WO1991003438A1

WO1991003438A1 - Material and method to manufacture light weight roof tiles

Info

Publication number: WO1991003438A1
Application number: PCT/GB1990/000242
Authority: WO
Inventors: Dennis Jon Hacker
Original assignee: Dennis Jon Hacker
Priority date: 1989-09-05
Filing date: 1990-02-15
Publication date: 1991-03-21
Also published as: AU5095790A

Abstract

The invention concerns a premix for an aircured composition comprising expanded perlite particles together with sodium silicate, diatomaceous earth, mica, hydrated clays, titanium dioxide, fibre glass strands and a catalytic binder that will allow the cold state air curing of said mixture which has been shaped/formed/molded/pressed into the shape and form of either one single roof tile or a one unit multiple of any number of roof tiles that would be joined, one to the other. The invention also concerns products made from the premix.

Description

MATERIAL AND METHOD TO MANUFACTURE LIGHT WEIGHT ROFF TILES

TECHNICAL FIELD :

THIS PRESENT INVENTION COVERS THE FIELD OF ROOF

TILES AND ROOF COVERINGS (PROTECTION FROM THE ELEMENTS).

BACKGROUND ART:

THE PRESENT STATE OF THE ART FOR PROTECTION FROM TH

ELEMENTS FOR ROOFS IS BY THE USE OF FIRE CLAY TILES SLATES, CERAMIC TILES, TAR OR PITCH (HOT APPLIED)

WITH AN AVERAGE TILE WEIGHT OF FROM 5 TO 10 LBS.

PER TILE. THE PRESENT METHODS OF TILING A ROOF,

EITHER FROM NEW, OR AS A RETROFIT REPAIR, IS VERY

LABOUR INTENSIVE OWING TO HAVING TO HANDLE EACH TILE SEPARATELY PLUS THE HEAVY WEIGHT FACTOR.

WHEREBY IN AMERICA, THE TENDANCY IS TO USE TILES

WITH A LIMITED LIFE COMPOSED OF TAR PAPE

(SHINGLES), WOOD SLICES (SHAKES), WOOD IN THE FORM

OF WEATHER PROOF (MARINE) 8 PLY WOOD OR TREATED PARTICLE BOARD. DISCLOSURE:

BY THE USE OF COLD STATE, PRE-EXPANDED PERLITE AS AN

AGGREGATE, ADMIXED WITH SODIUM SILICATE, HYDRATED 5

CLAYS, TITANIUM DIOXIDE, MICA, DIATEMATIOUS EARTH, \

TO 1 INCH FIBRE GLASS LENGTHS AND A WATER CATALYST

10 AND MIXING THE ONE TO THE OTHER IN A CONTROLLED

MANNER AS A PARTIAL CONTINUATION OF MY PAST PATENTS:

15 1973: MACHINE TO MAKE CONTINUOUS PERLITE BOARDS U.K. 1426375

1976: PANNEAUX DE PERLITE 20

....FRANCE 7605069

1978: INORGANIC BONDING (SELF HARDENING) COMPOSITION

25 GB 2026531

1980: FIRE PROOF DOORS FROM EXPANDED PERLITE GB. 2060746

30

1980: SELF HARDENING COMPOSITION

....SPAIN 488294

35 1980: FIRE PROTECTION ELEMENT FOR STEEL U.K. 2071078

1980: PRE-MIX FOR SELF HARDENING COMPOUND 40 AT.BE.CH.DE.GB.LI.FR.IT.LU.NL.SE.

....EUROPEAN 0031256 45 1980: THERMAL INSULATION CONTAINER GB 2071636

50

SUBSTITUTE SHEET 1981: COMPOSITION INSULATION STRUCTURE GB.LI.FR.IT.LU.NL.SE.EUROPEAN 0032605

1981: PATENTANSOKAN SWEDEN 800361

1981: SELF HARDENING COMPOSITION

10 USA 4263048

1980: SELF HARDENING COMPOSITION

15 JAPAN 12366/55

1982: SELF HARDENING COMPOSITION

....CANADA 1128257

20 1983: SELF HARDENING COMPOSITION KOREA 15509

25

(SOLE INVENTOR - DENNIS JON HACKER)

AND BY THE ADDITIONAL LEARNT SKILLS OF THE PRESENT

30

INVENTOR, A MASTIC MASS IS OBTAINED TO A PRE-

DESIGNATED VISCOSITY, THAT IS CALCULATED BACKWARDS

35 FROM, THE SIZE, WEIGHT, STRENGTH, PERFORMANCE

CRITERIA OF DESIRED END PRODUCT. SAID MASTIC MASS I

THEN FED DOWNSTREAM TO MOULDS OF THE REQUIRED 40

CONFIGURATION, THERE TO BE COMPACTED AND

FORMED/PRESSED INTO DESIRED SHAPE BY ANY KNOWN OR

45 ADAPTABLE MEANS OF FORM/PRESSING OR EXTRUDING

MATERIALS.

