WO2007064322A1 - Composition d'un produit composite de toiture resistant aux intemperies - Google Patents

Composition d'un produit composite de toiture resistant aux intemperies Download PDF

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Publication number
WO2007064322A1
WO2007064322A1 PCT/US2005/043443 US2005043443W WO2007064322A1 WO 2007064322 A1 WO2007064322 A1 WO 2007064322A1 US 2005043443 W US2005043443 W US 2005043443W WO 2007064322 A1 WO2007064322 A1 WO 2007064322A1
Authority
WO
WIPO (PCT)
Prior art keywords
layer
roof
roofing product
combination
foam
Prior art date
Application number
PCT/US2005/043443
Other languages
English (en)
Inventor
Frank Lane Italiane
Amit Kurupathi
Original Assignee
Armorlite Roofing, Llc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Armorlite Roofing, Llc filed Critical Armorlite Roofing, Llc
Priority to PCT/US2005/043443 priority Critical patent/WO2007064322A1/fr
Priority to CA002631298A priority patent/CA2631298A1/fr
Publication of WO2007064322A1 publication Critical patent/WO2007064322A1/fr
Priority to US12/129,587 priority patent/US20090241450A1/en

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Classifications

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    • 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
    • B32B27/08—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 of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • 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
    • B32B27/065—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 of foam
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    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
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    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/302—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers
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    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/304—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
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    • B32B7/04—Interconnection of layers
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    • 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
    • E04D1/20—Roofing elements shaped as plain tiles or shingles, i.e. with flat outer surface of plastics; of asphalt; of fibrous materials
    • E—FIXED CONSTRUCTIONS
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    • 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
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    • E04D1/29—Means for connecting or fastening adjacent roofing elements
    • E—FIXED CONSTRUCTIONS
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    • E04D3/00—Roof covering by making use of flat or curved slabs or stiff sheets
    • E04D3/24—Roof covering by making use of flat or curved slabs or stiff sheets with special cross-section, e.g. with corrugations on both sides, with ribs, flanges, or the like
    • E04D3/32—Roof covering by making use of flat or curved slabs or stiff sheets with special cross-section, e.g. with corrugations on both sides, with ribs, flanges, or the like of plastics, fibrous materials, or asbestos cement
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Definitions

  • This invention pertains to roofing materials. More specifically, the invention concerns a novel composition of materials to create lightweight, decorative, weatherable multi-layer polymeric roofing system to meet specific building code requirements set by the International Code Council (ICC).
  • ICC International Code Council
  • Tiles are quite durable; however, their disadvantage is that they require a substantial amount of labor in their installation and can break on impact. Tiles tend to be excessively heavy and dangerous in earthquakes and high winds, and will fall through the roof in the event of a fire. Tiles are also expensive to ship because they are so heavy. Wood shakes and shingles are also subject to breakage as well as rot and loss of coloration. Their cost is high and they are labor intensive to install. Furthermore, wood shakes and shingles can be relatively heavy, are flammable, porous and cannot withstand relatively high wind velocity.
  • plastics are known in the art. However, many of the plastics have disadvantages, which typically may include poor ability to insulate, poor ability to withstand the ultra violet (UV) radiation from the sun, and poor ability to withstand shock from an impact (such as from people walking on the roof or hail). Plastics tend to become brittle, deformed and break with age. Also, plastics tend to loose color over time.
  • UV radiation ultra violet
  • plastics tend to become brittle, deformed and break with age. Also, plastics tend to loose color over time.
  • Asphalt shingles excel over most natural looking roofing materials. However, the natural materials are still in high demand because the asphalt shingles are unattractive and simply utilitarian in appearance.
  • Prior art teaches layers that are internally adhered by an adhesive. This bonding method is not applicable for a roofing application because of the extreme weathering conditions and subsequent failure by delaminating of layers or adhesive chemical incompatibilities with materials including colorants.
  • the present invention has overcome these issues in a roofing material.
  • Prior art teaches protective coatings on polymers that can include clear coats to resist staining from airborne dirt and pollutants. For example, Samafil, Inc., Canton, MA for their Saranfil thermoplastic roofing membrane applies a sprayed lacquer coating to the top of the membrane for this purpose.
  • Prior art teaches printing on polymers that can include clear coats to protect the printing colorant from UV and weathering.
  • Products of Pawtucket, Rl print a composite shingle pattern on top of the PVC membrane and then apply a sprayed clear acrylic or acrylic/PVC coating to protect the printing.
  • the clear coat that protects the printing has a warranty of less than five years.
  • roofing materials must have at least a ten year life. This method will not hold up to the extreme weathering of a roof, where the protective coating peels, discolors, wears from blowing dirt and, most importantly, deteriorates the printed materials.
  • the present invention has overcome these problems and has increased the useful life of the substrate layers to over 30 years by molecularly bonding the materials and other means that are described herein.
  • the composition of the roofing material is highly important in order to maximize protection from the natural elements and chemical pollution. Chemical pollution results from chemicals contained in smog and other air pollutants. These chemicals contribute to color loss, brittleness and other factors that decrease the durability of many types of roofing materials.
  • a primary objective of the present invention to provide a composition of a roofing material that provides ultraviolet protection, flame and fire retardancy, insulation, weatherability, longevity, durability and a new level of beauty in roofing materials.
  • Another objective of the present invention is to provide a composition of a roofing material that is lightweight and provides maximum protection from the weather and chemical pollution.
  • the invention passes stringent building codes specific to roofing test requirements, where the majority of polymeric roofing materials have failed overtime.
  • the ICC AC07 & AC75 documents are universal construction standards issued by the
  • ICC AC07 & AC75 Plastic roofing Products
  • ICC AC07 & AC75 defines plastic roofing products as a "fire classified, finished product with specific performance standards”.
  • ICC AC37 which applies to siding, only defines a "process standard”.
  • a process standard is very specific as to what types of materials and manufacturing process can be used.
  • a performance standard is based solely on the performance of a finished product: not on the type of materials or manufacturing processes that may be used.
  • a plastic roofing product In order to conform to ICC AC07 & AC75, a plastic roofing product must meet specified Acceptance Criteria (AC) and independent testing requirements.
  • AC Acceptance Criteria
  • the Zabrocki et al. US patents do not define a plastic roofing product requirements or in any way indicate that these inventions meet roofing building code requirements.
  • US Patent No. 5,334,450 states only that their invention can be used as a weatherable film for lamination to a non-weatherable substrate, such as wood, metal or plastic. See claim 1 and column 9 line 1.
  • ICC AC07 & AC75 There is no reference to ICC AC07 & AC75.
  • the Zabrocki et al. US patents are not germane to a plastic roofing product and meeting ICC AC07 & AC75 requirements.
  • Zabrocki's formulations (US Patents Nos. 5,306,548 or 5,334,450) do not meet plastic roofing building code requirements.
  • Coloration of plastics is a common practice to provide visual enhancement.
  • decorative designs by coloration to resemble the intricate features of roofing materials such as shake, slate or tile have never been seen before.
  • coloration has been unsuccessful in meeting the long term performance of roofing or the weatherable demands placed on the materials such as chemical compatibility, UV protection of the colorants and materials used.
  • realistic coloration to resemble marble or wood grain in roofing is non-existent until the present invention.
  • Another problem with most coloration processes is that it is applied to the exterior of a surface to gain control over the design. This method is impractical in a roofing application because chemicals, pollutants, wind, sand and other forms of weather will wear the colorants off the surface in a short time. Still another problem is that if one is to encapsulate a decorative faux design between two solid layers, then the design would be covered from view by the top layer. The only way the design could be seen is if a clear or nearly clear top layer is used. Using a clear material invites UV degradation which would be fatal for a full sun roofing material. Creating decorative faux designs such as wood grain, marble or other natural designs has never been done in a roofing application to meet building code requirements until this present invention.
