Patent Application
20120244315
1. Field of the Invention
The field of the present invention is tarpaulins, particularly tarpaulins having a simulated roofing surface.
2. Background
Using a conventional tarpaulin to cover unfinished or damaged roofs presents numerous problems for building owners. Although tarpaulins can prevent deterioration, limit roofing damage, protect valuables, etc., they are unsightly. The appearance of conventional tarpaulins in a neighborhood connotes damage—roofing and aesthetic—to the neighborhood.
Manufacturers of conventional tarpaulins primarily use solid hues of bright blue and green. One example of such an unadorned tarpaulin used to cover a damaged roof is described in U.S. Pat. No. 7,299,588. These types of tarpaulins stand out and bring unnecessary, unwanted attention to a neighborhood. When exposed areas result from severe weather, e.g. hurricanes and tornadoes, often the roofs of entire neighborhoods are covered with blue tarpaulins. While in place, these blue tarpaulins can be a continuing reminder of death, destruction, and sometimes the continuing decline of property values, especially in hurricane and tornado prone areas.
During the time tarpaulins are temporarily in place, building owners need to select the best options for repair. In some cases, this will mean replacing a portion of a roof or selecting an entirely new roof. While roofing materials are available in a variety of shades and styles, owners who are replacing only a portion must use conventional tarpaulins to cover exposed areas. Many of these owners would likely prefer to use tarpaulin materials that bring less attention to exposed areas. In addition, owners who choose to replace an entire roof may find it difficult to assess how certain colors, finishes, and styles will appear.
Considering the lack of aesthetic value provided by conventional tarpaulins and the limited options available to building owners, choosing to repair or replace roofing materials, a clear need exists for improved tarpaulins.
The present invention is directed toward tarpaulins, particularly tarpaulins having a simulated roofing surface. Tarpaulins with surfaces that simulate other structural components are also contemplated.
In one aspect, the tarpaulin includes a plurality of warp strands and a plurality of weft strands, a protective weatherproof coating, impregnating and covering the strands, and a simulated roofing surface, printed on at least one surface of the tarpaulin. The warp and weft strands are woven into a weave pattern to form a mesh substrate. Once formed, a protective weatherproof coating is applied to the mesh substrate. The coating can include one or more pigments, an ultraviolet stabilizer, flame retardants, and other fillers that protect the mesh substrate from exposure to various conditions.
A simulated roofing surface is applied to the protective coating. The simulated roofing surface can have the appearance of roofing materials such as shingles, shakes, and tiles of various shapes, colors, finishes, and configurations.
Accordingly, an improved tarpaulin is disclosed. Advantages of the improvements will appear from the drawings and following description.
Turning in detail to the drawings,
The tarpaulin 10 is preferably lightweight but strong, due to the interwoven, cross-directional configuration of strands 12, 14. Once properly installed, the tarpaulin is adapted to temporarily protect exposed areas on a structure—usually for a period not longer than about three to six months. The tarpaulin, as described herein, is a covering designed for temporary—not permanent—coverage, particularly for exposed areas on a structure. Exposed areas can result from, among other things, improper installation, poor maintenance, mold, mildew, and various weather conditions, including hurricanes and tornadoes.
In its finished state, the tarpaulin 10 has a thickness ranging from about 0.005 inches to about 0.010 inches, depending upon whether the tarpaulin is designated as light duty, medium duty, or heavy duty. Light duty tarpaulins have an overall thickness ranging from about 0.005 inches to 0.006 inches. Medium duty tarpaulins have an overall thickness ranging from about 0.0075 inches to 0.0085 inches. And, heavy duty tarpaulins have an overall thickness ranging from about 0.0085 inches to 0.0010 inches.
Moreover, in its finished state, the tarpaulin 10 is preferably provided as a rectangular or square sheet. The tarpaulin may, however, be manufactured in any shape, including ovals, circles, and triangles. Sheet sizes typically have a width ranging from about 5 feet to about 50 feet and a length ranging from about 7 feet to about 100 feet.
As shown in
The warp strands 12 and the weft strands 14 are woven into a weave pattern 20 that provides multidirectional strength to the tarpaulin 10. The weave pattern 20 forms a mesh substrate 22. The strands are interwoven into a mesh substrate ranging from about 5 feet×7 feet to about 50 feet×100 feet. Although a plain weave pattern is shown in
Once formed, the mesh substrate 22 is coated on at least one side with a protective weatherproof coating 16. The protective weatherproof coating 16 can include one or more pigments, an ultraviolet stabilizer, flame retardants, and other fillers that protect the mesh substrate from exposure to various conditions. In one configuration, the protective weatherproof coating 16 includes low density polyethylene (LDPE) as a major component. Preferably, the protective weatherproof coating 16 is extruded such that it impregnates the mesh substrate.
As shown in
Under preferred conditions, the protective weatherproof coating 16 is extruded under heat such that it partially melts over one side of the mesh substrate 22. In addition, under preferred conditions, the die roller has a temperature significantly lower than that of the extruded coating as it exits the extruder, such that the coating is cooled.
As the coating 16 and the mesh substrate 22 pass through nip 76 between the press roller 84 and the die roller 86, the materials are compressed. This compression allows the protective weatherproof coating 16 to impregnate and attach itself to the mesh substrate 22. This process may then be repeated to coat the opposite side of the mesh substrate to form a second coating layer 17 (shown in
Pigments included in the protective weatherproof coating can produce a coating of any color or finish.
