Synthetic shake shingle
AssigneeLewis Akmakjian
InventorJoseph A. Tasso
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Abstract
A synthetic fire resistant and flame retardant shake shingle suitable for roofing construction is formed of a water-extended polyester resin that has been molded to the shape of a shake shingle and dried to form a semi-rigid, cellular lightweight structure containing a filler of fiberglass pieces substantially uniformly dispersed throughout the cross section of the molded and dried polyester resinous structure. In one embodiment, the ratio of polyester resin to fiberglass pieces to water in the molding formulation is about 3 to about 2 to about 5.5. In an alternative form of the invention, the fiberglass pieces are replaced with a coarse fiberglass mat impregnated with the polyester material to form a core of the resulting shake shingle.
Claims10
A method for making a synthetic fire resistant and flame retardant shake shingle suitable for roofing construction including the steps of mixing a water-extended polyester resin with water to form a viscous emulsion, adding chopped fiberglass pieces and a separate particulate fire retardant material different from the fiberglass to the polyester-water emulsion and mixing in a high shear mixer to uniformly disperse the fiberglass pieces and the fire retardant material throughout the emulsion, injecting a catalyst into the polyester-water emulsion to form a curable resin consisting essentially of the polyester resin-water emulsion with the uniformly dispersed chopped fiberglass pieces and particulate fire retardant material, immediately pouring the resulting curable resin into a mold having the shape of a shingle to harden the mixture to form a molded shingle, and thereafter removing the shingle from the mold to provide a roofing shingle in which essentially the entire cross section of the shingle is formed of the polyester resin which has been molded to the shingle shape and dried to form a semi-rigid, cellular lightweight structure containing the filler of fiberglass pieces and fire retardant material substantially uniformly dispersed throughout the entire cross-section of the polyester resinous structure.
A method for making a synthetic fire resistant and flame retardant shake shingle suitable for roofing construction comprising the steps of mixing a water-extended polyester resin with water to form a viscous emulsion, mixing a fine particulate fire retardant material with the polyester-water emulsion via a high shear mixer to uniformly disperse the fire retardant material throughout the mixture, placing a coarse fiberglass mat in a center portion of a mold shaped as a roofing shingle, injecting a catalyst into the polyester-water emulsion to form a curable resinous material consisting essentially of the polyester resin-water emulsion with uniformly dispersed fine particulate fire retardant material, pouring the curable resinous material into the mold and around the fiberglass mat to impregnate the mat and embed the mat in the curable material, thereafter allowing the material to cure and thereby form a semi-rigid, cellular lightweight structure with the fiberglass mat embedded in a central portion of its cross section, and removing the resulting molded and hardened shake shingle from the mold.
Dependencies are inferred from the claim text.