U.S. patent application number 11/747911 was filed with the patent office on 2008-06-05 for exterior roofing surface comprised of foam and cement coating.
Invention is credited to WILBUR DALE McINTIRE.
Application Number | 20080127587 11/747911 |
Document ID | / |
Family ID | 40002892 |
Filed Date | 2008-06-05 |
United States Patent
Application |
20080127587 |
Kind Code |
A1 |
McINTIRE; WILBUR DALE |
June 5, 2008 |
EXTERIOR ROOFING SURFACE COMPRISED OF FOAM AND CEMENT COATING
Abstract
An external roofing surface comprised of foam and a cement
coating that is Class A fire-resistant under the UL 790 standard,
insect resistant, very strong and extremely lightweight is
disclosed. The roofing surface is also easily shaped by a number of
shaping techniques, which allows for a more aesthetically pleasing
appearance and can be used to make a roofing system that interlocks
and has channels for underside ventilation. A cement coating is
applied to the roofing surface, imparting it with excellent water
repellant properties and increasing its strength, durability, and
aesthetic appeal. The roofing surface may also optionally be
reinforced with various materials to increase the strength and
durability. The roofing surface may optionally be coated with a
second coating material or a sheathing material to impart a desired
strength, durability and/or aesthetic look.
Inventors: |
McINTIRE; WILBUR DALE;
(Salinas, CA) |
Correspondence
Address: |
MANUEL F. DE LA CERRA
6885 CATAMARAN DRIVE
CARLSBAD
CA
92011
US
|
Family ID: |
40002892 |
Appl. No.: |
11/747911 |
Filed: |
May 13, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11348173 |
Feb 6, 2006 |
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11747911 |
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60717608 |
Sep 17, 2005 |
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Current U.S.
Class: |
52/309.12 |
Current CPC
Class: |
E04D 1/28 20130101; E04D
1/2914 20190801; E04D 1/08 20130101 |
Class at
Publication: |
52/309.12 |
International
Class: |
E04C 2/28 20060101
E04C002/28 |
Claims
1. An external roofing surface comprising: a structure comprised of
foam and a cement coating applied to the foam; wherein the cement
coating further comprises a redispersable additive comprising a
vinyl copolymer and a silane based agent; wherein the additive
imparts the following attributes to the cement coating: increased
water repellency, increased final strength, increased flexural
strength, increased abrasion resistance, increased flexibility,
improved resistance to freeze-thaw cycles, and reduced cracking;
the structure further comprises a reinforcing structure selected
from a group consisting of: ridges, ribs, channels, and
combinations thereof, and wherein the roofing surface meets or
exceeds the Class A certification requirements of the UL 790
Standard as issued by the Underwriter Laboratories.
2. An external roofing surface comprising: a structure comprised of
foam and a cement coating applied to the foam; wherein the cement
coating further comprises a redispersable additive; wherein the
additive imparts the following attributes to the cement coating:
increased water repellency and decreased absorption of water; and
wherein the roofing surface meets or exceeds the Class A
certification requirements of the UL 790 Standard as issued by the
Underwriter Laboratories.
3. The roofing surface of claim 2, wherein the additive is a vinyl
copolymer and wherein the additive imparts the following additional
attributes to the cement coating: high final strength; increased
flexural strength, and increased abrasion resistance.
4. The roofing surface of claim 2, wherein the additive is a vinyl
copolymer and wherein the additive imparts the following additional
attributes to the cement coating: increased flexibility, improved
resistance to freeze-thaw cycles, and reduced cracking.
5. The roofing surface of claim 2, wherein the additive is a silane
based agent and wherein the additive imparts the following
additional attributes to the cement coating: increased final
strengths, improved bending tensile strength and improved
compressive strength.
6. The roofing surface of claim 2, wherein the additive is a silane
based agent and wherein the additive imparts the following
additional attributes to the cement coating: reduced susceptibility
to dirt and improved abrasion resistance.
7. The roofing surface of claim 2, wherein the cement coating
further comprises a water dispersible natural polymer that imparts
water retentive properties to the cement coating.
8. The roofing surface of claim 2, wherein the foam comprises EPS
and the structure further comprises a fiberglass reinforcing
mesh.
9. The roofing surface of claim 2, wherein the structure is
shaped.