An ultraviolet stabilizer is also preferably a component of the protective weatherproof coating 16. In one configuration, the ultraviolet stabilizer is manufactured using a mixture of TINUVIN 784 UV powder and a flame retardant, among other fillers. Before extrusion and application of the coating, a master batch is made using the UV powder. In the master batch, the UV powder preferably does not exceed 0.5% of the total coating weight. In addition to the UV powder, the protective weatherproof coating can contain a flame retardant made from Bromine+Sb2O3 or other suitable flame retardant composition in compliance with recommended standards. In one type of coating composition, the flame retardant does not exceed about 8% of the overall coating weight. In addition to the pigments, UV stabilizer and the flame retardants described, the protective weatherproof coating can include other types of fillers that protect the mesh substrate from exposure to various conditions.
As shown in
After application of the coating(s) to the mesh substrate, a simulated roofing surface 18 is applied. This simulated roofing surface 18 can have the appearance of roofing materials such shingles, shakes, and tiles of various shapes, colors, finishes and configurations. Such tile types include, but are not limited to, Spanish tile, mission tile, barrel tile, straight tile, tapered tile, Roman tile, English tile, Shingle tile, and French tile. Roofing material shapes, in particular, can include bevel, scallop, pointed, rectangular, fish scale, and square.
In addition, the simulated roofing surface may have one or more patterns 19, depending upon the needs of the building owner. These patterns 19 may differ, depending on the style of roofing materials used from region to region. Further, the finish of the simulated roofing surface can vary. Types of finishes can include metallic, asphalt, concrete, slate, clay, rubber, copper, ceramic, wood, plastic, or a combination of finishes.
The simulated roofing surface 18 can also be designed to simulate the appearance of any roofing material such that the tarpaulin blends with surrounding materials, thereby avoiding unnecessary attention brought by conventional tarpaulins, as shown in
While the simulated roofing surface may be produced using any acceptable method, printing methods such as rotogravure and flexographic printing are preferred. The selection of the production method will depend, in part, on the continuity and complexity of the selected pattern or patterns. Other production methods include staining, dyeing, and painting the coating layer.
Regardless of the production process used for the simulated roofing surface, it preferably has properties that lend for easy application and installation of the tarpaulin. For example, when a printing process is used, inks containing additives that provide additional roof protection and installation benefits are preferred. Particularly, the simulated roofing surface 18 may be printed with inks having non-skid properties. These types of inks help prevent slipping by persons who must navigate across tarpaulins during and after installation. Also, preferably, the ink will contain a UV stabilizer that prevents deterioration due to sun exposure. Moreover, the simulated roofing surface 18 preferably has a matte finish that limits glare.
In the rotogravure printing process, the first step is image preparation. A roofing pattern or image is supplied from a photograph or other reproduction method. The chosen image is then engraved intaglio onto a printing cylinder which is copper coated. The engraved copper coated sections preferably include an additional coating of chrome.
During the rotogravure printing process, the tarpaulin is disposed between a press roller (not shown), having elastomeric sheathing, and the printing cylinder. The printing cylinder is further coupled to a dipping cylinder which retrieves ink from a reservoir. Preferably, the dipping cylinder is disposed under the printing cylinder. As the tarpaulin travels, the printing cylinder transfers the image onto the protective weather proof coating, creating a simulated roofing surface. Optionally, as the printing cylinder rotates, a cutting tool is used to remove excess ink from the surface of the printing cylinder. Generally, the rotogravure printing process is used for continuous roofing patterns.
In the flexographic printing process, the first step is also image preparation. In preparing the simulated roofing surface, one or more roofing patterns or images are supplied from a photograph or other type of reproduction method. The selected image is engraved onto one or more plates, preferably manufactured from an elastomeric material. These plates are further coupled to a printing cylinder.
During the flexographic printing process, the tarpaulin is disposed between a press roller, preferably manufactured from steel, and the printing cylinder. As the printing cylinder rotates, it retrieves ink from a reservoir. As the tarpaulin travels, the printing cylinder transfers the image onto the protective weather proof coating, creating a simulated roofing surface.
The printing process produces a simulated roofing surface 18, as shown particularly in
The tarpaulin 10 may also be provided with a hem 24, as shown in
Preferably contained within the hem is a reinforcement 28. In one configuration, the reinforcement 28 is a rope; however, other means of reinforcement may be used. The reinforcement 28 serves to reinforce the edges 30 of the tarpaulin 10. In addition, where the tarpaulin is configured with corners, a second reinforcement 32 (not shown) may be provided. In one configuration, the second reinforcement is a patch of material that is incorporated into the hem. The second reinforcement 32 may have a triangular shape or other configuration that allows for insertion into a corner or other area.
Preferably, grommets 34 are included as part of the hem 24. The grommets are designed such that a tarpaulin may be secured to a roof 36 or other roofing surface. The grommets may be manufactured from any material, including, but not limited to, plastic, aluminum, brass, and steel. The grommets 34 are preferably disposed within the hem at predetermined intervals, depending upon the length and width of the tarpaulin 10. For example, the grommets may be disposed at equal intervals of 1 foot, 2 feet or 3 feet.
As shown in
While embodiments of this invention have been shown and described, it will be apparent to those skilled in the art that many more modifications are possible without departing from the inventive concepts herein. The invention, therefore, is not to be restricted except in the spirit of the following claims.
