ROOFING, CLADDING OR SIDING PRODUCT

• US 20170362830A1
• Filed: 12/01/2015
• Published: 12/21/2017
• Est. Priority Date: 12/01/2014
• Status: Active Grant

• Current Assignee: Zinniatek Limited
• Original Assignee: Zinniatek Limited
• Inventors: Buckingham, Samuel Gwynn, McKee, John Wason, Haynes, Andrew Leo, Winton, James Robert
• Granted Patent: US 10,850,440 B2
• Time in Patent Office: Days
• CPC Class Codes: B29C 41/28 by depositing flowable material on an endless belt
• CPC Class Codes: B29C 41/32 Making multilayered or multicoloured articles
• CPC Class Codes: B29C 48/0014 producing flat articles having components brought in contact outside the extrusion die
• CPC Class Codes: B29C 48/07 Flat, e.g. panels
• CPC Class Codes: B29C 48/12 Articles with an irregular circumference when viewed in cross-section, e.g. window profiles
• CPC Class Codes: B29C 48/13 Articles with a cross-section varying in the longitudinal direction, e.g. corrugated pipes
• CPC Class Codes: B29C 48/21 the layers being joined at their surfaces
• CPC Class Codes: B29C 48/303 using dies or die parts movable in a closed circuit, e.g. mounted on movable endless support B29C48/35 takes precedence
• CPC Class Codes: B29L 2031/104 Tiles
• CPC Class Codes: B29L 2031/108 Roofs
• CPC Class Codes: B32B 2266/0214 Materials belonging to B32B27/00
• CPC Class Codes: B32B 2419/06 Roofs, roof membranes
• CPC Class Codes: B32B 27/06 as the main or only constituent of a layer, which is next to another layer of the same or of a different material next to a layer of a particular substance B32B9/045; next to a bituminous or tarry layer B32B11/046; next to a water setting substance layer B32B13/12; next to a metal layer B32B15/08; next to a glass layer B32B17/10; next to a layer formed of natural mineral fibres or particles B32B19/045; next to a wood layer B32B21/08; next to a cellulosic plastic layer B32B23/08; next to a natural or synthetic rubber layer B32B25/08
• CPC Class Codes: B32B 5/18 characterised by features of a layer of foamed material
• CPC Class Codes: E04D 1/22 of specified materials not covered by any one of groups E04D1/14 - E04D1/205, or of combinations of materials, where at least one is not covered by any one of groups E04D1/14 - E04D1/205
• CPC Class Codes: E04D 1/26 Strip-shaped roofing elements simulating a repetitive pattern, e.g. appearing as a row of shingles
• CPC Class Codes: E04D 1/28 Roofing elements comprising two or more layers, e.g. for insulation
• CPC Class Codes: E04F 13/0864 composed of superposed elements which overlap each other and of which the flat outer surface includes an acute angle with the surface to cover
• CPC Class Codes: E04F 13/0866 composed of several layers, e.g. sandwich panels or layered panels layered products as such in general B32B; producing decorative panels or veneers B44C5/04; E04F13/0864, E04F13/0875 take precedence
• CPC Class Codes: E04F 13/16 of fibres or chips, e.g. bonded with synthetic resins , or with an outer layer of fibres or chips E04F13/0864 takes precedence
• CPC Class Codes: E04F 13/165 : with an outer layer imitating natural stone, brick work, tiled surface or the like

Abstract

This invention relates to a roofing, cladding, or siding module, comprising an underlapping region extending from a head edge of the module and an exposed region extending from a foot edge of the module. The length of the foot edge defining the length of the module. The underlapping region is adapted to be substantially covered by the exposed region of an adjacent or overlapping module when installed on a building surface. The module is formed of at least one layer of extruded material. The layer so formed comprises at least 40% w/w filler and/or reinforcement, and one or more polymer(s).

Claims

1. A roofing, cladding, or siding module, comprising:

an underlapping region extending from a head edge of the module and an exposed region extending from a foot edge of the module, the length of the foot edge defining the length of the module,

wherein the underlapping region is adapted to be substantially covered by the exposed region of an adjacent or overlapping module when installed on a building surface,

wherein the module is formed of at least one layer of extruded material, wherein the layer so formed comprises;

at least 40% w/w filler and/or reinforcement,

one or more polymer(s).

2. The module as claimed in claim 1, wherein said module comprises a plurality of formed surfaces molded along the length of the module.

3. The module as claimed in claim 1 or 2, wherein the layer comprises about 60% to about 95% w/w filler and/or reinforcement.