  • the present invention has created decorative or faux (three dimensional) designs to resemble such roofing materials as shake, slate and tile and other designs such as leaves and sea shells or geometric patterns, in a weatherable manner that is able to achieve the required roofing building code performance requirements, including fire retardancy.
  • the present invention is a novel composition of weatherable (over 25 years) and semi- weatherable (less than 25 years) materials that can be injection molded, extruded or laminated into sheets or rolls to create a roofing system wherein the rolls or sheets are overlapped in order to provide a substantially weatherable covering on a roof.
  • the roll or sheet member has a top layer made of weatherable polymers and substrate layers made of semi-weatherable polymers. Decorative coloration is • applied to the layers and acts as a layer in itself.
  • the weatherable top layer materials include:
  • PMMA polymethyl methacrylate
  • ASA acrylonitrile/styrene/acrylate polymer
  • PC polycarbonate
  • PVC polyvinylchloride
  • the present invention defines "acrylic plastic" as base polymers that include polymers of acrylic acid and/or polymers of monomers structurally derived from acrylic acid or are copolymers of acrylic acid or its derivatives with other monomers.
  • An example of a popular plastic in this family is polymethyl methacrylate (PMMA), which term can be used interchangeably with acrylic plastic herein.
  • PMMA polymethyl methacrylate
  • the acrylic plastic can be formulated with butyl and ethyl acrylates.
  • This weatherable top layer polymer has high resistance to weathering because the molecular structure comprises a high concentration of stable, polymeric UV screener.
  • Acrylic plastic has a significantly higher resistance to UV radiation and attack by atmospheric oxygen than the butadiene rubber which is used, for example, in impact-modified polystyrene and acrylonitrile/butadiene/styrene (ABS).
  • ABS acrylonitrile/butadiene/styrene
  • ASA Acrylonitrile/Styrene/Acrylate polymer
  • the semi-weatherable substrate materials layers are made from formulations of:
  • HIPS high impact polystyrene
  • PET polyethylene terephthalate
  • CHDM cyclohexanedimethanol
  • PC polycarbonate
  • ASA acrylonitrile/styrene/acrylate polymer
  • PVC polyvinylchloride
  • thermoplastic olefin copolymers TPO
  • ABS acrylonitrile butadiene styrene
  • EPDM ethylene propylene diene terpolymer
  • thermoplastic elastomers TPE
  • PE polyethylene
  • fire retardant/fire resistant foams may include polyurethane foam, polyurea foam, polystyrene foam, polyethylene foam or PVC foam; or
  • substrate layers herein referred to as “substrate layers”.
  • Titanium Dioxide TiO 2
  • Antimony Oxide Sb 2 O 3
  • Magnesium Mg
  • Carbonate (CaCO 3 ), Zinc (Zn), Tin Oxide (SnO) and several other metal/metal-oxide powders as well as non-metal/non-metal-oxides and other metal/non-metal compounds can be incorporated during the compounding process and/or during the extrusion process.
  • These ingredients can incorporated as nanoparticles (1-100 nm), micron size particles or mixtures of nanoparticles and micron size particles.
  • the Heat Deflection Temperature (HDT) has been uniquely improved for use in roofing by these special and unique formulations and process for the semi-weatherable substrate layers.
  • the layers are injection molded, extruded, or laminated, but preferably multi-layer-extruded, and thus bonded. Then, the bonded materials may be used directly as a finished plastic roofing product or thermoformed or injection molded, to resemble more popular types of roof coverings such as shake or shingles, slate or tiles.
  • the exception of a semi-weatherable layer being applied by injection molding, extrusion, or lamination and thus bonded is where the fire-retardant/fire- resistant foams such as polyurethane foam, polyurea foam, polystyrene foam, polyethylene foam or the PVC foam are applied by filling, pouring, spraying or injecting after the injection molding, extrusion or thermoforming process.
  • the layers are engineered to pass stringent roofing building codes such as the International Construction Code (ICC), including fire rating.
  • ICC International Construction Code
  • the present invention (plastic roofing product) is a specialized polymeric formulated fire classified product unlike other construction material.
  • the present invention meets the requirement of ICC AC07 & AC75.
  • Other polymers, available in the marketplace will not meet the requirements of ICC AC07 & AC75.
  • the present invention was formulated and tested to specifically meet ICC AC07 & AC75 requirements.
  • the present invention (plastic roofing product) is useful only for its intended purpose, as a plastic roofing product and cannot be interchangeable with other material not intended as a plastic roofing product under the ICC AC07 & AC75 definition.
  • the present invention is a finished plastic roofing product, not a material for a variety of uses.
  • the present invention meets the need for a durable multi-layer polymeric roofing system with extended warranty.
  • the invention is not a film, but a finished product which is shaped to look like wood shake, shingles, tile, etc. or a flat roofing sheet with artistic designs that simulate three dimensional finished roofing products like wood shake, slate, clay tiles, etc.
  • the present invention teaches numerous ingredients formulated into a weatherable top layer and semi-weatherable substrate layers molecularly bonded with one another to meet ICC requirements.
  • the present invention has been designed to molecularly bond its layers without the need for an adhesive layer for bonding which would be impractical in the extreme environment that a roofing material experiences.
  • the present invention is improved over Zabrocki et al (5,306,548 or 5,334,450) without the need for adhesive interlaminate layers for bonding.
  • the present invention uses specialized proprietary formulated weatherable and non-weatherable polymers that are needed to meet roofing material performance building code tests such as Weatherometer, pre- and post-aging flexural and tension tests, impact, and fire resistance. Most colorants are introduced into the base material then injection molded or extruded.
  • the present invention created a process using colorant particles thst have been engineered to maintain their physical integrity creating a "streaking effect" during polymer flow that looks like the natural striations in marble or wood grain. These colorant particles flow with the other materials while traveling through the barrel across the screw inside the extruder.
  • the present invention created a new and innovative process of coloration to resemble three dimensional natural designs such as wood grain, leaves, marble or geometric patterns for a roofing application for the first time that can be applied by specialized inkjet, flexographic or rotogravure printing.
  • the preferred printing method is by inkjet in specific artistic applications.
  • the colorants used are compatible with the top and substrate layer materials. Many tests resulted in failure because the colorants contaminated the top layer or substrate layer causing, tearing, delaminating, degradation, brittleness, and discoloration. Printing colorants or inks are not normally compatible with the materials used in the invention.
  • the present invention must be fire tested and rated for its ability to retard ignition and flame spread.
  • the fire rated system of the present invention and the testing agency must be approved by building code officials.
  • photovoltaic (solar) panels have been integrated to look like traditional roofing materials such as tiles and shingles by such companies as BIPV, General Electric, PowerLight and Sharp.
  • the present invention has gone beyond integrating the look of the solar panels with roofing tiles and shingles.
  • the present invention incorporated photovoltaic generating film amorphous devices encapsulated under the top layer for weatherable and natural designs, such as tile and shake. Therefore, the present invention has utilized its unique coloration designs, UV stability, fire retardant, layer composite and building code approval materials to incorporate a photovoltaic generating system that has he natural look of roofing materials.
  • a photovoltaic module may serve as a shingle, tile or other building material such as in Bressler et al US Patent 5,590,495 or Younan et al US patent 5,437,735
  • the present invention is an actual polymeric shingle, tile or other roofing material with photovoltaic generating technology incorporated within the layers of the present invention with its advantages and innovations. There is no difference in the appearance of the roofing materials as with all other solar, photovoltaic roofing systems.
  • electrical connectors are used for connections between each of the present invention's (plastic roofing products) panels.
  • a "tie layer" may be used to tie the photovoltaic generating device to the composite of layers.
  • Figure 1 is a sketch showing an exploded view of the various layers of the non-thermoformed preferred embodiment of this invention. This product has an approximate 50 year life.
