US3830687A - Flame retardant and fire resistant roofing material - Google Patents

Flame retardant and fire resistant roofing material Download PDF

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US3830687A
US3830687A US00277896A US27789672A US3830687A US 3830687 A US3830687 A US 3830687A US 00277896 A US00277896 A US 00277896A US 27789672 A US27789672 A US 27789672A US 3830687 A US3830687 A US 3830687A
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water
barrier member
heat barrier
fiberglass
powdered
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US00277896A
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C Re
J Conrad
J Tasso
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Dyna-Shield Inc
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Dyna-Shield Inc
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B13/00—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material
    • B32B13/14—Layered products comprising a a layer of water-setting substance, e.g. concrete, plaster, asbestos cement, or like builders' material next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
    • B28B11/04—Apparatus or processes for treating or working the shaped or preshaped articles for coating or applying engobing layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/02—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts comprising combinations of reinforcements, e.g. non-specified reinforcements, fibrous reinforcing inserts and fillers, e.g. particulate fillers, incorporated in matrix material, forming one or more layers and with or without non-reinforced or non-filled layers
    • B29C70/021—Combinations of fibrous reinforcement and non-fibrous material
    • B29C70/025—Combinations of fibrous reinforcement and non-fibrous material with particular filler
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C70/00—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts
    • B29C70/68—Shaping composites, i.e. plastics material comprising reinforcements, fillers or preformed parts, e.g. inserts by incorporating or moulding on preformed parts, e.g. inserts or layers, e.g. foam blocks
    • B29C70/86—Incorporated in coherent impregnated reinforcing layers, e.g. by winding
    • B29C70/865—Incorporated in coherent impregnated reinforcing layers, e.g. by winding completely encapsulated
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04B—GENERAL BUILDING CONSTRUCTIONS; WALLS, e.g. PARTITIONS; ROOFS; FLOORS; CEILINGS; INSULATION OR OTHER PROTECTION OF BUILDINGS
    • E04B1/00—Constructions in general; Structures which are not restricted either to walls, e.g. partitions, or floors or ceilings or roofs
    • E04B1/62—Insulation or other protection; Elements or use of specified material therefor
    • E04B1/92—Protection against other undesired influences or dangers
    • E04B1/94—Protection against other undesired influences or dangers against fire
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D1/00—Roof covering by making use of tiles, slates, shingles, or other small roofing elements
    • E04D1/26—Strip-shaped roofing elements simulating a repetitive pattern, e.g. appearing as a row of shingles
    • E04D1/265—Strip-shaped roofing elements simulating a repetitive pattern, e.g. appearing as a row of shingles the roofing elements being rigid, e.g. made of metal, wood or concrete
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D3/00—Roof covering by making use of flat or curved slabs or stiff sheets
    • E04D3/35—Roofing slabs or stiff sheets comprising two or more layers, e.g. for insulation
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2067/00—Use of polyesters or derivatives thereof, as moulding material
    • B29K2067/06—Unsaturated polyesters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2309/00—Use of inorganic materials not provided for in groups B29K2303/00 - B29K2307/00, as reinforcement
    • B29K2309/08—Glass
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2309/00—Use of inorganic materials not provided for in groups B29K2303/00 - B29K2307/00, as reinforcement
    • B29K2309/12—Asbestos
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2709/00—Use of inorganic materials not provided for in groups B29K2703/00 - B29K2707/00, for preformed parts, e.g. for inserts
    • B29K2709/02—Ceramics
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2709/00—Use of inorganic materials not provided for in groups B29K2703/00 - B29K2707/00, for preformed parts, e.g. for inserts
    • B29K2709/08—Glass
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
    • B32B2262/10—Inorganic fibres
    • B32B2262/101—Glass fibres
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2419/00—Buildings or parts thereof
    • B32B2419/06—Roofs, roof membranes
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10S—TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10S428/00—Stock material or miscellaneous articles
    • Y10S428/92—Fire or heat protection feature
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/23—Sheet including cover or casing
    • Y10T428/232—Encased layer derived from inorganic settable ingredient

Definitions

  • 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.
