U.S. patent number 3,830,687 [Application Number 05/277,896] was granted by the patent office on 1974-08-20 for flame retardant and fire resistant roofing material.
This patent grant is currently assigned to Dyna-Shield, Inc.. Invention is credited to Jack R. Conrad, Carlo Re, Joseph A. Tasso.
United States Patent |
3,830,687 |
Re , et al. |
August 20, 1974 |
FLAME RETARDANT AND FIRE RESISTANT ROOFING MATERIAL
Abstract
An improved flame retardant and fire resistant roofing product
is provided which simulates wooden shake shingles, tiles, planking,
panels, or the like. The roofing product to be described can be
stained to a wood finish, and it can be nailed, sawn, or otherwise
treated in the same manner as wooden shakes. The product provides a
wood waterproof seal, and it is unaffected by wind, rain or snow.
The roofing product of the invention comprises fiberglass and
water-extended polyester mixed with a heat-proofing material, such
as powdered or fibrous asbestos, or powdered glass; and it may be
intermixed with other materials, such as vermiculite (processed
mica), ceramic glass modules, or the like; or it may include a core
composed, for example, of Hydrocol or other gypsum material with an
enclosing web of the fiberglass and water-extended polyester mixed
with the heat-proofing material.
Inventors: |
Re; Carlo (Glendale, CA),
Conrad; Jack R. (Costa Mesa, CA), Tasso; Joseph A.
(Santa Ana, CA) |
Assignee: |
Dyna-Shield, Inc. (Santa Ana,
CA)
|
Family
ID: |
23062839 |
Appl.
No.: |
05/277,896 |
Filed: |
August 4, 1972 |
Current U.S.
Class: |
428/70;
52/309.17; 428/426; 428/920; 52/309.15; 52/555; 428/703 |
Current CPC
Class: |
B32B
13/14 (20130101); B29C 70/025 (20130101); E04D
3/35 (20130101); E04B 1/94 (20130101); B29C
70/865 (20130101); B28B 11/04 (20130101); E04D
1/265 (20130101); B29K 2309/12 (20130101); B29K
2709/02 (20130101); B29K 2309/08 (20130101); B32B
2262/101 (20130101); B29K 2709/08 (20130101); Y10S
428/92 (20130101); Y10T 428/232 (20150115); B32B
2419/06 (20130101); B29K 2067/06 (20130101) |
Current International
Class: |
B29C
70/00 (20060101); B29C 70/02 (20060101); B29C
70/86 (20060101); B28B 11/04 (20060101); E04D
3/35 (20060101); E04B 1/94 (20060101); E04D
1/00 (20060101); E04D 1/26 (20060101); B32b
005/16 (); B32b 021/02 () |
Field of
Search: |
;161/168,162,169,170,43,194,195,205,151,164,DIG.4
;52/554,555,309 |
References Cited
[Referenced By]
U.S. Patent Documents
Primary Examiner: Lesmes; George F.
Assistant Examiner: Dixon, Jr.; William R.
Attorney, Agent or Firm: Jessup & Beecher
Claims
What is claimed is:
1. A fire resistant heat barrier member formed of fiberglass
intermixed with a polyester resin and particles of a fireproofing
material, and including a core of gypsum material.
2. The heat barrier member defined in claim 1, in which said
fireproofing material is powdered asbestos.
3. The heat barrier member defined in claim 1, in which said
fireproofing material is fibrous asbestos.
4. The heat barrier member defined in claim 1, in which said
fireproofing material is powdered glass.
5. The heat barrier member defined in claim 1, in which said
polyester resin is of a water-extended type.
6. The heat barrier member defined in claim 1, in which said
barrier member is formed of fiberglass, and a water-extenddd
polyester resin intermixed particles of asbestos.
7. The heat barrier member defined in claim 1, having a
configuration simulating wooden shake shingles.
8. The heat barrier member defined in claim 1, and which includes
vermiculite and ceramic glass modules intermixed with the
ingredients.