  • Figure 2 is a sketch illustrating, in exaggerated cross-section, the thermoformed preferred embodiment after thermoforming.
  • Figure 3 is a sketch showing an exploded view of the various layers of the non-thermoformed alternate embodiment of this invention. This embodiment has an approximate 25 year life.
  • Figure 3A is a sketch showing an exploded view of the various layers of the non-thermoformed second alternate embodiment of this invention.
  • Figure 4 is a sketch illustrating, in exaggerated cross-section, the thermoformed alternate embodiment and second alternate embodiment after thermoforming.
  • Figure 5 is a sketch illustrating, in exaggerated cross-section, the special alternate embodiment in which one layer of foam is shaped to produce a raised center portion for the thermoformed embodiments.
  • Figure 6 is a sketch illustrating the view from the bottom of an actual thermoformed embodiment, alternate embodiment or second alternate embodiment of this invention.
  • Figure 7 is a cross section along the lines 7-7 of Figure 6.
  • the present invention (plastic roofing product) comprises a sheet or roll member having a top layer and substrate layers.
  • FIG 1 illustrates the sheet or roll preferred embodiment 10 of this invention. This embodiment
  • a UV stabilized top layer 14 made of weatherable top layer materials
  • the invention 10 may also include a tie layer 20 to tie the top layer 14 and substrate layer 22 together.
  • the invention 10 may also include:
  • a second substrate layer 30 which is made of the same formulated semi-weatherable material.
  • the invention 10 may also include an intumescent fire retardant / fire-resistant layer 34 applied to the bottom 32 of the substrate layer 22 or 30.
  • the invention 10 may also include a fire-retardant/fire-resistant foam layer 66 applied before or after the intumescent fire retardant layer 34 to the bottom 32 of the substrate layer 22 or 30.
  • the invention 10 may also include a layer of photovoltaic film cells 18 between the top 14 and the substrate 22 or tie layer 20.
  • the invention 10 may also include a layer of skid- & UV resistant - material 12 applied to the top
  • This layer may, in addition, be UV resistant.
  • the invention 10 may also include a layer 16 of UV stable colorants, applied to the underside 15 of the top layer 14. In this case the top layer 14 must be clear.
  • the invention 10 may also include a layer 60 of fire retardant/fire resistant cloth, felt, paper or polymer.
  • the invention 10 may also include a second layer 17 of UV stable colorants, applied to the top side 19 of the layer of photovoltaics 18, the top side 21 of the tie layer 20, or the top side 23 of the substrate layer 22.
  • the layer 16 or layers 16, 17 of colorants thus become encapsulated between layers
  • the colorants 16 and 17 may be applied under heat and the composite 10 may be annealed after encapsulating the colorants 16, 17.
  • the layer 16 or layers 16, 17 of colorants can be applied in a pattern that simulates a three dimensional natural roofing product or a natural product (such as marble or sea shells) or any fanciful design, when viewed from a distance.
  • the top layer 14 may include colorant particles disbursed in the semi- weatherable plastic.
  • the properties of these colorant particles are engineered to release color in a predetermined manner. In other words, the size, hardness, melt rate and Vicat softening point, etc. are controlled so that they spread out at processing speeds and temperatures to create design patterns such as wood grain and marble appearance.
  • These colorant particles are also slightly miscible with the top layer 14 materials so that they also color the entire top layer.
  • Figure 2 illustrates the thermoformed preferred embodiment 10a of this invention 10.
  • This embodiment 10a comprises all the layers described above for the sheet or roll embodiment 10.
  • the layer of intumescent fire retardant 34, fire-retardant/fire-resistant foam layer 66 and fire retardant/fire resistant paper must be applied after thermoforming.
  • the invention 10, 10a is fastened over the underlayment 38 of a roof.
  • Methods of attachment include a layer of adhesive. This includes double sided adhesive tape and a bead of adhesive.
  • FIG. 1 illustrates the sheet or roll alternate embodiment 11 of this invention.
  • This embodiment 11 comprises:
  • a substrate layer 22 which is made of semi-weatherable materials and formulated with fire retardants and UV stable colorants.
  • the invention 11 may also include:
  • a second substrate layer 30 which is made of the same formulated semi-weatherable material.
  • the invention 11 may also include a tie layer 20 to tie the substrate layer 22 and scrim layer 26 together.
  • the invention 11 may also include an intumescent fire retardant layer 34 applied to the bottom 32 of the substrate layer 22 or 30.
  • the invention 11 may also include a fire-retardant/fire-resistant foam layer 66 applied before or after the intumescent fire retardant layer 34 to the bottom 32 of the substrate layer 22 or 30.
  • the invention 11 may also include a layer of photovoltaic film cells 18 between the substrate 22 and tie layer 20 or second substrate layer 30.
  • the invention 11 may also include a layer 60 of fire retardant/fire resistant cloth, felt, paper or polymer.
  • the invention 11 may also include a layer of skid resistant material 12 applied to the top 23 of the substrate layer 22.
  • This layer may, in addition, be UV resistant.
  • the invention 11 may also include a layer 16 of UV stable colorants, applied to the underside 32 of the substrate layer 22.
  • the substrate layer 22 must be clear.
  • the invention 11 may also include a second layer 17 of UV stable colorants, applied to the top side 19 of the layer of photovoltaics 18, or the top side 21 of the tie layer 20.
  • the layer 16 or layers 16, 17 of colorants thus become encapsulated between layers 22 and 18, or 20 of the invention 11.
  • the colorants 16 and 17 may be applied under heat and the composite 11 may be annealed after encapsulating the colorants 16, 17.
  • the layer 16 or layers 16, 17 of colorants can be applied in a pattern that simulates a three dimensio ⁇ ! natural roofing product or a natural product (such as marble or sea shells) or any fanciful design, when viewed from a distance.
  • the substrate layer 22 may include colorant particles disbursed in the semi- weatherable plastic.
  • the properties of these colorant particles are engineered to release color from in a predetermined manner. In other words, the size, hardness, melt rate and Vicat softening point, etc. are controlled so that they spread out at processing temperatures to create design patterns such as wood grain and marble appearance.
  • the layers indicated on Figure 3 by the bracket 44 are called the base.
  • FIG 3A illustrates the sheet or roll second alternate embodiment 25 of this invention.
  • This second alternate embodiment 25 is identical to the alternate embodiment 11 , previously described, except that it lacks the substrate layer 22 and the first or only layer of colorant 16.
  • the layers of colorant 17 can go on top 19 of the layer of photovoltaics 18, on the bottom 31 of the layer of photovoltaics 18 or on top 21 of the tie layer 20. If the colorant 17 is below the layer of photovoltaics 18, the layer of photovoltaics 18 is clear.
  • Figure 4 illustrates the thermoformed alternates 11 a, 25a of this invention 11 , 25.
  • These embodiment 11 a, 25a comprises all the layers described above for the sheet or roll embodiment 11 , 25.
  • the layer of intumescent fire retardant 34, fire-retardant/fire-resistant foam layer 66, and fire retardant/fire resistant paper 60 must be applied after thermoforming.
  • These embodiments are formed to have a raised central portion 50 and at least one flat lip 54.
  • the invention 11 , 11a, 25, 25a is. fastened over the underlayment 38 of a roof.
  • One method of attachment is by adhesive 36, including double sided adhesive tape.
  • the top layer 14 is made of weatherable materials to create a molecularly superior structure for use in certain applications which are described herein.
  • the substrate layers 22, 30 are made of specially formulated semi-weatherable components as described, for use as a roofing product.
  • the layers of the invention as defined in Fig. 1 and 2 can be laminated by extrusion, multi-layer-extrusion, laminating or injection molding. For a dimensional look of shake, slate, shingle or tile the laminate may be thermoformed or molded. Also, the material may be decoratively colored to resemble shake, slate, marble, shingle or tile for example.
