Siding system or roof shingle system comprising cementitious material, and systems and methods for manufacturing the same

Abstract

A board-type or log-shaped cementitious siding system, or a cementitious roof shingle system, having a reinforcement material contained therein, and an optional foam insert at least partially enveloped by a cementitious shell. Each system is molded from cementitious slurry, including gypsum cement and a latex/water mixture. A reinforcement material and an amount of the slurry are introduced into an open molding system or an alternative closed molding system, either molding system including a mold surface member having a face defining an exposed surface of the siding or roof shingle system. The slurry introduced to the mold surface member is to a desired depth and/or weight, or for a desired period of time. A foam insert is optionally introduced into the molding system. After sufficient curing, the siding or roof shingle system is separated from the mold surface member and is ready for immediate use and/or further processing. Alternatively, a system and method are provided for continually producing board-type cementitious siding systems and cementitious roof shingle systems that may be elongate and can be cut to an appropriate size, without the need to produce individual siding or roof shingle systems of limited size. The cementitious siding and roof shingle systems continually produced thereby are ready for immediate use and/or further processing.

1 . A siding system or roof shingle system configured to simulate, and intended to be a substitute for, traditional siding or roof shingles, respectively, said system comprising:
 at least one member of a plurality of members adapted for being mounted to a dwelling, said member comprising:
 a cementitious material defining a first surface exposed relative to a dwelling to which said plurality of members is adapted for being mounted, said first surface configured to simulate the appearance of at least one singular traditional siding element or roof shingle element; 
 a reinforcement material encapsulated by said cementitious material and proximately disposed beneath said first surface, said reinforcement material extending substantially over the area of said first surface; and 
 a second surface opposed to said first surface, said second surface defining a reverse surface that faces the dwelling surface to which said plurality of members is adapted for being mounted; 
   wherein said member first surface is configured to simulate the appearance of at least one singular traditional siding or roof shingle element.   
   
   
       2 . A siding system or roof shingle system according to  claim 1 , wherein said first surface is configured to simulate the appearance of a singular traditional siding or roof shingle element selected from the group consisting of: a wooden board, a wooden shake, a wooden shingle, a log, a slate roof tile, and an asphalt roof shingle. 
   
   
       3 . A siding system or roof shingle system according to  claim 1 , wherein each of said plurality of members is generally flat. 
   
   
       4 . A siding system or roof shingle system according to  claim 3 , wherein each of said plurality of members is elongate. 
   
   
       5 . A siding system or roof shingle system according to  claim 4 , wherein each of said plurality of members simulates the appearance of wooden board siding. 
   
   
       6 . A siding system or roof shingle system according to  claim 4 , wherein each of said plurality of members simulates the appearance of a plurality of adjacently positioned wooden shakes. 
   
   
       7 . A siding system or roof shingle system according to  claim 1 , wherein each of said plurality of members has a said first surface that is cylindrically curved and a said second surface that is substantially planar. 
   
   
       8 . A siding system or roof shingle system according to  claim 1 , wherein said member first surface has a three-dimensional pattern molded thereinto. 
   
   
       9 . A siding system or roof shingle system according to  claim 1 , wherein said member further comprises an optional foam core at least partially enveloped by said cementitious shell and disposed on the side of reinforcement material opposite said first surface. 
   
   
       10 . A siding system or roof shingle system according to  claim 9 , wherein said optional foam core defines at least a portion of said second surface. 
   
   
       11 . A siding system or roof shingle system according to  claim 9 , wherein said second surface is completely defined by said cementitious shell. 
   
   
       12 . A siding system or roof shingle system according to  claim 9 , wherein said optional foam core has a shape that is one of substantially planar and substantially semi-cylindrical. 
   
   
       13 . A siding system or roof shingle system according to  claim 9 , wherein said optional foam core has an aperture extending therethrough and defining a passage in which cementitious material is disposed. 
   
   
       14 . A siding system or roof shingle system according to  claim 1 , wherein said member first surface is exteriorly exposed relative to a dwelling to which said plurality of members is adapted for being mounted. 
   
   
       15 . A siding system or roof shingle system according to  claim 1 , wherein said system comprises a single said member. 
   
   
       16 . A siding system or roof shingle system according to  claim 1 , wherein said cementitious material comprises a mixture of gypsum cement and latex.