WO2020097231A1 - Tuile de toiture en mousse géopolymère et béton composite - Google Patents

Tuile de toiture en mousse géopolymère et béton composite Download PDF

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Publication number
WO2020097231A1
WO2020097231A1 PCT/US2019/060110 US2019060110W WO2020097231A1 WO 2020097231 A1 WO2020097231 A1 WO 2020097231A1 US 2019060110 W US2019060110 W US 2019060110W WO 2020097231 A1 WO2020097231 A1 WO 2020097231A1
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WO
WIPO (PCT)
Prior art keywords
tile
foam
foam core
outer shell
roof
Prior art date
Application number
PCT/US2019/060110
Other languages
English (en)
Inventor
David I. JENSEN
Original Assignee
Rosenblatt Innovations 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 Rosenblatt Innovations Llc filed Critical Rosenblatt Innovations Llc
Publication of WO2020097231A1 publication Critical patent/WO2020097231A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
    • B28B23/0062—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects forcing the elements into the cast material, e.g. hooks into cast concrete
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/24—Producing shaped prefabricated articles from the material by injection moulding
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/30—Producing shaped prefabricated articles from the material by applying the material on to a core or other moulding surface to form a layer thereon
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/30—Producing shaped prefabricated articles from the material by applying the material on to a core or other moulding surface to form a layer thereon
    • B28B1/32—Producing shaped prefabricated articles from the material by applying the material on to a core or other moulding surface to form a layer thereon by projecting, e.g. spraying
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/50—Producing shaped prefabricated articles from the material specially adapted for producing articles of expanded material, e.g. cellular concrete
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B1/00—Producing shaped prefabricated articles from the material
    • B28B1/52—Producing shaped prefabricated articles from the material specially adapted for producing articles from mixtures containing fibres, e.g. asbestos cement
    • B28B1/522—Producing shaped prefabricated articles from the material specially adapted for producing articles from mixtures containing fibres, e.g. asbestos cement for producing multi-layered articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
    • B28B11/14—Apparatus or processes for treating or working the shaped or preshaped articles for dividing shaped articles by cutting
    • B28B11/145—Apparatus or processes for treating or working the shaped or preshaped articles for dividing shaped articles by cutting for dividing block-shaped bodies of expanded materials, e.g. cellular concrete
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B13/00—Feeding the unshaped material to moulds or apparatus for producing shaped articles; Discharging shaped articles from such moulds or apparatus
    • B28B13/02—Feeding the unshaped material to moulds or apparatus for producing shaped articles
    • B28B13/021—Feeding the unshaped material to moulds or apparatus for producing shaped articles by fluid pressure acting directly on the material, e.g. using vacuum, air pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B19/00—Machines or methods for applying the material to surfaces to form a permanent layer thereon
    • B28B19/003—Machines or methods for applying the material to surfaces to form a permanent layer thereon to insulating material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B19/00—Machines or methods for applying the material to surfaces to form a permanent layer thereon
    • B28B19/0046—Machines or methods for applying the material to surfaces to form a permanent layer thereon to plastics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B23/00—Arrangements specially adapted for the production of shaped articles with elements wholly or partly embedded in the moulding material; Production of reinforced objects
    • B28B23/0068—Embedding lost cores
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C04B28/006—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements containing mineral polymers, e.g. geopolymers of the Davidovits type
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • E04C2/288—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and concrete, stone or stone-like material
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04C—STRUCTURAL ELEMENTS; BUILDING MATERIALS
    • E04C2/00—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels
    • E04C2/02—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials
    • E04C2/26—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups
    • E04C2/284—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating
    • E04C2/288—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and concrete, stone or stone-like material
    • E04C2/2885—Building elements of relatively thin form for the construction of parts of buildings, e.g. sheet materials, slabs, or panels characterised by specified materials composed of materials covered by two or more of groups E04C2/04, E04C2/08, E04C2/10 or of materials covered by one of these groups with a material not specified in one of the groups at least one of the materials being insulating composed of insulating material and concrete, stone or stone-like material with the insulating material being completely surrounded by, or embedded in, a stone-like material, e.g. the insulating material being discontinuous
    • 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
    • E04D1/16—Roofing elements shaped as plain tiles or shingles, i.e. with flat outer surface of ceramics, glass or concrete, with or without reinforcement
    • 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
    • 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
    • E04D1/29—Means for connecting or fastening adjacent roofing elements
    • E04D1/2907—Means for connecting or fastening adjacent roofing elements by interfitted sections
    • E04D1/2914—Means for connecting or fastening adjacent roofing elements by interfitted sections having fastening means or anchors at juncture of adjacent roofing elements
    • E04D1/2916—Means for connecting or fastening adjacent roofing elements by interfitted sections having fastening means or anchors at juncture of adjacent roofing elements the fastening means taking hold directly on adjacent elements of the same row
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00586—Roofing materials
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/00474—Uses not provided for elsewhere in C04B2111/00
    • C04B2111/00612—Uses not provided for elsewhere in C04B2111/00 as one or more layers of a layered structure
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
    • C04B2111/20—Resistance against chemical, physical or biological attack
    • C04B2111/28—Fire resistance, i.e. materials resistant to accidental fires or high temperatures
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
    • Y02P40/00—Technologies relating to the processing of minerals
    • Y02P40/10—Production of cement, e.g. improving or optimising the production methods; Cement grinding

