(cid:9) (cid:9)
`WO 00/71834 A2
`
`eql (cid:9)
`
`< T
`
`(12) INTERNATIONAL APPLICATION PUBLISHED UNDER THE PATENT COOPERATION TREATY (PCT)
`(12) INTERNATIONAL APPLICATION PUBLISHED UNDER THE PATENT COOPERATION TREATY (PCT)
`
`(19) World Intellectual Property Organization
`(19) World Intellectual Property Organization
`International Bureau
`International Bureau
`
`111111111111111111111111111111111111111111IIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIIII
`WO 00/71834 A2
`
`(43) International Publication Date
`(43) International Publication Date
`30 November 2000 (30.11.2000)
`30 November 2000 (30.11.2000)
`
`PCT
`PCT
`
`(10) International Publication Number
`(10) International Publication Number
`WO 00/71834 A2
`WO 00/71834 A2
`
`(51) International Patent Classification':
`(51) International Patent Classification7:
`
`(21) International Application Number: PCT/US00/14487
`(21) International Application Number:
`PCT/US00/14487
`
`E04D 5/00 (74) Agents: SABOURIN, Anne, Gerry et al.; BASF Corpo-
`E04D 5/00
`(74) Agents: SABOURIN, Anne, Gerry et al.; BASF Corpo
`ration, 26701 Telegraph Road, Southfield, MI 48034-2442
`ration, 26701 Telegraph Road, Southfield, MI 48034-2442
`(US).
`(US).
`
`(22) International Filing Date:
`(22) International Filing Date:
`
`25 May 2000 (25.05.2000)
`25 May 2000 (25.05.2000)
`
`(25) Filing Language:
`(25) Filing Language:
`
`(26) Publication Language:
`(26) Publication Language:
`
`English
`English
`
`English
`English
`
`(30) Priority Data:
`(30) Priority Data:
`09/320,049
`09/320,049
`
`26 May 1999 (26.05.1999) US
`26 May 1999 (26.05.1999)
`US
`
`(71) Applicant (for all designated States except US): BASF
`(71) Applicant (for all designated States except US): BASF
`CORPORATION [US/US]; Sabourin, Anne, Gerry,
`CORPORATION [US/US]; Sabourin, Anne, Gerry,
`Patent Department, 26701 Telegraph Road, Southfield, MI
`Patent Department, 26701 Telegraph Road, Southfield, MI
`48034-2442 (US).
`48034-2442 (US).
`
`(72) Inventors; and
`(72) Inventors; and
`(75) Inventors/Applicants (for US only): ALLMAN, Jack
`(75) Inventors/Applicants (for US only): ALLMAN, Jack
`[US/US]; 1500 Dietrick Drive, Twin Lakes, WI 53181
`[US/US]; 1500 Dietrick Drive, Twin Lakes, WI 53181
`(US). LEWARCHIK, Ronald [US/US]; 706 Pimlico
`(US). LEWARCHIK, Ronald [US/US]; 706 Pimlico
`Parkway, Sleepy Hollow, IL 60118 (US). SCARICA-
`Parkway, Sleepy Hollow,
`IL 60118 (US). SCARICA-
`MAZZA, Victor [US/US]; 2 North Deer Place, Mount
`MAZZA, Victor [US/US]; 2 North Deer Place, Mount
`Holly, NJ 08060 (US).
`Holly, NJ 08060 (US).
`
`(81) Designated States (national): AE, AG, AL, AM, AT, AU,
`(81) Designated States (national): AE, AG, AL, AM, AT, AU,
`AZ, BA, BB, BG, BR, BY, CA, CH, CN, CR, CU, CZ, DE,
`AZ, BA, BB, BG, BR, BY, CA, CH, CN, CR, CU, CZ, DE,
`DK, DM, DZ, EE, ES, F1, GB, GD, GE, GH, GM, HE, HU,
`DK, DM, DZ, EE, ES, FI, GB, GD, GE, GH, GM, HR, HU,
`ID, IL, IN, IS, JP, KE, KG, KP, KR, KZ, LC, LK, LR, LS,
`ID, IL, IN, IS, JP, KE, KG, KP, KR, KZ, LC, LK, LR, LS,
`LT, LU, LV, MA, MD, MG, MK, MN, MW, MX, NO, NZ,
`LT, LU, LV, MA, MD, MG, MK, MN, MW, MX, NO, NZ,
`PL, PT, RO, RU, SD, SE, SG, SI, SK, SL, TJ, TM, TR, TT,
`PL, PT, RO, RU, SD, SE, SG, SI, SK, SL, TJ, TM, TR, TT,
`17, UA, UG, US, UZ, VN, YU, ZA, ZW.
`TZ, UA, UG, US, UZ, VN, YU, ZA, ZW.
`
`(84) Designated States (regional): ARIPO patent (GH, GM,
`(84) Designated States (regional): ARIPO patent (GH, GM,
`KE, LS, MW, MZ, SD, SL, SZ, TZ, UG, ZW), Eurasian
`KE, LS, MW, MZ, SD, SL, SZ, TZ, UG, ZW), Eurasian
`patent (AM, AZ, BY, KG, KZ, MD, RU, TI, TM), European
