U.S. patent application number 12/137078 was filed with the patent office on 2009-12-17 for composite material roofing structure.
Invention is credited to Billibob J. Boor.
Application Number | 20090308009 12/137078 |
Document ID | / |
Family ID | 40825200 |
Filed Date | 2009-12-17 |
United States Patent
Application |
20090308009 |
Kind Code |
A1 |
Boor; Billibob J. |
December 17, 2009 |
Composite Material Roofing Structure
Abstract
The present invention is a composition for making high quality,
mold resistant, water proof building products. The composition from
which these products are formed is a mixture of various
polyethylene or polypropylene materials, in conjunction with
fillers which may comprise recycled rubber products such as
ethylene propylene-diene monomers, and styrene butadiene rubber, or
mineral fillers to achieve a different feel and texture to the
formulation without compromising the integrity of the product. This
is achieved by altering the melt and amount of the high and/or low
density polyethylene or polypropylene in the mix to end up with the
correct material integrity. Colorants may be additionally be added
to the mixture prior to final molding. This composition allows for
products to be made that resemble traditional building products,
but with a higher performance level that are also recyclable in
their entirety.
Inventors: |
Boor; Billibob J.;
(Hortonville, WI) |
Correspondence
Address: |
BOYLE FREDRICKSON S.C.
840 North Plankinton Avenue
MILWAUKEE
WI
53203
US
|
Family ID: |
40825200 |
Appl. No.: |
12/137078 |
Filed: |
June 11, 2008 |
Current U.S.
Class: |
52/309.13 |
Current CPC
Class: |
C08L 23/16 20130101;
C08K 5/005 20130101; C08L 23/10 20130101; C08K 5/0066 20130101;
C08L 19/003 20130101; C08L 23/10 20130101; C08L 19/003 20130101;
C08L 23/0853 20130101; C08K 3/013 20180101; C08L 23/06 20130101;
C08L 23/0815 20130101; C08L 23/0815 20130101; C08L 2666/02
20130101; C08L 2666/02 20130101; C08L 2666/02 20130101 |
Class at
Publication: |
52/309.13 |
International
Class: |
E04C 1/40 20060101
E04C001/40 |
Claims
1. A building product comprising a composition of: a) between about
10-60% by weight of a filler; b) about 10-40% by weight a binder;
c) about 0-40% by weight fire retardant; and d) about 5-80% by
weight of a polymeric resin.
2. The building product of claim 1 wherein the polymeric resin
comprises low density polyethylene and high density polyethylene in
an amount of between about 5-50% by weight.
3. The building component of claim 1 wherein the polymeric resin
comprises high density polyethylene in an amount of about 20% by
weight, and low density polyethylene in an amount of about 10% by
weight
4. The building product of claim 1 wherein the polymeric resin
comprises polypropylene present in an amount of up to about 75% by
weight
5. The building product of claim 1 wherein the filler comprises
recycled vulcanized rubber.
6. The building product of claim 5 wherein the filler comprises a
combination of ethylene propylene-diene monomers and scrap from
styrene butadiene rubber products in an amount of up to about 50%
by weight.
7. The building product of claim 1 wherein the filler comprises a
mineral filler.
8. The building product of claim 1 wherein the binder comprises
ethylene vinyl acetate in an amount of between about 10-40% by
weight.
9. The building product of claim 1 wherein the binder comprises
ultra low density polyethylene in an amount of between about 10-40%
by weight.
10. The building product of claim 1 further comprising about 0.1-8%
by weight of an antioxidant.
11. The building product of claim 1 further comprising about 0.1-8%
by weight of an U.V. inhibitor
12. The building product of claim 1 further comprising about 0.1-8%
by weight of an U.V. stabilizer.
13. The building product of claim 1 wherein the product is selected
from the group consisting of: roofing tiles, roofing sheathing,
siding materials, hand rails, deck panels, pallets, pavers, and
decorative construction accessories.
14. The building component of claim 1 further comprising a
colorant.
15. The building component of claim 1 wherein the entire building
component is recyclable.
16. The building component of claim 1 wherein the entire
composition is formed of recycled components.
17. A building product comprising a composition of: a)
polypropylene in an amount of up to about 75% by weight of the
composition; b) calcium carbonate in an amount of between about
10-50% by weight; c) a fire retardant present in an amount of
between about 20-50% by weight; d) a binder system present in an
amount of between about 1-20% by weight; e) a U.V. stabilizer
present in an amount of between about 0.1-8% by weight; and f) a
U.V. inhibitor present in an amount of between about 0.1-8% by
weight.