  • a heat-proofing material such as powdered or fibrous asbestos, or powdered glass
  • other materials such as vermiculite (processed mica), ceramic glass modules, or the like
  • 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.
  • 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.
  • the product of the present invention is flame retardant and fire resistant, and it retains such fireproof characteristics indefinitely.
  • 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 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.
  • 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.
  • 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.
  • the material of the web has a high strength.
  • 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 21113.3 as one constituent, and 35g styrene as another constituent.
  • the resulting mixture isstirred at a temperature of 10 C, for example, until a water-in-oil emulsion is formed.
  • the emulsion is mixed with 0.18g of dimethylp-toluidine and is subsequently polymerized and hardened by heating at 30 C for ten minutes.
  • the water in the pores of the resulting resin material can subsequently be evaporated by heat at a temperature between C and C.
  • Other examples of waterextended polyester resin material suitable for present purposes are also set out specifically in the patent.
  • DMA dimethylanaline
  • an inhibitor such as a mixture of methyl celosolve (80 percent) and hydroquinone (20 percent).
  • a catalyst such as methyl ethyl ketone (MEK) peroxide.
  • MEK methyl ethyl ketone
  • polyester resin, cobalt and the DMA and stabilizer are mixed together as one group which is desingated the carrier, as explained in the copending ap plicaton, 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. I
  • 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.
  • 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.
  • FIG. 3 is a section taken along the lines 3-3 of FIG. 2.
  • a mold 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.
  • the plaster is first poured into the mold l0 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.
  • the plaster core 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 l0, 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 mate rial is allowed to polymerize.
  • the resulting product 14 is then removed from the mold.
  • 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.
  • 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.
  • an appropriate material such as vermiculite and- /or ceramic glass modules
  • 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 gyp sum 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 heatproofing material.

Description

United States Patent [191 Re et al.
[ Aug. 20, 1974 FLAME RETARDANT AND FIRE RESISTANT ROOFING MATERIAL [75] Inventors: Carlo Re, Glendale; Jack R.
Conrad, Costa Mesa; Joseph A. Tasso, Santa Ana, all of Calif.
[73] Assignee: Dyna-Shield, Inc., Santa Ana, Calif.
[22] Filed: Aug. 4, 1972 [211 Appl. No.: 277,896
[52] U.S. Cl 161/168, 52/309, 161/116,
161/169, 161/161, 161/403, 161/151, 52/555 [51] Int. Cl B321) 5/16, B32b 21/02 [58] Field of Search 161/168, 162, 169, 170,
l6l/43,194, 195, 205,151,164, DIG. 4; 52/554, 555, 309
3,692,682 9/1972 Re et al. 161/403 Primary Examiner--George F. Lesmes Assistant ExaminerWi1liam R. Dixon, Jr. Attorney, Agent, or Firm-Jessup & Beecher [57] 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.
8 Claims, 3 Drawing Figures F/Zer 6/00 lz/e MIA fare FLAME RETARDANT AND FIRE RESISTANT ROOFING MATERIAL 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 21113.3 as one constituent, and 35g styrene as another constituent.
The resulting mixture isstirred at a temperature of 10 C, for example, until a water-in-oil emulsion is formed. The emulsion is mixed with 0.18g of dimethylp-toluidine and is subsequently polymerized and hardened by heating at 30 C for ten minutes. The water in the pores of the resulting resin material can subsequently be evaporated by heat at a temperature between C and C. Other examples of waterextended 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. l/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. l/l6th or a part (by weight) powdered or fibrous asbestos or powdered glass. g.
l/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 ap plicaton, 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. I
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; I
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 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 l0 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 l0, 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 mate rial 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.
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 gyp sum 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 I, 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.

Claims (7)

  1. 2. The heat barrier member defined in claim 1, in which said fireproofing material is powdered asbestos.