10. The roofing surface of claim 2, wherein the structure is shaped
by using a shaping technique selected from a group consisting of:
hotwire, routing, laser cutting, punching, extrusion, cutting,
drilling, casting, infusion and combinations thereof.
11. The roofing surface of claim 2, wherein the structure is shaped
by using computer assistance.
12. The roofing surface of claim 2, wherein the foam is selected
from a group consisting of: high density foam, blue board,
polystyrene, injection foams, MDI monomer, polyurethane resins,
extruded foam, expanded polystyrene, expanded plastic foam,
expanded polyethylene, nylon and mixtures thereof.
13. The roofing surface of claim 2, wherein the structure further
comprises a reinforcing material selected from a group consisting
of: foam, fiberglass mesh, shopped fiberglass, polypropylene
fibers, metal mesh, polyurethane mesh, nylon mesh, polymers and
mixtures thereof.
14. The roofing surface of claim 13, wherein the reinforcing
material is internal to the foam.
15. The roofing surface of claim 13, wherein the reinforcing
material is external to the foam.
16. The roofing surface of claim 15, wherein the structure further
comprises a second reinforcing material selected from a group
consisting of: foam, fiberglass mesh, shopped fiberglass,
polypropylene fibers, metal mesh, polyurethane mesh, nylon mesh,
polymers and mixtures thereof.
17. The roofing surface of claim 2, wherein the structure further
comprises a reinforcing structure selected from a group consisting
of: ridges, ribs, channels, and combinations thereof.
18. The roofing surface of claim 2, wherein the structure further
comprises a second coating material.
19. The roofing surface of claim 18, wherein the second coating
material is selected from a group consisting of: paint, cement,
concrete, polyurethane, vinyl, latex, oil, metal, plastic and
mixtures thereof.
20. The roofing surface of claim 2, wherein the structure further
comprises a sheathing structure.
21. The roofing surface of claim 20, wherein the sheathing
structure is selected from a group consisting of: metal, plastic,
natural rock and mixtures thereof.
Description
1. CLAIM OF PRIORITY
[0001] The present continuation-in-part patent application claims
priority to U.S. patent application Ser. No. 11/348,173 filed on
Feb. 6, 2006 by inventor Wilbur Dale McIntire, which is a
continuation-in-part of U.S. provisional patent application
60/717,608 filed on Sep. 17, 2005 by inventor Wilbur Dale McIntire.
The contents of these patent applications are incorporated herein
by reference.
2. THE FIELD OF THE INVENTION
[0002] This invention relates to building products and, more
particularly, to an external roofing surface comprised of foam and
a cement coating.
3. THE BACKGROUND
[0003] Roofing surfaces have been used since ancient times to
provide a weatherproof seal to living enclosures. Two of the most
common types of roofing surfaces are tiles and shingles.
[0004] Tiles are extremely popular in current construction and are
commonly made of clay or cement. They have many beneficial
attributes including aesthetic appeal, non-ignitability, weather
resistance and longevity. However, they also have several drawbacks
because they are extremely heavy and very fragile. In fact,
stepping on these tiles generally creates enough stress to break
them. One way of increasing their strength is by adding thickness
to the tile; however this added strength comes at the cost of
significantly increased weight.
[0005] The other types of common roofing surfaces are asphalt and
wood shingle. Asphalt is fire resistant but provides very little
additional strength to the roof, and consequently wears over time.
Asphalt roofs commonly must be replaced every 10 to 15 years. Wood
shingles also must be replaced because they suffer from rot and
have the added detriment of not being completely fire resistant.
Both of these shingle types are also very limited in their
aesthetic appeal. Whereas with concrete/clay tiles you can select
non-planar shapes, shingles are generally sheet-like structures
with no shape options.
[0006] Providing a weatherproof seal is a roofing surface's
fundamental purpose. Roofs are generally sloped to shed rain and
snow effectively. When the pitch of the roof is steep, the
installation, maintenance and support of the roofing surface
becomes an issue. Workmen may step on the roofing surface during
construction or repairs, so the strength of the tiles is a major
concern. The tiles often have a weak point at the overlap regions
or at their unsupported centers. Breaking tiles effectively defeats
the fundamental purpose of a roof by exposing the interior of the
structure to water. Thus, the roofing surface must be strong and
durable.