`patent (AM, AZ, BY, KG, KZ, MD, RU, TJ, TM), European
`patent (AT, BE, CH, CY, DE, DK, ES, FI, FR, GB, GR, 1E,
`patent (AT, BE, CH, CY, DE, DK, ES, FI, FR, GB, GR, IE,
`IT, LU, MC, NL, PT, SE), OAPI patent (BF, BJ, CF, CG,
`IT, LU, MC, NL, PT, SE), OAPI patent (BE, BJ, CF, CG,
`CI, CM, GA, GN, GW, ML, MR, NE, SN, TD, TG).
`CI, CM, GA, GN, GW, ML, MR, NE, SN, TD, TG).
`
`Published:
`Published:
`Without international search report and to be republished
`— Without international search report and to be republished
`upon receipt of that report.
`upon receipt of that report.
`
`For two-letter codes and other abbreviations, refer to the "Guid-
`For two-letter codes and other abbreviations, refer to the "Guid
`ance Notes on Codes and Abbreviations" appearing at the begin-
`ance Notes on Codes andAbbreviations " appearing at the begin
`ning of each regular issue of the PCT Gazette.
`ning ofeach regular issue ofthe PCT Gazette.
`
`11111111
`
`(54) Title: METAL ROOFING SHINGLE STOCK AND METHOD FOR MAKING IT
`(54) Title: METAL ROOFING SHINGLE STOCK AND METHOD FOR MAKING IT
`
`
`
``Tr
`T
`M (57) Abstract: This invention relates to a method for embedding a multiplicity of discrete masses of material in a resinous coating
`(57) Abstract: This invention relates to a method for embedding a multiplicity of discrete masses of material in a resinous coating
`CC
`oo
`CC on a sheet of metal in a coil coating system. The sheet is coated, the masses are embedded in the wet resinous coating, and the
`on a sheet of metal in a coil coating system. The sheet is coated, the masses are embedded in the wet resinous coating, and the
`coating is dried in a one-pass system. The resinous coating and the embedded masses are preferably resistant to ultra-violet radiation.
`coating is dried in a one-pass system. The resinous coating and the embedded masses are preferably resistant to ultra-violet radiation.
`The wet resinous coating, therefore, is preferably a liquid fluorocarbon resin. The discrete masses comprise pigmented particulate
`The wet resinous coating, therefore, is preferably a liquid fluorocarbon resin. The discrete masses comprise pigmented particulate
`© minerals and resins in the form of granules, beads, vesiculated beads, pellets, flakes, platelets, cylinders, coating powders, and coating
`minerals and resins in the form of granules, beads, vesiculated beads, pellets, flakes, platelets, cylinders, coating powders, and coating
`powder precursor chips. The minerals include glass, quartz, mica, pebbles, and ceramics. The particulate resins include polyesters,
`powder precursor chips. The minerals include glass, quartz, mica, pebbles, and ceramics. The particulate resins include polyesters,
`C acrylics, nylons, polyurethanes, polycarbonates, solid fluorocarbon resins, and solid mixtures of a fluorocarbon resin and an acrylate
`acryhcs, nylons, polyurethanes, polycarbonates, solid fluorocarbon resins, and solid mixtures of a fluorocarbon resin and an acrylate
`or methacrylate polymer or copolymer. Sheet metal decorated in such a manner is useful as stock in the manufacture of metal roofing
`or methacrylate polymer or copolymer. Sheet metal decorated in such a manner is useful as stock in the manufacture of metal roofing
`'00- shingles simulating the appearance of traditional asphalt shingles.
`shingles simulating the appearance of traditional asphalt shingles.
`
`O£
`
`Petitioner - Owens Corning
`
`Ex. 1006, p.
`
`1 of 24
`
`Petitioner - Owens Corning
`Ex. 1006, p. 1 of 24
`
`(cid:9)
`(cid:9)
`(cid:9)
`(cid:9)
`(cid:9)
`(cid:9)
`

