IP Library › Patent Application 12715421
Patent Application
App. No. 12/715,421

ROOFING MATERIAL

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Quick Facts
Patent No.
US None
App. No.
12/715,421
Abstract

A roofing material having the appearance of decorative shingles and/or roofing tiles. The roofing material comprises a bulk polymeric foam material which includes additional structural support which provides increased strength and durability at the front surface of the roofing material. The roofing material includes a mesh material which is disposed near the front surface of the roofing material. The roofing material may additionally include a barrier layer which further protects the surface of the roofing material.

Claims (34)

1 . A roofing material comprising:

a panel having the appearance of a plurality of roofing elements, said panel comprising a bulk polymeric foam material and a mesh material disposed in at least a portion of said polymeric material.

2 . The roofing material according to claim 1 , wherein said mesh material is disposed within said polymeric material at a position between the midpoint and the front surface of said roofing material.

3 . The roofing material according to claim 2 , wherein said mesh material is disposed adjacent to the front surface of said roofing material.

4 . The roofing material according to claim 1 , wherein said mesh material is disposed within 3 cm from the front surface of said roofing material.

5 . The roofing material according to claim 1 , wherein said mesh material is disposed within 2 cm from the front surface of said roofing material.

6 . The roofing material according to claim 1 , wherein said mesh material is disposed within 1 cm from the front surface of said roofing material.

7 . The roofing material according to claim 1 further comprising a barrier layer.

8 . The roofing material according to claim 7 , wherein said barrier layer is formed from a gel-based precursor material, a liquid based precursor material, or a powder based precursor material.

9 . The roofing material according to claim 1 , wherein said polymeric foam material is polyurethane free rise foam.

10 . The roofing material according to claim 9 , wherein said polyurethane free rise foam has a density in the range of 2 pounds per cubic feet to about 25 pounds per cubic feet.

11 . The roofing material according to claim 9 , wherein said polyurethane free rise foam has a density in the range of 8 pounds per cubic feet to about 14 pounds per cubic feet.

12 . The roofing material according to claim 1 , wherein said mesh material comprises metal, composite material, polymer material, fiberglass, or combinations thereof.

13 . The roofing material according to claim 1 , wherein said mesh material comprises a polymer coated fiberglass material

14 . The roofing material according to claim 1 , wherein said roofing material further comprises a topcoat layer.

15 . The roofing material according to claim 1 , wherein said panel has the appearance of a plurality of roofing tiles.

16 . The roofing material according to claim 1 , wherein said panel has the appearance of a plurality of shingles.

17 . A method for forming a roofing material comprising the steps of:

1) applying a barrier precursor material to the inner surface of the cavity of a mold;

2) placing a mesh material in said mold proximate to the inner surface of the cavity of the mold;

3) dispensing a polymeric foam precursor material into the cavity of said mold;

4) sealing said mold;

5) placing said mold into a press;

6) removing said roofing material from said mold.

18 . The method according to claim 17 further comprising the step of:

7) applying a topcoat layer to said roofing material.

19 . A method for forming an roofing material comprising the steps of:

1) placing a mesh material in a mold proximate to the inner surface of the cavity of said mold;

2) dispensing a polymeric foam precursor material into the cavity of said mold;

3) sealing said mold;

4) placing said mold into a press;

5) removing said roofing material from said mold.

20 . The method according to claim 19 further comprising the step of:

6) applying a topcoat layer to said roofing material.