18. A building component comprising a composition of: a) a fire
retardant in an amount of 45% by weight of the overall composition;
b) a binder in an amount of 25% by weight; c) a high density
polyethylene in an amount of about 20% by weight; and d) a low
density polyethylene in an amount of about 10% by weight.
19. The building component of claim 18 wherein the binder comprises
a combination of ethylene vinyl acetate and ultra low density
polyethylene.
20. The building component of claim 18 further comprising a
colorant.
Description
FIELD OF THE INVENTION
[0001] The present invention relates to building components, such
as roofing elements, and more particularly to building components
that are formed of specified combinations of synthetic materials to
simulate building components formed from natural materials and to
enhance the desirable properties of the building components.
BACKGROUND OF THE INVENTION
[0002] In the art of building components such as roofing with tiles
constructed of natural materials, it has been known for many years
to roof tiles with natural slates. Such slates, derived from
quarries, are cut to size, drilled or punched with nail holes, and
applied to roofs in a conventional manner. However, such natural
slates, while providing for roofs for many years, often 50-100
years, generally require a basic supporting roof structure capable
of withstanding great amounts of weight, such as on the order of
2,000 lbs. per square, with a square being a 10 feet by 10 feet
area of a roof.
[0003] Synthetic products have been developed which simulate
natural-appearing building components for use in decks, roofs, such
as slate roofs, and other building structures. However, these
synthetic building components are either very heavy, or if weight
is a consideration, rather thin, when constructed thinner than
natural slate or other natural roofing tiles, in order to reduce
the weight required.
[0004] Other synthetic building components have been developed,
such as from molded concrete with appropriate lightweight fillers,
sometimes with partial recesses for weight reduction purposes to
address these concerns.
[0005] However, such prior art synthetic products either have not
adequately simulated the natural materials in either appearance or
desirable impact, wear and fire resistance properties, or have not
been constructed in a manner that enables the building components
to be made with recycled materials, which are becoming more and
more prevalent with the continued usage of these types of
materials. Most of the synthetic materials used to form the
building components have a large carbon footprint, e.g., due to the
extra energy used to form the material and in its processing into
the building components. Further, because prior art building
components are formed exclusively from virgin materials, as the
reuse of the materials results in significant degradation of the
properties of the materials, the inability to use any forms of
recycled materials does not make the formation of prior art
synthetic building components environmentally friendly.
[0006] In addition, the properties of certain materials used to
form these materials necessitate that the processing of the
material be carefully controlled in order to form useful products.
For example, due to the properties of polypropylene that affect how
the material flows and cools, the molding process must be closely
controlled to prevent the item molded from the polypropylene from
having undesirable properties, such as limited impact resistance,
such as in compression molding processes.
[0007] As a result, it is desirable to develop a lightweight,
synthetic building component composition that enables composition
to be modified as desired to ensure that the building component
formed therewith in the specified process has sufficient durability
and a desired appearance for use in various building structures,
such as in forming a roof covering, and optionally without the need
for additional components when utilized to form a roof.
Additionally, the building component composition should allow for
increased ease of manufacture such that the building component can
be formed with the desired appearance in any suitable molding
process. Further, when the building components are to be removed
and replaced, it would be desirable to be able to recycle the
building components to form additional building components, as
opposed to simply disposing of them.
SUMMARY OF THE INVENTION
[0008] According to one aspect of the present invention, a
one-piece building component, such as a roofing element, is
provided that is formed of a molded synthetic material so as to
simulate a natural appearing element, with the building component
composition including various materials selected to provide various
benefits to the building component. The composition for the
building component is formed of a polymeric resin combined with a
binder. The presence of the binder allows for the manipulation of
the properties of the polymeric resin, especially in the case of
recycled polymeric resins, and the resulting building component, in
manner that improves the ability to process the resin to form a
building component using various molding techniques. These property
benefits include increased mold resistance, fire retardency,
increased wind resistance, increased impact resistance, and
appearance.
[0009] According to another aspect of the present invention, the
binder utilized in the composition of the roofing element enables
the composition for the building component to be formed with
synthetic components that can be obtained from scrap or other
recycled materials. Also, the use of these materials and the binder
renders the roofing component itself entirely recyclable for
forming additional building components The primary materials used
in forming the roofing tiles include polymeric resins or plastics
of various types, such as polypropylene, giving the composition a
large amount of flexibility when processing the composition into
the desired roofing element. The additional components of the
composition are then added to this initial starting material and
subsequently formed into the building component with the desired
shape, color and size.