[0007] Strength is also important to the manufacture, shipping and
handling of the roofing surface. The stronger the roofing surface
material, the less will be lost due to shipping and installation
breakage. But strength cannot come at the price of increased
weight. The shipping cost for such weighty cargo can be
significant, and tolling on the environment because of high
emissions during transport. Also, a heavy roof requires a sizeable
substructure, which also impacts the environment by requiring more
lumber. And ultimately a heavy roof can be a safety hazard in an
accidental roof collapse.
[0008] The porosity of roof tiles is also very important in
climates with a repetitive freeze-thaw cycle. The more porous a
roof surface is, the more water it will absorb. Once that water
freezes, the roofing surface can split or crack, compromising the
weatherproof seal.
[0009] Another important feature of a roofing system is its
insulation attributes. Asphalt shingles have a very low insulation
rating, meaning that heat is allowed to cross the roof structure.
In the winter, heat escapes the roof, while in the summer heat
enters the structure. In either event, the energy costs in managing
the heat transfer are significant. Therefore, a roofing system that
enjoys a high insulation rating will promote significant energy
savings.
[0010] A roofing system should also resist damage on the underside.
Roofing surfaces often obstruct free flow of air on the underside.
Air movement is beneficial because it evacuates condensation that
can form on the underside, as well as any moisture that may have
leaked through a crack in the roofing surface. Without ventilation,
however, the moisture can begin to compromise the roof by rotting
away the roof's support. When the moisture freezes it may
compromise the roofing surface by affecting the joints.
Unfortunately, most conventional roofs do not have sufficient
ventilation.
[0011] An important feature of a roofing surface is its ability to
protect the roof deck below it by resisting fire, both from direct
exposure to burning materials or flames and indirect exposure to
fire from adjacent burning materials. A roof deck may be
combustible, formed of wood such as sheathing boards or plywood, or
noncombustible, formed of metal, concrete, or poured gypsum. Roof
tile manufacturers submit their roofing surfaces to testing
laboratories, such as Underwriters Laboratories Inc..RTM. (UL),
that test the roofing surfaces using proprietary test standards.
Testing may result in a Class A, B, or C rating, or no rating at
all, with the A rating being the most rigorous; thus providing the
best fire protection. The rating gives consumers an indication of
the roofing surface's effectiveness against external fire
hazards.
[0012] As particularly applied to roof covering, UL has issued a
standard entitled "UL Standard for Safety for Standard Test Methods
for Fire Tests of Roof Coverings, UL 790", Eighth Edition, Dated
Apr. 22, 2004 (the "UL 790 standard") to test the fire protection
characteristics of a particular product. To receive a Class A
rating under the UL 790 standard, a roofing surface must pass Class
A tests, demonstrating it is effective against severe fire test
exposures, affords a high degree of fire protection to the roof
deck underneath the roofing surface, does not slip from its
position, and is not expected to produce flying brands. A brand is
a charred piece of wood or ember. Class B roof surfaces are only
effective against moderate fire test exposures, affording a
moderate degree of fire protection to the roof deck, while Class C
roof surfaces are effective against light fire test exposures, only
offering a light degree of fire protection to the roof deck.
[0013] For non-wood shake roofing surfaces, the UL 790 standard
employs three tests: Intermittent Flame, Spread of Flame and
Burning Brand. These tests simulate fire sources originating from
outside a building on which the roofing surface is installed. For
all three tests, the roofing surface is first installed over a test
roof deck. In addition, a twelve mile-per-hour air current,
simulating wind, flows uniformly over the top of the roofing
surface during each of the tests. The Intermittent Flame test
demonstrates a roofing surface's resistance to flames from adjacent
burning material. During a Class A test, a 1400.degree. F.
(+/-50.degree. F.) gas flame is intermittently applied to the
roofing surface for fifteen four-minute cycles (two minutes flame
on, two minutes flame off) to simulate the ebb and flow of fire.
During each cycle, the flame is applied for two minutes, then
turned off for two minutes. After the last application of fire, the
air current is maintained until all evidence of flame, glow, and
smoke has disappeared from the roofing surface.
[0014] The Burning Brand test exposes the roofing material to a
burning brand, or block of wood, to simulate exposure to burning
materials such as a burning ember produced in a large fire. Class A
tests use a twelve inch-by-twelve inch brand that is ignited by
exposure to flame for five minutes, during which time the brand is
rotated to present each surface to the flame. The burning brand is
then placed on the roofing surface. The test continues until the
brand is consumed and until all evidence of flame, glow, and smoke
has disappeared from the roofing surface and the underside of the
roof deck, or when the roof deck fails due to flame penetration, or
burn-through, to the underside of the deck. The burning brand must
fully extinguish without burning through or igniting the roof
deck.
