of
the module. Preferably, the ribs are positioned near the foot edge 5 of the module, so
that this edge of the exposed region of the module be adhered to the top of the adjacent
or overlapping module, and may sit flush on the top surface.
For this purpose, the module may also be formed with a convex precamber perpendicular
to the length of the module, such that the exposed region is curved downwardly of the
underlapping region. This pre-load pressure encourages the projections/ribs to contact
firmly onto the underlapping panel when installed on the building surface.
Preferably, as illustrated, there are a plurality of longitudinal ribs 15 (e.g., three ribs),
extending substantially parallel to each other and spaced approximately 1 to 100 mm
(preferably 1 to 10 mm) apart from each other. The height of the, or each, longitudinal
rib may be between 1 and 100 mm (preferably, between 1 and 10 mm). The or each
longitudinal rib may be between 1 and 1000 mm wide (preferably between 1 and 10 mm
wide, or sufficiently wide to provide surfaces for adhering the module to the top of an
adjacent or overlapping module when installed.
In the preferred embodiment, the under surface of the bottom layer may further
comprise a plurality of transverse ribs 16. These transverse ribs 16 may extend
substantially perpendicular to the longitudinal ribs 15 and/or perpendicular to the length
of the module. Alternatively, the transverse ribs may extend along any other direction,
but preferably still extends along a substantial portion of the width of at least the
exposed region of the module.
These transverse ribs may provide adhesion surfaces in addition to, or alternatively to
the longitudinal ribs. The transverse ribs preferably strengthen at least the exposed
region of the module, preventing warping or curling of the module along its width. The
transverse ribs 16 therefore preferably extends from at, or adjacent, the foot edge 5 to
at, or adjacent, the underlapping region of the module.
Preferably, the transverse ribs are spaced between 1 and 100 mm (preferably, 1 and 10
mm) apart from each other and extend substantially parallel to each other., The width of
each transverse rib may be between 1 and 1000 mm (preferably, between 1 and 10
mm).
In one embodiment as shown more clearly in Figure 3, the height of the transverse ribs
tapers from at or adjacent the foot edge to, at, or adjacent, the underlapping region. This
means that there is a decrease in spacing between the module and the building surface
from the exposed region towards the underlapping region. This enables at least the
exposed region of the adjacent overlapping module to be kept substantially parallel to
the building surface.
The projections are preferably molded into the under surface of the exposed region of the
module during the forming process, for example by one or more die faces on the second
forming surface 13.
Alternatively, the projections may be pre-formed or post-formed from the same material
as the under surface of the module and incorporated into the module during or after the
forming process.
Alternatively, the projections may be formed from a different material compared to the
under surface of the module, and may be incorporated into the module before, during or
after forming the module.
In one embodiment, as shown in Figure 14, the projections may further comprise surface
features 19, such as surface roughness, on one or more surfaces, preferably a bottom
surface. The features increase the surface area of the surface, to increase the peel
strength and/or bond strength of the projection to the upper surface of the underlapping
tile, to which the projection is adhered to.
Examples of surface features include corrugations, serrations, projections, ribs, nodes,
surface roughness, etc.
The shape and configuration of the ribs may be selected to provide different attachment
properties at different regions of the rib, e.g., a planar, bottom surface of the rib may
provide different resistance against shear and/or peel compared to lateral faces of the
rib.
Other surfaces of the module may also or alternatively comprise surface features to
increase the bond strength between adhered surfaces. For example, the top surface of
the underlapping region of the module may comprise surface features to increase the
peel and/or bond strength between the top surface and the under surface of the
overlapping module. The module may further comprise one or more continuous or
discontinuous strips of adhesive 25 on the top surface of the underlapping region of the
module (optionally which may be exposed upon removal of a release sheet), configured
to contact the projections on the under surface of the exposed region of an adjacent or
overlapping module when installed. Additionally or alternatively, adhesive may be
provided on a bottom surface of the module (e.g., the bottom surface of the projections,
if provided) to be adhered to a top surface of an underlapping module during installation.
In some embodiments, for example as shown in Figure 16, the release sheet 26 may be
integrally molded or otherwise formed with or incorporated into the module. Prior to
installation, the release sheet 26 may contact the adhesive region 25 of an adjacent
module. During installation, the two modules may be separated to expose the adhesive
on one module, and the release sheet can remain on the other module. In this way, the
modules may be provided and/or transported in stacks of two or more modules.