Description
RELATED PATENT APPLICATION
Serial No. 886,075 filed Dec. 18, 1969 in the names of Carlo Re,
Earl O. Conrad and Jack R. Conrad, and entitled "Heat Barrier
Material and Process " which issued Sept. 19, 1972 as U.S. Pat. No.
3,692,682.
BACKGROUND OF THE INVENTION
Shake roofs are extremely popular in the building trade, and
especially for homes, principally because of their attractive and
rich appearance. However, such roofs normally constitute a fire
hazard. In the past, attempts to treat the individual wooden shake
shingles so as to render them fire resistant have not been entirely
successful; principally because of the expense involved, and
because of the tendency for the treated shingles to dry out in time
so as to nullify their fire resistant characteristics.
The roofing product of the present invention is in the form of
synthetic shake shingles which, as mentioned above, closely
simulate the wooden shakes, and which may be sawn, nailed, or
otherwise handled, in much the same manner as the wooden shakes.
However, the product of the present invention is flame retardant
and fire resistant, and it retains such fireproof characteristics
indefinitely.
Moreover, the product of the present invention is advantageous in
that it is relatively inexpensive, and can be mounted on the roof
to provide a waterproof finish without expensive preparation or
additional structures.
The product of the present invention, as mentioned above, is formed
of water-extended polyester mixed with a heat-proofing material,
and it may include a core composed of gypsum, plaster, Hydrocal, or
a mixture of Perlite and Hydrocal, or other suitable material. Such
a core is advantageous in that it is relatively inexpensive, and
also since it provides an appropriate heat barrier because of its
heat resistant characteristics. The core is enclosed by a web
which, as mentioned above, is formed of fiberglass intermixed with
a heat barrier material composed of water-extended polyester and
particles of appropriate heatproofing material, as described in the
aforesaid copending application. As mentioned above, the heat
barrier material is composed of a mixture of water-extended
polyester (WEP) and particles of heatproofing material, such as
powdered or fibrous asbestos, or powdered glass.
Water-extended polyester resins which are suitable for use in the
heat barrier material are described, for example, in U.S. Pat No.
3,256,219. The resin plastic material described in the patent has a
porous structure and a sponge-like consistency, and a liquid, such
as water, is trapped in the pores of the material. In addition, the
material of the web has a high strength.
As described in one specific example in the aforesaid patent, the
water-extended polyester resin may be formed by adding 2g of
Benzoylperoxide and 100 cc of water to a mixture consisting of 65g
of an unsaturated polyester of an acid prepared from maleic acid,
Phthalic acid and propylene gycol of a molar ratio of 2:1:3.3 as
one constituent, and 35g styrene as another constituent.
The resulting mixture is stirred at a temperature of 10.degree. C,
for example, until a water-in-oil emulsion is formed. The emulsion
is mixed with 0.18g of dimethyl-p-toluidine and is subsequently
polymerized and hardened by heating at 30.degree. C for ten
minutes. The water in the pores of the resulting resin material can
subsequently be evaporated by heat at a temperature between
80.degree. C and 100.degree. C. Other examples of water-extended
polyester resin material suitable for present purposes are also set
out specifically in the patent.
A specific example of the consistency of the material which, in
accordance with the present invention, is mixed with the fiberglass
to constitute the synthetic shake, is as follows:
a. One part (by weight) water-extended polyester resin such as
described in the patent. This material is availabe commerically and
may be purchased, for example, from the Ashland Chemical Company of
Los Angeles, California. The particular material is marketed by
that company and is designated by them as "WEP- 27."
b. 1/100th of a part (by weight) cobalt.
c. 1/200th of a part (by weight) dimethylanaline (DMA).
d. 1 part (by weight) water.
e. 2/100,000 of a part (by weight) of an inhibitor such as a
mixture of methyl celosolve (80 percent) and hydroquinone (20
percent).
f. 1/16th or a part (by weight) powdered or fibrous asbestos or
powdered glass. g.
1/200th or a part (by weight) of a catalyst such as methyl ethyl
ketone (MEK) peroxide.