`

`WO 00/71834 (cid:9)
`WO 00/71834
`
`PCT/US00/14487
`PCT/US00/14487
`
`METAL ROOFING SHINGLE STOCK AND METHOD FOR MAKING IT
`METAL ROOFING SHINGLE STOCK AND METHOD FOR MAKING IT
`
`5
`5
`
`FIELD OF THE INVENTION
`FIELD OF THE INVENTION
`
`.
`
`This invention relates to a method for embedding a
`This invention relates to a method for embedding a
`
`multiplicity of discrete masses of material in a
`multiplicity of discrete masses
`of material
`in a
`
`resinous coating on a sheet of metal in a coil coating
`resinous coating on a sheet of metal
`in a coil coating
`
`10 system. More particularly, it relates to a one-pass
`10
`system. More particularly,
`it
`relates to a one-pass
`
`system wherein the sheet is coated, the masses are
`system wherein the sheet
`is coated,
`the masses are
`
`embedded in the wet resinous coating, and the coating is
`embedded in the wet resinous coating, and the coating is
`
`dried. It further relates to a coil of metal decorated
`dried.
`It further relates to a coil of metal decorated
`
`with said embedded masses. It relates particularly to
`with said embedded masses.
`It
`relates particularly to
`
`15 the decoration of sheet metal so that it is useful as
`15
`the decoration of sheet metal so that
`it is useful as
`
`stock in the manufacture of metal roofing shingles
`stock in the manufacture of metal
`roofing shingles
`
`simulating the appearance of traditional asphalt
`simulating
`the
`appearance
`of
`traditional
`asphalt
`
`shingles. To that end, this invention relates to coil
`shingles. To that end,
`this invention relates to coil
`
`coated sheet metal to which the coating adheres
`coated
`sheet metal
`to which
`the
`coating
`adheres
`
`20 sufficiently well to permit post-coating forming,
`20
`sufficiently well
`to
`permit
`post-coating
`forming,
`
`molding, bending, and shaping of the metal without
`molding,
`bending,
`and
`shaping of
`the metal without
`
`delamination or flaking of the coating. It further
`delamination or
`flaking of
`the coating.
`It
`further
`
`relates to coil coated sheet metal on which the resinous
`relates to coil coated sheet metal on which the resinous
`
`coating is resistant to ultra-violet radiation and the
`coating is resistant
`to ultra-violet
`radiation and the
`
`25 embedded masses are ultra-violet resistant color bodies
`25
`embedded masses are ultra-violet resistant color bodies
`
`of various hues. The surface of the coating may be
`of various hues.
`The surface of
`the coating may be
`
`substantially free of protrusions but at least a portion
`substantially free of protrusions but at
`least a portion
`
`of the discrete masses may protrude above the surface of
`of
`the discrete masses may protrude above the surface of
`
`the coating to impart slip resistance to shingles made
`the coating to impart slip resistance to shingles made
`
`30 from the coated stock.
`30
`from the coated stock.
`
`Petitioner - Owens Corning
`Ex. 1006, p. 2 of 24
`
`Petitioner - Owens Corning
`Ex. 1006, p. 2 of 24
`
`