Alternatively, adhesive may be applied to the projections/ribs and/or to the top of the
underlapping region of the module on-site.
In the preferred embodiment, the module comprises a plurality of formed surfaces 9,
wherein each of the formed surfaces comprises three-dimensional surface features, as
shown in Figure 1. In this embodiment, each formed surface is a molded segment along
the length of the module. For reference, we have defined the length of the foot edge 5 as
the length of the module, and the distance between the foot edge 5 and the head edge 4
as the width of the module.
Each formed surface 9 may resemble an individual tile, shingle, slate or shake.
Alternatively, each formed surface may resemble a set of tiles, shingles, slates or shakes.
Each formed surface 9 comprises an underlapping region 2 and an exposed region 3,
wherein the underlapping region is adapted to be substantially covered by the exposed
region of an adjacent or overlapping module when installed on a building surface.
The module 1 may therefore be installed with the row of formed surfaces 9 simulating a
row of tiles, shingles, slates, shakes, etc.
Alternatively, the module may be subsequently sectioned (or divided or partitioned) to
provide a plurality of smaller module sections for installation onto the building surface.
The smaller module sections may each contain a single formed surface 9 simulating an
individual tile, shingle, slate, shake, etc. Alternatively, the smaller module sections may
resemble a set of tiles, shingles, slates or shakes. Examples of these smaller module
sections are shown in Figures 3 and 6. Alternatively, each smaller module section may
contain a plurality of formed surfaces.
In one embodiment, each formed surface 9 is molded by an individual die or mold of a
continuous forming machine. Where there are a plurality of formed surfaces 9 in the
module, all the formed surfaces are preferably joined or laminated to each other without
weld lines, attachments (such as gluing, etc) or injection molding points. Use of the term
"joined" in this context is not intended to require that each of the formed surfaces were
ever separated, i.e., the formed surfaces maybe integrally formed together in situ during
the manufacturing/molding process.
The preferred method of forming a module having a plurality of formed surfaces joined
together without weld lines, attachments or injection molding points is described as
follows, and with reference to Figure 9. The continuous forming machine 11 is fed a feed
material able to assume and retain a form after being molded between a first forming
surface 12 and a second forming surface 13. At least the first forming surface 12
comprises a plurality of die faces 21 provided in sequence, configured to mold the three-
dimensional surface features onto the module. That is, each formed surface 12 along the
module is molded by one die face. It should be understood that, while the drawings show
the first forming surface 12 on the top and the second forming surface 13 on the bottom
of the continuous forming machine, the relative positions of the two surfaces may be
reversed. Accordingly, in some embodiments, the module may be molded upside down
(i.e., the bottom surface is molded with the surface features, which when installed,
becomes the top/exposed surface of the module).
In some embodiments, each die face is (at least slightly) different from the adjacent die
face, in order to produce a module with formed surfaces 9 which appear (at least slightly)
different from at least the adjacent formed surfaces. When installed, the module-clad
surface may therefore more closely resemble a surface covered with individual asphalt
shingles, slate, shingles, shakes, concrete tiles, stone chips, weatherboard, etc. Further,
it would be desirable to produce modules, each having a different arrangement of formed
surfaces, to increase the variation in appearance when a plurality of modules are
installed overlapping each other. While this may be achieved by replacing or swapping
individual die faces along the first forming surface 12, it would be desirable to be able to
produce different modules in a batch or continuous forming process. Alternatively, the
die faces may be the same as each other in order for formed surface 9 to be formed
which are substantially identical or matching of each other.
Accordingly, in the preferred embodiment, the number of die faces is offset from the
number of formed surfaces in each module to be formed. That is, there are more or
fewer die faces compared to the number of formed surfaces in each module.
Alternatively, the number of die faces may match the number of surfaces to be formed
on a module or along a length of a layer – thereby contributing to the matched or
substantially identical nature of the formed surface (e.g. where copper tiles or tiles which
are of matching resemblance are to be provided as a part of a module).
This means that the process may continuously produce a set of modules, in which each
module has a series of formed surfaces which are arranged in a non-identical manner to
the series of formed surfaces on at least the previously formed module and the next
module to be formed. More preferably, each module has a series of formed surfaces
which are arranged in a non-identical manner to the series of formed surfaces on a
plurality of previously formed modules and a plurality of module to be subsequently
formed.