The polyester resin, cobalt and the DMA and stabilizer are mixed
together as one group which is desingated the carrier, as explained
in the copending applicaton, and the asbestos (or powdered glass),
water, inhibitor and catalyst are mixed as another group which is
designated as the heat retarder. The two components form the
material which is intermixed with the fiberglass to form the
synthetic shake of the invention. The proportions of the various
ingredients, as listed above, are not critical and may be varied
considerably to meet specific requirements.
For example, the various ingredients may be varied to meet specific
requirements of handling, heat resistivity, rigidity, and in the
time. That is, the catalyst and inhibitor percentages inthe total
mix affect gel time, and are coordinated with the technical
requirements of the process, and with the production requirements.
For example, if a fast gel time is required, more catalyst and less
inhibitor is used. However, if a slower gel time is required for
any reason, more inhibitor and less catalyst is used.
If a lower heat transfer rate or coefficient is required, the
quanitity of asbestos, or other retardants, is increased. Another
available variable for specific needs is the availability of
various grades of water-extended polyester resin, as described in
the aforesaid patent, which can be selected to provide anything
from a very rigid material to a resilient material.
BRIEF DESCRIPTION OF THE DRAWING
FIG. 1 is a schematic representation of a press and mold which may
be used in the fabrication of shakes in accordance with the
invention;
FIG. 2 is a perspective representation of a shake constructed in
accordance with the invention; and
FIG. 3 is a section taken along the lines 3--3 of FIG. 2.
DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENT
As shown in FIG. 1, a mold 10 is provided which has a bottom
surface configured to correspond to the surface shape of the
simulated shake. The mold, for example, may be formed of metal,
epoxy, polyurethane, or other appropriate material, and the
configuration of its lower surface may be formed by known
techniques, and by the use, for example, of actual wooden
shakes.
In the construction of the synthetic shake of one embodiment of the
present invention, the plaster is first poured into the mold 10 and
allowed to set, so as to form a core. The core may be formed, as
mentioned above, of an appropriate gypsum product such as plaster,
cement, Hydrocal, Perlite, or a mixture of the aforesaid materials.
The purpose of the core is to provide bulk and thickness to the
synthetic shake of the invention at low cost, and to seal in
moisture. The plaster core also provides heat protection for the
material.
After the plaster core has set, it is removed from the mold, and a
fiberglass is sprayed or wrapped around it to form a matte. A
quantity of the water-extended polyester (WEP) and the fire
retardant material is then placed in the mold 10, and the
fiberglass-wrapped core is placed in the mold. More of the mixture
is then placed around the top of the wrapped core, so that the
entire core is surrounded by fiberglass saturated with the (WEP)
mixture. An appropriate press 12 is then moved into place firmly to
press the composite body against the bottom of the mold, and the
polyester material is allowed to polymerize. The resulting product
14 is then removed from the mold.
It will be observed that the product simulates a group of shakes,
and is composed of a core 16, as shown in FIG. 3, composed of
plaster, and a web 18 which completely surrounds the core. The
resulting product may be stained further to simulate the wooden
shake, and it may be sawn, nailed, or otherwise handled in the same
manner as the wooden shake, in order to mount it on the roof. The
synthetic shake 14 has an advantage that it may be directly nailed
onto the roof without expensive sub-bases and the like.
The resulting product 14 also has an advantage in that it has no
tendency to warp, and it provides an excellent roofing material.
The core of the synthetic shake of the invention is fire resistant,
and the surrounding web is not only fire resistant, but also flame
retardant, so that it protects the core from flames in the event of
fire, so that the complete structure provides an excellent heat
barrier.
In another embodiment, a mixture of fiberglass and the (WEP) and
the fire retardant material is intermixed with an appropriate
material, such as vermiculite and/or ceramic glass modules, is
placed in the aforesaid mold and the shake is formed by a single
molding step. The vermiculite and/or ceramic glass modules migrate
towards the center of the shake and replace the core of the
previous embodiment.
While particular embodiments of the invention have been shown and
described, modifications may be made. It is intended to cover all
modifications in the following claims which come within the spirit
and scope of the invention.
* * * * *