`

`WO 00/71834 (cid:9)
`WO 00/71834
`
`PCT/US00/14487
`PCT/US00/14487
`
`BACKGROUND OF THE INVENTION
`BACKGROUND OF THE INVENTION
`
`Mineral covered asphalt sheets, by far the most
`Mineral covered asphalt sheets,
`by far
`the most
`
`commonly used shingles, are sold with guarantees of from
`commonly used shingles, are sold with guarantees of
`from
`
`15 to 30 years depending on the weight per 100 square
`15 to 3 0 years depending on the weight per 10 0 square
`
`5 feet. The mineral granules are gradually dislodged by
`5
`feet. The mineral granules are gradually dislodged by
`
`wind and rain to expose the asphalt binder to the
`wind and
`rain to expose
`the asphalt binder
`to the
`
`destructive effects of ultra-violet light. Because of an
`destructive effects of ultra-violet light. Because of an
`
`increasing desire to replace the asphalt with a
`increasing
`desire
`to
`replace
`the
`asphalt with
`a
`
`substrate that has a much longer useful life - on the
`substrate that has a much longer useful
`life - on the
`
`10 order of about 60 to 80 years - the development of metal
`10
`order of about 60 to 80 years -
`the development of metal
`
`roofing shingles has become more and more important.
`roofing shingles has become more and more important.
`
`STONECREST Steel Shingles having multilayered coatings
`STONECREST Steel Shingles having multilayered coatings
`
`are made from a combination of steel, aluminum, and zinc
`are made from a combination of steel, aluminum, and zinc
`
`by Metal Works of Pittsburgh. The cost of simulating the
`by Metal Works of Pittsburgh. The cost of simulating the
`
`15 appearance of mineral covered asphalt shingles by
`15
`appearance
`of mineral
`covered asphalt
`shingles
`by
`
`forming shingles from coated sheet metal stock may in
`forming shingles from coated sheet metal stock may in
`
`part be reduced to a commercially acceptable level by
`part be reduced to a commercially acceptable level by
`
`reducing the number of coating steps and the
`reducing
`the
`number
`of
`coating
`steps
`and
`the
`
`corresponding time.
`corresponding time.
`
`20 (cid:9)
`20
`
`In a conventional coil coating system, paint is
`In a conventional coil coating system, paint
`is
`
`picked up by a roller rotating in a paint pan and
`picked up by a
`roller
`rotating in a paint pan and
`
`transferred to an applicator roller and a coil of sheet
`transferred to an applicator roller and a coil of sheet
`
`metal is uncoiled as the metal is pulled through a
`metal
`is uncoiled as
`the metal
`is pulled through a
`
`series of rollers, one or more of which is a paint
`series of
`rollers,
`one or more of which is a paint
`
`25 applicator roller, at up to 1000 feet per minute. The
`25
`applicator roller, at up to 1000 feet per minute. The
`
`coated metal is then passed through an oven for drying
`coated metal
`is then passed through an oven for drying
`
`or curing and coiled again. The sheet is passed through
`or curing and coiled again. The sheet
`is passed through
`
`the system each time a separate coating layer is to be
`the system each time a separate coating layer is to be
`
`applied.
`applied.
`
`2
`
`Petitioner - Owens Corning
`Ex. 1006, p. 3 of 24
`
`Petitioner - Owens Corning
`Ex. 1006, p. 3 of 24
`
`

`

`(cid:9) (cid:9)
`
`5 in the wet surface of that coating in a single pass of
`5
`in the wet surface of
`that coating in a single pass of
`
`the metal through a coil coating system. Several patents
`the metal
`through a coil coating system. Several patents
`
`teach the coating of moving flexible substrates with two
`teach the coating of moving flexible substrates with two
`
`materials. The principal substrates are sheets of
`materials.
`The principal
`substrates
`are
`sheets
`of
`
`asphalt, PVC and fabric but metal is often mentioned as
`asphalt, PVC and fabric but metal
`is often mentioned as
`
`10 a potential substrate. U.S. Patent 5,827,608, for
`10
`a potential
`substrate. U.S.
`Patent
`5,827,608,
`for
`
`example, teaches the electrostatic fluidized bed
`example,
`teaches
`the
`electrostatic
`fluidized
`bed
`
`application of a coating powder (e.g., a blend of two
`application of a coating powder
`(e.g.,
`a blend of
`two
`
`distinct, chemically incompatible resins) onto the
`distinct,
`chemically
`incompatible
`resins)
`onto
`the
`
`underside of a vinyl sheet being drawn from a coil at
`underside of a vinyl sheet being drawn from a coil at
`
`WO 00/71834 (cid:9)
`WO 00/71834
`
`PCT/US00/14487
`PCT/US00/1 4487
`
`To the knowledge of the instant inventors, none of
`To the knowledge of
`the instant
`inventors, none of
`
`the many patents directed to coil coating teach the
`the many patents directed to coil coating teach the
`
`coating of a face of sheet metal with a resinous
`coating of
`a
`face of
`sheet metal with a
`resinous
`
`composition and embedment of a second coating material
`composition and embedment of a second coating material
`
`15 about 4 feet per minute, heating the powder and pressing
`15
`about 4 feet per minute, heating the powder and pressing
`
`it to fuse and bond it to the vinyl, and rewinding the
`it to fuse and bond it to the vinyl, and rewinding the
`
`coated sheet into a coil.
`coated sheet
`into a coil.
`
`SUMMARY OF THE INVENTION
`SUMMARY OF THE INVENTION
`
`It is an object of this invention, therefore, to
`It
`is an object of
`this invention,
`therefore,
`to
`
`provide a coil of sheet metal having a resinous coating
`provide a coil of sheet metal having a resinous coating
`
`on one face and a multiplicity of discrete masses of
`on one face and a multiplicity of discrete masses of
`
`material embedded in said coating.
`material embedded in said coating.
`
`20
`20
`
`It is another object of this invention to provide
`It is another object of
`this invention to provide
`
`25 metal roofing shingle stock having a resinous coating on
`25 metal roofing shingle stock having a resinous coating on
`
`one face and a multiplicity of discrete masses of
`one
`face and
`a multiplicity of discrete masses of
`
`material embedded in said coating.
`material embedded in said coating.
`
`3
`
`Petitioner - Owens Corning
`Ex. 1006, p. 4 of 24
`
`Petitioner - Owens Corning
`Ex. 1006, p. 4 of 24
`
`