50

SUBSTITUTE SHEET SAID ROOF TILE CAN BE FORMED AS A SINGLE TILE UNIT OR, OWING TO THE VERY LOW WEIGHT, INTO A SINGLE TILE COMPOSED OF AN IDEAL 6 TO 10 TILES BEING IN THE SHAPE AND FORMAT OF OVERLAPPING TILES BUT WITH THE COVERING (ROOF) CAPABILITIES OF FROM 6 TO 10 TILES PER EACH UNIT (TILES) SET IN PLACE (SEE DRAWING "A"), EACH TILE SECTION WILL BE SO FORMED AS TO CONFORM TO THE OVERLAPPING TILE FORMATION THAT IS THE NORM WITH A MALE AND FEMALE OVERLAP ON EACH ABUTTING SIDE THAT CAN BE JOINED TOGETHER BY A COMPATABLE ADHESIVE (OF THE SAME FAMILY) OR BY THE USE OF CONVENTIONAL CEMENT ADHESIVES.

OWING TO THE PROVEN INORGANIC INSULATION VALUES OF

SAID MATERIALS, COMPLETED ROOF, WHETHER IT BE A NEW ROOF OR A ROOF REPLACEMENT/REPAIR, WILL RESIST ALL

WEATHER EXTREMES AND WILL ALSO INSULATE THE BUILDING

FROM HEAT OR COLD (OR HEAT LOSS) AS IS THE PRESENT

SITUATION WITH CONVENTIONAL TILES ALLOWING THE

PASSAGE OF BUILDING HEAT TO PASS THROUGH CONVENTIONAL ROOFS (TILES) INTO FREE AIR AT A COST

TO BUILDING OCCUPIER.

OWING TO THE LOW WEIGHT RATIO OF A SECTION FROM 6 TO

10 TILES IN A SINGLE UNIT, SAID UNITS CAN BE USED TO

COVER (RETROFIT) SHAKE SHINGLES, TAR PAPER,

SUBSTITUTESHEET SHINGLES, SLATES, FLAT OR PITCHED ROOFS AND ARE MUC LESS LABOUR INTENSIVE THAN CONVENTIONAL ROOF 5 COVERINGS.

TILES MAY BE COLOURED TO CHOICE AT THE POINT OF

10 MANUFACTURE. ALSO CAN BE SURFACE FIRED (GLAZED) BY

PASSING UNDER CONTACT FLAME/HEAT TO GLAZE TO DESIRE

FINISH WITHOUT NEED TO PRE-HEAT COLD STATE TILES 15

BEFORE GLAZING COMMENCES CAN BE A CONTINUATION O

THE END OF THE COLD STATE MANUFACTURING PROCESS.

20

OTHER AREAS OF USE FOR THIS INVENTION ARE: SIDE &

FLANK WALLS, CHIMNEY STACKS _ BREASTS, GABLE ENDS,

25 BUILT UP FELT, ASPHALT, DORMER ROOF _ SIDE WALLS,

FIRE WALLS, CONCRETE FLAT WALLS, TAR/TARPAULINE

ROOFS, ASBESTOS TILE ROOFS ETC AND WILL GIVE A VER 30

HIGH DEGREE OF INSULATION WEATHER PROTECTION WHEN

PLACE. OWING TO THE VERY LIGHT WEIGHT OF EACH UNIT,

35 CAN BE USED OVER THE TOP OF CONVENTIONAL ROOF

COVERINGS WITH THE MINIMAL^' SUPPORT REQUIREMENTS.

40

45

50

SUBSTITUTE SHEET

Claims

CLAIMS:WHAT I CLAIM IS:-

1. A PREMIX FOR AN AIR CURED COMPOSITION OF SODIUM SILICATE, HYDRATED CLAY, TITANIUM DIOXIDE, DIATMETIOUS EARTH, MICA, WATER.