  2. 3. The heat barrier member defined in claim 1, in which said fireproofing material is fibrous asbestos.
  3. 4. The heat barrier member defined in claim 1, in which said fireproofing material is powdered glass.
  4. 5. The heat barrier member defined in claim 1, in which said polyester resin is of a water-extended type.
  5. 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.
  6. 7. The heat barrier member defined in claim 1, having a configuration simulating wooden shake shingles.
  7. 8. The heat barrier member defined in claim 1, and which includes vermiculite and ceramic glass modules intermixed with the ingredients.
US00277896A 1972-08-04 1972-08-04 Flame retardant and fire resistant roofing material Expired - Lifetime US3830687A (en)

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US3908062A (en) * 1974-01-21 1975-09-23 United States Gypsum Co Fire-resistant, composite panel and method of making same
US3969567A (en) * 1973-03-13 1976-07-13 Tac Construction Materials Ltd. Improvements in and relating to board products
US4201833A (en) * 1973-03-16 1980-05-06 Isovolta Osterreichische Isolierstoffwerke Aktiengesellschaft Building material elements, particularly building boards, and a process for their production
US4210070A (en) * 1978-03-06 1980-07-01 Dayus Barry R Ceiling fixture with thermal protection
US4242406A (en) * 1979-04-30 1980-12-30 Ppg Industries, Inc. Fiber reinforced composite structural laminate composed of two layers tied to one another by embedded fibers bridging both layers
US4308700A (en) * 1979-10-10 1982-01-05 Romig Jr Byron A Fiberglass structural member of layer construction and method of making same
US4498267A (en) * 1982-11-29 1985-02-12 Ermon Beck Simulated clay tile roof construction and method of making same
US4647486A (en) * 1983-12-28 1987-03-03 United States Gypsum Company Fire resistant gypsum board . . . anhydrite
US4726881A (en) * 1983-02-28 1988-02-23 Masonite Corporation Method of making wet process panels of composite wood material with semi-matching contoured pressure plates
US4756945A (en) * 1985-01-18 1988-07-12 Backer Rod Manufacturing And Supply Company Heat expandable fireproof and flame retardant construction product
EP0288287A2 (en) * 1987-04-24 1988-10-26 Minnesota Mining And Manufacturing Company Welding blanket
US4810569A (en) * 1984-02-27 1989-03-07 Georgia-Pacific Corporation Fibrous mat-faced gypsum board
US4936064A (en) * 1989-02-16 1990-06-26 Backer Rod Manufacturing And Supply Company Fireproof panel
GB2261229A (en) * 1991-10-02 1993-05-12 Ampco Private Limited Insulating roofing
GB2271583A (en) * 1992-09-23 1994-04-20 Univ Salford Business Services Fire-resistant component
US5307604A (en) * 1990-08-17 1994-05-03 Lewis Akmakjian Synthetic shake shingle
US5319900A (en) * 1984-02-27 1994-06-14 Georgia-Pacific Corporation Finishing and roof deck systems containing fibrous mat-faced gypsum boards
US5342680A (en) * 1988-01-06 1994-08-30 Georgia-Pacific Corporation Glass mat with reinforcing binder
WO1994025237A2 (en) * 1993-04-29 1994-11-10 Redland Technologies Limited Reinforced concrete tiles and methods of making the same
US5435669A (en) * 1992-09-11 1995-07-25 Don Morin, Inc. Laggin members for excavation support and retaining walls
WO1995030061A1 (en) * 1994-05-03 1995-11-09 Akmakjian, Lewis Synthetic shake shingle
US5492562A (en) * 1995-02-07 1996-02-20 Pettinato; Dana M. Low freezing point roofing shingle containing a chloride salt
US5615523A (en) * 1995-04-24 1997-04-01 Owens-Corning Fiberglas Technology, Inc. Roof having resinous shingles
US5644880A (en) * 1984-02-27 1997-07-08 Georgia-Pacific Corporation Gypsum board and systems containing same
US5711126A (en) * 1996-05-13 1998-01-27 Owens-Corning Fiberglass Technology, Inc. Resinous angled shingles for roof ridge lines
US6021611A (en) * 1995-04-24 2000-02-08 Wells; James R. Shingle having ribs and a cavity on its underside
US6276107B1 (en) * 1998-05-07 2001-08-21 Pacific International Tool & Shear, Ltd. Unitary modular shake-siding panels, and methods for making and using such shake-siding panels
US6338230B1 (en) 1999-10-25 2002-01-15 Davey John F Simulated shake shingle
US6776150B2 (en) 1998-03-06 2004-08-17 Shear Technologies, Inc. Method and apparatus for cutting fiber-cement material along an arcuate path
BE1015681A3 (en) * 2003-09-11 2005-07-05 Dumoulin Marc Gaston Adrien Sandwich panel and method for manufacturing thereof.
