Recherche Images Maps Play YouTube Actualités Gmail Drive Plus »
Connexion
Les utilisateurs de lecteurs d'écran peuvent cliquer sur ce lien pour activer le mode d'accessibilité. Celui-ci propose les mêmes fonctionnalités principales, mais il est optimisé pour votre lecteur d'écran.

Brevets

  1. Recherche avancée dans les brevets
Numéro de publicationUS20050086907 A1
Type de publicationDemande
Numéro de demandeUS 10/988,865
Date de publication28 avr. 2005
Date de dépôt15 nov. 2004
Date de priorité25 mai 2001
Autre référence de publicationCA2387273A1, DE60227603D1, EP1260649A2, EP1260649A3, EP1260649B1, US20030054148, US20100003458, US20110232060
Numéro de publication10988865, 988865, US 2005/0086907 A1, US 2005/086907 A1, US 20050086907 A1, US 20050086907A1, US 2005086907 A1, US 2005086907A1, US-A1-20050086907, US-A1-2005086907, US2005/0086907A1, US2005/086907A1, US20050086907 A1, US20050086907A1, US2005086907 A1, US2005086907A1
InventeursRandal Jolitz
Cessionnaire d'origineJolitz Randal J.
Exporter la citationBiBTeX, EndNote, RefMan
Liens externes: USPTO, Cession USPTO, Espacenet
Composite shingle
US 20050086907 A1
Résumé
Disclosed is a composite roofing shingle. The preferred roofing shingle includes a mixture of a polymer and a filler. The preferred blend includes between about 35-65% polyethylene and 50-70% crushed limestone filler.
Images(2)
Previous page
Next page
Revendications(6)
1. A composite roofing shingle comprising a mixture of:
a. about 36 to 64% polymer; and
b. about 36 to 64% filler.
2. A shingle according to claim 1 where the polymer is a polyolefin.
3. A shingle according to claim 1 where the polymer is polyethylene.
4. A shingle according to claim 1 where the filler is an inorganic material.
5. A shingle according to claim 1 where the filler is crushed limestone.
6. A roofing shingle:
a. that is less than an inch think;
b. between about 3-12 inches wide;
c. between about 6-24 inches long;
d. comprising at least about 36% polyolefin; and
e. comprising no more than about 64% filler.
Description
    BACKGROUND
  • [0001]
    1. Field of the Invention
  • [0002]
    The present invention relates to roofing shingles. Specifically, the present invention relates to composite roofing shingles composed primarily or exclusively of a polyolefin polymer and a filler.
  • [0003]
    2. Background of the Invention
  • [0004]
    Traditional roofing products include asphalt shingles, wood shakes, slates, and metal panels. Each of these products has benefits. For instance, wood shakes and slate roofing are very aesthetic. However, wood shakes are considered a fire hazard and slate is very expensive and subject to cracking.
  • [0005]
    Less expensive roofing products have been introduced to simulate wood shakes and slate roofing. Some asphalt shingles have been developed that resemble slate or shake roofing. However, asphalt products typically do not have the structural rigidity of slate or shake. Metal and plastic shingles have been developed that simulate shake and slate. However, those products are subject to denting and breakage.
  • [0006]
    Composite shingles are typically composed of an organic/polymer component and a filler component. The composition may be molded to simulate the shape and appearance of various types of roofing including shakes or slates. The amount of polymer in these composite shingles is substantially less than the amount of filler. For instance, U.S. Pat. No. 5,711,126 discloses that the amount of polymer in the composite to range from 12 to 35% and the preferred amount of filler ranges from 65 to 88%.
  • [0007]
    Although these composite shingles are capable roofing systems, there are some problems. For instance, the large amount of filler causes the product to be excessively heavy while the low amount of polymer reduces flexibility and increases the possibility of cracking and splitting. Accordingly, a need exists to improve composite shingles.
  • SUMMARY OF THE INVENTION
  • [0008]
    The present invention comprises a composite roofing shingle composed primarily of a mixture of a polyolefin based polymer composition and a filler. The blend includes 70-35% polymer and 30-65% filler. The preferred mineral is crushed limestone and the preferred polymer is polyethylene. The shingles may be molded to simulate the appearance of traditional roofing or any other configuration that may be advantageous for a particular roofing application.
  • BRIEF DESCRIPTION OF DRAWINGS
  • [0009]
    FIG. 1 is an isometric environmental view of the preferred roofing material as assembled on a roof.
  • [0010]
    FIG. 2 is an isometric view of a preferred single piece of roofing material.