Definitions

  • the present invention relates generally to roofing materials and roofing systems. More particularly the present invention relates to roofing tiles fabricated from clay, ceramic, and/or concrete. Still more particularly, the present invention relates to a new thermal insulating material and system for thermally insulating conditioned spaces in commercial and residential building structures using a geopolymer foam and an AAC (aerated autoclaved concrete).
  • AAC aerated autoclaved concrete
  • Thatched roofs were developed around 735 CE. Wood shingles were introduced 300 years later. In an effort to prevent fires from spreading in England, King John (John Lackland) decreed a law in London that citizens must replace thatch and reed and wood roof coverings with clay tiles.
  • roofing technology has developed rapidly in the past 200 years. Even so, people generally still use the most readily available materials in their respective regions. Wood, clay, and metal are used for roof tiles in the southern part of North America, slate in the northeast, wood and metal in the Mid- and Northwest, and tile in the Southeastern area of North America. In the last 50 years, asphalt composition shingles have become nearly ubiquitous throughout North America.
  • Thermal management of conditioned space buildings in the developing world represents one of the single largest sectors of global energy consumption. Therefore, the thermal efficiency of conditioned space buildings offers one of the largest opportunities to reduce the growth of the global carbon footprint.
  • the use of thermally insulating materials constitutes the most effective way to increase efficiencies of these conditioned space buildings.
  • Asphalt composition shingle, cement tile, clay tile, metal, wood shingle and slate roofing represent the current state of the art in hi-slope roofing systems, the foregoing order corresponding to current market share.
  • Imperial R-values of conventional roofing materials include: (1) Asphalt variable. R-0.44 to R-0.88 (depending on material thickness and lap); (2) Cement and clay tiles R- 0.22 to 0.44 (depending on material thickness and lap); (3) Metal R-0.00; (4) Wood Shingles Variable. R-0.87 to R-1.07 (depending on material thickness and lap); (5) Slate 1 ⁇ 2" R- 0.05; (5) Imperial R-values (thermal resistance factors) of conventional roofing substrate materials, R- 1.06; and (6) 5/8" plywood and peel-n-stick R-1.27.
  • Fire Rating Classifications Class A Roofing. To achieve a Class A rating, the roof must be effective against fire exposure and demonstrate the following performance characteristics: (1) it must experience maximum flame spread of 6 feet; (2) it must withstand a burning brand measuring 12" x 12" and weighing 2,000 grams; (3) it must resist ignition for 2 to 4 hours; and (4) it must resist 15 cycles of a gas flame turned on and off.
  • Class A roof coverings include clay and concrete tiles, slate, and specially-treated asphalt glass fiber composition shingles.
  • Assembly-rated Class A roof coverings are complete system assemblies that meet Class A standards when combined with other elements. For example, shake roofing with a fire-retardant treatment achieves a Class B rating standing alone, but it achieves a Class A rating when combined with specified underlayment materials, such as Type 72 roll roofing material.
  • Class B roofing is effective against fire exposure and demonstrates the following performance characteristics: (1) it experiences a maximum flame spread of 8 feet; (2) it withstands a burning brand measuring 6" by 6" and weighing 500 grams; (3) it resists ignition for 1 hour; (4) it resists eight cycles of a gas flame turned on and off
  • Class C roofing provides only light fire protection.
  • roofing with a Class C rating is able to: (1) experience maximum flame spread of 13 feet; (2) withstand a burning brand measuring 1.5" x 1.5" and weighing 1 ⁇ 4 gram; (3) resist ignition for 20 minutes; and (4) it resists three cycles of a gas flame turned on and off.
  • Examples of common Class C building materials include untreated wood shakes and shingles, plywood, and particleboard. The materials are not recommended for use in roof coverings.
  • Class A fire rating is not a non-flammable rating. All three classes A, B and C are all based on the flammability _of the materials currently used in roofing systems.
  • HVHZ High-Velocity Hurricane Zones
  • Miami-Dade and Broward Counties As in previous editions of the Florida Building Code, a single wind speed is used for the HVHZ for each Risk Category Map.
  • the design wind speeds in the HVHZ are as follows:
  • FM 4473 is an industry standard test used for more rigid roofing materials such as clay, concrete, or slate.
  • ice ball missiles are fired by a special launcher at a prepared roofing assembly.
  • the test is intended to simulate the impact energy of a natural hail stone.
  • Class ratings are given for impact resistance, Class 4 being the highest possible rating.
  • Many of the rigid roofing materials perform at only Class 1 and 2 of this test.