US20060010800A1 (en) * 2002-11-05 2006-01-19 Bezubic William P Jr Cementitious exterior sheathing product with rigid support member
US20060068188A1 (en) * 2004-09-30 2006-03-30 Morse Rick J Foam backed fiber cement
US7049251B2 (en) 2003-01-21 2006-05-23 Saint-Gobain Technical Fabrics Canada Ltd Facing material with controlled porosity for construction boards
US7155866B2 (en) 2002-11-05 2007-01-02 Certainteed Corporation Cementitious exterior sheathing product having improved interlaminar bond strength
US20070137131A1 (en) * 2003-06-30 2007-06-21 Nagarajan Venkata S Lofted mat for shingles
US20080185748A1 (en) * 2007-02-05 2008-08-07 Husnu Kalkanoglu Panel of Roofing Shingles
US7846278B2 (en) 2000-01-05 2010-12-07 Saint-Gobain Technical Fabrics America, Inc. Methods of making smooth reinforced cementitious boards
US20110247289A1 (en) * 2010-04-09 2011-10-13 Malcolm Schmidt Building Block Having The Appearance of Wood Shake
US8136322B2 (en) 2009-08-25 2012-03-20 Tamko Building Products, Inc. Composite shingle
US8197952B2 (en) 2005-06-09 2012-06-12 United States Gypsum Company High starch light weight gypsum wallboard
CN102787498A (en) * 2012-08-06 2012-11-21 衡阳星鑫绝缘材料有限公司 Protecting sleeve of high-temperature heat-insulation electromagnetic shielding instrument and production method thereof
US8323785B2 (en) 2011-02-25 2012-12-04 United States Gypsum Company Lightweight, reduced density fire rated gypsum panels
USRE44070E1 (en) 2005-06-09 2013-03-12 United States Gypsum Company Composite light weight gypsum wallboard
US9802866B2 (en) 2005-06-09 2017-10-31 United States Gypsum Company Light weight gypsum board
US9840066B2 (en) 2005-06-09 2017-12-12 United States Gypsum Company Light weight gypsum board
WO2018118549A1 (en) * 2016-12-21 2018-06-28 Eastman Chemical Company Polyester-based tape composites for construction panel reinforcement
US10377108B2 (en) * 2012-02-17 2019-08-13 United States Gypsum Company Gypsum products with high efficiency heat sink additives
US11306028B2 (en) 2005-06-09 2022-04-19 United States Gypsum Company Light weight gypsum board
US11338548B2 (en) 2005-06-09 2022-05-24 United States Gypsum Company Light weight gypsum board

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Publication number Priority date Publication date Assignee Title
US3969567A (en) * 1973-03-13 1976-07-13 Tac Construction Materials Ltd. Improvements in and relating to board products
US4201833A (en) * 1973-03-16 1980-05-06 Isovolta Osterreichische Isolierstoffwerke Aktiengesellschaft Building material elements, particularly building boards, and a process for their production
US3908062A (en) * 1974-01-21 1975-09-23 United States Gypsum Co Fire-resistant, composite panel and method of making same
US4210070A (en) * 1978-03-06 1980-07-01 Dayus Barry R Ceiling fixture with thermal protection
US4242406A (en) * 1979-04-30 1980-12-30 Ppg Industries, Inc. Fiber reinforced composite structural laminate composed of two layers tied to one another by embedded fibers bridging both layers
US4308700A (en) * 1979-10-10 1982-01-05 Romig Jr Byron A Fiberglass structural member of layer construction and method of making same
