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Composite roofing panel

a composite roofing and composite technology, applied in the field of composite roofing panels, can solve the problems of short life, weighing against the high source, production and installation cost of these materials, and reducing their usefulness and other attractive aspects, so as to achieve the effect of better imitating natural products

Inactive Publication Date: 2005-11-24
FELTON COLIN C
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  • Summary
  • Abstract
  • Description
  • Claims
  • Application Information

AI Technical Summary

Benefits of technology

The present invention provides a construction panel that looks like natural materials like tile, shingles, or slate. The panel is made of a polymer and a natural fiber like wood flour or sugar cane bagasse. The panel can be attached to surfaces using conventional tools like nail guns. The invention also provides a material composition for making the construction panel and a method for making it. The technical effect of the invention is that it provides a construction panel that looks natural and can be easily attached to surfaces.

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.

Method used

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Examples

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example 1

[0048] The present example provides a panel having Class A fire resistance according to UL standards. A construction panel consisting of: (a) 57% rice hulls 16 / 80 mesh; (b) 0.4% UV stabilizer available from Ciba Geigy as 783 FDL (a hindered amine); (c) 0.2% Heat stabilizer available from Ciba Geigy as B225; (d) 1% available from Bayer as bayferrox 645 T brown pigment; (e) 15% Aluminum hydroxide; (f) 2% maleic acid grafted polyethylene (MAPE)—available from Dupont as MB226; (g) 18.7 % recycled milk jug flakes (having a melt flow index of about 0.6); (h) 4.7% HDPE (having a melt flow index of about 35); and(i) 1% zinc borate available from U.S. Borax as firebrake ZB,was mixed together to form a homogenous composition. This composition was then placed into a mold and compression molded into a construction panel 43 inches wide, 21.5 inches tall and 0.75 inches thick at its butt end. The panel was comprised of 7 shakes (fingers) resembling hand-split cedar shakes with widths between 4 an...

example 2

[0049] This example provides a panel having Class C fire resistance according to UL standards. A construction panel consisting of: (a) 50% rice hulls 16 / 80 mesh; (b) 0.4% UV stabilizer available from Ciba Geigy as 783 FDL (hindered amine); (c) 0.2% Heat stabilizer available from Ciba Geigy as B225; (d) 1% available from Bayer as bayferrox 645 T brown pigment; (e) 2% maleic acid grafted polyethylene (MAPE) available from Dupont as MB226; (f) 36.3 % recycled milk jug flakes (having a melt flow index of about 0.6); (g) 9.1% HDPE (having a melt flow index of about 35); and (h) 1% zinc borate available from U.S. Borax as firebrake ZB, was mixed together to form a homogenous composition. This composition was then placed into a mold and compression molded into a construction panel 43 inches wide, 21.5 inches tall and 0.75 inches thick at its butt end. The panel was comprised of 7 shakes (fingers) resembling hand-split cedar shakes with widths between 4 and 8 inches. The construction panel ...

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PUM

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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...

Claims

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Application Information

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Patent Type & Authority Applications(United States)
IPC IPC(8): E04D1/26E04D13/00
CPCE04D13/002E04D1/265
Inventor FELTON, COLIN C.
Owner FELTON COLIN C
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