  • the top layer 14 can also be colored with a colorant so that it has a solid color.
  • colorant particles can be incorporated into this layer 14 during processing so that the particles melt and spread out during processing to create random patterns of marbleized or wood grain effects.
  • the colorant 16, 17 used in this invention 10, 10a is preferably specially formulated acrylic so as to be molecularly compatible with the layers 14 and 18, 20 or 22 between which it is encapsulated. Alternatively it can be designed to etch into and bond with the layers 14 and 18, 20 or 22.
  • the sheet or roll member has a top surface 13 exposed to the elements, intermediate substrate layers 22, 30 and a bottom surface 46 that faces the sub surface 38 of the roof when the plastic roofing product 10 is placed on the roof.
  • the substrate layers 22, 30 are made of proprietary formulations of semi-weatherable compounds for use in roofing materials.
  • the present invention uses a proprietary specialized weatherable top layer 14 and semi-weatherable substrate layers 22, 30 needed to meet required roofing material performance codes such as impact and fire resistance.
  • This weatherable top layer 14 includes a specialized compound that works in concert with the specialized compounds of the semi-weatherable substrate layers 22, 30 that can be injection molded, extruded and bonded, laminated, or multi-layer-extruded.
  • the weatherable top layer 14 is a weatherable polymer or copolymer with resistance to weathering, impact, aging and yellowing.
  • weatherable top layer 14 used in this invention as described herein has specific additives that other weatherable materials do not have. These additives impart resistance to UV, weathering, heat aging, high mechanical strength, impact resistance, fire retardance and corrosion resistance.
  • Figure 5 is a sketch illustrating, in exaggerated cross-section, the special alternate embodiment in which the fire-retardant / resistant fire foam layer 66 or one of the substrate layers 22, 30 (when made of foam) is shaped to have a thick central portion 86.
  • the layers 78 above the specially shaped foam layer 22, 30 or 66 are as described above.
  • the layer 34 or 74 below the foam 22, 30 or 66 is applied so as to fully encapsulate the foam layer 22, 30 or 66.
  • the layer 34 or 74 is made of intumescent fire retardant as described below, or the same semi-weatherable materials as described below other than foam.
  • the weatherable top layer 14 is a specially formulated polymer made up of several monomers and/or copolymer and was designed to be flexible because of its molecular structure.
  • ASA Acrylonitrile/Styrene/Acrylate
  • PVC polyvinyl styrene
  • PC copolymer for the top layer of the present invention for certain applications where an acrylic resin or an ASA would not be applicable on their own.
  • ASA is an excellent weatherable capsheet although it is not clear to reveal coloration designs such as shake or tile from and on the under surface.
  • Acrylic is an excellent clear weatherable capsheet, although higher in cost as compared to an ASA, where the ASA has superior weatherable properties to Acrylic.
  • the glass transparency is not as critical.
  • the copolymer of any of the weatherable top layers can have cloudiness to the point of showing through the coloration designs on the under side of the copolymer.
  • these weatherable top layer copolymers can be designed to have refractive index ratio (velocity of light in a vacuum to its velocity in a substance). This was measured using the ratio of the sine of the angle of incidence to the sine of the angle of refraction to find a reflective balance to find clarity when creating the copolymer formulation. For example, in some applications a ratio of 20% ASA and 80% Acrylic was applicable, whereas the reverse was true in other coloration applications of 80% ASA and 20% Acrylic was applicable. Refractive index was measured by a process specified in ASTM D542.
  • indexes (1.375) of refraction were used to reduce surface or back reflection and are desirable for certain applications.
  • high indexes of refraction tend to correspond to higher brilliance.
  • the refractive indexes of these weatherable top layer copolymers had to be then tied to the three dimensional effect of the coloration to bring out the most realistic three dimensional look on a two dimensional surface.
  • the ASA and PVC has a natural yellow color that needed to be neutralized with a blue toner giving greater clarity in balance with cost and durability.
  • the refractive index of these weatherable top layer copolymers is a function of the ratio of these polymers. This is a valuable tool for adjusting the appearance of the decorative effects applied to the backside 15 of the top layer 14.
  • the natural color of the ASA and PVC polymer is a pale yellow. Blue dye is commonly used in transparent polymers to offset this natural color. Adjusting the level of blue dye adds another means to enhance the decorative effects or clarity desired.
  • Skid and UV resistant materials 12 such as any of the semi-weatherable or weatherable top layer materials can be combined with silica sand and may be applied in a rough manner, such as a course sprayed, to the top surface 13 to add a rough surface to help in the resistance of slipping by foot traffic on the present invention 10, 10a (plastic roofing product) on a roof.
  • the present invention 10, 10a, 11 , 11a uses proprietary formulations and ingredients, as listed herein, that are needed to meet roofing material performance codes such as impact and fire resistance.
  • the semi-weatherable substrate layer 22, 30 compounds are specially formulated with flame retardant to provide a substantially flame retardant and flame extinguishing material for the flammable top layer 14.
  • This present invention 10, 10a has created a unique polymer chain with certain desirable properties so the semi-weatherable substrate layer 22, 30 polymer compounds bond with the weatherable layer 14 polymer compound and have resistance to delaminating, heat, toughness, and flexibility. Most importantly, the layers 14, 22 and 30 can bond without the need of any adhesive. For the reinforcing strength of the substrate layers 22, 30 a continuous filament yarn in an open-mesh construction called a scrim 26, may be used for further reinforcement of the structure between layers 22 and 30.
  • the present invention's substrate layer 22, 30 formulations use additives such as plasticizers, co- stabilizers and heat stabilizers to prevent degradation caused by the high temperatures during processing.
  • Pigments, inks or dyes, generally called colorants can be added to the present invention so that the finished product will be colored throughout.
  • Flame retardants are added to impart good flame retardant properties to the product.
  • Flame extinguishing material is added to the semi-weatherable layer 22, 30 polymer compound specifically to extinguish the flammable weatherable top layer 14. Processing aids and lubricants are used to assist in production and to improve the viscosity of the resin during processing.
  • the polymer formulations used in the invention have been researched and tested to meet the requirements of AC07 and AC75.
  • the specialized formulation of the weatherable top layer 14 was researched and exhaustively tested to work with the semi-weatherable compounds of the substrate layer 22, 30 materials.
  • This top layer 14 is a high density material that has enhanced mechanical properties with special characteristics such as high tensile strength, elongation at break, modulus of elasticity in tension, good impact strength. Also, it has good thermal stability and high Vicat softening temperature. It has good chemical resistance, and resistant to weathering, aging and yellowing. It might not be feasible to bond weatherable materials and semi or non-weatherable films and expect good molecular compatibility as well as to meet stringent building codes.
  • a weatherable top layer 14 must have special characteristics to work with the material formulations of the semi-weatherable substrate layer 22, 30 material formulation to meet building codes for roofing and pass physical properties tests as indicated below.
  • the present invention passes ICC AC07 & AC75 required ASTM, UBC & UL tests as indicated herein to meet building code requirements:
  • AC75 Weatherometer A. AC-75- (Section 4.1.1); Tensile Strength A. (ASTM D-638); Flexural Strength A. (ASTM D-2137); Wind Resistance A. Static Wind Testing; Uplift Bend A. AC-75 (Section 4.1.5); Penetration A. AC-75 (Section 4.2.2); Roof Classification A. Class A Burning Brand (ASTM E-108), B. Class A Int. Flame (ASTM E-108), C. Class A Spread-of-Flame (ASTM E-108); Temperature Cycling A. AC-75 (Section 4.2.3); Wind-Driven Rain A. AC-75 (Section 4.2.6); Burn Rate A. UBC 2603.6; Ignition Properties A. UBC 2603.6 The following chart shows the significant test methods used to establish the physical properties requirements for the present invention 10, 10a and the typical properties achieved by said invention 10, 10a:
  • the tie layer 20 is used to tie a non-polar polymer such as a TPO sheet and a polar polymer such as an acrylic film.