US4498267A (en) * 1982-11-29 1985-02-12 Ermon Beck Simulated clay tile roof construction and method of making same
US4726881A (en) * 1983-02-28 1988-02-23 Masonite Corporation Method of making wet process panels of composite wood material with semi-matching contoured pressure plates
US4647486A (en) * 1983-12-28 1987-03-03 United States Gypsum Company Fire resistant gypsum board . . . anhydrite
US5791109A (en) * 1984-02-27 1998-08-11 Georgia-Pacific Corporation Gypsum board and finishing system containing same
US5371989A (en) * 1984-02-27 1994-12-13 Georgia-Pacific Corporation Use of fibrous mat-faced gypsum board in exterior finishing systems for buildings and shaft wall assemblies
US4810569A (en) * 1984-02-27 1989-03-07 Georgia-Pacific Corporation Fibrous mat-faced gypsum board
US5704179A (en) * 1984-02-27 1998-01-06 Georgia-Pacific Corporation Finishing and roof deck systems containing fibrous mat-faced gypsum boards
US5644880A (en) * 1984-02-27 1997-07-08 Georgia-Pacific Corporation Gypsum board and systems containing same
US5319900A (en) * 1984-02-27 1994-06-14 Georgia-Pacific Corporation Finishing and roof deck systems containing fibrous mat-faced gypsum boards
US4756945A (en) * 1985-01-18 1988-07-12 Backer Rod Manufacturing And Supply Company Heat expandable fireproof and flame retardant construction product
EP0288287A3 (en) * 1987-04-24 1989-02-22 Minnesota Mining And Manufacturing Company Welding blanket
EP0288287A2 (en) * 1987-04-24 1988-10-26 Minnesota Mining And Manufacturing Company Welding blanket
US5981406A (en) * 1988-01-06 1999-11-09 G-P Gypsum Corporation Glass mat with reinforcing binder
US5718785A (en) * 1988-01-06 1998-02-17 Georgia-Pacific Corporation Glass mat with reinforcing binder
US5342680A (en) * 1988-01-06 1994-08-30 Georgia-Pacific Corporation Glass mat with reinforcing binder
US4936064A (en) * 1989-02-16 1990-06-26 Backer Rod Manufacturing And Supply Company Fireproof panel
US5307604A (en) * 1990-08-17 1994-05-03 Lewis Akmakjian Synthetic shake shingle
GB2261229A (en) * 1991-10-02 1993-05-12 Ampco Private Limited Insulating roofing
US5435669A (en) * 1992-09-11 1995-07-25 Don Morin, Inc. Laggin members for excavation support and retaining walls
GB2271583A (en) * 1992-09-23 1994-04-20 Univ Salford Business Services Fire-resistant component
WO1994025237A3 (en) * 1993-04-29 1995-01-05 Redland Technology Ltd Reinforced concrete tiles and methods of making the same
WO1994025237A2 (en) * 1993-04-29 1994-11-10 Redland Technologies Limited Reinforced concrete tiles and methods of making the same
WO1995030061A1 (en) * 1994-05-03 1995-11-09 Akmakjian, Lewis Synthetic shake shingle
US5492562A (en) * 1995-02-07 1996-02-20 Pettinato; Dana M. Low freezing point roofing shingle containing a chloride salt
US5615523A (en) * 1995-04-24 1997-04-01 Owens-Corning Fiberglas Technology, Inc. Roof having resinous shingles
US6021611A (en) * 1995-04-24 2000-02-08 Wells; James R. Shingle having ribs and a cavity on its underside
US6112492A (en) * 1995-04-24 2000-09-05 Owens Corning Fiberglas Technology, Inc. Shingle having ribs and cavity on its underside
US5711126A (en) * 1996-05-13 1998-01-27 Owens-Corning Fiberglass Technology, Inc. Resinous angled shingles for roof ridge lines