`

`WO 00/71834 (cid:9)
`WO 00/71834
`
`PCT/US00/14487
`PCT/US00/1 4487
`
`It is a related object of this invention to provide
`It is a related object of
`this invention to provide
`
`metal roofing shingle stock having a multiplicity of
`metal
`roofing shingle stock having a multiplicity of
`
`discrete color bodies embedded in a resinous coating.
`discrete color bodies embedded in a resinous coating.
`
`It is another object of this invention to provide a
`It is another object of this invention to provide a
`
`5 method for coating one face of sheet metal with a
`5 method
`for coating one
`face of
`sheet metal with a
`
`resinous composition and embedding a particulate coating
`resinous composition and embedding a particulate coating
`
`material in the wet surface of that coating during one
`material
`in the wet surface of
`that coating during one
`
`pass of the metal through a coil coating system.
`pass of
`the metal
`through a coil coating system.
`
`These and other objects of this invention which
`These and other objects of
`this invention which
`
`10 will become apparent from the appended drawings and the
`10 will become apparent
`from the appended drawings and the
`
`following description are achieved in one embodiment of
`following description are achieved in one embodiment of
`
`the invention by a method for coating sheet metal which
`the invention by a method for coating sheet metal which
`
`comprises unwinding the sheet metal from a coil thereof
`comprises unwinding the sheet metal
`from a coil
`thereof
`
`and directing the sheet metal through a series of
`and directing the sheet metal
`through a series of
`
`15 rollers, one or more of which is an applicator roller,
`15
`rollers, one or more of which is an applicator roller,
`
`placing a liquid resinous coating composition in a paint
`placing a liquid resinous coating composition in a paint
`
`pan, picking up said resinous coating composition on a
`pan, picking up said resinous coating composition on a
`
`rotating roller in the pan and and transferring it to an
`rotating roller in the pan and and transferring it to an
`
`applicator roller; thenceforth transferring it as a
`applicator
`roller;
`thenceforth transferring it
`as
`a
`
`20 protective coating to the moving sheet metal,
`20
`protective
`coating
`to
`the moving
`sheet metal,
`
`distributing discrete masses of material uniformly on
`distributing discrete masses of material uniformly on
`
`the liquid or at least plastic protective coating and
`the liquid or at
`least plastic protective coating and
`
`causing at least a portion of them to submerge at least
`causing at
`least a portion of
`them to submerge at
`least
`
`partially in said protective coating, drying said
`partially in said protective coating,
`drying
`said
`
`25 protective coating, and rewinding the coated metal sheet
`25
`protective coating, and rewinding the coated metal sheet
`
`into a take-up coil. The method of this invention is
`into a take-up coil. The method of
`this invention is
`
`characterized by distributing the discrete masses to
`characterized by distributing the discrete masses
`to
`
`form a discontinuous field coextensive with the area of
`form a discontinuous field coextensive with the area of
`
`4
`
`Petitioner - Owens Corning
`
`Ex. 1006, p. 5 of 24
`
`Petitioner - Owens Corning
`Ex. 1006, p. 5 of 24
`
`