4. The module as claimed in any one of claims 1-3, wherein the layer comprises at least about 5% w/w reinforcement.

5. The module as claimed in any one of claims 1-4, wherein the layer comprises about 5% to about 30% w/w reinforcement.

6. The module as claimed in any one of claims 1-5, wherein the layer comprises at least about 80% filler and at least about 10% reinforcement.

7. The module as claimed in any one of claims 1-6, wherein the layer comprises one or more of the following polymers:

a) polystyrene (GPPS),

b) polyethylene terephthalate (PET),

c) polyester methacrylate (PEM),

d) high impact polystyrene (HIPS),

e) acrylonitrile butadiene styrene (ABS),

f) polyvinyl chloride (PVC),

g) polyurethanes (PU),

h) polyethylene (PE) including homopolymer, copolymer, block copolymer and terpolymer forms,

i) polylactic acid (PLA),

j) nylon (PA),

k) acrylics (PMMA),

l) high density polyethylene (HDPE),

m) low density polyethylene (LDPE),

n) linear low density polyethylene (LLDPE),

o) medium density polyethylene (MDPE),

p) cross linked polyethylene (PEX),

q) thermoplastic elastomer (TPE),

r) thermoplastic polyolefin (TPO),

s) thermoplastic rubber (TPR),

t) polypropylene (PP), including homopolymer and copolymer forms,

u) polybutylene terephthalate (PBT),

v) styrene-acrylonitrile resin (SAN),

w) ethylene tetrafluoroethylene (ETFE),

x) vinyl,

y) methacrylate copolymers,

z) foamed polymer.

8. The module as claimed in any one of claims 1-7, wherein the filler comprises one or more of the following:

a) talc,

b) calcium carbonate,

c) mica,

d) silica,

e) kaolin,

f) calcium sulphate,

g) magnesium hydroxide

h) stabilizers

i) dolomite.

9. The module as claimed in any one of claims 1-8, wherein the reinforcement comprises one or more non-conductive natural or synthetic fibres.

10. The module as claimed in any one of claims 1-9, wherein the reinforcement comprises one or more of the following:

a) glass fibres,

b) glass beads,

c) glass flakes,

d) flax,

e) cellulose,

f) wood fibres,

g) wood flour,

h) cotton,

i) sawdust,

j) inorganic fibres,

k) polymer fibres,

l) polymer scrim,

m) polymer knit,

n) polymer weave,

o) aramids,

p) ceramics.

11. The module as claimed in any one of claims 1-10, wherein the layer further comprises one or more of the following:

colorants (including but not limited to carbon black, titanium dioxide),

flame retardants (including but not limited to magnesium hydroxide, aluminum trihydrate),

stabilizers (including but not limited to UV light stabilizers such as hindered amine light stabilizers (HALS), and thermal stabilizers such as phenolics),

foaming agents (including but not limited to exothermic, endothermic or gas foaming agents),

lubricants,

biocides (including but not limited to particles of silver, including nano-sized silver particles).

12. The module as claimed in any one of claims 1-11, wherein the layer comprises about 5% to about 25% w/w reinforcement, or about 5% to about 20%.

13. The module as claimed in any one of claims 1-12, wherein the layer comprises at least about 10% w/w reinforcement.

14. The module as claimed in any one of claims 1-13, wherein at least a portion of a top surface of the exposed region comprise(s) three dimensional surface features, whether as surface relief or surface texturing.

15. The module as claimed in claim 14, said portion comprises surface features resembling one of:

a) asphalt shingle,

b) slate,

c) shingles,

d) shakes,

e) concrete tiles,

f) stone chips,

g) weatherboard,

h) thatch,

i) stone,

j) woodgrain,

k) metal.

16. The module as claimed in claim 14 or 15, wherein the surface features are, at least in part, due to coloring, patterning, surface cracking or polymer fracturing or other two-dimensional or three-dimensional ornamentation of said portion.

17. The module as claimed in any one of claims 14-16, wherein the surface features further comprise three-dimensional features including one or more of:

surface texturing,

surface relief,

other three-dimensional pattern or ornamentation configured or arranged to simulate a natural or manufactured material.

18. The module as claimed in any one of claims 1-17, wherein the module further comprises a plurality of formed surfaces, wherein each of the formed surfaces comprises said surface features, and wherein the formed surfaces are joined without weld lines, attachments or injection molding points.

19. The module as claimed in claim 18, wherein each formed surface is a molded segment along the length of the module.

20. The module as claimed in claim 18 or 19, wherein each formed surface resembles an individual tile or shingle or slate or shake within the module.

21. The module as claimed in any one of claims 18-20, wherein the module is subsequently sectioned (or divided or partitioned) to provide a plurality of smaller module sections for installation onto a building surface.