  • the tie layer 20 is a co-polymer including an acrylate and ethylene component that will bond with both the top layer 14 and lower substrate layer 22.
  • the top layer 14 of acrylic plastic and tie layer 20 would preferably be co-extruded from a two-layer die and then laminated to the substrate layers 22.
  • the "tie layer” 20 consists of Ethylene Methyl Acrylate Copolymers (EMAC) and/or Ethylene Butyl Acrylate Copolymers resins.
  • EMC Ethylene Methyl Acrylate Copolymers
  • the tie layer 20 is made and formulated to be compatible with the incompatible semi-weatherable layer 22.
  • the tie layer 20 is soft, pliable and tough at ambient and freezing temperatures and exhibits excellent environmental stress crack resistance (ESCR).
  • the tie layer polymer is formulated to exhibit high solids fillability and compatibility with the top 14 and substrate layer 22.
  • the formulation for the tie layer 20 must be created in a manner to setup an ion exchange with the resins so they are cross-linked polymers.
  • the ion exchange resins that are used to affect such exchanges are of two types: cation exchange and anion exchange resins. By using the two types either singly or in combination the incompatibility of non polar and polar polymers becomes possible when these ions are altered, removed, or recovered.
  • the cation exchange resin or substrate 22 and top layer 14 act as a solid organic acid, resinified and containing replaceable hydrogen (or sodium), which will readily release in exchange of any cation (sodium, potassium, ammonium, etc.).
  • Anion exchange resins are resinous organic bases are activated by acid removal and anion exchange.
  • the copolymer of styrene and divinyl benzene is treated with chlorosulfonic acid, a polymer is produced that has cation-capturing properties because of the free sulfonic acid groups.
  • the polymerized product is insoluble during all phases of an ion exchange reaction.
  • the anion exchanges are made by including a chloride-bearing monomer with the styrene divinyl benzene copolymer.
  • a reaction with a tertiary base gives a salt, which yields a strong, insoluble polymeric hydroxide.
  • thermoplastic ionomers have ethylene as their major component by contain both covalent and ionic bonds.
  • the io ⁇ omer polymer exhibits very strong interchain ionic forces.
  • the anions hang from the hydrocarbon chain, and the cations are metallic (sodium, potassium, magnesium).
  • roofing materials and underlayments are classified by a fire rating system into Class A, B or C.
  • Class A is the most stringent and includes three specific fire tests; burning brand, spread of flame and intermittent flame.
  • Many roofing materials use a system of underlayments in combination with the roofing material to achieve a fire rating such as 30 Ib felt combined with a roofing material.
  • the present invention 10, 10a can use a system to gain a class A fire rating, the present invention has also developed a novel application of a special and proprietary application of a fire-retardant/fire-resistant layers applied or attached to the bottom layer. This is in addition to the fire retardants used in the formulations of the other layers.
  • the present invention has fire retardants in its substrate layers 22, 30 to extinguish flames of the top layer 14.
  • the present invention 10a, 11a can have an additional fire retardant/fire-resistant intumescent layer 34 in the chamber 62 as an alternative to applying underlayments necessary for a Class A fire rating and or increasing the fire protection of the present invention to bring the present invention into compliance with federal, state and local building code requirements.
  • This fire-retardant/fire- resistant intumescent layer 34 is applied to the chamber 62 above the specially shaped foam layer 86.
  • the layer 34 is applied by spray that could be a two step catalyst epoxy process. When the fire-retardant/fire-resistant intumescent layer 34 is exposed to high heat such as fire, it will expand creating foam to encapsulate the fuel and oxygen of the fire, thus extinguishing the fire.
  • the fire retardant/fire-resistant intumescent layer 34 is applied to the chamber 62 above specially shaped foam layer 86 and also to the bottom 32, 70 of the specially shaped foam layer 86.
  • the foam layer 86 helps to add impact strength, insulation and another fire barrier.
  • the foam layer 86 is preferably selected from foams such as polyurethane foam, polyurea foam, polystyrene foam, polyethylene foam and PVC foam.
  • the surface of the chamber 62 might have to be prepared and treated with special chemicals prior to the application of the foams for enhanced adhesion. These foams can be applied by filling, spraying, pouring or injecting into the chamber 62 of the roof panels 10a, 11a.
  • the fire retardant/fire-resistant foam layer 34 is applied to the bottom 32, 70 of the shaped foam layer 86.
  • a layer 76 of specially formulated fire-resistant mineral core is attached in the chamber 62 between the shaped foam 86 and the fire retardant/fire resistant foam 34.
  • a layer of fire-retardant/fire-resistant cloth, felt, paper or polymer 60 is attached to the bottom 46 of the fire retardant/fire resistant foam 34 or the encapsulating layer 74.
  • the fire-retardant/fire-resistant foam layer is filled, poured, injected or sprayed into the chamber or by packing a pre-formed block of high-density fire-retardant/fire-resistant foam in the chamber.
  • foams can be of many forms (physical structure) like a liquid foam, rolls, planks or sheets depending on their densities, the higher the density, the heavier and harder it is.
  • the foams also can be categorized as flexible, rigid, close-celled or open celled.
  • fire retardant/fire resistant grade foams that are compatible with the said weatherable and semi-weatherable layer materials that may include polyurethane foams, polyurea foams, polystyrene foams, polyethylene foams and PVC foams.
  • the polyurethane materials are formed by the reaction of isocyanates and polyols where the Polyurea materials have a chemical reaction between an isocyanate and an amine where Polystyrene, a polymer made from the monomer styrene, a liquid hydrocarbon that is commercially manufactured from petroleum. All these foams and their chemical reactions have been specially formulated to create compatibility with the said semi-weatherable and weatherable layers.
  • the foams can be impregnated with several fillers such as wood-chips, saw-dust and other fibers including minerals and in-organic fillers such as ceramics including silica, glass fillers (fiber glass, glass wool) either purely in the micron-size range / nano-size range or as a mixture of micron and nano-size fillers.
  • fillers such as wood-chips, saw-dust and other fibers including minerals and in-organic fillers such as ceramics including silica, glass fillers (fiber glass, glass wool) either purely in the micron-size range / nano-size range or as a mixture of micron and nano-size fillers.
  • the specially formulated fire-resistant mineral core layer may consist of several ingredients such as fiber glass, fiber wool, gypsum, wood-chips, saw-dust other fibers including minerals and in-organic fillers such as ceramics including silica, glass fillers (fiber glass, glass wool) either purely in the micron- size range / nano-size range or as a mixture of micron and nano-size fillers. It is applied to the chamber by pouring, injecting, spraying or filling.
  • the semi-weatherable and weatherable layers surface may have to be modified physically by etching, abrading or roughening its surface and/or pre-treated with special chemicals/solvents prior to application of the foams for enhanced adhesion.
  • These said semi-weatherable foams can be applied by filling, spraying, pouring or injecting into the chamber.
  • the fire-retardant/fire-resistant intumescent layer can be coated or sprayed onto the chamber.
  • the intumescent layer when applied to a separate fire-rstardant/fire-resistant layer like felt, paper, fabric, or polymer may be treated with phosphate salts and coated with other non-combustible materials.
  • the top 14 and substrate layers 22, 30 interact with the fire- retardant 34 to create a charred block and then the top 14 and substrate layers 22, 30 form a composite with the underlayment 38.
  • the underlayment 38 is then protected by this charred block composite by the fire-retardant layer 34 producing water and gases, which smother the oxygen and confront the flame's energy forcing the dense char to continue to form creating further protection to the underlayment 38 from combustion.
