| abstract |
A novel composition of weatherable and semi-weatherable materials that can be injection molded or extruded into sheets or rolls to create a roofing product wherein the roofing product overlaps in order to provide a substantially weatherable covering on a roof. The roofing product has a top layer (14) made of weatherable polymers and multiple substrate layers (22, 30) made of semi-weatherable polymers. A decorative, three dimensional appearing layer (16) of colorants is uniquely applied to the bottom surface (15) of the top layer (14). The weatherable top layer (14) is preferably an ASA or acrylic-type copolymer. The semi-weatherable bottom layers (22, 30) are specialized formulations of fire resistant polymers, where the semi-weatherable bottom layers (22, 30) have had the Heat Deflection Temperature (HDT) uniquely improved for use in roofing. The product has multi-layering UV stability. The multiple layers can be injection molded or extruded or laminated or preferably multi-layer-extruded, thus bonded. Then the bonded materials maybe used directly as a finished roofing product (10) or thermoformed product (10a) (if not injection molded) to resemble more popular types of roof coverings such as shake or shingles or slate or tiles or geometric and natural patterns. The multiple layers are engineered to pass stringent roofing building codes such as the International Construction Code (ICC), including fire rating. |