[0015] And third, a Spread of Flame test ensures there will be no
significant lateral spread of a flame on the roof deck. In a Class
A test, the roofing surface is exposed to a gas flame of
1400.degree. F. for ten minutes or until such time as the spread of
flame, or flaming of the roofing surface being tested, permanently
recedes from a point of maximum spread, whichever is shorter.
[0016] Successful completion of each of these tests requires that
no portion of the roofing surface be blown or fall off the test
deck in the form of flaming or glowing brands, that the roof deck
not be exposed by breaking, sliding, cracking, or warping of the
roofing surface, and that no portion of the roof deck fall away in
the form of glowing particles. In addition, at no time during the
tests can there be any sustained flaming of the underside of the
deck. Sustained flaming is considered uninterrupted flaming for
five seconds or more. In addition, for the Spread of Flame Class A
test, the flaming of the roofing surface cannot spread beyond six
feet and there can be no significant lateral spread of flame from
the path directly exposed to the test flame.
[0017] Currently available roofing surfaces may provide Class A, B,
or C fire resistance protection, depending on the fire-resistance
properties of the specific roofing material and compliance with the
manufacturer's installation instructions. However, some roofing
surfaces have not undergone certification testing and may not
designate any level of protection. In addition to cost, strength,
porosity, insulation rating, ventilation properties, and aesthetic
appeal, consumers consider the increased fire protection afforded
by a Class-A certified roofing surface to be a highly desirable
feature.
[0018] What is needed therefore is a roofing surface that is
lightweight, strong, and fire-resistant and has a high insulation
rating. Such a surface should also have various cross-sectional
shapes to increase aesthetic appeal and finally should offer
ventilation to the underside. Thus, a roofing system is provided in
accordance with the invention that obtains several structural
advantages, manufacturing advantages and advantages in
installation.
4. SUMMARY OF THE INVENTION
[0019] An external roofing surface comprised of foam and a cement
coating is disclosed. The roofing surface is certified Class A
fire-resistant under the UL 790 standard, very strong and extremely
lightweight. The surface also resists insects including termites
and carpenter ants. Various types of foam may be used; including
expanded polystyrene, high density foam, Styrofoam, blue board,
polystyrene, injection foams, MDI monomer, polyurethane resins,
extruded foam, expanded polystyrene, expanded plastic foam,
expanded polyethylene and nylon. The foam is also easily shaped by
a number of shaping techniques (including hotwire, extrusion,
casting, routing, punching, cutting, drilling, hand carving,
infusion, laser cutting, and water jet cutting), which allows for a
more aesthetically pleasing appearance and can be used to make a
roofing system that interlocks and has channels for underside
ventilation.
[0020] A cement coating is applied to the foam. The coating
includes one or more additives that impart excellent water
repellant properties to the roofing surface and also increase its
strength, durability, and aesthetic appeal. Reinforcement materials
may also be applied internally or externally to the roofing
surface. These materials may include fiberglass mesh, shopped
fiberglass, polypropylene fibers, metal mesh, polyurethane mesh,
nylon mesh, and polymers. A second coating of paint, cement,
concrete, polyurethane, vinyl, latex, oil, metal, epoxy, plastic
and copolymers may also be applied for enhanced strength,
durability, or aesthetic appeal.
5. BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 depicts a cross-sectional view and overall view of a
novel foam and cement tile with an interlocking area.
[0022] FIG. 2 depicts a cross-sectional view and overall view of a
novel foam and cement tile.
[0023] FIG. 3 depicts a cross-sectional view and overall view of a
novel foam and cement tile with an interlocking area.
[0024] FIG. 4 depicts a cross-sectional view and overall view of a
novel foam and cement ridge cap tile.
[0025] FIG. 5 depicts a cross-sectional view and overall view of a
novel foam and cement ridge cap tile.