  • DESCRIPTION OF PREFERRED EMBODIMENT
  • [0011]
    The preferred roofing system is shown in FIGS. 1 and 2. The preferred shingles are composed of a mixture including a polymer and an inorganic. Colorants and other additives may be used to improve or alter the aesthetics or performance of the shingles. Nevertheless, the preferred composition includes a polyolefin and an inorganic filler.
  • [0012]
    The polymer component is a polyolefin such as polyethelene, polypropelene or mixture of polyolefin polymers. Preferably, this component is polyethelene. The preferred range of this component is 35 to 70% of the composition by weight.
  • [0013]
    The filler material may include any number or combinations of materials. The preferred filler is an inorganic material such as sand, talc, mica, slate, shale, limestone or fly, volcanic or bottom ash. The preferred filler is crushed limestone. Use of various materials can affect the resulting color of the shingle so selection of the filler can reduce the need for a colorant
  • [0014]
    The preferred composition includes a mixture of between 35 to 65% of the polymer component and 65-30% filler component. That mixture provides a lower weight and/or more flexible composite shingle. The preferred composition includes 60% crushed limestone and 40% polyethylene by weight.
  • [0015]
    The preferred roofing material is made by blending crushed limestone with polyethylene beads or pellets. The mixture is first fed into a mixer, preferably a kinetic mixer. The mixer not only blends the materials but also heats the material to a preferred state where the plastic encapsulates the filler. Color or other additives may be added at this stage. Once the material is mixed, it is conveyed to a piston type extruder and extruded out in shots. A typical shot will weigh between 30 and 35 pounds.
  • [0016]
    The blend is extruded onto the bottom platen of a mold. Once the material fills the bottom platen of the mold, the top platen of the mold is closed. Pressure is then applied to the top platen to compress the material to fill the entire mold. The preferred mold will be configured to have the shape of wood shakes, or the surface of slate. The preferred mold is approximately 16 feet by 12 inches. The material is cooled to form a board. That board is then cut to length and bundled in different sizes to be shipped.
  • [0017]
    The shape including the width, thickness contour and length of the shingle may be altered depending on the application. The preferred shingle shown in FIG. 1 will be 0.25 inches thick, 5 inches wide and 12 inches long, where one side is molded to simulate shake or slate. Color may be added to the mixture during processing or added later.
Citations de brevets
Brevet cité Date de dépôt Date de publication Déposant Titre
US2124384 *20 juin 193519 juil. 1938Ellis Foster CoFloor tile and process of making same
US2959563 *20 juil. 19568 nov. 1960Goodrich Co B FResinous 1-monoolefinic hydrocarbon compositions stabilized with silicon monoxide
US2993799 *20 août 195725 juil. 1961Blake Charles LPlastic containing composition and the process of making the same
US3037897 *8 avr. 19575 juin 1962Tru Scale IncMethod of making structural panel articles
US3070557 *3 août 195925 déc. 1962Exxon Research Engineering CoThermoplastic polymer-bonded aggregate compositions, and manufacture thereof
US3224997 *23 mars 196221 déc. 1965Union Carbide CorpAluminum-titanium dioxide filled thermoplastic resin compositions
US3238175 *22 juil. 19601 mars 1966Phillips Petroleum CoMolded articles of spent oil shale and thermoplastic materials and process for preparing same
US3795646 *21 avr. 19725 mars 1974Gen ElectricCross-linking polyethylene compositions with silicone additive
US3846366 *22 nov. 19715 nov. 1974Wallace RStructural material and method
US3981840 *13 mars 197421 sept. 1976Joto Chemical Company LimitedMethod for molding thermoplastic resin compositions
US3991006 *31 déc. 19749 nov. 1976Gaf CorporationPlastic molding formulation reinforced with organic fibers
US4070843 *16 déc. 197631 janv. 1978Robert LeggiereSimulated shingle arrangement
US4307552 *4 oct. 197929 déc. 1981Votte Andre TSynthetic roofing elements of the slate type and a method of manufacturing same
US4508842 *29 mars 19832 avr. 1985Union Carbide CorporationEthylene polymerization using supported vanadium catalyst
