Synthetic
nylon fiber composite materials having embossed or molded surfaces that emulate
shingles or roofing tiles are disclosed, for providing waterproof, high-strength, durable substitute for
shingles or roofing tiles. In one embodiment, these materials can be relatively thin, and designed to rest on supporting sheets of plywood,
oriented strand board (OSB), or
nylon fiber composite board that have been nailed to rafters. In an alternate embodiment, these materials can be manufactured in sheets with sufficient thickness, stiffness, and strength to allow them to be nailed directly to rafters, thereby eliminating the need for a supporting layer of plywood or OSB. In a third embodiment, these materials can be molded or embossed to emulate Spanish tiles, or to provide enhanced drainage or other useful traits. For improved
waterproofing, the lower edge of each segment can be provided with an overhang that will overlap the upper edge of an adjacent sheet on the next lower horizontal row, to provide overlapping material at each juncture between these composite segments. These materials also can be coated or embedded with chemicals that provide increased resistance to water, fire, and
ultraviolet damage. They provide excellent
thermal insulation, and can reduce heating and
air conditioning costs. A preferred manufacturing process uses needle-punched
fiber mats, and any combination of nylon-6 and nylon-6,6 fibers can be used.