For example, to form the module of Figure 1 which has seven formed surfaces 9, there
are preferably at least eight die faces 21 along at least the first forming surface 12. The
last die face therefore molds the first formed surface of the next module in this
continuous forming process. Accordingly, this module and the next will have a different
arrangement of formed surfaces.
It will be appreciated that the number of different permutations that may be obtained will
depend on the number of die faces compared to formed surfaces.
Alternatively, there may be fewer die faces 21 compared to the number of formed
surfaces in each module to be formed. For example, if there is one less die face
compared to formed surfaces, the first and last formed surfaces along a single module
will be identical. Nevertheless, each module will have a different sequence of formed
surfaces compared to the previously formed and subsequently formed modules.
As discussed above, each formed surface preferably has three dimensional surface
features which are different from the surface features of at least the adjacent formed
surfaces. More preferably, the die faces are configured such that each of the formed
surfaces within the module has three dimensional surface features which are different
from the surface features of all other formed surface within the module.
Additionally, the sequence of formed surfaces in each module may be further varied by
swapping a die face with another die face along the first forming surface.
Additionally or alternatively, each die face may be rotated in place to provide for a
different orientation of three dimensional surface features on the formed surface to be
molded, and hence a variation in the overall appearance of the formed surface.
In other embodiments, the die faces may be the same, so as to produce similar or
identical formed surfaces. For example, this embodiment may be used to produce
modules which resemble ceramic tiles or metallic tiles such as copper tiles. Further, in
some embodiments, the die faces may not mould three-dimensional surface features into
the module, but may simply serve to divide the module into formed surfaces to resemble
individual tiles.
While the preceding description relates to the modules being produced as discontinuous
units via the batch or continuous forming process (i.e., each feed input into the
continuous forming machine produces a single length of module), an alternative method
may involve producing a long length of precursor which is subsequently sectioned to
obtain multiple modules. In this case, the precursor will comprise multiple repeating
sequences of formed surfaces. In order to produce modules with different sequences of
formed surfaces, the precursor is not sectioned at the intersections where the sequences
repeat.
For example, to obtain the module of Figure 1, the precursor may have multiple
repeating sequences of eight formed surfaces. The precursor is sectioned to obtain
modules containing only seven formed surfaces. This sectioning may occur during or
after the molding process.
It will be appreciated that regardless of whether the modules are produced as
discontinuous units or as a continuous precursor which is subsequently sectioned, in
embodiments where the modules are formed to have different arrangements of formed
surfaces, the important feature is that the number of die faces 21 provided in sequence
on the first forming surface 12 is offset from the number of formed surfaces 9 in each
module.
In some embodiments, the module may be post-treated once formed, for example by
shaping, folding, coloring, corrugating, adding surface treatment(s) (e.g. biocides),
perforating, laminating, coating, etc.
In some embodiments, the module is shaped and/or cut and/or folded, once formed, to
produce a ridge tile, a hip tile, a barge tile, an apex tile or other shaped/angled tiles,
such as corrugated tiles. Examples of folded modules are shown in Figures 15a, 15b and
15c. It will be appreciated that the angle of the fold depends on the application.
In some embodiments, the region to be folded or shaped may be heated or re-heated in
order to be bent or folded into shape after the module has been formed. In some
embodiments, the region to be folded or shaped 17 may comprise a reinforcing layer to
increase the toughness and/or durability of this region.
As shown in Figures 15b and 15c, the folded/shaped modules may, be arranged in any
suitable overlapping arrangement (over similar folded/shaped modules or other unfolded
modules) for or when installing onto the building surface.
Methods for coloring the module, preferably to resemble another type of natural or
manufactured material as discussed above, will now be described in more detail. It
should be appreciated that the following methods of coloring the module are not specific
to the preferred forms of the module as described herein. For example, the coloring
methods may be applied to modules comprising only one layer of polymer, etc.
Preferable, however, at least the top surface of the exposed portion of the module is
colored.
For brevity, the following description will refer to a “precursor”, being the precursor to
the final molded module. The precursor may therefore refer to a single layer, or to the
layered precursor just prior to molding the layers together into the final product.
In one embodiment, a colored material is added to the one or more layers, before or
while the layer is formed (whether by extrusion, injection molding or other forming
methods as described above).
In another embodiment, the colored material is added onto the module after it has been
formed/molded.