  • freezer ice balls in the standard correspond to the classes shown below:
  • Un-commercialized Known Art Bellavia; U.S. Patent 9,038,330, issued May 26, 2015, teaches a lightweight, molded, polyurethane foam roofing tile having a spray-applied cementitious outer coating.
  • the goal for the invention was to provide a roof tile with a thermal insulation benefit and a high wind up-lift rating.
  • Another object was to provide a molded, wedge-shaped profile design in an individual tile to fill the void caused by overlapping tiles of an assembled roofing system to resist breakage of the low density foam tile body underfoot.
  • Another objective was to provide a star-shaped recess on a bottom tile surface to facilitate adequate adhesion to the roofing substrate with adhesive foam.
  • Still another object of the present invention is to provide a composite roofing tile with high thermal insulating values.
  • the present invention is a roofing tile unit having a core made from a binary, masonry composite structure of a non-flammable, lightweight ceramic, geopolymer and/or cementitious foam material. This material comprises a substantial portion of the core of the roof tile.
  • the core is encased on at least 2 of its 6 outer surface sides with a molded, non flammable, lightweight, polymer reinforced cementitious mortar and/or a laminated composite layer of Portland cement based GFRC.
  • the present invention is a masonry composite roof tile providing a single unit in a tile roofing system comprising a plurality of like units assembled over conventional roofing substrate in consecutive courses, one after and on top of the prior course with variable amounts of overlap, similar to the assembly of conventional concrete, and clay tile, slate, or wood shake shingle roofing systems.
  • the masonry composite tiles of the present invention can be glued to the roof substrate and to prior tile courses with expanding, adhesive foam approved for use in roof systems such as Miami Dade approved AH160 adhesive foam or a similar adhesive.
  • the present invention includes a masonry composite roof tile system in which individual tiles of the roof system may have a bottom surface, or at least one side of six outer surface sides, consisting of an open cell structure of porous masonry foam.
  • the exposed surface optimizes surface area adhesion of the roof tile to the roofing substrate with the above-mentioned expanding, adhesive foam.
  • the invention includes a masonry composite roof tile variably
  • the inventive roofing tile provides higher thermal insulation than covering materials employed in conventional roofing systems.
  • FIG. 1 is an upper perspective lower end view of a simplified embodiment of the cementitious and geopolymer foam roofing tile of the present invention, this embodiment having five of six of the sides of the cuboid shape finished with a molded, lightweight polymer reinforced cementitious coating and one side (viz., the bottom side) unfinished;
  • FIG. 2 is a lower perspective view thereof
  • FIG. 3 is an upper perspective view of another embodiment of the invention, this having two of the six sides of the cuboid surface coated and finished with a molded lightweight polymer reinforced, cementitious surface;
  • FIG. 4 is a corresponding lower perspective view thereof
  • FIG. 5 is an upper perspective view of yet another embodiment of the inventive composite roofing file, this embodiment having approximately half of the tile entirely unfinished with a ceramic coating and the other half coated on four sides;
  • FIG. 6 is a lower perspective view thereof.
  • FIG. 7 is an upper perspective view showing a single course of roof tiles with interior tiles configured with a right and a left lap interface and end tiles configured with an interior lap interface. Best Mode for Carrying Out the Invention
  • FIGS. 1-2 illustrate an embodiment of the combination lightweight concrete and geopolymer foam composite roof tile of the present invention.
  • FIGS. 3-4 illustrate a second embodiment.
  • FIGS. 5-6 show a third embodiment.
  • FIG. 7 shows a single course of a further embodiment of the inventive roof tile of the present invention.
  • FIGS. 1-2 there is shown an embodiment of the combination lightweight concrete and geopolymer foam composite roof tile 10 of the present invention.
  • This embodiment is seen to be a six-sided low-profile elongate cuboid block 12 with a top side 14, right and left sides 16, 18, and first (lower) and second (upper) ends 20, 22, and a bottom side 24.
  • the tile core 26 (shown schematically as having amorphous particles and empty cell spaces) is fabricated from non-flammable, lightweight ceramic and or cementitious foam material that comprises the major portion of the tile volume.
  • the cementitious foam material is encased on some or all of its various sides. In embodiments is it encased on at least two of its six outer surface sides with a molded, non-flammable, lightweight, polymer reinforced cementitious mortar 28 (shown schematically as having smooth surfaces). As will be appreciated, in this embodiment, only the bottom surface remains uncoated. All other surfaces are coated and encased.
