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.

1 . A panel comprising: 
 an upper portion; and    a lower portion, the lower portion extending from the upper portion;    wherein the upper portion and the lower portion are formed from a material comprising a natural plant fiber, and a synthetic polymeric material;    and further wherein the panel is suitable for use as a construction material that provides the appearance of a shingle, shake, or tile.    
   
   
       2 . The panel of  claim 1 , wherein the lower portion comprises a plurality of vertically extending members, wherein each of said vertically extending members is an appropriate size and shape to provide the appearance of the shingle, shake, or tile.  
   
   
       3 . The panel of  claim 2 , wherein the panel has two to seven vertically extending members.  
   
   
       4 . The panel of  claim 1 , wherein the lower portion of the panel further comprises a textured surface, and further wherein the textured surface replicates the appearance of a material selected from the group consisting of wood, clay, ceramic, slate, tile, and combinations thereof.  
   
   
       5 . The panel of  claim 1 , wherein the natural plant fiber is selected from the group consisting of wood flour, sugar cane bagasse, hemp, coconut coir, jute, kenaf, sisal, flax, coir pith, rice-hulls and cotton, and combinations thereof.  
   
   
       6 . The panel of  claim 1 , wherein the synthetic polymeric material is selected from the group consisting of polyethylene, polypropylene, and combinations thereof.  
   
   
       7 . The panel of  claim 6 , wherein the polyethylene is selected from the group consisting of low density polyethylene, high density polyethylene, linear low density polyethylene, and linear high density polyethylene.  
   
   
       8 . The panel of  claim 1 , wherein the material comprises from about 40 percent to about 75 percent natural plant fiber by weight.  
   
   
       9 . The panel of  claim 1 , wherein the material comprises from about 20 percent to about 60 percent synthetic polymeric material by weight.  
   
   
       10 . The panel of  claim 1 , wherein the material further comprises a pigment in the amount of up to about two percent of the material by weight.  
   
   
       11 . The panel of  claim 10 , wherein the pigment is an inorganic metal oxide.  
   
   
       12 . The panel of  claim 11 , wherein the pigment is selected from the group consisting of Fe 2 O 3 , Fe 3 O 4 , MnFe 2 O 4 , and ZnFe 2 O 4 .  
   
   
       13 . The panel of  claim 10 , wherein the pigment is in the amount from about 0.1 percent to about 1.5 percent of the material by weight.  
   
   
       14 . The panel of  claim 1 , wherein the material further comprises an ultra-violet stabilizer in the amount of up to about one percent of the material by weight.  
   
   
       15 . The panel of  claim 1 , wherein the material further comprises a fungicide in the amount of up to about five percent of the material by weight.  
   
   
       16 . The panel of  claim 1 , wherein the material further comprises a flame retardant material in the amount of up to about 20 percent of the material by weight.  
   
   
       17 . The panel of  claim 1 , wherein the material further comprises a coupling agent in the amount of up to about three percent of the material by weight.  
   
   
       18 . The panel of  claim 1 , wherein the material further comprises an inorganic filler in the amount of up to about ten percent of the material by weight.  
   
   
       19 . The panel of  claim 1 , wherein the material further comprises an antioxidant material in the amount of up to about 0.5 percent of the material by weight.  
   
   
       20 . The panel of  claim 1 , wherein the panel has an impact rating of class 3 or 4 under UL standard 2218.  
   
   
       21 . The panel of  claim 1 , wherein the panel has a class A, B, or C fire classification under UL standard 790.  
   
   
       22 . The panel of  claim 1 , wherein the panel is up to about six feet by four feet.  
   
   
       23 . A method of manufacturing a construction panel, the method comprising: 
 mixing a natural plant fiber and a synthetic polymeric material to form a homogenous material;    placing the homogenous material in an open mold in the shape of a construction panel; and    molding the homogenous mixture into a construction panel by compressing the homogenous mixture into the mold, wherein the construction panel is suitable for use as a construction material that provides the appearance of a shingle, shake, or tile.    
   
   
       24 . The method of  claim 23 , wherein said mold comprises a die for forming: 
 an upper portion; and    a lower portion, the lower portion extending from the upper portion.