`

`WO 00/71834 (cid:9)
`WO 00/71834
`
`PCT/US00/14487
`PCT/US00/14487
`
`the coating, thus simulating the appearance of
`the
`coating,
`thus
`simulating
`the
`appearance
`of
`
`conventional asphalt-based shingles.
`conventional asphalt-based shingles.
`
`BRIEF DESCRIPTION OF THE DRAWINGS
`BRIEF DESCRIPTION OF THE DRAWINGS
`
`5 (cid:9)
`5
`
`Fig. 1 is a schematic drawing of a coil coating
`Fig.
`1
`is a schematic drawing of
`a coil coating
`
`line suitable for the distribution of color bodies on
`line suitable for the distribution of color bodies on
`
`wet resinous coated sheet metal moving on the line.
`wet resinous coated sheet metal moving on the line.
`
`Fig. la is perspective view of one embodiment of
`Fig.
`la is perspective view of one embodiment of
`
`the particle distributor of Fig. 1.
`the particle distributor of Fig. 1.
`
`10 (cid:9)
`10
`
`Fig. lb is a perspective view of another embodiment
`Fig.
`lb is a perspective view of another embodiment
`
`of the particle distributor of Fig. 1
`of
`the particle distributor of Fig. 1.
`
`Fig. 2 is a schematic drawing of a flame spray
`Fig.
`2
`is a schematic drawing of
`a
`flame spray-
`
`system for projecting fused particles onto wet resinous
`system for projecting fused particles onto wet
`resinous
`
`coated sheet metal moving on a coil coating line.
`coated sheet metal moving on a coil coating line.
`
`15 (cid:9)
`15
`
`Fig. 3 is a plan view, partially broken away, of a
`Fig.
`3
`is a plan view, partially broken away, of a
`
`flame spray gun for the system of Fig. 2.
`flame spray gun for the system of Fig. 2.
`
`Fig. 4 is a schematic drawing of a coil coating
`Fig.
`4
`is a schematic drawing of
`a coil coating
`
`line suitable for the distribution of ceramic granules
`line suitable for the distribution of ceramic granules
`
`on wet resinous coated sheet metal and the interleaving
`on wet
`resinous coated sheet metal and the interleaving
`
`20 of a backing sheet with the coated sheet metal as it is
`20
`of a backing sheet with the coated sheet metal as it is
`
`rewound on a take up coil.
`rewound on a take up coil .
`
`DETAILED DESCRIPTION OF THE INVENTION
`DETAILED DESCRIPTION OF THE INVENTION
`
`As used herein, substantially means largely if not
`As used herein, substantially means largely if not
`
`25 wholly that which is specified but so close that the
`25 wholly that which is specified but
`so close that
`the
`
`difference is insignificant.
`difference is insignificant.
`
`In the coil coating operation of this invention,
`In the coil coating operation of
`this invention,
`
`substantially the full expanse of an aluminum or
`substantially the
`full
`expanse of
`an
`aluminum or
`
`galvanized steel sheet is coated as it travels at 250-
`galvanized steel sheet
`is coated as it travels at 250-
`
`5
`
`Petitioner - Owens Corning
`
`Ex. 1006, p. 6 of 24
`
`Petitioner - Owens Corning
`Ex. 1006, p. 6 of 24
`
`(cid:9)
`(cid:9)
`(cid:9)
`

`

`WO 00/71834 (cid:9)
`WO 00/71834
`
`PCT/US00/14487
`PCT/US00/1 4487
`
`1000 feet per minute. Hot dipped galvanized (HDG) steel
`1000 feet per minute. Hot dipped galvanized (HDG) steel
`
`is suitable for low cost operations but a zinc/aluminum
`is suitable for low cost operations but a zinc/aluminum
`
`alloy such as that sold under the trademark GALVALUME is
`alloy such as that sold under the trademark GALVALUME is
`
`preferred for its corrosion resistance. Aluminum is more
`preferred for its corrosion resistance. Aluminum is more
`
`5 preferred when cost is not a limiting factor.
`5
`preferred when cost
`is not a limiting factor.
`
`Pretreatment of the metal is important for increased
`Pretreatment of
`the metal
`is important
`for
`increased
`
`corrosion protection and adhesion of the coatings.
`corrosion protection and
`adhesion of
`the
`coatings.
`
`Typical conversion coating compositions used in the
`Typical
`conversion coating compositions
`used
`in the
`
`pretreatment include those sold under the trademarks
`pretreatment
`include those sold under
`the trademarks
`
`10 BONDERITE 1303 or 1310 for the GALVALUME metal, and BETZ
`10
`BONDERITE 1303 or 1310 for the GALVALUME metal, and BETZ
`
`1500 and Morton's FIRST COAT for aluminum.
`1500 and Morton's FIRST COAT for aluminum.
`
`For optimum adhesion and corrosion resistance, it
`For optimum adhesion and corrosion resistance,
`it
`
`is preferable that the metal is coated with a primer
`is preferable that
`the metal
`is coated with a primer
`
`over the conversion coating. Suitable primers for this
`over
`the conversion coating. Suitable primers for this
`
`15 invention include epoxy, acrylic, polyester, or
`15
`invention
`include
`epoxy,
`acrylic,
`polyester,
`or
`
`polyurethane resins as binders. U.S. Patent No.
`polyurethane
`resins
`as
`binders.
`U.S.
`Patent
`No.
`
`5,001,173 is incorporated herein by reference for its
`5,001,173 is incorporated herein by reference for
`its
`
`description of primers that are suitable here. The
`description of primers
`that are suitable here.
`The
`
`primer thickness may be from 0.2 mil to 1.6 mils,
`primer
`thickness may be
`from 0.2 mil
`to 1.5 mils,
`
`20 preferably about 0.8 mil or more. Flexible primers are
`20
`preferably about 0.8 mil or more. Flexible primers are
`
`preferred when the coated metal stock is to be post
`preferred when the coated metal stock is to be post
`
`formed in the manufacture of a roofing shingle. Greater
`formed in the manufacture of a roofing shingle. Greater
`
`flexibility may be achieved by the use of thick film
`flexibility may be achieved by the use of
`thick film
`
`primers such as are described in U.S. Patent No.
`primers
`such
`as
`are described in U.S. Patent No.
`
`25 5,688,598, which is incorporated herein by reference,
`25
`5,688,598, which is incorporated herein by reference,
`
`and are available from Morton International, Inc. The
`and are available from Morton International,
`Inc. The
`
`peak metal temperature (PMT) for the curing of the
`peak metal
`temperature
`(PMT)
`for
`the curing of
`the
`
`primer is that recommended by the supplier but it is
`primer
`is that
`recommended by the supplier but
`it is
`
`usually in the range of 435-465°F (about 225-240°C)
`usually in the range of 435-4650F (about 225-240oC) .
`
`6
`
`Petitioner - Owens Corning
`Ex. 1006, p. 7 of 24
`
`Petitioner - Owens Corning
`Ex. 1006, p. 7 of 24
`
`

