Roofing products with carbon fiber substrate
A roofing material comprising a substrate constructed at least in part of a carbon fiber material and a weather-resistant or water-proof coating affixed or applied to the substrate. Aesthetic or reflective materials may be applied to the exposed portion of said roofing material. The substrate may include woven and/or nonwoven fibers. The substrate may comprise a single layer or two or more layers of carbon-fiber material laminated by one or more binding layer. In addition, the present roofing material may include a bonding agent or primer for promoting adhesion between one or more carbon fiber substrate layers and/or a carbon fiber substrate layer and the weather-resistant or water-proof coating.
1. A roofing material comprising:
a substrate comprising a carbon fiber material comprising at least one of woven or non-woven carbon fibers, the substrate having a top side and a bottom side;
a weather-proof or water-resistant coating applied or affixed to at least one of said top side or said bottom side of said substrate, said weather-proof or water-resistant coating comprising an asphalt or bituminous medium; and
wherein the substrate comprises a laminated construction, the laminated construction comprising at least a first layer of carbon fiber material and a second layer of carbon fiber material, and at least one binding layer disposed between said first and said second carbon fiber layers, wherein said binding layer comprises an asphalt or bituminous medium.
2. The roofing material of claim 1 , wherein the roofing material is a roofing shingle having a tab portion and a headlap portion, and the roofing material further comprises granules applied to said tab portion of said shingle.
3. The roofing material of claim 1 , wherein the roofing material is a roofing shingle, and the roofing material further comprises a reflective coating applied to the water resistant coating of said shingle.
4. The roofing material of claim 1 , wherein said carbon fiber material comprises only woven fibers.
5. The roofing material of claim 1 , wherein said carbon fiber material comprises only non-woven fibers.
6. The roofing material of claim 1 , wherein said carbon fiber material includes graphene, graphene laminates, or one or more honey-combed lattice of graphite molecules.
7. The roofing material of claim 1 , further comprising a bonding agent disposed between said substrate and said weather-proof or water-resistant coating.
8. The roofing material of claim 1 , wherein said weather-proof or water-resistant coating comprises a bonding agent.
9. The roofing material of claim 1 , wherein said carbon fiber material comprises one or more of polyacrylonitrile (PAN), pure carbon, carbon-fiberglass composites, or graphene material in the form of a honeycombed lattice of graphite molecules.
10. The roofing material of claim 1 , further comprising a film layer adhered to the asphalt coating on a head-lap portion of a first surface; and a layer of granules adhered to the asphalt coating on a tab portion of a first surface.
11. The roofing material of claim 1 , further comprising;
a top asphalt layer applied to the top side of the substrate;
a layer of granular material applied to the top asphalt layer opposite the substrate; and
a reinforcing layer adhered directly to the bottom side of the substrate.
12. An asphalt roofing shingle comprising:
a substrate comprising a carbon fiber material comprising at least one of woven or non-woven carbon fibers, the substrate having an exposed side and an unexposed side;
a flexible asphalt or bituminous coating applied to at least the exposed side of said substrate; and
wherein the substrate comprises a laminated construction, the laminated construction comprising multiple carbon fiber material layers and an asphalt-based binding layer between said carbon fiber layers, wherein the asphalt-based binding layer comprises one of (i) an asphalt-based bonding agent, or (ii) the flexible asphalt or bituminous coating.
13. An asphalt coated roofing shingle comprising:
a substrate comprising a carbon fiber material comprising at least one of woven or non-woven carbon fibers, the substrate having an exposed side and an unexposed side;
a flexible asphalt or bituminous coating applied to said substrate, wherein said substrate is impregnated with said flexible asphalt or bituminous coating; and
wherein the substrate comprises a laminated construction, the laminated construction comprising a plurality of carbon fiber material layers and an asphalt-based binding layer between each of said carbon fiber layers, wherein the asphalt-based binding layer comprises one of (i) an asphalt-based bonding agent, or (ii) the flexible asphalt or bituminous coating.