Metal Flake-Surfaced Roofing Materials

Abstract

The present invention relates to roofing materials for roofs, sidewalls and other exterior surfaces exposed to the weather such as, but not limited to, asphaltic and non-asphaltic roofing materials, wherein metal flakes cover up to 100% of the weathering surface of the roofing materials. The metal flakes may be applied to the surface in striations or bands separated by conventional roofing granules or may be blended with conventional roofing granules. The metal flakes may have antimicrobial potential and may provide resistance to microbial growth to roofing materials when dispersed in or applied thereto. The present invention also relates to methods of making the roofing materials.

Description

[0001]This application is a continuation-in-part of U.S. patent application Ser. No. 10 / 210,501, filed on Aug. 1, 2002, which is a continuation of U.S. patent application Ser. No. 09 / 590,222, filed on Jun. 8, 2000, now abandoned.FIELD OF THE INVENTION[0002]The present invention relates to metal flake-surfaced roofing materials which may be used for roofs and also for sidewalls and other exterior surfaces exposed to the weather. The roofing materials which may be surfaced with metal flakes include, but are not limited to, asphaltic roofing materials and non-asphaltic roofing materials such as concrete, plastic, rubber or metal roofing materials that have other materials on the exposed surface to provide a weathering surface or which are used for aesthetic purposes. The present invention further relates to methods of making the metal flake-surfaced roofing materials. Metal flakes may be applied to the surface of roofing materials as the sole surfacing material or in combination with t...

AI Technical Summary

Benefits of technology

[0013]The present invention is a metal flake-surfaced roofing material comprising a headlap and a weathering surface, wherein the weathering surface comprises metal flakes and the headlap is substantially free of metal flakes, wherein the metal flakes cover greater than 0.001% and up to 100% of the weathering surface. Roofing materials that may be surfaced with metal flakes in accordance with the invention include, but are not limited to, asphaltic roofing materials, non-asphaltic roofing materials (such as concrete, rubber and plastic materials) and other exterior cladding building materials. The metal flake-surfaced roofing materials of the present invention provide the advantages of metal shingles and the water proofing and easy installation of asphalt shingles. In addition, metal flake-surfaced roofing shingles have an improved appearance and durability. Further, the metal flake-surfaced roofing materials of the present invention may exhibit resistance to microbial growth-induced staining thereon. Moreover, the flakes may be made using recycled metal, so that the use of metal flakes to cover an asphaltic shingle with the flakes is cheaper than conventional metal sheet roofing. Furthermore, the metal flake-surfaced roofing materials are less expensive on an installed basis than conventional metal shingles, such as copper shingles or tin shingles, and can be manufactured by the same production process as used, for example, for asphaltic shingles. In particular, labor costs for the installation of the roofing materials of the present invention are up to three times lower than the costs required for the installation of metal or slate shingles.

Problems solved by technology

Furthermore, asphalt roofs require little upkeep and are easily repaired when damaged.

However, many asphalt roofing materials do not have the same aesthetic qualities as metal and slate roofs and most do not have the equivalent life span.

Moreover, asphalt shingles, as well as certain non-asphaltic shingles, such as concrete shingles and plastic shingles, are prone to microbial growth staining.

The patent also discloses that chips having a larger size than 200 mils on a side are not suitable due to their inability to withstand wind gusts when the cap sheet having the metal chips is applied on a roof.

The disadvantages of metal roofs are that they are expensive, require installation by a professional trained in metal roofing installation, and can be damaged or dented by outdoor elements, such as hail.

Slate roofs, however, are heavy and expensive.

Further, slate exists in limited color choices, requires frequent maintenance, can be easily damaged (particularly during maintenance due to walking on the roof), and relies on underlayment which usually fails before the slate.

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