[0010] Numerous other aspects, features and advantages of the
present invention will be made readily apparent from the following
detailed description of the preferred embodiments, and the appended
claims.
DETAILED DESCRIPTION OF THE INVENTION
[0011] According to the present invention, the synthetic roofing
element comprises a body composed of a material which is molded so
as to very closely resemble the appearance of natural building
materials, such as slate, ceramic, wood, and stone, among others.
Moreover, the synthetic building component of the present invention
may be manufactured, such as in any suitable molding, extrusion or
similar process for composite plastic materials, to realistically
resemble other natural materials for use in building structure
applications and for use, generally, in other cladding capacities
not limited to roofing applications, including but not limited to
siding, foundation, decking and decorative trim applications, among
others. By way of example only, such natural materials to be
emulated according to the present invention may include stone,
clay, cedar and other finishes intended to emulate the look and
texture of stone and wood materials. Thus, the synthetic building
component of the invention when emulating a stone or ceramic finish
may be formed to replicate the shape, size, structure and texture
of clay, terra cotta, Spanish/mission tile, barrel tile and ceramic
tile. When emulating a wood finish, the synthetic building
component may be formed to replicate the shape, size, structure,
texture and grain of any of a variety of hardwoods and soft woods,
such as cedar, oak, mahogany, and the like.
[0012] The building component of the present invention is formed of
a composition including as a primary component or ingredient a
plastic or polymeric resin material that comprises one or more
plastics selected from polyesters, polyolefins, polyethylenes,
including high-, medium- and low-density polyethylene,
polystyrenes, polyamides, polypropylenes, and equivalents and
combinations thereof. The plastic or resin component of the
composition of the roofing element is present within a range of
about 10% to 90% by weight of the composition for the roofing
element.
[0013] The plastic ingredient of the building component of the
present invention gives the building component the mechanical
properties of hardness, rigidness, being infusible and insoluble
(i.e., waterproof), and, optionally has extensive cross-linking. By
way of example, the plastic or polymeric resin material may be
obtained as virgin thermoplastic polymer materials, or can be
obtained from recycled material streams formed essentially of the
above polymers.
[0014] In preferred embodiments of the building component, the
plastic ingredient is formed from at least partially from
polypropylene materials. Polypropylene has previously been used for
constructing building components, but has been limited in its use
to only virgin polypropylene. The use of exclusively virgin
polypropylene has resulted in building components having limited
desirable qualities, such as fire and impact resistance, due to the
issues with processing the virgin polypropylene in an injection
molding process.
[0015] The other essential component of the building component
composition is one or more binders that are present preferably in
an amount of up to about 90% by weight of the overall composition,
and more preferably between about 1% and about 75% by weight. The
binder effectively alters the properties of the polymeric resin
used to form the building component to provide a building component
having the desired fire, impact and wear resistance, while also
allowing the building component to be formed utilizing multiple
molding processes. In particular, the presence of the binder alters
the melt index of the polymeric resin thereby allowing the resin
and binder to be used in different molding processes to form the
building component, such as injection molding, compression molding,
and extrusion, among others. Additionally, the binder changes the
physical properties of the resulting building component, including
the impact resistance without degrading the natural properties of
the primary ingredient, such as it fire resistance.
[0016] The binder itself takes the form of another polymeric resin
distinct from that used as the primary ingredient of the building
component, but can be similar to those resins used as the primary
ingredient. For example, the polyethylene resins discussed
previously can also be utilized, or function in the composition as
the binder for the other resins present in the composition. In
addition to polyethylene, other suitable plastics or polymeric
resins that can be used as the binder include ethylene/vinyl
acetate polymers, which can be used alone or in combination with an
ultra low density polyethylene to form the binder, such as
EVAC--Ethylene-Vinyl Acetate Copolymer, as well as LLDPE--Linear
Low Density Polyethylene, LDPE--Low Density Polyethylene,
Metalocine, EAA--Ethylene/Acrylic Acid Copolymer, ultra low density
polypropylene, EEA Poly(Ethylene-Ethyl Acrylate),
EAA--Ethylene/Acrylic Acid Copolymer, PVB--Poly(Vinyl Butyral),
EMAC--Poly(Ethylene Methyl Acrylate), TPO--Thermoplastic Polyolefin
(often applied to elastomers), TPU--Thermoplastic Polyurethene
(often applied to elastomers), or materials of comparable physical
properties.
