Composite Material Roofing Structure

Abstract

The present invention is a composition for making high quality, mold resistant, water proof building products. The composition from which these products are formed is a mixture of various polyethylene or polypropylene materials, in conjunction with fillers which may comprise recycled rubber products such as ethylene propylene-diene monomers, and styrene butadiene rubber, or mineral fillers to achieve a different feel and texture to the formulation without compromising the integrity of the product. This is achieved by altering the melt and amount of the high and/or low density polyethylene or polypropylene in the mix to end up with the correct material integrity. Colorants may be additionally be added to the mixture prior to final molding. This composition allows for products to be made that resemble traditional building products, but with a higher performance level that are also recyclable in their entirety.

1 . A building product comprising a composition of:
 a) between about 10-60% by weight of a filler;   b) about 10-40% by weight a binder;   c) about 0-40% by weight fire retardant; and   d) about 5-80% by weight of a polymeric resin.   
   
   
       2 . The building product of  claim 1  wherein the polymeric resin comprises low density polyethylene and high density polyethylene in an amount of between about 5-50% by weight. 
   
   
       3 . The building component of  claim 1  wherein the polymeric resin comprises high density polyethylene in an amount of about 20% by weight, and low density polyethylene in an amount of about 10% by weight 
   
   
       4 . The building product of  claim 1  wherein the polymeric resin comprises polypropylene present in an amount of up to about 75% by weight 
   
   
       5 . The building product of  claim 1  wherein the filler comprises recycled vulcanized rubber. 
   
   
       6 . The building product of  claim 5  wherein the filler comprises a combination of ethylene propylene-diene monomers and scrap from styrene butadiene rubber products in an amount of up to about 50% by weight. 
   
   
       7 . The building product of  claim 1  wherein the filler comprises a mineral filler. 
   
   
       8 . The building product of  claim 1  wherein the binder comprises ethylene vinyl acetate in an amount of between about 10-40% by weight. 
   
   
       9 . The building product of  claim 1  wherein the binder comprises ultra low density polyethylene in an amount of between about 10-40% by weight. 
   
   
       10 . The building product of  claim 1  further comprising about 0.1-8% by weight of an antioxidant. 
   
   
       11 . The building product of  claim 1  further comprising about 0.1-8% by weight of an U.V. inhibitor 
   
   
       12 . The building product of  claim 1  further comprising about 0.1-8% by weight of an U.V. stabilizer. 
   
   
       13 . The building product of  claim 1  wherein the product is selected from the group consisting of: roofing tiles, roofing sheathing, siding materials, hand rails, deck panels, pallets, pavers, and decorative construction accessories. 
   
   
       14 . The building component of  claim 1  further comprising a colorant. 
   
   
       15 . The building component of  claim 1  wherein the entire building component is recyclable. 
   
   
       16 . The building component of  claim 1  wherein the entire composition is formed of recycled components. 
   
   
       17 . A building product comprising a composition of:
 a) polypropylene in an amount of up to about 75% by weight of the composition;   b) calcium carbonate in an amount of between about 10-50% by weight;   c) a fire retardant present in an amount of between about 20-50% by weight;   d) a binder system present in an amount of between about 1-20% by weight;   e) a U.V. stabilizer present in an amount of between about 0.1-8% by weight; and   f) a U.V. inhibitor present in an amount of between about 0.1-8% by weight.   
   
   
       18 . A building component comprising a composition of:
 a) a fire retardant in an amount of 45% by weight of the overall composition;   b) a binder in an amount of 25% by weight;   c) a high density polyethylene in an amount of about 20% by weight; and   d) a low density polyethylene in an amount of about 10% by weight.   
   
   
       19 . The building component of  claim 18  wherein the binder comprises a combination of ethylene vinyl acetate and ultra low density polyethylene. 
   
   
       20 . The building component of  claim 18  further comprising a colorant.