Geometry of polymeric roof shingles
AssigneePrecision Materials Group Holdings, LLC
InventorsScott Stickler, Charles Morton Gould
Life of this patent
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Abstract
Roof shingles and methods of production thereof are provided. The roofing tiles or shingles may feature a unique surface texture and relief, obtained through the use of granules of varying sizes and a preferably multi-tiered substrate. The disclosure further encompasses methods of manufacturing such tiles, preferably including the use of molding techniques to combine different materials for enhanced performance and aesthetic effects. The disclosure also defines parameters for fixing surface texture, granule size, and material selection, and describes various manufacturing processes for creating a desired surface geometry and texture.
Claims24
A roofing tile comprising a reveal and a conceal, the reveal comprising:
- a textured surface having a total depth of up to about 6 millimeters (“mm”), said textured surface comprising:
- a step-top texture region with a random depth between about 0 mm and about 3.5 mm;
- a step-bottom texture region with a random depth between about 0 mm and about 2.5 mm;
- and
- a substrate underlying the textured surface, said substrate comprising:
- a region underlying the step-top texture region;
- and
- a region underlying the step-bottom region;
- wherein:
- the region underlying the step-top texture region is about 2.0 mm;
- and
- the region underlying the step-bottom region is 1.0 mm or greater than 1.0 mm.
A method of manufacturing a roofing tile, the method comprising:
- manufacturing a reinforcement core;
- molding a selected polymeric material, said molded material having a cavity formed therewithin, said cavity for receiving fixed placement of the reinforcement core, the polymeric material comprising a reveal and a conceal, the reveal being visible when the roofing tile is installed and the conceal being covered by an upslope adjacent roofing tile when the roofing tile is installed;
- and
- forming, on the reveal, an upward facing surface comprising:
- a step-top texture region;
- and
- a step-bottom texture region, wherein:
- a relief between the step-top texture region and the step-bottom texture region creates a visible shadow line between the step-top texture region and the step-bottom texture region;
- the step-top texture region comprises a top surface with first random-depth granules and the step-bottom texture region comprises a top surface with second random-depth granules, and
- the relief is formed from, at least in part, a difference in substrate thickness between a substrate thickness under the step-top texture region and a substrate height under the step-bottom texture region, wherein the difference is not less than 1.0 mm.
Dependencies are inferred from the claim text.