Additionally or alternatively, the colored material may be added onto at least a portion of
the top surface of a precursor. That is, the colored material is applied before and/or
during the final molding process.
The colored material may be one or more dyes or pigments or colored particles which
may be used to add surface color and/or decoration and/or texture to the module. The
colored material may be transparent, translucent or opaque, and may comprise multiple
components of different types of coloring or colored agents. The colored material may be
applied to a precursor or module that has already been colored during the forming
process. One embodiment is shown in Figure 10, in which the precursor is molded
between a first forming surface 12 and a second forming surface 13. The colored material
is applied at 30 to at least a portion of one of the forming surfaces. Subsequently, the
colored material is transferred to the precursor during the molding step, when the
precursor is formed between the first and second forming surfaces.
As shown schematically in Figure 10, the colored material may be sprayed or otherwise
applied onto the first forming surface 12 and/or second forming surface 13. In some
embodiments, the specific gravity of the colored material is preferably greater than 1.
The colored material may be applied directly or indirectly to the precursor and/or the
forming surface by one or more of stamping, injecting, embossing, spraying, rolling,
feeding, brushing, melting, immersing, dipping, sprinkling, depositing, by drawing or
suctioning the colored material onto the precursor and/or forming surface using a
vacuum system, etc. Alternatively, the first and/or second forming surface may comprise
a printer head, etc., for depositing the colored material onto the precursor during the
molding step.
In addition, or alternatively, colored material may be applied (whether directly or
indirectly) to a surface of a layer or layer precursor or a surface of a die face or a surface
of the formed module, using a vacuum system. For example, in one embodiment a
colored material may be applied to a top surface of an upper layer to be used in forming
a module, and a vacuum system may remove at least some of the applied colored
material. The removal of the colored material may be removal from pre-defined areas of
the surface upon which the colored material has been applied.
In the embodiment where the precursor is molded in a continuous forming process
between first and second forming surfaces, and the first forming surface comprises at
least one die face configured to mold surface features onto at least a portion of a top
surface of the module, the colored material is preferably applied to at least a portion of
the die face(s) prior to the molding step. The colored material is therefore subsequently
stamped, injected, embossed or otherwise applied onto or into a portion of formed
surface(s) during the molding step.
The application of colored material onto the different die faces may be consistent or
different. For example, the amount of colored material applied and/or the areas on which
the colored material is applied may be different for each die face, in order to produce a
module with color variations throughout the different formed surfaces, so that they more
closely simulate individual tiles, shingles, etc.
In another embodiment, the colored material may comprise a plurality of components
having different melt flow indices/viscosities, so as to produce a visual effect such as a
tortoiseshell coloring effect. In some embodiments, one or more components of the
colored material may be a solid that does not melt (at least in the range of temperatures
that the colored material undergoes), i.e., the component(s) may not have a melt flow
index as such.
In the preferred embodiment where at least a portion of the module comprises a plurality
of layers, the colored material is preferably applied to at least a portion of the upper
surface of the top-most layer prior to, or during the step of joining or lamination of the
layers to form the module.
In another embodiment, the precursor is extruded prior to molding, and the colored
material is applied at 35 to a portion of the upper surface of the layer as the layer
emerges from the extruder. This is schematically shown in Figure 11.
It will be appreciated that both the coloring methods illustrated in Figures 10 and 11 may
be employed, such that the precursor may be colored after extrusion, and once again
during the molding step.
For example, Figure 12 shows additional or alternative locations where the colored
material may be applied. The colored material may be applied at 40, before a layer is
extruded, or onto a layer which may be later formed with other extruded layers.
Additionally or alternatively, the colored material may be applied at 50, after the module
has been formed. The colored material preferably comprises a powder and/or a fluid
capable of being dispersed upon at least the or a portion of the top surface of the
exposed region, whether the application is direct or indirect to the surface, or whether a
die face is used to convey the colored material to the surface.
In one example, the colored material may be or may comprise charged particles. The
charged particles may be configured to be attracted to the die face, or directly onto the
precursor. Alternatively, the charged particles may be configured to be ejected from a
source of such charged particles onto the precursor.
In another embodiment, the colored material may be or may comprise an adhesive for
attaching the colored material to the precursor.
In any case, the colored material may be applied through a stencil and/or a mask (not
shown), to selectively color one or more portions of the top surface of the precursor.
