Exterior roofing surface comprised of foam

Abstract

An external roofing surface comprised of foam is non-ignitable, insect resistance, very strong and extremely lightweight. The foam is also easily shaped by a number of shaping techniques, which allows for a more aesthetically pleasing appearance and can be used to make a roofing system that interlocks and has channels for underside ventilation. The foam may also optionally be reinforced with various materials to increase the strength and durability. The foam may optionally be coated with a material to impart a desired strength, durability and/or aesthetic look.

1 . An external roofing surface comprising: 
 a structure with a top surface and a bottom surface, wherein the structure is comprised of EPS and wherein the top surface comprises a weatherproofed treatment;    wherein the treatment is comprised of a fiberglass reinforcing mesh; and    wherein the treatment is further comprised of cement coating.    
   
   
       2 . An external roofing surface comprising a structure with a top surface and a bottom surface, wherein the structure is comprised of foam and wherein the top surface is comprised of a weatherproof treatment.  
   
   
       3 . The roofing surface of  claim 2 , wherein the structure is shaped.  
   
   
       4 . The roofing surface of  claim 1 , wherein the structure is shaped by using a shaping technique selected from a group consisting of: hotwire, routing, laser cutting, punching, extrusion, cutting, drilling, casting, infusion and combinations thereof.  
   
   
       5 . The roofing surface of  claim 2 , wherein the structure is shaped by using computer assistance.  
   
   
       6 . The roofing surface of  claim 2 , wherein the foam is selected from a group consisting of: high density foam, blue board, polystyrene, injection foams, MDI monomer, polyurethane resins, extruded foam, expanded polystyrene, expanded plastic foam, expanded polyethylene, nylon and mixtures thereof.  
   
   
       7 . The roofing surface of  claim 2 , wherein the treatment comprises a reinforcing material selected from a group consisting of: foam, fiberglass mesh, shopped fiberglass, polypropylene fibers, metal mesh, polyurethane mesh, nylon mesh, polymers and mixtures thereof.  
   
   
       8 . The roofing surface of  claim 7 , wherein the reinforcing material is internal to the foam.  
   
   
       9 . The roofing surface of  claim 7 , wherein the reinforcing material is external to the foam.  
   
   
       10 . The roofing surface of  claim 7 , wherein the bottom surface comprises a second treatment comprised of a second reinforcing material selected from a group consisting of: foam, fiberglass mesh, shopped fiberglass, polypropylene fibers, metal mesh, polyurethane mesh, nylon mesh, polymers and mixtures thereof.  
   
   
       11 . The roofing surface of  claim 2 , wherein the treatment comprises a reinforcing structure selected from a group consisting of: ridges, ribs, channels, and combinations thereof.  
   
   
       12 . The roofing surface of  claim 2 , wherein the treatment comprises a coating material.  
   
   
       13 . The roofing surface of  claim 12  wherein the coating material is selected from a group consisting of: paint, cement, concrete, polyurethane, vinyl, latex, oil, metal, plastic and mixtures thereof.  
   
   
       14 . The roofing surface of  claim 2 , wherein the treatment comprises a sheathing structure.  
   
   
       15 . The roofing surface of  claim 14 , wherein the sheathing structure is selected from a group consisting of: metal, plastic, natural rock and mixtures thereof.  
   
   
       16 . The roofing surface of  claim 12 , wherein the bottom surface comprises a second treatment comprised of a second coating material selected from a group consisting of: paint, cement, concrete, polyurethane, vinyl, latex, oil, metal, plastic and mixtures thereof.  
   
   
       17 . A method for manufacturing a roofing surface, comprising: 
 (a) shaping a structure with a top surface and a bottom surface, wherein the structure is made of foam;    (b) applying a weatherproof treatment to the surface; and    (c) curing or drying the treatment.    
   
   
       18 . The method of  claim 17 , wherein the shaping step (a) is selected from a group consisting of: hotwire, routing, laser cutting, punching, extrusion, cutting, drilling, casting, infusion, and combinations thereof.  
   
   
       19 . The method of  claim 17 , wherein the shaping step (a) introduces a second structure selected from group consisting of: ribs, channels, ridges, fastening points and combinations thereof.  
   
   
       20 . The method of  claim 17 , wherein the shaping step (a) shapes the structure to be interlocking.  
   
   
       21 . The method of  claim 17 , wherein the foam is selected from a group consisting of: 
 high density foam, blue board, polystyrene, injection foams, MDI monomer, polyurethane resins, extruded foam, expanded polystyrene, expanded plastic foam, expanded polyethylene, nylon and mixtures thereof.    
   
   
       22 . The method of  claim 17 , wherein the applying step (b) comprises applying a reinforcement material selected from a group consisting of: foam, fiberglass mesh, shopped fiberglass, polypropylene fibers, metal mesh, polyurethane mesh, nylon mesh, polymers, and mixtures thereof.  
   
   
       23 . The method of  claim 17 , wherein the applying step (b) comprises applying a coating material selected from a group consisting of: paint, cement, concrete, polyurethane, vinyl, latex, oil, metal, plastic and mixtures thereof.  
   
   
       24 . The method of  claim 17 , wherein the applying step (b) comprises applying a sheathing material selected from a group consisting of: metal, plastic, natural rock, and combinations thereof.