[0017] Because there is a wide range of ingredients that can be
utilized in combination with one another as either the primary
polymeric resin component or the binder for the building component
composition, this makes the formation of the building components
from recycled materials possible. As opposed to the prior art
synthetic material building components that required the use of
virgin materials in part based on the specific conditions in which
the component is formed, the use of the binder in combination with
the different polymeric resins as the primary ingredient
essentially allows the composition to be modified as necessary to
provide a building component with the desired properties based on
the type and amount of the binder that is used. In particular, if
the characteristics of a selected primary ingredient do not allow
the ingredient to be formed or function properly for the desired
building component, the binder is selected based on its properties
to create a composition that can be formed into the desired
building component using the specified process, and that has the
desired impact, wear and heat or fire resistance properties.
Therefore, in the case of use of a recycled polymeric resin
material as the primary component which may not have the desired
initial characteristics, a binder can be selected and added to the
recycled resin to provide a composition that has the desired
properties and can effectively be used to form a building
component. Further, because each of the resin components used in
the composition can come from recycled materials, the entire
building component formed from the composition can itself be fully
recycled.
[0018] In addition to the primary resin ingredient and the binder,
the building components of the present invention may preferably
include other ingredients in the composition. One of these
ingredients is a filler compound. The compounds that can be
utilized as the filler for the building component composition of
the present invention include chemical constituents that are
inactive chemical compounds which act as reinforcing agents that
impart to a composition matrix considerable stiffness and rigidity,
as compared with those of a pure thermoplastic or polymeric resin
component. The filler compounds for the composition of the building
component of the present invention are used to increase the modulus
of elasticity and strength of the composition forming the building
component. Additionally, this combination of the thermoplastic or
polymeric resin component with the filler compound is used to
produce a composite building component that is less brittle and
more resistant to impact stresses, and at the same time maintaining
adequate compressive, tensile, flexural and shear strengths,
respectively, to the formed building component. The filler
compounds that can be used in the composition for the roofing
elements include filler compounds selected from the group
consisting of calcium oxide; calcium carbonate; cement; fly ash;
fiberglass fibers; metal shavings; metal oxides, such as zinc
oxide; polyester fibers; aluminum oxides; mica; perlite; zeolites;
vermiculite; silica; silicates; quartz sands, #12 sand; #30 sand,
#60 sand; aggregate particles/granules of stone, rock, marble,
gravel, glass, clay and talc and equivalents and combinations
thereof.
[0019] One additional filler compound that is most preferably
utilized in the composition for the building component of the
present invention is composed of polymeric compounds and recycled
tire bits. Both ethylene propylene-diamine monomer copolymers and
styrene butadiene rubber, which is obtained from shredded vehicle
tires, are excellent filler materials in the molded products of the
invention, and are typically obtained by recycling waste materials
which would otherwise go to already full land fills. Such filler
materials have already been "vulcanized", so they are fire
retardant as well, which provides additional benefit to he roofing
elements of the present invention. They are relatively inexpensive,
water repellant and high temperature resistant, so they are
especially suitable for use in building components such as roofing
materials (shingles), floor coverings (tiles and sheet material),
and other construction materials among other items. Other filler
compounds, such as those described previously, could also be used
to replace all or a part of the preferred copolymer and rubber
materials, so long as the replacement filler compounds have the
needed properties to the building component, especially water and
heat resistance.
[0020] In addition to the primary resin ingredient, binder and the
filler compound, the composition used to form the building
component of the present invention also preferably contains various
additional additives. The additives can include compounds such as
thermal stabilizers, ultraviolet (UV) light stabilizers, pigments
or colorants, compatibilizers, processing aids, flame retardant
additives, and other functional chemicals capable of improving
processing of the materials and performance of the building
components formed from the composition.
[0021] With regard to the colorants, the colorants are preferably
present in an amount of up to 15% by weight of the overall
composition, and more preferably up to about 10% by weight between
preferred coloring in the formulation is natural iron oxide.
However, any other suitable natural or synthetic coloring materials
may also be used to provide the building components with the
desired appearance.
