Composite roofing panel

Abstract

The present invention provides a composite panel for use in construction, and particularly for shingling, which comprises natural fiber and a polymer. Due to its composition and layout the construction panel provides all of the advantages of natural materials and high end roofing materials, particularly an attractive appearance, while at the same time allowing for ease of installation, little or no maintenance requirements, and providing superior impact and fire resistance when compared to other roofing materials. The construction panels can also be installed using conventional equipment and methods similar to the installation of 3-tab asphalt shingles with little or no learning curve.

Description

CLAIM OF PRIORITY [0001] This application is a continuation of U.S. patent application Ser. No. 09 / 966,423 filed Sep. 28, 2001, which claims priority from U.S. Provisional Patent Application No. 60 / 236,528, filed Sep. 29, 2000.TECHNICAL FIELD [0002] The present invention relates to construction panels, compositions and methods for making construction panels. More particularly, the present invention relates to construction panels made of natural fibers and polymers and which look like natural and ceramic roof surfacing materials. BACKGROUND [0003] Natural wood shingles, shakes and ceramic or clay tiles have been used for years to provide roofing and other construction materials. Their pleasing appearance however has to be weighed against the high source, production and installation costs of these materials. In addition, the propensity of wood shakes and shingles or ceramic or clay tiles to deteriorate results in a short lifetime and diminishes their usefulness and other attractive as...

AI Technical Summary

Benefits of technology

[0011] In one embodiment, the present invention provides a construction panel which comprises an upper portion and a lower portion. The lower portion of the construction panel is characterized by having the appearance of multiple vertically extending members, such as fingers, divided by gaps. The vertically extending members extend from the upper portion of the panel and are of the appropriate size and shape to imitate the appearance of tile, naturally occurring shingles or shakes, or slate. The construction panel itself is made up of at least a polymeric material, for example polyethylene or polypropylene, and a natural fiber, such as wood flour, sugar cane bagasse, hemp, coconut coir, jute, kenaf, sisal, flax, coir pith, rice-hulls, cotton, and combinations thereof. The appearance of the fingers and gaps of the present construction panel can be of varying or non-uniform widths, lengths, or both to give the desired aesthetic appearance sought for the construction panel. The fingers of the construction panel according to the present invention can further have a textured surface exposed to the elements and non-uniform lengths and angled lower edges to better imitate natural products. Materials other than wood can also be imitated by the panels of the present invention including clay, slate, ceramic tile or combinations thereof. The construction panels of the present invention are well suited for attachment to surfaces using conventional tools including nail guns.

Problems solved by technology

Their pleasing appearance however has to be weighed against the high source, production and installation costs of these materials.

In addition, the propensity of wood shakes and shingles or ceramic or clay tiles to deteriorate results in a short lifetime and diminishes their usefulness and other attractive aspects.

In fact, due to harsh environmental conditions in different climates, such as wildfires, hail and extreme temperature changes, many construction materials have been found to be completely unworkable or deemed unacceptable because the products do not meet even the minimum safety standards required by law.

However, the substantially planar appearance and artificial look of these materials has made them considerably less pleasing to the eye than natural materials.

Additionally these materials have useful lifetimes which are much shorter than the structure which they are designed to protect and are made of environmentally unfriendly materials that are not easily amenable to being disposed of or recycled.

Although these products reportedly have long lifetimes and increased environmental friendliness, often these products are expensive to produce and are only capable of imitating the appearance of one type of natural product, either wood or slate, but not both wood and slate.

Many types of recycled shingling products require complex installation procedures that can only be performed with special equipment by trained personnel.

Additionally, the cost for recycled materials is rising at a rapid pace due to the demand for their use in ‘green’ products, thus limiting the potential cost benefits of using recycled materials.

None of the prior art examples have solved all the existing needs of the shingling industry.

Nor do any of the shingles made of recycled materials permit easy installation using commonly available tools standard in the roofing industry.

Quick installation and a minimum of panel tooling costs will impact considerably on the cost of manufacturing and installing the panel.

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