6. DETAILED DESCRIPTION
[0026] An external roofing surface comprised of foam and a cement
coating is disclosed and overcomes the deficiencies that mar
conventional roofing systems. The roofing surface is
fire-resistant, insect resistant, very strong and extremely
lightweight. One embodiment of the external roofing surface is
comprised of expanded polystyrene (EPS). EPS is generally produced
from a mixture of about 95% polystyrene and 5% gaseous blowing
agent (e.g. pentane). The solid plastic can be expanded into a foam
by using heat, usually steam. During the pre-expansion, steam
softens the plastic resin causing the pentane to expand the plastic
into beads at least 100 times their original size. As long as the
plastic is exposed to steam, the pentane expands enlarging the size
of the beads by filling the voids with trapped air. Before all of
the pentane is displaced by air, the pre-expanded bead is then
placed into a mold of any shape or block that can be easily cut.
Polystyrene can also be extruded and is commonly known by the trade
name Styrofoam.RTM..
[0027] The foam can be manufactured such that the surface is
treated to be weatherproof--i.e., the ability to withstand exposure
to weather without damage. For example, the foam may be extruded,
cast or laser cut (as described below), which may result in a
smooth surface that may be inherently weatherproof. Or, as
described below, materials can optionally be added internally or
externally to the foam, which may increase the foam's strength and
water resistance.
[0028] The large void space makes EPS foam very lightweight and
thus requires much less rigid structural supports. This, in turn,
reduces construction costs and saves valuable lumber.
[0029] An added advantage of EPS is that it is an exceptionally
good insulation material. Because the foam generally consists of
air-filled pockets--in some instances 0.2-0.5 mm across with
polystyrene walls about 0.001 mm thick--the polystyrene walls
occupy only about 2% of the total volume. Air is a very poor
conductor of heat, thus little heat can move through the EPS
structure. The roof therefore acts as an insulator that cuts down
on construction costs (less insulation needed elsewhere, smaller
heating and air conditioning equipment, etc.) and cuts down on the
buildings energy costs.
[0030] EPS also creates a tile that is much more durable than
conventional materials. In comparison to clay tiles that are very
brittle and will break during shipment and installation, a
foam-based tile can be dropped on the ground and stepped on without
damaging it. Because it is so lightweight, it is easier to handle,
install and does not pose the danger of accidental injury from a
falling tile. EPS is also weather and insect resistant and does not
wear as easily as other convention roofing materials.
[0031] While the roofing surface has been described as comprised of
EPS, other types of foam would be apparent to those skilled in the
art. Those foams include high density foam, Styrofoam.RTM., blue
board, polystyrene, injection foams, MDI monomer, polyurethane
resins, extruded foam, expanded polystyrene, expanded plastic foam,
expanded polyethylene and nylon.
[0032] a. Shaping the Foam
[0033] In one embodiment of the roofing surface, a roofing tile is
constructed of EPS. This type of foam can be purchased in large
blocks that measure 49''W.times.37''H.times.96''L. The block is cut
and shaped to size by using a computer assisted cutting machine.
Before cutting however, the precise cuts must be programmed into
the computer. For the shape depicted in FIG. 1, the cross sectional
shape 5 is programmed into the computer first. The block is then
placed on the computer assisted cutting machine, in this case hot
wire, which cuts the block into several tiles that are 96'' long.
To assist in shipping, handling and installation, the 96'' long
tiles are further cut into 18'' sections by the computer assisted
machine.
[0034] In another method of shaping, the foam is extruded into the
desired shape. For example, again referencing FIG. 1, the foam can
be extruded through a die that yields the cross-sectional shape 5.
This is advantageous because it negates the first shaping step
described above and cuts down on wasted material. The extruded foam
block, with the desired cross-sectional area, could further be
separated into the desired sections (i.e., 18'' in the embodiment
above). This can be accomplished by interrupting extrusion when the
desired length is achieved, or by cutting the extruded foam to the
desired length by any of the shaping methods described herein.
[0035] In yet another shaping method embodiment, the foam can be
cast into the desired shape. By injecting the foam, which is still
in an unhardened state, into a preformed cast, no other shaping
methods may be necessary. This again cuts down on material
waste.
[0036] These shaping techniques can be used to provide channels on
the underside of the tile that promote ventilation. For example,
the foam can be extruded in the shape depicted in FIG. 1, which
shows a ventilation channel 10. The channel may reduce the amount
of condensation on the underside of the roof, which will cut down
on the deleterious effects of condensation. Examples of other cross
sectional shapes are shown in FIGS. 2 to 5.