22. The module as claimed in any one of claims 1-21, wherein said layer so formed of a said extruded material is provided as a base or bottom layer of the module, and the module further comprises one or more additional upper layers provided as further layers upon said base or bottom layer.

23. The module as claimed in claim 22, wherein said one or more upper layer(s) is formed of an extruded material, said one or more upper layer(s) comprising a different weight percentage of filler and/or reinforcement relative to the base or bottom layer.

24. The module as claimed in claim 22 or 23, wherein each of said layers are co-extruded to form the or at least a part of said module.

25. The module as claimed in any one of claims 22-24, wherein layers are joined together in a continuous forming process to form the or at least a part of said module.

26. The module as claimed in any one of claims 1-25, wherein the module is at least about 36 inches long or at least about 1 metre long.

27. The module as claimed in any one of claims 1-26, wherein the module is at least about 0.3 m or about 12 inches wide or at least about 0.8 m wide.

28. The module as claimed in any one of claims 1-27, wherein said at least one layer so formed, such as a base or bottom layer of said module, has a coefficient of thermal expansion of less than about 30·

10<sup>−

6</sup> m/(m K).

29. The module as claimed in any one of claims 1-28, wherein at least a portion of the module comprises a top layer (or an upper layer or a plurality of upper layers forming a said top layer), a base or bottom layer (or a lower layer or a plurality of lower layers forming a said base or bottom layer), and an intermediate layer (or a plurality of layers forming a said intermediate layer) between the top and base or bottom layers.

30. The module as claimed in any one of claims 1-29, wherein a layer so formed extends across at least a part of the width and/or at least a part of the length of the module to provide for a variation to one or more properties to the module so formed by the at least one layer, the properties selected from one or more of:

a) thickness,

b) surface area

c) tensile strength

d) shear strength

e) resilience

f) elasticity

g) flexibility

h) toughness

i) fire resistance

j) water resistance

k) continuity or uniformity

l) impact resistance

m) resistance to pull through

n) fixing capability

o) chemical resistance

p) puncture resistance

q) content of filler and/or reinforcement

r) concentration of filler and/or reinforcement

s) color

t) microbial resistance

u) temperature resistance

v) light/heat absorption/reflectivity,

w) thermal transfer.

31. The module as claimed in any one of claims 1-30, wherein the module comprises an intermediate layer, the intermediate layer being one or more of:

a) a film,

b) a sheet,

c) a mesh,

d) a scrim,

e) a weave,

f) a fibre,

g) a fabric,

h) a wire,

i) a string,

j) a web.

32. The module as claimed in any one of claims 1-31, wherein the module comprises an intermediate layer, the intermediate layer being a reinforcing layer that provides for one or more of:

a) resistance against shrinkage,

b) resistance against warping,

c) resistance against tearing,

d) increased toughness,

e) prevention against unwanted deflections of the module,

f) weather resistance,

g) resistance against delamination of the layers,

h) reduced flammability,

i) water resistance,

j) impact resistance,

k) resistance to pull through,

l) fixing capability,

m) chemical resistance,

n) puncture resistance,

o) sealing

p) shape memory

q) adhesive/gluing/bonding capability.

33. The module as claimed in claim 31 or 32, wherein, the intermediate layer is chemically and/or mechanically bonded, welded, fused, co-extruded and/or connected to the top layer and/or the base or bottom layer.

34. The module as claimed in any one of claims 31-33, wherein the intermediate layer comprises one or more of the following three-dimensional surface features to increase or improve the mechanical bond or connection with the top and/or base or bottom layers:

a) surface texturing,

b) surface roughness,

c) projections,

d) corrugations,

e) reinforcements,

f) chemical coating(s),

g) protrusions,

h) apertures,

i) perforations.

35. The module as claimed in any one of claims 31-34, wherein the intermediate layer, when being joined to the top and base or bottom layers, is in a molten or semi-molten or cold but pliable state.

36. The module as claimed in any one of claims 31-35, wherein the module is shaped and/or contoured during the joining or lamination process, while the intermediate layer is in a molten or semi-molten or cold but pliable state or a formable or moldable condition.

37. The module as claimed in any one of claims 1-31, wherein at least a top layer of the module comprises sections of non-homogenous and/or non-compatible materials, and wherein an intermediate layer provides a binder layer for binding said non-homogenous and/or non-compatible sections to the intermediate layer.

38. The module as claimed in any one of claims 1-37, wherein at least a top layer (with an exposed region) of the module has a relatively high UV resistance.

39. The module as claimed in any one of claims 31-36, wherein one or more property/properties of the intermediate layer is/are optimized preferentially along the direction of the length and/or width of the module.