US6776150B2 (en) 1998-03-06 2004-08-17 Shear Technologies, Inc. Method and apparatus for cutting fiber-cement material along an arcuate path
US6276107B1 (en) * 1998-05-07 2001-08-21 Pacific International Tool & Shear, Ltd. Unitary modular shake-siding panels, and methods for making and using such shake-siding panels
US20030110729A1 (en) * 1998-05-07 2003-06-19 Kurt Waggoner Unitary modular shake-siding panels, and methods for making and using such shake-siding panels
US7575701B2 (en) 1998-05-07 2009-08-18 Shear Tech, Inc. Method of fabricating shake panels
US6338230B1 (en) 1999-10-25 2002-01-15 Davey John F Simulated shake shingle
US9017495B2 (en) 2000-01-05 2015-04-28 Saint-Gobain Adfors Canada, Ltd. Methods of making smooth reinforced cementitious boards
US7846278B2 (en) 2000-01-05 2010-12-07 Saint-Gobain Technical Fabrics America, Inc. Methods of making smooth reinforced cementitious boards
US20070098907A1 (en) * 2002-11-05 2007-05-03 Bezubic Jr William P Cementitious Exterior Sheathing Product Having Improved Interlaminar Bond Strength
US9435124B2 (en) 2002-11-05 2016-09-06 Plycem Usa, Inc. Cementitious exterior sheathing product having improved interlaminar bond strength
US7155866B2 (en) 2002-11-05 2007-01-02 Certainteed Corporation Cementitious exterior sheathing product having improved interlaminar bond strength
US7028436B2 (en) 2002-11-05 2006-04-18 Certainteed Corporation Cementitious exterior sheathing product with rigid support member
US7861476B2 (en) 2002-11-05 2011-01-04 Certainteed Corporation Cementitious exterior sheathing product with rigid support member
US8192658B2 (en) 2002-11-05 2012-06-05 Certainteed Corporation Cementitious exterior sheathing product having improved interlaminar bond strength
US20060010800A1 (en) * 2002-11-05 2006-01-19 Bezubic William P Jr Cementitious exterior sheathing product with rigid support member
US7300515B2 (en) 2003-01-21 2007-11-27 Saint-Gobain Technical Fabrics Canada, Ltd Facing material with controlled porosity for construction boards
US7049251B2 (en) 2003-01-21 2006-05-23 Saint-Gobain Technical Fabrics Canada Ltd Facing material with controlled porosity for construction boards
US7300892B2 (en) 2003-01-21 2007-11-27 Saint-Gobain Technical Fabrics Canada, Ltd. Facing material with controlled porosity for construction boards
US7827753B2 (en) * 2003-06-30 2010-11-09 Owens Corning Intellectual Capital, Llc Lofted mat for shingles
US20070137131A1 (en) * 2003-06-30 2007-06-21 Nagarajan Venkata S Lofted mat for shingles
BE1015681A3 (en) * 2003-09-11 2005-07-05 Dumoulin Marc Gaston Adrien Sandwich panel and method for manufacturing thereof.
US20080028705A1 (en) * 2004-09-30 2008-02-07 Certainteed Corporation Foam backed fiber cement
US20060068188A1 (en) * 2004-09-30 2006-03-30 Morse Rick J Foam backed fiber cement
US7712276B2 (en) 2004-09-30 2010-05-11 Certainteed Corporation Moisture diverting insulated siding panel
US9434131B2 (en) 2004-09-30 2016-09-06 Plycem Usa, Inc. Building panel having a foam backed fiber cement substrate
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US20100154973A1 (en) * 2007-02-05 2010-06-24 Husnu Kalkanoglu Panel of roofing shingles
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