Accordingly, there may be more than one color application steps, in which the same or a
different colored material may be applied through the same or a different stencil, or to
another portion of the top surface of the precursor.
Layering the application of colored material like this may produce variations in color or
surface patterning which better emulate the simulated material.
The foregoing description of the invention includes preferred forms thereof. Modifications
may be made thereto without departing from the scope of the invention.
Claims (24)
1. A roofing, cladding, or siding module, comprising: an underlapping region extending from a head edge of the module and an exposed region extending from a foot edge of the module, the length of the foot edge defining the length of the module, wherein the underlapping region is adapted to be substantially covered by the exposed region of an adjacent or overlapping module when installed on a building surface, wherein the module is formed of at least one layer of extruded material, wherein the layer so formed comprises: at least 40% w/w filler and reinforcement or at least 40% w/w reinforcement, and one or more polymer(s), wherein the reinforcement comprises one or more non-conductive natural or synthetic fibres, and wherein the layer so formed comprises at least 6% w/w of said one or more non-conductive natural or synthetic fibres, and wherein the fibres are aligned along the length of the module; and wherein the module comprises a plurality of formed surfaces molded along the length of the module, each of the formed surfaces comprising at least one three- dimensional surface feature.
2. The module as claimed in claim 1, wherein the layer comprises 60% to 95% w/w filler and/or reinforcement.
3. The module as claimed in claim 1 or 2, wherein the layer comprises at least 5% w/w reinforcement.
4. The module as claimed in any one of claims 1 to 3, wherein the layer comprises 5% to 30% w/w reinforcement.
5. The module as claimed in any one of claims 1 to 4, wherein the layer comprises one or more of the following polymers: a) polystyrene (GPPS), b) polyethylene terephthalate (PET), c) polyester methacrylate (PEM), d) high impact polystyrene (HIPS), e) acrylonitrile butadiene styrene (ABS), f) polyvinyl chloride (PVC), g) polyurethanes (PU), h) polyethylene (PE) including homopolymer, copolymer, block copolymer and terpolymer forms, i) polylactic acid (PLA), j) nylon (PA), k) acrylics (PMMA), l) high density polyethylene (HDPE), m) low density polyethylene (LDPE), n) linear low density polyethylene (LLDPE), o) medium density polyethylene (MDPE), p) cross linked polyethylene (PEX), q) thermoplastic elastomer (TPE), r) thermoplastic polyolefin (TPO), s) thermoplastic rubber (TPR), t) polypropylene (PP), including homopolymer and copolymer forms, u) polybutylene terephthalate (PBT), v) styrene-acrylonitrile resin (SAN), w) ethylene tetrafluoroethylene (ETFE), x) vinyl, y) methacrylate copolymers, z) foamed polymer.
6. The module as claimed in any one of claims 1 to 5, wherein the filler comprises one or more of the following: a) talc, b) calcium carbonate, c) mica, d) silica, e) kaolin, f) calcium sulphate, g) magnesium hydroxide, h) stabilizers, i) dolomite.
7. The module as claimed in any one of claims 1 to 6, wherein the reinforcement comprises one or more of the following: glass fibres, glass beads, glass flakes, flax, cellulose, wood fibres, wood flour, cotton, sawdust, inorganic fibres, polymer fibres, polymer scrim, polymer knit, polymer weave, aramids, ceramics.
8. The module as claimed in any one of claims 1 to 7, wherein at least a portion of a top surface of the exposed region comprises at least one of the formed surfaces, whether as surface relief or surface texturing, optionally wherein said portion comprises surface features resembling one of: a) asphalt shingle, b) slate, c) shingles, d) shakes, e) concrete tiles, f) stone chips, g) weatherboard, h) thatch, i) stone, j) woodgrain, k) metal.
9. The module as claimed in any one of claims 1 to 8, wherein each of the formed surfaces comprises said surface features, and wherein the formed surfaces are joined without weld lines, attachments or injection molding points, optionally wherein each of the formed surfaces resembles an individual tile or shingle or slate or shake within the module.
10. The module as claimed in any one of claims 1 to 9, wherein said layer so formed of a said extruded material is provided as a base or bottom layer of the module, and the module further comprises one or more additional upper layers provided as further layers upon said base or bottom layer, optionally wherein said one or more upper layer(s) is formed of an extruded material, said one or more upper layer(s) comprising a different weight percentage of filler and/or reinforcement relative to the base or bottom layer.