`

`WO 00/71834 (cid:9)
`WO 00/71834
`
`PCT/US00/14487
`PCT/USOO/14487
`
`Pigments such as those described below in regard to the
`Pigments such as those described below in regard to the
`
`topcoat and embedded particles are used to impart
`topcoat
`and
`embedded particles are used
`to impart
`
`ultraviolet light resistance to the primers also.
`ultraviolet light resistance to the primers also.
`
`For the purposes of this invention, the liquid
`For
`the purposes of
`this invention,
`the liquid
`
`5
`resinous coating composition preferably comprises
`5 resinous coating composition preferably comprises an
`an
`
`ultraviolet light resistant pigment and a thermoplastic
`ultraviolet
`light resistant pigment and a thermoplastic
`
`or thermosettable fluorocarbon resin. As used herein, a
`or thermosettable fluorocarbon resin. As used herein,
`a
`
`fluorocarbon resin is a homopolymer of vinyl fluoride or
`fluorocarbon resin is a homopolymer of vinyl
`fluoride or
`
`vinylidene fluoride or a copolymer of either of those
`vinylidene fluoride or a copolymer of either of
`those
`
`10
`two
`10 two monomers with one another and/or other
`monomers
`with
`one
`another
`and/or
`other
`
`copolymerizable, fluorine-containing monomers such as
`copolymerizable ,
`fluorine-containing monomers
`such as
`chlorotrifluoroethylene, (cid:9)
`chlorotrif luoroethylene,
`
`tetrafluoroethylene (cid:9)
`and
`tetraf luoroethylene
`and
`hexafluoroethylene. Fluorocarbon resins are available
`hexaf luoroethylene . Fluorocarbon resins are available
`
`under the trademarks KYNAR and HYLAR. Fluorocarbon
`under
`the
`trademarks
`KYNAR
`and HYLAR.
`Fluorocarbon
`
`15
`resins
`15 resins and coating compositions comprising a
`and
`coating
`compositions
`comprising
`a
`
`fluorocarbon and an acrylate or methacrylate monomer or
`fluorocarbon and an acrylate or methacrylate monomer or
`
`mixture of the two are described in U.S. Patent No.
`mixture of
`the two are described in U.S. Patent No.
`
`5,185,403, which is incorporated herein by reference.
`5,185,403, which is incorporated herein by reference.
`
`Coating compositions particularly suitable for the
`Coating
`compositions particularly suitable
`for
`the
`
`20
`purposes of
`20 purposes of this invention are, available under the
`this invention are, available under
`the
`
`trademark FLUOROCERAM. A mixture of a vinylidene
`trademark
`FLUOROCERAM.
`A mixture
`of
`a
`vinylidene
`
`fluoride/chlorotrif luoroethylene
`fluoride/chlorotrifluoroethylene copolymer (55:45 by
`copolymer
`(55:45
`by
`
`weight percent) and methylmethacrylate (MMA) wherein the
`weight percent) and methylmethacrylate (MMA) wherein the
`
`weight ratio of
`weight ratio of the MMA to the copolymer is from about
`the MMA to the copolymer
`is from about
`
`25 2:1 to about 5:1 is also suitable.
`25
`2 : 1 to about 5:1 is also suitable.
`
`A fluoropolymer particularly suited to the top
`A f luoropolymer particularly suited to the top
`
`coating over the conversion coating on unprimed sheet
`coating over
`the conversion coating on unprimed sheet
`
`metal is described by Yamabe et al in U.S. Patent No.
`metal
`is described by Yamabe et al
`in U.S. Patent No.
`
`4,345,057. Commercially available fluoropolymer resins
`4,345,057. Commercially available f luoropolymer
`resins
`
`7
`
`Petitioner - Owens Corning
`Ex. 1006, p. 8 of 24
`
`Petitioner - Owens Corning
`Ex. 1006, p. 8 of 24
`
`

