Composite building product
AssigneeCertainTeed Corporation
InventorsJoong Kim, Thomas MacKinnon, Richard Snyder, Husnu Kalkanoglu, Gregory Jacobs
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Abstract
A simultaneously molded plurality of composite shingles or double walled shingles or other substantially planar exterior building products are provided, each being comprised of two or more layers of thermoplastic shingle material, such that a weatherable capstock material is provided outside a core material, in the form of a composite parison that is then blow molded in a hollow mold, to produce novel shingles. Ventilation and/or insulation can be provided to a hollow interior between spaced apart walls of a double walled shingle.
Claims35
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A shingle made in accordance with the process of simultaneously molding a plurality of substantially planar exterior building products, each having two layers of thermoplastic substantially planar building product material, comprising the steps of:
- (a) providing a molten core material;
- (b) providing a molten weatherable capstock material;
- (c) with one of the core material and capstock material being disposed about the other material, as a parison;
- (d) delivering the parison into a hollow mold;
- (e) closing the mold;
- (f) blow molding the parison into a plurality of substantially planar configurations by injecting a gas into the parison in the mold to expand the parison in the mold outwardly against interior surfaces of the mold;
- and
- (g) cooling the expanded parison and removing it from the mold;
- whereby
- (h) a plurality of substantially planar exterior building products are formed from the parison each with a layer of core material and a layer of capstock material.
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A composite intermediate building product comprising a plurality of substantially planar exterior building products, connected together by connection zones, and with each substantially planar building product having:
- (a) two layers of thermoplastic substantially planar building product material;
- with one said layer being a core material;
- (b) with another said layer being a weatherable capstock material;
- and
- (c) with one of the core material and capstock material being disposed overlying the other material.
Dependencies are inferred from the claim text.