11. The module as claimed in any one of claims 1 to 10, wherein said at least one layer so formed has a coefficient of thermal expansion of less than 30 · 10 m/(m K), and optionally wherein said at least one layer so formed is provided as a base or bottom layer of said module.
12. The module as claimed in any one of claims 1 to 11, wherein at least a portion of the module comprises a top layer, a base or bottom layer, and an intermediate layer between the top and base or bottom layers.
13. The module as claimed in any one of claims 1 to 12, wherein a layer so formed extends across at least a part of the width and/or at least a part of the length of the module to provide for a variation to one or more properties to the module so formed by the at least one layer, the properties selected from one or more of: a) thickness, b) surface area c) tensile strength d) shear strength e) resilience f) elasticity g) flexibility h) toughness i) fire resistance j) water resistance k) continuity or uniformity l) impact resistance m) resistance to pull through n) fixing capability o) chemical resistance p) puncture resistance q) content of filler and/or reinforcement r) concentration of filler and/or reinforcement s) color t) microbial resistance u) temperature resistance v) light/heat absorption/reflectivity, w) thermal transfer.
14. The module as claimed in any one of claims 1 to 13, wherein the module is post- treated after being formed, optionally comprising one or more of: shaping, folding, coloring, corrugating, adding surface treatment(s), perforating, laminating, coating.
15. The module as claimed in any one of claims 1 to 14, wherein an under surface of at least the exposed region of the module surface comprises a plurality of projections, optionally wherein the projections provide surfaces for one or more of: - adhering the exposed region of the module to the top surface of the underlapping region of an adjacent or overlapping module when installed, - providing reinforcement for the module.
16. The module as claimed in claim 1, wherein said at least one layer so formed has a coefficient of thermal expansion of less than about 165 · 10 m/(m K), and optionally wherein said at least one layer so formed is provided as a base or bottom layer of said module.
17. The module as claimed in claim 1, wherein the reinforcement comprises or consists of glass fibres, and wherein the glass fibres are aligned along the length of the module.
18. The module as claimed in claim 1, wherein the layer so formed comprises at least 10% w/w of said one or more non-conductive natural or synthetic fibres.
19. The module as claimed in claim 17, wherein the layer so formed comprises at least 10% w/w of said glass fibres.
20. The module as claimed in claim 17, wherein the glass fibres prior to extrusion are between about 0.5 and 5 mm in length.
21. The module as claimed in claim 1, wherein the length of the module is at least 0.5m.
22. The module as claimed in claim 10, wherein the percentages and/or material of the polymer(s) and/or filler and/or reinforcement are the same in each layer.
23. The roofing, cladding, or siding module as claimed in claim 1, comprising: an underlapping region extending from a head edge of the module and an exposed region extending from a foot edge of the module, the length of the foot edge defining the length of the module, wherein the underlapping region is adapted to be substantially covered by the exposed region of an adjacent or overlapping module when installed on a building surface, wherein the module is formed of at least one layer of extruded material, wherein the layer so formed comprises: at least 40% w/w filler and reinforcement or at least 40% w/w reinforcement, and one or more polymer(s), the one or more polymer(s) comprising a foamed polymer, wherein the reinforcement comprises one or more non-conductive natural or synthetic fibres, and wherein the layer so formed comprises at least 6% w/w of said one or more non-conductive natural or synthetic fibres, and wherein the fibres are aligned along the length of the module; and wherein the module comprises a plurality of formed surfaces molded along the length of the module, each of the formed surfaces comprising at least one three- dimensional surface feature.
24. A roofing, cladding, or siding module as claimed in claim 1, substantially as herein described with reference to any example thereof and with or without reference to any one or more of the accompanying figures.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
NZ770461A NZ770461A (en) | 2014-12-01 | 2015-12-01 | A roofing, cladding or siding product |
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US201462085733P | 2014-12-01 | 2014-12-01 | |
US62/085,733 | 2014-12-01 | ||
PCT/IB2015/059230 WO2016088026A1 (en) | 2014-12-01 | 2015-12-01 | A roofing, cladding or siding product |
Publications (2)
Publication Number | Publication Date |
---|---|
NZ732088A NZ732088A (en) | 2021-11-26 |
NZ732088B2 true NZ732088B2 (en) | 2022-03-01 |
Family
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