  • the unique and specific formulations of the semi-weatherable polymers are compounded to interact with the specialized weatherable polymer to bond and be flame retardant. Most important is the ability of the present invention's 10, 10a novel compound of said semi-weatherable polymer and the weatherable polymer to meet building codes such as Underwriters Laboratories Inc. or ICC AC07 & AC75 Evaluation Service, Inc.
  • ASA Acrylonitrile/Styrene/Acrylate Polymer
  • ABS Acrylonitrile/Butadiene/Styrene
  • Heat Stabilizer - Mark 1900 Magnesium, Chlorines, Bromines
  • PH 800-662-2927; Ingredient: Acrylonitrile/Styrene/Acrylate Polymer (ASA), Acrylonitrile/Butadiene/Styrene (ABS) , styrene acrylonitrile copolymers (SAN)
  • ASA Acrylonitrile/Styrene/Acrylate Polymer
  • ABS Acrylonitrile/Butadiene/Styrene
  • SAN styrene acrylonitrile copolymers
  • Ethylene Methyl Acrylate Copolymers (EMAC)
  • Ethylene Butyl Acrylate Copolymers '
  • Pigments - R 101 (TI02), Ketone ethylene ester and ethylene interpolymer, thermoplastic polyolefin (TPO), thermoplastic elastomers (TPE), Polypropylene (PP), Elvaloy Plasticizer
  • ASA Acrylonitrile/Styrene/Acrylate Polymer
  • ABS Acrylonitrile/Butadiene/Styrene
  • PPO Poiyphenylene
  • PC polycarbonate
  • Heat Stabilzers including co-stabilizers H1214.
  • the product 10a, 11a that have a raised central portion 50 and substantially flat lips 54 extending from the edges 58.
  • the product 10a, 11a is installed so that the lips 54 overlap.
  • the lips 54 lay substantially flat on the roof to define a chamber 62 between the plastic roofing product 10a, 11a and the underlayment 38.
  • the raised central portion 50 does not contact the underlayment 38 and is formed and designed to simulate the appearance of at least one predetermined type of roofing material including but not limited to tile, slate, and wood shake or shingle.
  • the chamber 62 defined by the plastic roofing product 10a, 11a and the underlayment 38 traps a pocket of air that along with the semi-weatherable polymer layer 22 provides good insulation and heat dispersion.
  • the bottom layer 22, 30 or 34 faces the roof, and the top layer 14 is exposed to the weather.
  • the composition of the top layer 14 and substrate layer 22 and the unique combination of the layers 14 and 22 offer optimal benefits.
  • the top layer 14, being made of weatherable polymer compounds has been found to be highly resistant and durable against water as well as the wearing effects of the UV rays of the sun.
  • the substrate layer 22, being made of specialized semi-weatherable polymer compounds offers good insulation and has been found to be highly resistant to impact and fire.
  • the semi-weatherable substrate layer 22 is also protected from UV rays by the top layer 14, although the substrate layer 22 has UV protection in case the substrate layer 22 becomes exposed to the sun.
  • the colorants for the decorative designs are applied to the underside "15, 32 of the top layer 14, 22 by using specific print technology that is tied to corresponding graphic computer software designs. Then, the top layer 14, 22 is laminated to the next substrate layer 18, 20, 22 or 26 with the colorants16, 17 between the two layers to protect them from the weather.
  • a special formulated colorant is used that bonds and etches into the top layer 14, 22 and is made from special formulated acrylic based colorants with bonding properties and UV properties compatible with the top and substrate materials. In effect the colorants 16, 17 become the second layer.
  • the colorant 16, 17 is compatible with the adjacent layers so as not to cause damage such as delaminating, degradation of layers, color change or other long-term chemical reactions that would cause the material to fail ICC building code requirements.
  • Preferred decorative designs resemble the three-dimensional appearance of shake, slate or tile for a roofing application. Again, these decorative faux designs have never before been seen in roofing materials for reasons the present invention has overcome by combining specific manufacturing methods, specific industrial print technology, colorant formulation, computer software graphic design, polymer/colorant compatibility, flammability and durability to pass ICC roofing requirements.
  • the semi-weatherable substrate layers 22, 30 use specialized formulations that may use compatible recycled material and may include scrap, including: polyvinyl chloride (PVC), Acrylonitrile/Styrene/Acrylate polymer (ASA), Acrylic Plastic, polymethyl methacrylate (PMMA), thermoplastic olefin copolymers (TPO) or acrylonitrile butadiene styrene (ABS) or copolymer alloy (CPA) or ethylene propylene diene terpolymer (EPDM) or thermoplastic elastomers (TPE) or styrene butadiene (SB) or rubber or polyethylene (PE) or polypropylene (PP) or specialized fire-retardant/fire-resistant foams that may include polyurethane foam, polyurea foams, polystyrene foams, polyethylene foams and
  • PVC foams or any of the said weatherable 14 or semi-weatherable layers 22, 30 or other additives that are compatible to the requirements of the formulation to meet building code requirements may be applied by laminating, pouring, filling, injecting or spraying.
  • the present invention 10, 10a, 11, 11a can be attached to the sheeting over the framing of a roof or to the underlayment 38 on top of the sheeting in a variety of ways.
  • roofing nails or a double or single sided adhesive peel and stick film can attach the present invention 10, 10a, 11 , 11a to the sub surface 38.
  • the overlapping seams of the present invention 10, 10a, 11, 11a may be heat welded when installed on a roof to form a water proof membrane.
  • the invention 10, 11 includes a decorative faux appearance of dimension, i.e. a three dimensional look, that is actually flat.
  • the flat decorative faux design simulates the appearance of at least one predetermined type of roofing material including but not limited to tile, slate, and wood shake or tile.
  • the appearance can also be made to simulate marble, sea shells, and any fanciful design.
  • the flat plastic roofing substrate layers 22, 30 When placed on a roof, the flat plastic roofing substrate layers 22, 30 provide good insulation. Also, when placed on a roof, the bottom layer 22, 30 or 34 faces the underlayment 38, and the top layer 14 is exposed to the weather.
  • the composition of the top layer 14 and substrate layers 22, 30 and the unique combination of the layers offer optimal benefits.
  • the top layer 14, being made of weatherable polymer compounds, has been found to be highly resistant and durable against water as well as the wearing effects of the UV rays of the sun.
  • Specialized semi-weatherable polymer compounds offer good insulation and have been found to be highly resistant to impact and fire.
  • the semi-weatherable substrate layers 22, 30 are also protected from the UV rays by the top layer 14, although the substrate layers 22, 30 have UV protection in case of the substrate layers 22, 30 become exposed to the sun.
  • Skid & UV resistant materials 12 such as silica sand coated with any compatible material such as the said weatherable or semi weatherable materials may be applied in a rough manner, such as by course spraying, to the top surface 13, 23 to add a rough surface to help in the resistance of slipping by foot traffic on the present invention 10, 10a, 11, 11a (plastic roofing product) on a roof.
  • the present invention 10, 10a, 11 , 11 a has gone beyond integrating the look of the solar panels with roofing tiles and shingles.
  • the present invention 10, 10a, 11, 11a can incorporate photovoltaic generating film amorphous devices 18 encapsulated under the top layer 14 or semi-weatherable layer 22 for weatherable and natural designs, such as tile and shake. Therefore, the present invention 10, 10a, 11 , 11 a has utilized its unique coloration designs, UV stability, fire retardant, layer composite and building code approval materials to incorporate a photovoltaic generating system that appears to be the natural look of roofing materials.
  • a photovoltaic module 18 may serve as a shingle, tile or other building material such as in Bressler et al US Patent 5,590,495 or Younan et al US patent 5,437,735, the present invention 10, 10a, 11, 11a is an actual polymeric shingle, tile or other roofing material with photovoltaic generating technology incorporated within the layers of the present invention 10, 10a, 11 , 11 a 10, 10a, 11 , 11 a with its advantages and innovations. There is no appearance difference in the roofing materials as is with all other solar, photovoltaic roofing systems.