  • FIGS. 3-4 show another embodiment, 40, identical in shape and composition with the above-described embodiment, but in this instance having only two of the six sides of the cuboid shape surface-coated and finished with a non-flammable, molded, lightweight, polymer reinforced cementitious mortar.
  • the unfinished sides include the bottom side 42, the upper end 44, and the right and left sides 46, 48.
  • FIGS. 5-6 illustrate another embodiment 60, again identical with that of the first described embodiment, but with only half of the tile coated on any of its sides. Thus, it includes a lower half 62, coated on four of its sides, and an upper half 64 entirely uncoated.
  • FIG. 7 shows yet another embodiment, which includes interior roof tiles configured with a right and a left lap interface and end tiles configured with an interior lap interface having the molded finish on the exposed surfaces.
  • a plurality of units constituting a linear course in a tile system 70.
  • the linear course includes mid-course tiles 72, having right and left sides 74, 76, with an L-shaped lap interface, which provides an enhanced abutting tile joint, resists water penetration, and better resists heat transfer.
  • Right and left end tiles 78, 80 include a single interior lap interface edge, 82, 84, respectively, and a flat outer edge 86, 88.
  • each tile of a course in the roof tile system of the present invention is configured to have a molded, finished surface on all of its visually and environmentally exposed surfaces.
  • FIG. 1 A variety of systems having particular method steps can be employed for the fabrication of more specific variations of the general binary composite roof tile of the present invention. Examples of these systems and their method steps are outlined in the following descriptions. Figs.l - 7 are simplified examples of the present invention. Particular methods of tile fabrication are outlined in the following four tile fabrication systems for the inventive binary composite roof tile.
  • System 1 In a first approach to tile fabrication, the following six fabrication steps apply.
  • Step 1) The cementitious and/or geopolymer foam core of the binary composite is cut and milled to size from a larger cast stock of expanded masonry foam.
  • Step 2) Separately, the molded outer shell of the binary composite roof tile is formed by spraying a particular formulation of cementitious mortar in a thickness of 3 to 9mm using a spray deposition system of the kind typically employed for GFRC face coat applications.
  • the deposition is sprayed into a form to create a“negative” mold matching the finish surfaces of the roof tile and is sized to capture the foam body core. The same deposition can be applied to the opposing interface surfaces of the foam core.
  • Step 3) The foam core is pressed into the mold and the applied face coat while the face coat material is still wet and workable.
  • Step 4) The mold and the composite cast captured in the mold is then moved to an in-mold curing environment until an initial set of the cast is achieved.
  • Step 5 After the initial set of the cast is complete, the mold and the composite cast are removed from the curing environment for removal. The product is then de-molded and produces a unified binary composite roof tile comprising a lightweight masonry foam core with a hard, molded outer masonry shell.
  • Step 6) In a final step, the composite roof tile is returned to a curing
  • Step 1) Providing injection mold cavities comprising an assembly of multiple parts having mold surfaces for the top or finish sides of the roof tile and opposing bottom or unfinished sides of the roof tile.
  • the injection mold assembly is separated and/or broken down and configured to allow the deposition of a sprayed face coat 3 to 9mm thick to be applied to the internal parts of the mold. This will produce the finish mold surfaces of the roof tile.
  • Step 2) The mold parts of the injection mold cavity with the applied face coat are coupled with their respective opposing un-coated cavity parts to provide a fully encapsulated mold cavity.
  • Step 3) The fully assembled mold cavities are injected with the pre-expanded cementitious and/or geopoly meric foam to fill the remaining cavity of the mold that defines the tile body core; together with the encapsulated face coat provides the binary composite cast within.
  • Step 4) A plurality of filled injection mold assemblies are moved either separately or together as multiple cavity units into an in-mold curing environment to achieve the initial set of the cure cycle.
  • the injection mold assemblies can be equipped with heating elements to expedite the initial set time of the cure cycle and thus to expedite the de-molding of the cast products and recycling of the molds into the production cycle.
  • Step 5 After the initial set in the cure cycle is complete, the molds are again broken down to release the cast product, and the unified binary composite is returned to a curing environment to complete the final cure. The molding system is reconfigured for continued production.
