Synthetic roofing shingle or tile

Abstract

A synthetic roofing shingle or tile is provided, in which a core material is formed, of generally less expensive material, and with a skin material provided, disposed on a plurality of surfaces of the shingle or tile, with the skin material being generally of greater expense and having desirable weather-withstanding qualities.

What is claimed is:  
     
         1 . A roofing element of the shingle or tile type, for exterior application, comprising a multi-layer structure having: 
 (a) a skin including a first thermoplastic material;    (b) a core including a second thermoplastic material;    (c) wherein the first material is a highly weather resistant polymer relative to the second material;    (d) wherein the second material is a polymer having filler therein and;    (e) wherein the core is comprised of a substantially greater volume of second material than the volume of first material that comprises the skin; and    (f) wherein the skin encapsulates a plurality of surfaces of the core.    
     
     
         2 . The roofing element of  claim 1 , wherein the skin encapsulates surfaces of the roofing element that would be weather-exposed in the installed condition of the roofing element on a roof.  
     
     
         3 . The roofing element of any one of claims  1 - 2 , wherein the polymer of the first material is selected from the group consisting of: 
 (a) Polyethylene;    (b) Polypropylene;    (c) Polymethylpentene;    (d) Polybutene;    (e) Polyacrylates; and    (f) copolymers and/or blends of any of (a) through (e).    
     
     
         4 . The roofing element of any one of claims  1 - 2 , wherein the polymer of the second material is selected from the group consisting of: 
 (a) Polyvinylchloride;    (b) Polyethylene;    (c) Polypropylene;    (d) Polybutene;    (e) Polymethylpentene;    (f) Polyacrylates;    (g) Polyethyleneterephthalate;    (h) Polybutyleneterephthalate;    (i) Polyethylenenaphthalate;    (j) Ethylene-Propylene-Diene Monomer Copolymers; and    (k) copolymers and/or binary or ternary blends of any of (a) through (j) above.    
     
     
         5 . The roofing element of  claim 3 , wherein the polymer of the second material is selected from the group consisting of: 
 (a) Polyvinylchloride;    (b) Polyethylene;    (c) Polypropylene;    (d) Polybutene;    (e) Polymethylpentene;    (f) Polyacrylates;    (g) Polyethyleneterephthalate;    (h) Polybutyleneterephthalate;    (i) Polyethylenenaphthalate;    (j) Ethylene-Propylene-Diene Monomer Copolymers; and    (k) copolymers and/or binary or ternary blends of any of (a) through (j) above.    
     
     
         6 . The roofing element of any one of claims  1 - 2 , wherein the filler of the second material is selected from the group consisting of: 
 (a) mineral filler;    (b) organic filler;    (c) nanofiller;    (d) reinforcing filler;    (e) reinforcing fiber;    (f) recycled polymer of any of; 
 (i) Polyvinylchloride;  
 (ii) Polyethylene;  
 (iii) Polypropylene;  
 (iv) Polybutene;  
 (v) Polymethylpentene;  
 (vi) Polyacrylates;  
 (vii) Polyethyleneterephthalate;  
 (viii) Polybutyleneterephthalate;  
 (ix) Polyethylenenaphthalate;  
 (x) Ethylene-Propylene-Diene Monomer Copolymers; and  
 (xi) copolymers and/or binary or ternary blends or any combinations of any of (i) through (x) above.  
   
     
     
         7 . The roofing element of  claim 4 , wherein the filler of the second material is selected from the group consisting of: 
 (a) mineral filler;    (b) organic filler;    (c) nanofiller;    (d) reinforcing filler;    (e) reinforcing fiber;    (f) recycled polymer of any of; 
 (i) Polyvinylchloride;  
 (ii) Polyethylene;  
 (iii) Polypropylene;  
 (iv) Polybutene;  
 (v) Polymethylpentene;  
 (vi) Polyacrylates;  
 (vii) Polyethyleneterephthalate;  
 (viii) Polybutyleneterephthalate;  
 (ix) Polyethylenenaphthalate;  
 (x) Ethylene-Propylene-Diene Monomer Copolymers; and  
 (xi) copolymers and/or binary or ternary blends or any combinations of any of (i) through (x) above.  
   
     
     
         8 . The roofing element of any one of claims  1 - 2 , wherein the first material includes at least one additive therein, with said additive(s) being selected from the group consisting of: 
 (a) thermal stabilizers;    (b) ultraviolet light stabilizers;    (c) pigments;    (d) compatibilizer(s);    (e) flame retardants; and    (f) processing aids.    
     
     
         9 . The roofing element of any one of claims  1 - 2 , wherein the second material includes at least one additive therein, with said additive(s) being selected from the group consisting of: 
 (a) thermal stabilizers;    (b) ultraviolet light stabilizers;    (c) pigments;    (d) compatibilizer(s);    (e) flame retardants; and    (f) processing aids.    
     
     
         10 . The roofing element of any one of claims  1 - 2 , wherein each of said first and second materials include at least one additive therein, with said additive(s) being selected from the group consisting of: 
 (a) thermal stabilizers;    (b) ultraviolet light stabilizers;    (c) pigments;    (d) compatibilizer(s);    (e) flame retardants; and    (f) processing aids.    
     
     
         11 . The roofing element of  claim 3 , wherein the first material includes at least one additive therein, with said additive(s) being selected from the group consisting of: 
 (a) thermal stabilizers;    (b) ultraviolet light stabilizers;    (c) pigments;    (d) compatibilizer(s);    (e) flame retardants; and    (f) processing aids.    
     
     
         12 . The roofing element of  claim 4 , wherein the second material includes at least one additive therein, with said additive(s) being selected from the group consisting of: 
 (a) thermal stabilizers;    (b) ultraviolet light stabilizers;    (c) pigments;    (d) compatibilizer(s);    (e) flame retardants; and    (f) processing aids.    
     
     
         13 . The roofing element of  claim 5 , wherein the first and second materials each include at least one additive therein, with said additive(s) being selected from the group consisting of: 
 (a) thermal stabilizers;    (b) ultraviolet light stabilizers;    (c) pigments;    (d) compatibilizer(s);    (e) flame retardants; and    (f) processing aids.    
     
     
         14 . The roofing element of  claim 8 , wherein the filler of the second material is selected from the group consisting of: 
 (a) mineral filler;    (b) organic filler;    (c) nanofiller;    (d) reinforcing filler;    (e) reinforcing fiber;    (f) recycled polymer of any of; 
 (i) Polyvinylchloride;  
 (ii) Polyethylene;  
 (iii) Polypropylene;  
 (iv) Polybutene;  
 (v) Polymethylpentene;  
 (vi) Polyacrylates;  
 (vii) Polyethyleneterephthalate;  
 (viii) Polybutyleneterephthalate;  
 (ix) Polyethylenenaphthalate;  
 (x) Ethylene-Propylene-Diene Monomer Copolymers; and  
 (xi) copolymers and/or binary or ternary blends or any combinations of any of (i) through (x) above.