  • a photovoltaic panel When the present invention 10, 10a, 11 , 11 a is for used as a photovoltaic panel, electrical connectors are used for connections between each of the present invention's (plastic roofing products) panels. As stated herein, a "tie layer" 20 or some other means may be used to tie the photovoltaic generating device 18 to the substrate layer 22, 26.
  • a method to release heat build up in the invention's composite and to mitigate deformation was invented. This was necessary where the use of dark colors on the top layer 14 would have a considerable heat build up, transferring to the substrate 22, 30, as opposed to light colors. Therefore, UV protection is applied to the top layer material and colorants, where Infrared (IR) passes through the top layer 14 to be reflected out by the substrate layer 22, 30.
  • the substrate layer 22, 30 has reflective additives such as TiO 2 to reflect back and out of the composite, keeping the IR from building-up heat in the substrate 22, 30.
  • the present invention 10, 10a has proven that a black substrate will have higher heat build-up than white even through the opacity is 90-100% UV blocked by the weatherable top layer 14. Therefore, a method of reflecting IR through the weatherable materials, colorants and substrate was engineered by the use of materials, reflectants, layering, colorants and by controlling thickness. To prove this theory, the following tests were preformed:
  • Samples of roofing Laminates were exposed to two IR lamps.
  • the samples were the streaked blue-gray (Midnight Gray) ASA cap laminated to PVC backing.
  • the backing formulation was that of the present invention 10, 10a with 30% PVC-ASA regrind.
  • the PVC substrate 22 was extruded at 0.070 in.
  • Two backing colors were made - natural (a light beige color) and black.
  • the samples were exposed to the IR Lamps with the light shining on the cap surface 13. Exposure time was one hour. Non-contact surface temperature measurements were taken of the front 13 and the back 32 surface at one hour exposure time. Two samples with natural-colored backing and two with black colored backing were exposed. The temperatures reported are averages of the measurements.
  • IR is a type of electromagnetic radiation of wavelengths 700 nm -1 nm longer than visible light, but shorter than microwave radiation. It was discovered that the infrared absorptions or reflections depends a lot on the particle size of the colorants used in the formulation. Therefore, in this scenario, though some of the IR of smaller wavelengths are blocked or absorbed by the colorants present in the top layer 14 due to the fact that IR wavelength is closer to the particle-size of the pigments present, longer wavelengths of IR pass through the top layer 14 with little or no absorption.
  • the certain percentage of IR that goes through the top layer 14 heats up the substrate layer 22 which absorbs or reflects the radiation that is incident upon it. It was further discovered, that the top layer 14 heats up more than the substrate layer 22 due to the fact that the top layer 14 has a lot of UV blocking colorants like TiO 2 and other metal/metal oxide additives
  • the IR passes through the top layer 14, it heats up a black substrate layer 22 more than a white substrate layer as the color black absorbs more heat than white. Also as the substrate layer is heated up, it transfers some of its heat back to the top Iayer14 by conduction and therefore you see a difference in temperatures of the top layers 22 with 2 different substrate layers.
  • Thickness Plastic roofing products were fabricated in accordance with the above description.
  • the top layer 14 of the weatherable polymer compound was from 0.002 to 0.015 in. thick and the layer 22 of semi-weatherable polymer compound was from 0.010 to 0.125 in. thick before thermoforming. Based on the current design of the plastic roofing product it is estimated that the desirable thickness of the product should between 0.045" and 0.090" in roll applications and between 0.045" and 0.125" in thermoformed applications.
  • thermoformed plastic roofing product sizes experimented with range from Vi' - 1.5" thick by 12"-36" by 36"-60".
  • the rolls measure 40"- 120" by 100 ft to 600 ft.
  • Weight Dependent upon thickness ranges from 25 pounds to 120 pounds approximately per 100 square feet. This product is one of the lightest weight roofing materials available.
  • the present invention 10, 10a, 11 , 11a can be attached to the sheeting over the framing of a roof or to the underlayment 38 on top of the sheeting in a variety of ways. This includes nail, hot mopping with bitumen or other material. Alternatively, a double-sided adhesive peel and stick film 36 can be attached to the present invention to adhere it to the sub surface.
  • the plastic roofing product 10, 10a, 11 , 11a was tested and passed ICC AC07 & AC75 requirements.
  • PVC and other polymers are not used in roofing where a certain dimensional shape or dimensional form is needed to be maintained such as in a profile of shake, shingle, slate or tile. This is because some polymers have a lower Heat Deflection Temperature (HDT), than other polymer materials, for example PVC will deform at about 150 0 F, have color loss and cracking, leading to performance degradation at higher temperatures. Depending upon the color of a roof, darker colors have greater heat absorption. Temperatures on the roof can exceed ambient temperatures by 40 0 F, or more if the surface is a dark color. Low HDT is common to PVC and therefore heat stabilizing additives are use for protecting and stabilizing the material primarily in the high heat processing of the PVC. With the use of high temperature additives HDT may increase to as much as155 0 F. But these temperatures will not allow dark colors in desert regions, which the present invention has overcome by creating a method of increasing HDT in these materials.
  • HDT Heat Deflection Temperature
  • the heat deflection temperature is the relative measure of a material's ability to perform for a short time at elevated temperatures while supporting load. It is the temperature at which a standard test bar (ASTM D648) deflects 0.010 in. under a flexural load of either 64 psi or 264 psi.
  • the HDT test simulates only a very narrow range of conditions. Many high-temperature applications involve higher temperatures, greater loading, and unsupported conditions, which is certainly the case with the extreme weather conditions of roofing.
  • the results obtained by this test method do not represent maximum use temperatures, because, in real life, essential factors such as time, loading, and nominal surface stress may differ from the standard test conditions.
  • the present invention 10, 10a, 11 , 11a was tested for HDT, where a sample is deflected to produce a defined surface stress and then placed in a temperature bath at 23 0 C. The force is allowed to act for 5 minutes, and then the temperature is raised at a uniform rate of 2 0 C / min. The deflection of the test bar is continuously observed: the temperature at which the deflection reaches 0.010 in. is reported as the heat deflection temperature.
  • the present invention 10, 10a, 11 , 11a has created a new and innovative process to increase HDT in its substrate layer 22, 30 formulation polymers so the polymer can be used in dimensional shapes of roofing applications with dark colors in high temperature regions of about 110o F ambient.
  • the substrate layers 22, 30 of the PVC formulation are specifically compounded with the ingredients listed herein.
  • the PVC compound is extruded at between 325 0 F and 425 0 F to gain annealed qualities or can be compatible recycled materials. Up to 50% of this extruded and annealed PVC compound is added to less annealed or virgin compounded PVC. Then either alone or combined acrylic- styrene-acrylonitrile (ASA) or acrylic plastic or acrylonitrile-butadiene-styrene copolymer (ABS) or polycarbonate (PC) are extruded between 375 0 F and 450 0 F.
  • ASA acrylic- styrene-acrylonitrile
  • ABS acrylonitrile-butadiene-styrene copolymer
  • PC polycarbonate
  • the PVC formulation is particular additives such as acrylic-styrene-acrylonitrile (ASA) or acrylic plastic or acrylonitrile-butadiene-styrene copolymer (ABS) or polycarbonate (PC).
  • ASA acrylic-styrene-acrylonitrile
  • ABS acrylic plastic or acrylonitrile-butadiene-styrene copolymer
  • PC polycarbonate
  • the present invention has overcome this by engineering the semi-weatherable formulation to react to natural environmental temperature cycling, thus the material becoming annealed from this process and resulting in increased HDT.
  • the present invention 10 was designed to continually increase HDT over time stimulated by the natural effect of temperature cycling on roofing product.