US5288772 *23 juin 199222 févr. 1994Clemson UniversityPre-treated cellulosic materials for producing molded composite articles therefrom and process
US5417904 *5 mai 199323 mai 1995Razi; Parviz S.Thermoplastic polymer composites and their manufacture
US5486553 *7 avr. 199423 janv. 1996Andersen CorporationAdvanced polymer/wood composite structural member
US5497594 *20 oct. 199412 mars 1996Andersen CorporationAdvanced polymer and wood fiber composite structural component
US5506031 *7 févr. 19949 avr. 1996Avery Dennison CorporationPlastic siding panels with outdoor weatherable embossed surfaces
US5539027 *20 oct. 199423 juil. 1996Andersen CorporationAdvanced polymer/wood composite structural member
US5614307 *7 juin 199525 mars 1997E. Khashoggi IndustriesSheets made from moldable hydraulically settable compositions
US5615523 *24 avr. 19951 avr. 1997Owens-Corning Fiberglas Technology, Inc.Roof having resinous shingles
US5620642 *4 mars 199415 avr. 1997Misawa Homes Co., Ltd.Simulated wood product manufacturing method and simulated wood product
US5626954 *3 août 19936 mai 1997E. Khashoggi IndustriesSheets made from moldable hydraulically settable materials
US5635125 *24 févr. 19953 juin 1997Re-New Wood, IncorporatedMethod for forming simulated shake shingles
US5690876 *25 juil. 199425 nov. 1997Gallo, Jr.; Francis AnthonySystem for continuous production of roofing shakes
US5711126 *13 mai 199627 janv. 1998Owens-Corning Fiberglass Technology, Inc.Resinous angled shingles for roof ridge lines
US5770820 *7 mai 199623 juin 1998Belden Wire & Cable CoPlenum cable
US5773138 *7 janv. 199730 juin 1998Andersen CorporationAdvanced compatible polymer wood fiber composite
US5810961 *9 avr. 199622 sept. 1998E. Khashoggi Industries, LlcMethods for manufacturing molded sheets having a high starch content
US5827607 *17 oct. 199527 oct. 1998Andersen CorporationAdvanced polymer wood composite
US5938994 *29 août 199717 août 1999Kevin P. GohrMethod for manufacturing of plastic wood-fiber pellets
US5973049 *26 juin 199726 oct. 1999The Dow Chemical CompanyFilled polymer compositions
US5981067 *14 oct. 19979 nov. 1999Andersen CorporationAdvanced compatible polymer wood fiber composite
US5985429 *7 juin 199516 nov. 1999Andersen CorporationPolymer fiber composite with mechanical properties enhanced by particle size distribution
US6004668 *26 oct. 199821 déc. 1999Andersen CorporationAdvanced polymer wood composite
US6015611 *26 oct. 199818 janv. 2000Andersen CorporationAdvanced polymer wood composite
US6015612 *4 mai 199918 janv. 2000Andersen CorporationPolymer wood composite
US6017595 *15 sept. 199725 janv. 2000Brenot; Stephen E.Structural building materials or articles obtained from a composite including polymeric materials, solid waste material, and reinforcing materials
US6025052 *15 juil. 199715 févr. 2000Maurer; Ronald L.Synthetic building member
US6054207 *21 janv. 199825 avr. 2000Andersen CorporationFoamed thermoplastic polymer and wood fiber profile and member
US6083582 *24 juil. 19984 juil. 2000Regents Of The University Of MinnesotaCellulose fiber based compositions and film and the process for their manufacture
US6099516 *30 oct. 19978 août 2000Kimberly-Clark Worldwide, Inc.Fastener system for use with personal care articles
US6112492 *30 avr. 19985 sept. 2000Owens Corning Fiberglas Technology, Inc.Shingle having ribs and cavity on its underside
US6117924 *22 oct. 199612 sept. 2000Crane Plastics Company Limited PartnershipExtrusion of synthetic wood material
US6126883 *13 nov. 19983 oct. 2000Lindauer Dornier Gesellschaft MbhMethod and apparatus for cooling hot-pressed panels, especially wood chip and fiber panels
US6133378 *20 nov. 199817 oct. 2000Bridgestone/Firestone, Inc.EPDM-based roofing shingle compositions
US6164034 *31 août 199826 déc. 2000Poly Proximates, Inc.Fiber-reinforced molded plastic roofing unit and method of making the same
US6194519 *20 juil. 199827 févr. 2001Christopher BlalockProducts useful as roof shingles and a process for making such products
US6210792 *12 nov. 19983 avr. 2001Andersen CorporationAdvanced compatible polymer wood fiber composite
US6214924 *30 août 200010 avr. 2001The Dow Chemical CompanyFilled polyethylene compositions
US6228301 *9 avr. 19998 mai 2001Misawa Homes Co., Ltd.Cement bonded wood chip product, resin bonded wood chip product, simulated wood product and manufacturing method thereof
