Prefabricated roofing element

Details Prefabricated roofing element Prefabricated roofing element

2000-04-14

2001-06-26

Dixon, Merrick (Department: 1774)

Stock material or miscellaneous articles

Web or sheet containing structurally defined element or...

Noninterengaged fiber-containing paper-free web or sheet...

C428S061000, C428S195100, C428S198000

Reexamination Certificate

active

06251511

ABSTRACT:

FIELD OF THE INVENTION
The present invention relates to a prefabricated roofing element in the form of a laminate.
It relates more particularly to a roofing element comprised, from its internal toward its external surface exposed to the weather, at least one first continuous layer constituting the core of said element and formed from a mixture of at least one binder and reinforcing material, a second continuous layer of a product that protects against ultraviolet and weather, called a GELCOAT, constituted of a mixture of at least one synthetic resin, preferably thermosetting, such as a polyester resin, of a constituent covering the mass of said resin and of a catalyst.
BACKGROUND OF THE INVENTION
Settable tiles have been used at present in many processes for covering dwellings. These tiles are generally constituted of baked clay permitting obtaining coverings that are quite sealed and resistant but heavy and exposed to breakage, in particular in the case of hail. There has accordingly appeared on the market, as a roof covering, plates of synthetic material on which has been stamped the shape of interfitting tiles. These lightweight plates, resistant to the weather, have nevertheless not been entirely a commercial success, essentially for two reasons. On the one hand, the use of materials such as Fibrociment (trademark), is dangerous to the health of users. On the other hand, these plates only badly imitate the natural appearance of conventional materials, such as tiles and slates, this poor imitation being moreover by a rapid degradation with time of their appearance.
Solutions of the first problem set forth above have been found and are set forth particularly in French patents FR-A-2.451.429 and FR-A-2.522.348. The roofing elements described in these patents are obtained by use of reinforced resins that do not risk the health of the occupants of a dwelling. However, the composition of such roofing elements and the processes for production are not satisfactory in terms of appearance of the product and in terms of long-term strength of this product.
The patent FR-A-2.522.348 teaches, to imitate the appearance of traditional products, the use of granulates which give rise to problems of homogeneity of the mixture and of the distribution of the granulates on the surface of the final product.
The patent FR-A-2.451.429 relates itself to the use of a colored GELCOAT having a rough appearance adapted to give rise to a certain number of drawbacks such as retention of dirt and the growth of moss in its roughened surface.
The patent FR-A-2.363.195 relates essentially to the production of a production mold in polyester or other thermal hardenable substance from a core clad with a plastic or hydraulic coating. This patent also describes a process for mass production of pieces by such a mold. This process comprises a step of cladding one wall of the mold with a colored GELCOAT, then a step of cladding this mold with a mixture of resin plus fibers. The GELCOAT could be present in the form of a continuous layer or in the form of specks of different colors. Such a document corresponds to the conventional production of a closed covering element of two layers, one constituting the core of the element, the other formed by a GELCOAT that gives long-term strength.
SUMMARY OF THE INVENTION
An object of the present invention is to overcome the drawbacks mentioned above by providing a prefabricated roofing element that very closely resembles conventional products, such as tiles and slates, which ages well and remains water-resistant and which will be producible by means of an industrial process.
Another object of the present invention is to provide a process for the production of a prefabricated roofing element that is easy to use and permits rapidly obtaining the finished product.
To this end, the invention has for its object a prefabricated roofing element of laminated form comprised, from its internal surface toward its external surface exposed to the weather, of at least one first continuous layer constituting the core of said element and formed from a mixture of at least one thermosetting binder and a reinforcing material, a second continuous layer of a protective coating against ultraviolet and weather, a so-called “GELCOAT” constituted by a mixture of at least one synthetic resin, preferably thermosetting, such as a polyester resin, a covering material throughout the mass of the resin, and a catalyst, these elements being characterized in that it moreover comprises at least one third discontinuous layer of paint distributed irregularly over the surface of the second layer and comprised by material immiscible with the constituents of the second layer to form at the surface of the second layer spots conferring in cooperation with the second layer of said element an appearance imitating the appearance of conventional materials such as slates or tiles.
According to a preferred embodiment of the invention, the third layer of the covering element is constituted of paint essentially thermoplastic-based resins which are polyurethane, acrylic, or two-component acrylic-urethane resins, a catalyst adapted to promote polymerization of said resin, and pigments.
The invention also has for its object a process for the production of a prefabricated roofing element, characterized in that there are deposited by projection in the form of irregular droplets on the surface of the mold cavity of a mold of a shape corresponding to the shape of a portion of the covering element to be reproduced, a paint to form the so-called upper layer of a covering element of laminated roofing, in that after hardening this layer is covered with a second continuous layer of a coating that protects against weather and ultraviolet, a so-called gel coat, constituted by a synthetic resin-based mixture, which is preferably thermosetting and colored, which is not miscible with the paint of the upper layer, and that there is applied after hardening of this second layer, a layer adapted to form the core of said element, this layer being constituted by at least one reinforcing material and a thermosetting binder.


REFERENCES:
patent: 4018017 (1977-04-01), Schoop
patent: 4155482 (1979-05-01), Swaney
patent: 4617818 (1986-10-01), Fukuyori
patent: 4760679 (1988-08-01), Thompson
patent: 1 802 391 (1969-06-01), None
patent: 2 360 395 (1978-03-01), None

Affiliated with

Also associated with

Rating

Prefabricated roofing element does not yet have a rating. At this time, there are no reviews or comments for this patent.

If you have personal experience with Prefabricated roofing element, we encourage you to share that experience with our LandOfFree.com community. Your opinion is very important and Prefabricated roofing element will most certainly appreciate the feedback.

Rate now

Comments { 0 }

Profile ID: LFUS-PAI-O-2485590