  • the semi-weatherable material was formulated and the said method of increasing HDT as the material is exposed to the effects of natural temperature cycling of weather, such as exposure on a roof.
  • the semi-weatherable material was formulated to begin annealing over 50 0 C, thus continually increasing HDT over time. This was accomplished by two separate processes. First, by the increasing HDT method described above and then second by specifically balancing the physical properties of each formulation component to affect a compatible relationship to its Vicat, inherent viscosity, stability and torque.
  • the present invention 10, 10a, 11 , 11a has overcome problems by developing a process of creating decorative or faux designs to resemble such roofing materials like wood grain, marble, shake, slate and tile, in a weatherable manner to achieve the required roofing building code performance requirements, including fire retardancy.
  • the present invention 10, 10a, 11 , 11a created an additional process, specific for roofing materials, using colorant particles that have been engineered to maintain their integrity, without completely blending in the base color or repelling the base color and then melting or disseminating creating a "streaking effect" looking like marble or wood grain.
  • These colorant particles vary in size, hardness, melt temperature and color, and are engineered to create specific effects. These colorant particles combine with the other materials while traveling through the screw in the extruder to the die lips.
  • the present invention 10, 11 also created another process of coloration to resemble a greater number of three dimensional natural designs such as wood grain, tile, slate, sea shells, leaves and marble looks for a roofing application.
  • the colorants used are compatible with the top layer 14 and substrate layers 22, 30-of material, are UV resistant and do not to affect roofing requirements, such as flammability or bonding.
  • the colorants are protected from weathering by the encapsulation of the layer 16 of colorants between the first layer 14 and adjacent layer 18, 20, or 22 without affecting the decorative design in the lamination or extrusion process.
  • decorative and faux designs are processed on the underside surface 15 of the top layer 14 material to be bonded, preferable by extrusion heat in a molecular bond, to the adjacent layer, so as to not expose the colorants to the weather but still be able to see the encapsulated decorative and faux designs through the clear top layer 14.
  • the colorants for the decorative designs are applied to the underside surface 15 of the top layer 14 by using some print method such as flexographic, inkjet or rotogravure printing.
  • the top layer 14 is laminated to the substrate layers 18, 20 or 22 with the colorant layer 16 encapsulated. This protects the decorative designs resembling wood grain, marble or slate for a roofing application. By special process, these decorative designs appear three-dimensional and have never been seen before in roofing materials.
  • UV block spray sealers are used to help prevent UV material degradation; this is not applicable for the harsh environment of a roof.
  • a UV multi layering method of protecting the coloration design such as shake, tile or slate from UV material degradation has been formulated in colored, clear and opaque materials in the following manner.
  • the first step of the process is accomplished by adding/blending UV protection, such as titanium dioxide or carbon black, into the substrate layers 22, 30, then by adding UV stable colorant on the substrate layers 22, 30 if needed in the design, then by applying colorants to the underside surface 15 of the top layer 14 to also protect the substrate layers 22, 30 and whereby applying colorants to the top layer 14, the colorants are encapsulated between the substrate layers 22 or 30 and the top layer 14.
  • the clear top layer 14 provides UV protection for the layer of colorants 16 applied to the underside surface 15 of the top layer
  • fire-retardant coatings are applied to the bottom layer 22 or 30 to form a fire- retardant roofing material meeting building code requirements.
  • the fire-retardant layers 34 works by suppressing flame through intumescence. This means the materials puff up on exposure to flame or excessive heat, solidifying into rigid foam. This foam insulates the substrate layer 22 or 30 from the flame.
  • the present invention has overcome this by using a proprietary flame retardant two-part epoxy layer creating a forceful adherent fire retardant block. In fire condition applied to the top surface 13, the top layer 14 and substrate layers 22, 30 interact with the fire retardant to create a charred block under fire.
  • the fire-retardant layer 34 has high moisture content and produces water and gases, which smother the oxygen and confront the flame's energy forcing a dense char to form creating further combustion protection for the underlayment 38.
  • the fire-retardant layer 34 can be applied by spray or as a film lamination to the bottom layer 22 or 30.
  • the bottom layer 22 or 30 to which the fire-retardant layer 34 is adhered is specifically formulated in combination with the fire-retardant to be molecularly bonded when adhered so as not to delaminate in the extreme conditions of roofing weathering.
  • the fire-retardant layer 34 becomes the bottom layer.
  • the flame retardant intumescent formula that has antimony oxide and epoxy resin is produced by the condensation reaction of epichlorhydrin and bisphenol-A.
  • Phosphorus compounds are used to remove the carbon fuel source and provide an insulation layer against the fire's heat.
  • Metal hydrates such as aluminum trihydrate (ATH) or magnesium hydroxide remove heat by using it to evaporate water in their structure. More specifically, these materials are used in the nanosize range (1-100 nm) and particles in these dimensions are used to create the composite to be applied by spray or a film layer.
  • FIGS 6 and 7 illustrate that the thermoformed embodiments 10a, 11a of this invention are more typically fabricated in units with several chambers 62 with lips on 54 on two sides and a ridge 82 separating each chamber 62. Each chamber is about 0.5 inch deep. In this way each unit can be installed on a roof so that the lips 54 overlap in order to provide a good seal.
  • the present invention has overcome the long-term (30-50 years) weatherablity issues with roofing materials, although the demand for less expensive short-term (10-25 years) semi-weatherable roofing materials serves a market segment.
  • the present invention with all of its methods and processes as indicated herein can be applied to the semi-weatherable materials without the use of the weatherable top layer materials for roofing applications.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Laminated Bodies (AREA)
  • Roof Covering Using Slabs Or Stiff Sheets (AREA)

Abstract

La présente invention concerne une nouvelle composition de matériaux résistants et semi-résistants aux intempéries, susceptible d'être moulée par injection ou extrudée en feuilles ou en rouleaux pour créer un produit de toiture, ledit produit de toiture se chevauchant afin de donner sur un toit une couverture sensiblement résistante aux intempéries. Le produit de toiture présente une couche (14) supérieure constituée de polymères résistants aux intempéries et des couches (22, 30) de substrats multiples constituées de polymères semi-résistants aux intempéries. Une couche (16) décorative tridimensionnelle de colorants d'aspect est appliquée de façon unique à la surface (15) inférieure de la couche (14) supérieure. La couche (14) supérieure résistante aux intempéries est de préférence en copolymère d'ASA ou de type acrylique. Les couches (22, 30) inférieures semi-résistantes aux intempéries sont des formulations spécialisées de polymères résistant au feu, la température de déformation thermique (HDT) des couches (22, 30) inférieures semi-résistantes aux intempéries ayant été améliorée de façon unique en vue de l'utilisation en toiture. Le produit présente une stabilité multicouche aux UV. Les couches multiples peuvent être moulées par injection, extrudées, stratifiées ou, de préférence, extrudées par procédé multicouche et ainsi collées. Les matériaux collés peuvent alors être utilisés directement comme un produit (10) fini de toiture ou un produit (10a) thermoformé (s'il n'est pas moulé par injection) pour ressembler à des types de couverture de toit plus populaires tels que des bardeaux, ardoises ou tuiles à motifs géométriques et naturels. Les multiples couches sont conçues pour être homologuées selon des codes contraignants de construction de toitures tels que le Code International de la Construction (ICC), y compris en termes de résistance au feu.
PCT/US2005/043443 2005-11-30 2005-11-30 Composition d'un produit composite de toiture resistant aux intemperies WO2007064322A1 (fr)

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CA002631298A CA2631298A1 (fr) 2005-11-30 2005-11-30 Composition d'un produit composite de toiture resistant aux intemperies
US12/129,587 US20090241450A1 (en) 2005-11-30 2008-05-29 Composition of a weatherable roofing composite product

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