[0037] These shaping techniques can also be used to provide
reinforcement structures such as ribs, ridges and channels. FIG. 1
depicts ridges 15 and channels 20 that add strength and aesthetics.
The shaping technique employed can also be used to preferentially
shape more foam on areas that need more strength, such as the
unions between tiles where conventional tiles often fail. FIG. 2
depicts a tile that has more foam placed on the top of the arch
35.
[0038] These shaping techniques can also be used to manufacture
interlocking tiles. For example, the tiles may have appropriate
ridges, channels and fastening points to allow the interlocking of
successive rows of roof tile, with the bottom edge of each row
overlapping the top edge of a lower row along the line. Tiles
shaped and installed in this layout produce an effective moisture
barrier and an aesthetically pleasing appearance. For example, FIG.
1 depicts an interlocking area 25 that would mate with interlocking
area 30. FIG. 3 also has a similar interlocking feature where area
40 mates with are 45. While the shaping of the tiles is described
with reference to a computer-assisted hotwire, extrusion and
casting, other shaping methods would be apparent to those skilled
in the art. Those methods may include, but are not limited to,
routing, punching, cutting, drilling, hand carving, infusion, laser
cutting, and water jet cutting. They may further include any of
these methods controlled or assisted by a computer. It should also
be apparent that these shaping techniques could be used to form
several shapes and sizes of tiles, such as those depicted in FIGS.
1-5.
[0039] b. Reinforcement Materials and Methods
[0040] Generally, reinforcement can be applied internally or
externally to the foam. In one embodiment of an external
reinforcement material, a self-adhesive fiberglass mesh is applied
to the exterior of the foam after shaping. The mesh provides added
strength to the foam. Other types of mesh may also be used and
would be apparent including: shopped fiberglass mesh, polypropylene
fiber mesh, metal mesh, polyurethane mesh, nylon mesh, and
polymer-based mesh.
[0041] Non-mesh materials may also be applied to the exterior of
the foam. For example, the copolymer known in the trade as
Elotex.RTM. FX2320 may be appropriate. It is a redispersible binder
based on a copolymer of ethylene and vinyl acetate. In the cured
state, this polymer has a high strength, has an excellent
freeze-thaw cycling resistance, is very flexible and impact
resistant. It also adheres very strongly to foam. Alternatively,
Elotex.RTM. product FX2300 can be used in place of FX2320. More
information on Elotex.TM. FX2320 and FX2300 may be obtained by
contacting ELOTEX AG or by visiting www.elotex.com.
[0042] Reinforcement applied internally may also increase strength.
One method introduces nylon or fiberglass fibers to the foam prior
to curing. Adding co-polymers and plastics to the non-cured foam
may also strengthen it. In yet another embodiment, adding a
fiberglass mesh that is imbedded in the foam provides added
strength. Of course several other types of embedded structures may
be used; including shopped fiberglass, polypropylene fibers, metal
mesh, polyurethane mesh and nylon mesh.
[0043] While reinforcement is described with reference to above
embodiments, other reinforcement materials and methods would be
apparent to those skilled in the art. Instead of applying a certain
material (or in conjunction therewith), structural modifications
can also be used for reinforcement. Ridges, ribs or channels may be
introduced to the foam structure of the roofing tile such that
forces applied to the surface of the tile are more effectively
balanced. Additional foam may be added to areas on the tile that
may need more strength, such as the union between tiles where
conventional tiles often fail. Alternatively or in conjunction,
additional reinforcement material may be added to the areas that
require more strength.
[0044] c. Coating Materials and Methods
[0045] A cement coating is applied to the surface of the foam and
may serve one or more of the following general attributes:
appearance, protection, and strength. Specific attributes may
include high compressive and tensile strength, corrosion
resistance, temperature durability, inertness and colorfastness.
The coating material may also serve the function of the
reinforcement materials discussed above.
[0046] The coating is made from a cement mixture. Specifically, the
mixture may include the following components: cement, sand, fly
ash, pigment, water, hydration agent, and a waterproofing agent.
The mixture is prepared and applied to the surface of the tile. The
mixture is then dried, so as to harden it and affix it to the foam.
This drying may simply be done at room temperature or by exposing
the coating to heat. It is also important to note that depending on
the coating material, drying may not be necessary.