40. The module as claimed in any one of claims 1-39, wherein the exposed region and/or the underlapping region comprises a top layer, an intermediate layer and a base or bottom layer.

41. The module as claimed in any one of claims 1-40, wherein the module comprises an intermediate layer extending from at or adjacent the foot edge, to at or adjacent the underlapping region of the module.

42. The module as claimed in any one of claims 1-41, wherein the module comprises a fastening region adapted to receive one or more fasteners for fixing the module to the or a building surface, optionally the fastening region including a visual guide or boundary markers to allow visual identification of said fastening region.

43. The module as claimed in claim 42, wherein the fastening region is substantially adjacent the exposed region and within the underlapping region.

44. The module as claimed in claim 42 or 43, wherein an intermediate layer of the module is thicker or comprises thickened regions or other 3-dimensional qualities within the fastening region of the module, optionally the thicker or thickened or other 3-dimensional qualities of the intermediate layer provide for a fastening region capable of retaining a fastener penetrating or pulling through the fastening region or resisting tear of the module by shear force applied to the module or each of the said layers by the fastener.

45. The module as claimed in any one of claims 1-44, wherein the module comprises one or more of:

a. discrete intermediate layers in different regions of the module,

b. different intermediate layers in different regions of the module,

c. multiple intermediate layers in one or more regions of the module.

46. The module as claimed in any one of claims 1-45, wherein the module is post-treated after being formed, optionally comprising one or more of:

shaping,

folding,

coloring,

corrugating,

adding surface treatment(s),

perforating,

laminating,

coating.

47. The module as claimed in any one of claims 1-46, wherein an under surface of at least the exposed region of the module surface (e.g. an under surface being a surface of the module to be placed substantially adjacent to or facing of the building surface upon which the module is to be fastened) comprises a plurality of projections.

48. The module as claimed in claim 47, wherein the projections provide surfaces for one or more of:

adhering the exposed region of the module to the top surface of the underlapping region of an adjacent or overlapping module when installed,

providing reinforcement for the module.

49. The module as claimed in any one of claims 1-48, wherein at least the or a portion of a top surface of the exposed region is colored or treated in a manner so as to yield a visually observable color, by applying a colored material onto at least a portion of the top surface of the top layer, either before or after one or more layers are joined together.

50. The module as claimed in claim 49, wherein the module is formed by molding, and at least a portion of a top surface of the module is a colored and/or decorated and/or textured by applying a colored material onto at least a portion of the top surface of a precursor of the module, wherein the colored material is applied before and/or during the molding process.

51. The module as claimed in claim 50, wherein the precursor is molded between a first forming surface and a second forming surface to form the module, and the colored material is applied to at least a portion of the first forming surface, wherein the colored material is transferred to said portion of the precursor during the molding step.

52. The module as claimed in claim 50 or 51, wherein the colored material is applied directly or indirectly to the precursor and/or the forming surface by one or more of:

a) stamping,

b) injecting,

c) embossing,

d) spraying,

e) rolling,

f) feeding,

g) brushing,

h) melting,

i) immersing,

j) dipping,

k) sprinkling,

l) depositing,

m) by drawing or suctioning the colored material onto the precursor and/or forming surface using a vacuum system.

53. The module as claimed in any one of claims 49-52, wherein a colored material comprises a powder and/or a fluid capable of being dispersed upon at least the or a portion of the top surface of the exposed region, whether the application is direct or indirect to the surface or whether a die face is used to convey the colored material to the surface.

54. The module as claimed in any one of claims 49-53, wherein at least a portion of a top surface of the module is a colored and/or decorated and/or textured by applying a colored material onto at least a portion of the top surface of the module after the module has been formed by a molding/joining/laminating process.

55. The module as claimed in claim 1 or 2, wherein the layer so formed comprises at least 60% w/w filler and/or reinforcement.

57. An assembly for installation on a building surface comprising a plurality of the modules as claimed in any one of claims 1-56.

58. A building surface or a building comprising a plurality of the modules as claimed in any one of claims 1-56.

56. A roofing, cladding, or siding module, comprising:

an underlapping region extending from a head edge of the module and an exposed region extending from a foot edge of the module, the length of the foot edge defining the length of the module,

wherein the underlapping region is adapted to be substantially covered by the exposed region of an adjacent or overlapping module when installed on a building surface, and

wherein at least a portion of the module comprises a top layer (or an upper layer or a plurality of upper layers forming a said top layer), a bottom layer (or a lower layer or a plurality of lower layers forming a said bottom layer), and an intermediate layer (or a plurality of layers forming a said intermediate layer) between the top and bottom layers,

and wherein at least one or more of said top layer or said intermediate layer or said base or bottom layer comprises a foamed polymer.