US6248271 *16 déc. 199919 juin 2001Owens Corning Fiberglas Technology, Inc.Method of making an insert for use in a mold for molding roof covering products
US6253512 *15 avr. 19993 juil. 2001Owens Corning Fiberglas Technology, Inc.Method of applying tiles to a roof
US6254814 *11 févr. 19993 juil. 2001Daiho Industrial Co., Ltd.Molding compound for articles including a cellulose fiber and a method for molding the same
US6255368 *3 mai 19993 juil. 2001Kevin P. GohrPlastic wood-fiber pellets
US6261496 *15 juil. 199917 juil. 2001Alliedsignal Inc.Continuous compounding of aqueous injection molding feedstocks
US6265037 *16 avr. 199924 juil. 2001Andersen CorporationPolyolefin wood fiber composite
US6290885 *1 nov. 200018 sept. 2001Poly Proximates, Inc.Method of making a fiber-reinforced molded plastic roofing unit
US6306518 *19 mai 199923 oct. 2001Montell Technology Company BvHigh surface gloss, co-extruded sheets from propylene polymer materials
US6380296 *5 oct. 199930 avr. 2002Nitto Boseki Co., Ltd.Interior resin article
US6418692 *6 déc. 200116 juil. 2002Elk Corporation Of DallasAesthetic, self-aligning shingle for hip, ridge, or rake portion of a roof
US6495635 *26 mai 200017 déc. 2002Gerald E. EdsonWaterproof, durable products made from recycled rubber products
US6508800 *8 juil. 199921 janv. 2003Baxter International Inc.Dual-filled twin bag, a package and a method for forming a package administering a solution
US6586026 *18 mars 19991 juil. 2003Cryovac, Inc.Package with contoured seal
US6899839 *21 févr. 200131 mai 2005Shell Oil CompanyBuilding products
US6916863 *22 août 200212 juil. 2005Boral Material Technologies, Inc.Filler comprising fly ash for use in polymer composites
US6939496 *19 déc. 20006 sept. 2005Psa Composites, LlcMethod and apparatus for forming composite material and composite material therefrom
US6983571 *28 sept. 200110 janv. 2006Teel Plastics, Inc.Composite roofing panel
US20070135548 *6 févr. 200714 juin 2007Manish SethMethod of fabrication for synthetic roofing and siding material
Référencé par
Brevet citant Date de dépôt Date de publication Déposant Titre
US778551015 sept. 200531 août 2010Certainteed CorporationProcess of and apparatus for making a shingle, and shingle made thereby
US79343466 mars 20083 mai 2011Certainteed CorporationProcess of treating a synthetic shingle and shingle made thereby
US80170527 janv. 201013 sept. 2011Certainteed CorporationProcess of and apparatus for making a shingle, and shingle made thereby
US820662922 nov. 201026 juin 2012Certainteed CorporationFence or decking materials with enhanced solar reflectance
US82068071 mai 200726 juin 2012Certainteed CorporationSynthetic roofing shingle or tile
US83371885 mars 201025 déc. 2012Certainteed CorporationApparatus for making a shingle, and shingle made thereby
US8850771 *24 oct. 20077 oct. 2014Certainteed CorporationSynthetic shingle or tile with stress relief spacing feature
US8894901 *1 oct. 200725 nov. 2014G.R. Green Building Products Inc.Method of making a sheet of building material
US20060029775 *15 sept. 20059 févr. 2006Mackinnon Thomas KevinProcess of and apparatus for making a shingle, and shingle made thereby
US20080236079 *6 mars 20082 oct. 2008Mackinnon Thomas KevinProcess of Treating a Synthetic Shingle and Shingle Made Thereby
US20100043331 *24 oct. 200725 févr. 2010Certainteed CorporationSynthetic Shingle or Tile With Stress Relief Spacing Feature
US20100127425 *7 janv. 201027 mai 2010Certainteed CorporationProcess of and Apparatus for Making a Shingle, and Shingle Made Thereby
US20100159053 *5 mars 201024 juin 2010Certainteed CorporationApparatus for Making a Shingle, and Shingle Made Thereby
US20100215946 *1 oct. 200726 août 2010G.R. Green Building Products Inc.Method of making a sheet of building material
US20100239816 *21 sept. 200923 sept. 2010Kinkade Jerald EComposite building panel and method of making same
US20110061796 *22 nov. 201017 mars 2011Ming-Liang ShiaoFence or decking materials with enhanced solar reflectance
WO2006122583A1 *19 mai 200523 nov. 2006Jan DaansShaped plastic building panels and manufacturing method for making such panels
Classifications
Classification aux États-Unis52/782.1
Classification internationaleE04D1/26, E04D1/20, E04D1/22
Classification coopérativeY10T428/24372, E04D1/20, E04D1/22, Y10T29/49799
Classification européenneE04D1/22, E04D1/20