[0047] Another coating material known by the trade name "Blue Eagle
Brand Eaglebond" is available from Eagle Building Materials at 1407
N. Clark, Fresno, Calif. 93703-3615. This material is a proprietary
blend of cement modified with redispersible powders, copolymers and
inert aggregate. This coating is mixed as per the instructions of
the vendor and applied to the foam. The vendor further recommends a
curing time of at least 24 hours before performing any further
work.
[0048] The coating may optionally be comprised of a copolymer agent
such as Elotex.RTM. FX2320 described above.
[0049] Elotex.RTM. also makes sealing and waterproofing agents that
may optionally be used. SEAL80, as it is known in the trade, is a
redispersible, silane based waterproofing/water-repellency agent.
It may be used alone or mixed with the cement coating already
described. If mixed with cement and other dry additives, SEAL80
provides between 0.2 and 2.0% of the dry mixture. SEAL80 is very
hydrophobic and offers excellent water repellancy. The effect of
adding SEAL80, with its high degree of water repellency and
hydrophobicity, is to decrease permeation of water into the cement
coating and decrease the absorption of water by the coating. In its
cured state, SEAL80 also provides the additional benefits of
resisting dirt and slightly improving the final strength, bending
tensile strength, compressive strength and abrasion resistance of
the final coating. Alternatively, Elotex.RTM. product ERASEAL120
can be used in place of SEAL80. In addition to the SEAL80
properties noted above, ERASEAL 120 has the additional advantage of
minimizing any potential color change in the final coating. More
information on Elotex.RTM. SEAL80 and ERASEAL 120 may be obtained
by contacting ELOTEX AG or by visiting www.elotex.com.
[0050] Another Elotex.RTM. product, HD1501, can also be used to
greatly enhance the coating's strength and resistance to weather. A
redispersable binder based on a copolymer of vinyl acetate and
vinyl verstate, HD1501 is particularly suitable in cement-based
systems where it provides a high final strength and increased
flexural strength and abrasion resistance in its cured state.
HD1501 also increases cohesion and adhesive bond strengths,
particularly when used on polystyrene foam products. HD1501
increases plasticity and flexibility, such that it provides greatly
improved resistance to freeze-thaw cycles and reduced cracking. As
with SEAL80, HD1501 increases the water repelling and waterproofing
properties of the cement coating and decreases the absorption of
water by the coating. Alternatively, Elotex.RTM. products HD1500
and HD 1510 may be used in place of HD1501. More information on
Elotex.RTM. HD1500, 1501 and 1510 may be obtained by contacting
ELOTEX AG or by visiting www.elotex.com.
[0051] Finally, ELOSET.RTM. CP3901 can be used by itself or in
combination with the above products to enhance the coating's
performance. CP3901 is a water dispersible natural polymer that is
designed to impart water retentive properties in cement coatings
and to ensure the proper level of cement hydration. Again, more
information on Elotex.TM. ELOSET.RTM. CP3901 may be obtained by
contacting ELOTEX AG or by visiting www.elotex.com.
[0052] Several other coatings would be apparent to those of
ordinary skill in the art, such as, materials that may strengthen,
protect and/or improve the appearance of the foam. These coatings
may include paint, cement, concrete, polyurethane, vinyl, latex,
oil, metal, epoxy, plastic and copolymers. These coating may also
be a sheathing structure such as metal, plastic, and natural
rock.
[0053] In some cases it may be favorable to coat the entire tile.
For example, where condensation may collect on the interior surface
of the tile, a coating material may help protect the integrity of
the foam. Another alternative is to apply the coating to only the
surface of the foam that will be exposed to the elements. Or,
different coatings may be applied to different surfaces to optimize
the resilience of the tile. For example, a less durable coating may
be applied to surfaces that are not exposed to the elements, while
a more durable coating is applied to the surface that is exposed.
Also, one or more layers of different coatings may be used. Various
implementations would be obvious to one skilled in the art.
[0054] In one embodiment the coating mixture shown in Table 1 is
used and applied to the EPS foam in two separate coatings. First,
the EPS foam is shaped in one of the methods described above. Then
fiberglass netting with a density of 5 oz./yd.sup.2 is applied to
the top surface of the roofing surface. Fiberglass netting with a
density of 2.5 oz./yd.sup.2 is also applied to the bottom surface
of the roofing surface. Then a 1/8'' cement coating (see Table 1)
is applied to the top surface and allowed to cure. A second 1/16''
thick coating is applied to the top surface and a similar 1/16''
thick coating is applied to the bottom surface. These coating may
optionally have pigments to add color to the final roofing surface.