[0022] Concerning the fire retardants that can be utilized in the
composition for the building components, the components are
preferably present in an amount of up to 60% by weight of the
overall composition, and more preferably between about 1% and about
50% by weight, with a couple of preferred components are aluminum
trihydrate and magnesium hydroxide. Other fire retardants may be
used instead of either the aluminum trihydrate or the magnesium
hydroxide. These include Plastisan B made by 3V Corp., Georgetown,
S.C., Phos-check, available from Solutia Corp., St, Louis, Mo. and
Dover-phos-9228 made by Dover Chemical, Dover, Ohio. In addition,
other components of the composition for the roofing elements can
contribute to the fire retardency of the building components other
than the actual fire retardant, such as the preferred filler
material including the recycled tire rubber which as a result of
being vulcanized, already has a fire retardant aspect to it.
[0023] The UV components can be present in the composition in an
amount of up to about 20% by weight of the overall composition, and
more preferably from between about 0.1% to about 16% by weight, and
can include UV inhibitors and UV stabilizers. The UV stabilizers
can include Tinuvin.RTM.783 FDL or Univol 5050H, from Ciba.RTM. of
Basel, Switzerland, which each show significant contribution to
long-term thermal stability for the composite material element, and
helps to keep the material from chalking on the surface over time.
The UV inhibitors may include Chimassorb.RTM. 81 or Univol 3008,
from Ciba.RTM. of Basel, Switzerland, which are each a solid-form
UV absorber of the 2-hydroxy-benzophenone class. The absorbance
spectrum (in the UVB range only) for the inhibitor and relatively
low photo-permanence makes it useful in this application, as it
helps to absorb the UV rays that could otherwise cause premature
degradation of the material performance for the composition forming
the building components.
[0024] The composition can also include antioxidants as an
ingredient preferably present in an amount of up to 10% by weight
of the overall composition, and more preferably between about 1%
and about 8% by weight, such as Irganox.RTM. B225 or Annox B8011,
from Ciba.RTM. of Basel, Switzerland, which are phenolic based
anti-oxidants that hinder thermally induced oxidation of polymers
in high temperature applications. The antioxidants function to
stabilize the color and appearance of the surface of the composite
material used to form the building components. The stabilization
function of the antioxidants effectively controls the look of the
building components throughout the varying temperatures of the
processing of the material, instead of allowing the high processing
temperatures to negatively affect the look of the color and surface
of the building components.
[0025] The following are a few examples of building components
formed utilizing the polymer resin and binder compositions of the
present invention:
EXAMPLE 1
[0026] A Spanish replica tile roofing element can be formed with
the following components in a preferred embodiment of the
composition of the present invention: [0027] 1. ethylene
propylene-diene monomers and scrap from styrene butadiene rubber
products as filler in an amount of up to about 50% by weight (of
the overall composition); [0028] 2. ethylene vinyl acetate and
ultra low density polyethylene as a binder in an amount of between
about 10-40% by weight, and more preferably about 15% by weight;
[0029] 3. a fire retardant (i.e., aluminum tri-hydrate or magnesium
hydroxide) in an amount of 10-35% by weight, [0030] 4. iron oxide
in an amount of between about 1-10% by weight; [0031] 5. high
density polyethylene as a primary resin ingredient in an amount of
between about 5-50% by weight; [0032] 6. U.V. stabilizer in an
amount of between about 1-8% by weight; [0033] 7. U.V. inhibitor in
an amount of between about 1-8% by weight; [0034] 8. antioxidant in
an amount of between about 1-8% by weight.
[0035] The above materials are added together in the form of dry
powders into a suitable mixing apparatus and agitated therein for a
sufficient time period to achieve a uniform and homogeneous
building component composition. The desired coloring for the
particular building component desired is added to the composition
in the mixing apparatus during the agitation of the composition
within the apparatus to achieve a uniform and homogeneous
distribution of the coloring throughout the composition. This
uniformly mixed composition can then be utilized in various forms
to form the desired roofing element by introducing the composition
into a suitably-shaped mold to form the building component therein
under sufficient temperature and pressure. By way of example only,
certain methods that can be utilized to process the composition
into the building element having the desired shape include
extrusion, compression molding, injection molding, and
thermoforming.
[0036] Additionally, the uniform composition can be further
processed, such as to enable the composition to be stored for later
use, or to place the composition in a form, e.g., forming the
composition into multiple pellets, to increase the ease of use of
the composition in other processes to form building components, to
maximize quality of the composition and the roofing elements formed
therefrom, and to aid in creating a less hazardous production
environment by reducing the dust generated from the use of the
composition.
[0037] One additional advantage of the building component
compositions of the present inventions is the lack of the need for
any pre-heating step in the processing of the composition. In some
other similar processes using similar materials it is necessary to
preheat or to chemically cure the virgin polymer composition while
processing the composition prior to forming the building component.