2. A PREMIX AS IN CLAIM 1 TOGETHER WITH EXPANDED PERLITE PARTICLES OF A MESH SIZE OF 5-7 MM.

3. A PREMIX AS IN CLAIMS 1 & 2 TOGETHER WITH FIBRE GLASS LENGTHS OF FROM TO 1 INCH LONG.

4. PREPARED VOLUMES BY WEIGHT OF CLAIMS 1, 2, 3 TO BE MIXED TOGETHER AS BY THE LEARNT SKILLS OF THE PRESENT INVENTOR.

5. CLAIMS 1, 2, 3 TO BE MIXED AT A SPEED AS A LEARNT SKILL OF THE INVENTOR.

6. CLAIMS 1, 2, 3, 5 TO BE MIXED TOGETHER FOR A PERIOD (TIME) AS A LEARNT SKILL OF THE PRESENT INVENTOR, EASILY IMPARTED TO UNSKILLED LABOUR.

7. RESULTANT SLURRY WHEN SHAPED/MOULDED INTO TILE/SIDING FORM WILL AIR CURE TO GIVE PROTECTION FROM WEATHER EXTREMES.

8. CURED PRODUCTS WILL GIVE HIGH DEGREES OF INSULATION FROM HEAT AND COLD PASSING THROUGH.

SUBSTITUTE SHEET

9. CURED PRODUCT WILL GIVE FIRE PROTECTION TO DIRECT FLAMES TO 1,000 DEG. F. WITH NO COMBUSTION OR TOXICS BEING EMITED.

10. CLAIMS 1, 2, 3, 4, 5, 6 CAN BE ADJUSTED, SINGLY OR JOINTLY TO ALTER THE LOAD BEARING AND INSULAR QUALITIES OF END PRODUCT(S).

11. END PRODUCT(S) IS DESIGNED TO BE AFFIXED AT 6 POINTS OF CONTACT WHEN IN POSITION.

12. THERE IS NO WASTE, AIRBORNE POLLUTION OR OTHER TOXIC ELEMENTS GENERATED IN THE MANUFACTURING PROCESSES.

13. END PRODUCT(S) WILL INSULATE AND PROTECT (FROM THE ELEMENTS/FIRE) THE SUB-STRATE THAT IT COVERS.

14. AN ADDITION TO ANY ONE OF CLAIMS 1, 2, 3, 4, 5, 6 OF ANY MEDIUM TO ADD A TONE OR COLOUR TO THE DESIRED END PRODUCT THAT IS COMPATIBLE TO SAID CLAIMS.

15. RESULTANT END PRODUCTS, BY THEIR LOW WEIGHT AND SIZE (COVERAGE) WILL CUT THE ON-SITE LABOUR FORCE REQUIRED TO FIX SAID PRODUCTS TO A SUB-STRATE BY AT LEAST 50%.

16. RESULTANT END PRODUCT(S) CAN BE USED WHERE THE HEAVY DENSITY (WEIGHT) PROHIBITS THE USE OF CONVENTIONAL TILES OR COVERINGS.

SUBSTITUTESHEET %

17. RESULTANT END PRODUCT(S) BY THEIR LOW DENSITY (WEIGHT) AND ROOF LOADING CAN BE STRUCTURED TO COVER A MUCH LARGER AREA THAN CONVENTIONAL SUB-STRATE (ROOFS/SIDINGS/FLANK WALLS ETC) AREAS.

18. THE INVENTION AS DESCRIBED WILL PROTECT THE UNDER-FELT (TAR PAPER) FROM DEGRADING OWING TO WATER SEEPAGE OF CONVENTIONAL OVERLAPPING TILES.

19. END PRODUCT(S) WILL NOT BE SUBJECT TO HIGH (GALE FORCE) WINDS OWING TO THE FACT OF BEING MANUFACTURED IN A MANNER THAT GIVES NO PURCHASE FOR WIND ACTION I.E. EVERY TILE SHAPE IS AN INTEGRAL PART OF THE WHOLE WITH THE WHOLE BEING ANCHORED IN SIX PLACES.

20. END PRODUCT(S) WILL NOT CRACK OR BREAK WHEN LADDERS ARE LAID OVER THEM AND WILL SUPPORT WORKER'S WEIGHT PLUS LADDER.

SUBSTITUTESHEET