Roofing shingles, tiles and shakes

Patent metadata

Field	Value
Publication number	US-10837176-B2
Application number	US-201715857531-A
Country	US
Kind code	B2
Filing date	Dec 28, 2017
Priority date	Dec 31, 2016
Publication date	Nov 17, 2020
Grant date	Nov 17, 2020

Abstract

The present disclosure relates generally to roofing elements and methods for making them. In one embodiment, the disclosure provides a roofing element in the form of a roofing shingle that includes a body of a foamed cured cross-linked polymer, the body having a top surface and a bottom surface, the body extending substantially in a plane and having a thickness in the range of 0.5 mm to 35 mm; and a layer of weather-resistant roofing granules disposed on and adhered at the top surface of roofing element. The roofing element can be made by providing a body of wet foamed curable composition, and allowing the curable composition to cure to provide the body of foamed cured cross-linked polymer.

First claim

We claim:

1. A roofing element in the form of a roofing shingle, shake or tile extending substantially in a plane, the roofing element having a top surface, the roofing element comprising:
a body of a foamed cured cross-linked polymer, the body having a top surface at the top surface of the roofing element and a bottom surface, the body extending substantially in the plane and having a thickness in the range of 2 mm to 35 mm; and
a layer of weather-resistant roofing granules disposed on and adhered at the top surface of the roofing element,
wherein the weather-resistant roofing granules are adhered directly to the foamed cured cross-linked polymer;
the body of foamed cured cross-linked polymer is in the form of a substantially closed-cell foam; and
wherein the shingle, shake or tile has an asphalt content of less than about 5 wt %.

2. The roofing element of claim 1 , having an asphalt content of less than about 1 wt %.

3. The roofing element of claim 1 , further comprising a support sheet disposed at least partially within the body of foamed cured cross-linked polymer.

4. The roofing element of claim 3 , wherein the support sheet is a fibrous mat, a fiberglass mat, a roofing felt, or a fibrous mat of metallic strands, of polymeric fibers, of glass fibers, or of a combination thereof.

5. The roofing element of claim 1 , further comprising a mesh sheet disposed at least partially within the body of foamed cured cross-linked polymer, or on the bottom surface of the body of foamed cured cross-linked polymer.

6. The roofing element of claim 1 , further comprising a backing sheet disposed on the bottom surface of the body of foamed cured cross-linked polymer.

7. The roofing element of claim 1 , further comprising a polymer film disposed within the body of foamed cured cross-linked polymer.

8. The roofing element of claim 1 , wherein the roofing granules are disposed directly on and embedded in a top surface of the body of foamed cured cross-linked polymer.

9. The roofing element of claim 1 , comprising a support sheet that is a glass mat, and a polymer film disposed on a bottom surface of the body of foamed cured cross-linked polymer.

10. The roofing element of claim 1 , wherein the body of foamed cured cross-linked polymer has a density in the range of 1 g/mL to 2 g/mL.

11. The roofing element of claim 1 , wherein the body of foamed cured cross-linked polymer has a void volume, and wherein no more than 10% of the void volume is formed by foam cells having a longest dimension in excess of 100 microns.

12. The roofing element of claim 1 , wherein the polymer of the body of foamed cured cross-linked polymer is a poly(meth)acrylate-based polymer, a polyurethane/acrylate hybrid polymer, a polyurethane, a polyvinylidine difluoride or a copolymer thereof.

13. The roofing element of claim 1 , wherein the body of foamed cured cross-linked polymer further comprises a filler.

14. The roofing element of claim 1 , having a headlap portion and an exposure portion, wherein the headlap portion is adapted to have its top surface generally covered in the installed condition of the element on a roof, and the exposure portion being adapted to have its top surface generally uncovered and weather-exposed in the installed condition of the element on a roof.

15. The roofing element of claim 1 , wherein the body of foamed polymer has a thickness in the range of 2 mm to 5 mm.

16. An array of the roofing elements according to claim 1 , disposed on a roof deck.

17. The roofing element of claim 1 , wherein the polymer of the body of foamed cured cross-linked polymer is a acrylate-based polymer.

18. A process for preparing a roofing element according to claim 1 , comprising:
providing a wet body of a foamed curable composition, the foamed curable composition being adapted to provide the foamed cured cross-linked polymer upon curing, the foamed curable composition having a wet foam density of about 0.1 to about 1.0 g/mL to provide a wet roofing element precursor;
disposing the granules on a top surface of the wet body of foamed curable composition; and then
allowing the wet body of foamed curable composition to cure to provide the body of foamed cured cross-linked polymer having the granules embedded in and adhered to the top surface thereof.

19. The method of claim 18 , wherein the wet body of foamed curable composition has a wet foam density in the range of 0.2 to 0.7 g/mL.

20. The roofing element of claim 19 , wherein the polymer of the body of foamed cured cross-linked polymer is a poly(meth)acrylate-based polymer or a polyurethane/acrylate hybrid polymer.

Assignees

• Certain Teed Corp
• Certainteed Llc

Inventors

• Lai Choung-Houng
• Kamath Mithun N
• Liu Jia
• Ma Liyan
• Jacobs Gregory F

Classifications

• E04D1/20 Primary

  of plastics; {of asphalt;} of fibrous materials · CPC title

• B32B2307/712

  Weather resistant · CPC title

• B32B2307/72

  Density · CPC title

• B32B5/32

  at least two} layers being foamed {and next to each other · CPC title

• B32B7/12

  using interposed adhesives or interposed materials with bonding properties · CPC title