Unfortunately, this required step has the drawback of degrading the
properties of the virgin material being processed, which results in
a building component with degraded properties. In the process for
forming the roofing component of the composition of the present
invention, there is no preheat or chemical curing step. The
materials or ingredients for the composition are simply mixed
together in dry powdered form and then either immediately heated
for molding the building components, or cooled and pelletized, such
that the pellets can be stored or transported for later use when
they can be heated and molded into the finished product. This
reduces the energy consumption and stress on the material by
reducing the number of heat cycles. And also saves on the amount of
fossil fuel used in the processing of the building components as no
additional heat needs to be applied to the composition.
EXAMPLE 2
[0038] A roof sheathing material is manufactured with a formulation
similar to that employed in Example 1, but without styrene
butadiene rubber and a mineral filler. [0039] 1. TPO Thermoplastic
Polyolefin as a binder up to about 50% by weight (of the overall
composition); [0040] 2. ethylene vinyl acetate and ultra low
density polyethylene as a binder in an amount of between about
10-40% by weight, and more preferably about 15% by weight; [0041]
3. a fire retardant (i.e., aluminum tri-hydrate or magnesium
hydroxide) in an amount of 10-35% by weight, [0042] 4.
polypropylene as a primary ingredient in an amount of between about
5-50% by weight;
[0043] The polypropylene is used to make the product slightly
flexible but is still rigid enough to be used as the desired
component, such as for decking, due to the presence of the binder
which alters the natural properties of the polypropylene, even when
in recycled form, to achieve these properties. Additionally, since
this component is designed for use under other building materials,
no colorants are added to the composition. The material composition
provides a strong non-rotting material that tightly seals and/or
engages with fasteners to prevent water intrusion. The product
formed from this composition is impact-resistant, and is has a much
greater useful life than the natural product it replaces, such that
this particular application of the building component composition
can eliminate the need for underlayments that degrade over time.
The sheathing can also be made in a standard size without any loss
of the composition in the manufacturing process. This material
composition is also fully recyclable.
EXAMPLE 3
[0044] To achieve the highest fire and hail ratings, the following
formula may be utilized to form a roofing element: [0045] 1. a fire
retardant in an amount of 45% by weight (of the overall
composition); [0046] 2. ultra low density polyethylene and/or
ethylene vinyl acetate as a binder in an amount of 25% by weight;
[0047] 3. high density polyethylene as a portion of the primary
ingredient in an amount of about 20% by weight; [0048] 4. low
density polyethylene as a portion of the primary ingredient in an
amount of about 10% by weight; and [0049] 5. a small amount of
color, i.e., less than 10% by weight.
EXAMPLE 4
[0050] A Spanish replica tile that is very lightweight and which is
class A fire and Class 4 hail rated can be molded from the
following composition of the present invention formed in a manner
similar to Example 1: [0051] 1. polypropylene a primary ingredient
in an amount of up to about 75% by weight (of the overall
composition); [0052] 2. calcium carbonate in an amount of between
about 10-50% by weight, and more preferably about 35% by weight;
[0053] 3. a fire retardant present in an amount of between about
20-50% by weight; [0054] 4. Linear Low Density Polyethylene as a
binder system present in an amount of between about 1-20% by
weight; [0055] 5. a U.V. stabilizer present in an amount of between
about 0.1-8% by weight; and [0056] 6. a U.V. inhibitor present in
an amount of between about 0.1-8% by weight.
EXAMPLE 5
[0057] A shake or cedar replica shingle can be formed with the
following components in another preferred embodiment of the
composition of the present invention: [0058] 1. polypropylene a
primary ingredient present in an amount of up to about 75% by
weight of the overall composition; [0059] 2. calcium carbonate
present in an amount of between about 10-50% by weight, and more
preferably present in an amount of about 35% by weight; [0060] 3. a
fire retardant present in an amount of between about 20-50% by
weight; [0061] 4. ultra low density polypropylene as a binder
system present in an amount of between about 1-20% by weight;
[0062] 5. a U.V. stabilizer present in an amount of between about
0.1%-8% by weight; and [0063] 6. a U.V. inhibitor present in an
amount of between about 0.1%-8% by weight.
[0064] While particular percentages of materials have been
disclosed herein, it is intended in this specification to include
all equivalent materials which would occur to those of skill in the
art via reasonable experimentation with the compounds and processes
disclosed herein.
* * * * *