  • System 3 A third fabrication system involves fabricating contrasting elements of the binary composite separately and at least partially curing each element, then subsequently laminating the parts together.
  • the cementitious and/or geopolymer foam that provides the body core is milled from a pre-cast foam block.
  • the hard, molded outer shell of the binary composite is a pre-cast composite of GFRC (glass fiber reinforced concrete) comprising a cementitious face coat and structural layers of glass fiber reinforced cementitious mortar.
  • GFRC glass fiber reinforced concrete
  • Step 1) The cementitious foam is cast and expanded into large millable cubes. It is then at least partially cured and then milled into slabs of a predetermined length, width, and thickness to fit and mate with a corresponding outer surface element produced with GFRC.
  • Step 2) Separately but concurrently with the first step, a GFRC production system is employed to produce the finish surfaces of the binary composite, wherein a mold of predetermined length and width to fit and mate with the foam slab production of Step 1 is configured. This will provide the finish surface top and sides and desired textures of the finish tile.
  • the mold is sprayed or rolled with a cementitious face coat, followed with depositions of structural glass fiber reinforced cementitious mortar laminations typical of GFRC laminate systems to a combined thickness of 6 to l2mm thick. It is then cured in the mold until the initial set is achieved.
  • the GFRC face component mold thus the cast face laminate, consists of a substantially planar slab with at least one side wall extending from the plan of the slab at 90 degrees on at least one of its 4 terminate boundaries providing the end and/or side profiles of the roof tile.
  • Step 3 Once the initial set of the laminates cure is achieved, the GFRC finish face component is de-molded and (optionally) returned to the curing environment until ready for the lamination process in the next step.
  • Step 4) The two components (i.e., the milled slab of cementitious foam and the cast GFRC finish shell) are configured to receive a deposition of expanding, adhesive glue to evenly coat the interface of the opposing components to be laminated together.
  • the two components are then mated, pressed together, and glued side-to-glue side while the glue is still wet and malleable. Pressure is sustained to complete the bond between the two components before returning to a curing environment.
  • the expanding adhesive glue can be an adaptation of any one of the following material types: expanding geopolymer foam, expanding cementitious (Portland cement) paste, or expanding petro chemical and/or PU foam.
  • Step 5 After the bonded composite slabs are adequately cured they are milled and cut into predetermined lengths and widths of the finished roofing tiles. Alternatively, the opposing components of the binary composite can be milled and cut to the finish roof tile sizes prior to lamination.
  • System 4 In still another, fourth system, a cementitious face coat material is applied topically to a cementitious and/or geopoly meric foam slab cut from a larger pre-cast stock, and the finished textures of a topically applied face coat is achieved with a screeded, tooled, rolled or pressed finish or a combination thereof. Five steps are involved.
  • Step 1) This step involves producing and curing the pre-cast cementitious and/or geopolymeric foam into a cubic stock of a predetermined size suitable for the subsequent milling of a slab of a predetermined length, width and thickness, suitable for the following steps.
  • Step 2) - The milled slab is configured to receive a topically applied deposition of a cementitious face coat material uniformly covering the top and at least one side profile of the milled slab.
  • the cementitious face coat paste can be applied with either a hopper and screed system, or a sprayed deposition, or a combination thereof.
  • Step 3 After and/or in between multiple face coat depositions, face coat materials are either screeded, brushed, rolled, or pressed on at least two of the five exposed surfaces. After final deposition the finish face coat textures and colors are either tooled, rolled, sprayed or pressed or in combinations therein.
  • Step 4) After face coat is finished, the coated slab is moved to a curing environment for the fished cure of the face coat material.
  • Step 5 After the final cure is achieved, the coated slab is cut and milled to the finished dimensions of the roof tiles.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Structural Engineering (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Geochemistry & Mineralogy (AREA)
  • Geology (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Inorganic Chemistry (AREA)
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  • Life Sciences & Earth Sciences (AREA)
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  • Fluid Mechanics (AREA)
  • Curing Cements, Concrete, And Artificial Stone (AREA)