`

`WO 00/71834 (cid:9)
`WO 00/71834
`
`PCT/US00/14487
`PCT/US00/14487
`
`which are believed to be substantially similar to those
`which are believed to be substantially similar to those
`
`described in the Yamabe et al patent include those sold
`described in the Yamabe et al patent
`include those sold
`
`under the trademarks ICI 302, ICI 504, and ICI 916. For
`under the trademarks ICI 302,
`ICI 504, and ICI 916. For
`
`the purposes of this invention, the word "drying" is
`the purposes of
`this invention,
`the word "drying"
`is
`
`5 used to mean the solidification of molten material and
`5
`used to mean the solidification of molten material and
`
`the curing of thermosettable resins as well as the
`the curing of
`thermosettable resins as well
`as
`the
`
`evaporation of solvents. The thickness of the liquid
`evaporation of solvents.
`The thickness of
`the liquid
`
`resinous coating is such that it forms a 0.5 to 1.0 mil
`resinous coating is such that it forms a 0.5 to 1.0 mil
`
`thick dry coating, preferably one that is about 0.8 mil
`thick dry coating, preferably one that
`is about 0.8 mil
`
`10 or greater, to provide sufficient holding power for the
`10
`or greater,
`to provide sufficient holding power
`for the
`
`discrete masses of submerged particulate material. (cid:9)
`discrete masses of submerged particulate material .
`
`It
`It
`
`is preferable that the liquid resinous coating is still
`is preferable that
`the liquid resinous coating is still
`
`wet so as to promote the submergence and bonding of the
`wet so as to promote the submergence and bonding of
`the
`
`discrete masses but a baked coating which is not fully
`discrete masses but a baked coating which is not
`fully
`
`15 cured may serve when softened as a plastic medium for
`15
`cured may serve when softened as a plastic medium for
`
`the submergence of such particulate material. Thus, for
`the submergence of such particulate material. Thus,
`for
`
`the purposes of this invention, the term "liquid
`the
`purposes of
`this
`invention,
`the
`term "liquid
`
`resinous coating" is defined to include a coating which
`resinous coating"
`is defined to include a coating which
`
`is sufficiently plastic to be susceptible to penetration
`is sufficiently plastic to be susceptible to penetration
`
`20 by a particulate material under the conditions of this
`20
`by a particulate material under
`the conditions of
`this
`
`invention without otherwise fracturing the coating.
`invention without
`otherwise fracturing the
`coating.
`
`When the particulate material is a resin, it is suitable
`When the particulate material
`is a resin,
`it is suitable
`
`for the purposes of this invention to fuse the resin and
`for the purposes of this invention to fuse the resin and
`
`cause it to merge with the protective coating. In some
`cause it to merge with the protective coating.
`In some
`
`25 cases, such as when the particulate material is a
`25
`cases,
`such
`as when
`the particulate material
`is a
`
`thermosettable coating powder or an uncured
`thermosettable
`coating
`powder
`or
`an
`uncured
`
`thermosettable resin in some other form such as a chip,
`thermosettable resin in some other form such as a chip,
`
`concurrent curing of the liquid protective coating and
`concurrent curing of
`the liquid protective coating and
`
`the particulate material may take place. The curing
`the particulate material may
`take place.
`The curing
`
`8
`
`Petitioner - Owens Corning
`Ex. 1006, p. 9 of 24
`
`Petitioner - Owens Corning
`Ex. 1006, p. 9 of 24
`
`

`

`(cid:9) (cid:9)
`
`5
`5
`
`WO 00/71834 (cid:9)
`WO 00/71834
`
`PCT/US00/14487
`PCT/US00/14487
`
`temperature for the fluoropolymers is usually at a PMT
`temperature for the f luoropolymers is usually at a PMT
`
`in the range of 465-480°F (about 240-280°C). The
`in the
`range
`of
`465-480oF
`(about
`240-280oC) .
`The
`
`discrete masses of particulate material must, therefore,
`discrete masses of particulate material must,
`therefore,
`
`be able to withstand such high temperatures.
`be able to withstand such high temperatures.
`
`As used herein, the term " discrete masses" means
`As used herein,
`the term " discrete masses" means
`
`individual particles of material as well as masses of
`individual particles of material as well as masses of
`
`particles such as are used in powder gravure coating
`particles such as are used