1. Field of the Invention
This invention is directed to an article of manufacture and to a method. More specifically, this invention relates to a foam tile roof panel and system; and, to a method for fabrication thereof.
2. Description of the Prior Art
The use of the synthetic (polymeric) materials as a replacement for more traditional construction materials has and continues to evolve, as the sources of the more traditional materials (wood) increase in costs and will become increasingly scarce.
Accordingly, plastic or synthetic based building products (once reserved primarily for decorative or cosmetic applications) are, and continue to find uses as structural materials as building codes become more relaxed, or in recognition of the functional equivalency or superiority of the engineering component prepared from the synthetic material.
Structural foam panels from closed cell expanded foam polystyrene and other common polymers have and continue to be used in lieu of plywood in the construction industry as underlayment for house siding and other construction applications where enhanced energy conservation is desired.
The following patents are represented of a use of foam materials (both polymer and concrete) in the fabrication of and in situ manufacture of construction materials: U.S. Pat. No. 3,962,841 (to Carol); U.S. Pat. No. 4,013,614 (to Self); U.S. Pat. No. 4,071,984 (to Larrow); U.S. Pat. No. 4,658,554 (to Riley); U.S. Pat. No. 4,774,794 (to Grieb); U.S. Pat. No. 4,712,349 (to Riley); and U.S. Pat. No. 4,799,982 (to Vicino).
U.S. Pat. No. 3,962,841 (to Carol) describes an insulating decking structure utilizing a sheet metal structural shape (envelope) containing a perforated foam synthetic board (16) having vertical holes to allow penetration of concrete through the foam board. In brief, the structure of the Carol system comprises a wire reinforced sub-purlin, or purlin, structure that includes a sheet metal envelope (12) or form, containing gypsum foam board (12), a perforated formed synthetic polymer board (13) and poured concrete (15) which penetrates through the polymer board (13) to the gypsum board (12). The exterior surface of the foregoing composite is finished with alternating layers of roofing felt and tar (16) and a waterproof wearing surface of tar and gravel (17).
U.S. Pat. No. 4,013,614 (to Self) describes a method for preparation of spray-up laminates by foaming-in-place an unsaturated polyester resin (hereinafter "synthetic resin"). The synthetic resin can be applied on both sides of expanded metal lathe (Example 3) and applied directly to corrugated metal building panels having a spray applied polyurethane base (example 4). The fabrication of laminated panels (in accordance with the teachings of Example 4) further contemplate a sequential application of these materials to the structure of metal panel (column 5, lines 36-58).
U.S. Pat. No. 4,071,984 (to Larrow) describes a structure, such as a house, assembled from pre-fabricated panels. The wall panels of the structure comprise a laminate, or composite, structure having an interior section of foamed material, such as polystyrene or urethane foam, with another surface comprising wood, aluminum or plastic. The apparent invention resides in the configuration of the panels to allow for their interlocking or integration with one another in the construction of a shelter.
U.S. Pat. No. 4,658,554 (to Riley) describes an insulated roofing system in which a waterproof plastic film or membrane is bonded to the under surface of a panel to positively exclude water. The panels to which this membrane is applied are preferably foam can be provided on a its upper surface with integral ribs, such as grooves, and of sufficient structural integrity to support concrete panels which can be placed upon and supported by the integral ribs. The integral ribs which are positioned between the foam panel and the concrete surface member provide (what is referred to in the Riley patent) "channels" for ventilation and moisture removal on hot, dry days. The concrete panels are not, according to Riley, are "simply abutted against one another, and preferably are laid so that the butted junctions do not coincide with the butted junctions of the underlying foam panels" (column 3, lines 31-34). Thus, it is apparent from Riley that the waterproof membrane on the interior of the composite is necessary to exclude water which penetrates between the concrete block and is not otherwise carried away by the ribs (16) which are intermediate between the concrete and the styrofoam panels. To the extent that any moisture does intrude beyond the interior ribs, the waterproof membrane (12), positioned between the ribs and the foam will presumably prevent any further intrusion thereof.
U.S. Pat. No. 4,774,794 (to Grieb) describes a foam cement building having walls, roof and/or floor formed from a plurality of self-supporting foam building blocks of varying densities. The exterior surface from the foam building blocks are coated with an architectural finish-such finish being formed from cement, reinforced with fiberglass mesh or fiberglass rovings or strands. The blocks are connected to one another by a "tongue and groove" arrangement which provides, once assembled, a monolithic structure.
U.S. Pat. No. 4,712,349 (to Riley) is essentially the same, (at least in relation to the instant invention), as U.S. Pat. No. 4,658,544 (discussed above).
U.S. Pat. No. 4,799,982 (to Vicino) describes a method and system for the manufacture of a modular, monolithic molded building structure from a dismantleable mold. The Vicino patent describes the sequential application of an expandable foam to various mold components along with reinforcing materials. The purpose and effect of the process described by Vicino is to provide a seamless building structure, (with the exception of windows and doors).
As is evident from the foregoing discussion, the techniques utilized in the past for the fabrication of foam based building products, including those prepared from synthetic polymers and concrete, has involved a variety of different expedients to accomplish the specific objective of their respective inventors. As is further apparent, none of the art discussed above provides a building product having both structural and finished features incorporated into a single panel, or panel array, suitable for use as a roofing material. In virtually all of the structures described above in the prior art, the use of an expandable foam has been simply to provide an insulating element without appreciation of its versatility; specifically the combination of its aesthetic and structural properties in a single element, while at the same time eliminating other unnecessary components which can reduce costs, construction complexities and weight, (which can be a material factor in engineering the trusses and other load bearing components).