Abstract

L'invention concerne une tuile de toit composite de maçonnerie, laquelle tuile a un cœur en mousse géopolymère ininflammable, de faible poids, à six côtés, ayant un mortier à base de ciment Portland constituant une enveloppe externe dure recouvrant au moins deux côtés dudit cœur en mousse; laquelle tuile de toit est configurée pour servir d'unité unique dans un système de toiture constitué par une pluralité d'unités analogues.
PCT/US2019/060110 2018-11-06 2019-11-06 Tuile de toiture en mousse géopolymère et béton composite WO2020097231A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201862756503P 2018-11-06 2018-11-06
US62/756,503 2018-11-06

Publications (1)

Publication Number Publication Date
WO2020097231A1 true WO2020097231A1 (fr) 2020-05-14

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Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN112358313A (zh) * 2020-10-30 2021-02-12 徐州安联木业有限公司 一种单板饰面的发泡无机胶凝材料及其制备方法
CN116442354A (zh) * 2023-06-15 2023-07-18 北京惠诚基业装配式建筑科技有限公司 一种轻型无机材料复合板材的生产方法及装置

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20100269440A1 (en) * 2005-09-17 2010-10-28 Torres Carlos T Roof tiles and roof tile structures and methods of making same
US20130305642A1 (en) * 2010-01-20 2013-11-21 Propst Family Limited Partnership Roof panel and method of forming a roof
US8925284B2 (en) * 2009-09-11 2015-01-06 Halok Pty Ltd Building panel
WO2017006102A1 (fr) * 2015-07-03 2017-01-12 Alsitek Limited Produits composites
US20170283324A1 (en) * 2016-04-04 2017-10-05 Futong Cui Fire retardant construction materials

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20100269440A1 (en) * 2005-09-17 2010-10-28 Torres Carlos T Roof tiles and roof tile structures and methods of making same
US8925284B2 (en) * 2009-09-11 2015-01-06 Halok Pty Ltd Building panel
US20130305642A1 (en) * 2010-01-20 2013-11-21 Propst Family Limited Partnership Roof panel and method of forming a roof
WO2017006102A1 (fr) * 2015-07-03 2017-01-12 Alsitek Limited Produits composites
US20170283324A1 (en) * 2016-04-04 2017-10-05 Futong Cui Fire retardant construction materials

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
CN112358313A (zh) * 2020-10-30 2021-02-12 徐州安联木业有限公司 一种单板饰面的发泡无机胶凝材料及其制备方法
CN116442354A (zh) * 2023-06-15 2023-07-18 北京惠诚基业装配式建筑科技有限公司 一种轻型无机材料复合板材的生产方法及装置

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