After curing, the roofing surface may be installed.
TABLE-US-00001 TABLE 1 Cement Coating Mixture Material Approx. % of
Dry Weight Cement 34 Sand 58 Fly Ash .3 Water dispersible natural
.02 polymer, hydration agent Redispersable (vinyl 4.7 copolymer)
water-repellency agent Redispersible silane based .28
water-repellency agent
[0055] c. Fire Protection Test Results
[0056] The roofing surface described herein is designated by
Underwriters Laboratories Inc..RTM. (UL) for installation as a
Class A prepared roof covering under the UL790 standard, for use on
either combustible or noncombustible roof decks when the roofing
surface is applied as intended. The combination of light weight
(due to EPS composition) and superior fire resistance allows
someone additional time to exit a burning building without fear of
the roof caving in as it may in the case of heavier clay and
concrete roofing tiles.
[0057] The roofing surface's Class A resistance to external fire
provides significant assurances and greatly increases its
effectiveness. The roofing surface passed three rigorous UL
certification tests to attain a Class A certification.
Specifically, the roofing surface passed Intermittent Flame tests,
during which a 1400.degree. F. gas flame was intermittently applied
to the roofing surface during fifteen four-minute cycles and a
twelve mile-per-hour air current flowed over the roofing surface.
No portion of the roofing surface was blown or fell off the roof
deck in the form of flaming or glowing brands, nor was the roof
deck exposed by breaking, sliding, cracking, or warping of the
roofing surface. No part of the combustible 15/32 inch plywood roof
deck (the roof deck used during the certification process) fell
away in the form of glowing particles, nor did it sustain flaming
on its underside.
[0058] The roofing surface also passed Burning Brand tests, in
which a twelve inch-by-twelve inch brand was ignited and placed on
the roofing surface. Test observations were made until the brand
was consumed and testing ceased. No portion of the roof surface was
blown or fell off the roof deck in the form of flaming or glowing
brands, and the roofing surface protected the roof deck such that
it was not exposed by breaking, sliding, cracking, or warping of
the roofing surface. The underside of the roof deck experienced no
sustained flaming, and no portions of the roof deck fell away in
the form of glowing particles.
[0059] In a Spread of Flame test, the roofing surface was exposed
to a gas flame of 1400.degree. F. for ten minutes. With a maximum
spread of flame of 3.5 feet and no significant lateral spread of
the flame from the path directly exposed to the test flames, the
roofing surface passed the test. As with the other tests, no
portion of the roofing surface was blown or fell off the roof deck
in the form of flaming or glowing brands, the roof deck was not
exposed by breaking, sliding, cracking or warping of the roof
surface, and no portions of the roof deck fell away in the form of
glowing particles.
[0060] Thus, the roofing surface is certified to carry the UL Class
A listing mark for Prepared Roof Covering Materials. This certifies
the roofing surface is effective against severe fire test
exposures, under which it affords a high degree of fire protection
to the roof deck. The roofing surface is also certified not to slip
from its position and is not expected to produce flying brands
during severe fire test exposure. In sum, this significant degree
of fire resistance is a particularly advantageous and effective
feature.
[0061] The embodiments above provide a roofing surface that is
certified Class A fire-resistant under the stringent UL 790
standard. The surface is strong, lightweight and resists insects
including termites and carpenter ants. The surface promotes a
healthier environment because of it is light weight which (1) cuts
down on transportation exhaust emission and (2) requires less
lumber to support the surface. Also, the foam used in the roofing
surface acts as an insulator that cuts down on construction costs
(less insulation needed elsewhere, smaller heating and air
conditioning equipment, etc.) and cuts down on the buildings energy
costs.
[0062] Having described the methods and structures in detail and by
reference to several preferred embodiments thereof, it will be
apparent that modifications and variations are possible without
departing from the scope of the invention defined in the following
claims. Moreover, the applicant expressly does not intend that the
following claims "and the embodiments in the specification to be
strictly coextensive." Phillips v. AHW Corp., 415 F.3d 1303, 1323
(Fed. Cir. 2005) (en banc).
* * * * *
References