Coating compositions for roofing granules, dark colored roofing granules with increased solar heat reflectance, solar heat-reflective shingles and process for producing the same

• US 10,214,449 B2
• Filed: 11/30/2015
• Issued: 02/26/2019
• Est. Priority Date: 03/31/2008
• Status: Active Grant

• Current Assignee: Certainteed, LLC (Compagnie de Saint-Gobain SA)
• Original Assignee: CertainTeed Corp. (Compagnie De Saint-Gobain)
• Inventors: Kalkanoglu, Husnu M., McShea, Thomas, Shiao, Ming Liang
• Primary Examiner(s): Le, Hoa (Holly)
• Application Number:
  US14/954,377
• Publication Number:
  US 20160107929A1
• Time in Patent Office: 1,184 Days
• Field of Search: 428403, 428323, 428330, 428409
• CPC Class Codes: C04B 12/04 Alkali metal or ammonium silicate cements ; Alkyl silicate cements; Silica sol cements; Soluble silicate cements alkali metal silicates per se, their preparation C01B33/32; ammonium silicates per se, their preparation C01C1/00
• CPC Class Codes: C04B 14/042 Magnesium silicates, e.g. talc, sepiolite
• CPC Class Codes: C04B 14/045 Alkali-metal containing silicates, e.g. petalite waterglass C04B12/04
• CPC Class Codes: C04B 14/048 Granite
• CPC Class Codes: C04B 14/06 Quartz; Sand
• CPC Class Codes: C04B 14/062 Microsilica, e.g. colloïdal silica preparing microsilica slurries or suspensions C04B18/148
• CPC Class Codes: C04B 14/10 Clay sepiolite C04B14/042; grog C04B18/025
• CPC Class Codes: C04B 14/20 Mica; Vermiculite mechanical splitting B28D
• CPC Class Codes: C04B 14/285 Marble
• CPC Class Codes: C04B 14/303 Alumina
• CPC Class Codes: C04B 14/305 Titanium oxide, e.g. titanates
• CPC Class Codes: C04B 14/308 Iron oxide
• CPC Class Codes: C04B 14/309 Copper oxide or solid solutions thereof
• CPC Class Codes: C04B 14/34 Metals , e.g. ferro-silicon
• CPC Class Codes: C04B 18/141 Slags
• CPC Class Codes: C04B 18/16 from building or ceramic industry
• CPC Class Codes: C04B 20/0076 characterised by the grain distribution
• CPC Class Codes: C04B 20/008 Micro- or nanosized fillers, e.g. micronised fillers with particle size smaller than that of the hydraulic binder colloidal silica C04B14/062 ; silica fume C04B18/146
• CPC Class Codes: C04B 20/1059 Pigments or precursors thereof
• CPC Class Codes: C04B 20/1062 Metals
• CPC Class Codes: C04B 20/107 : Acids or salts thereof
• CPC Class Codes: C04B 20/1085 : Waterglass
• CPC Class Codes: C04B 2103/54 : Pigments; Dyes
• CPC Class Codes: C04B 2111/00586 : Roofing materials
• CPC Class Codes: C04B 2111/80 : Optical properties, e.g. transparency or reflexibility
• CPC Class Codes: C04B 22/126 : Fluorine compounds, e.g. silico-fluorine compounds
• CPC Class Codes: C04B 28/04 : Portland cements
• CPC Class Codes: C04B 28/26 : Silicates of the alkali metals
• CPC Class Codes: C04B 41/5018 : with fluorine compounds
• CPC Class Codes: C04B 41/5024 : Silicates C04B41/5022 takes precedence; silico-fluorides C04B41/5018
• CPC Class Codes: C04B 41/524 : Multiple coatings, comprising a coating layer of the same material as a previous coating layer
• CPC Class Codes: C04B 7/02 : Portland cement
• CPC Class Codes: C09D 1/00 : Coating compositions, e.g. paints, varnishes or lacquers, based on inorganic substances
• CPC Class Codes: E04D 7/005 : characterised by loose or embedded gravel or granules as an outer protection of the roof covering
• CPC Class Codes: Y02W 30/91 : Use of waste materials as fillers for mortars or concrete
• CPC Class Codes: Y10T 428/24372 : Particulate matter
• CPC Class Codes: Y10T 428/24413 : Metal or metal compound
• CPC Class Codes: Y10T 428/24421 : Silicon containing
• CPC Class Codes: Y10T 428/252 : Glass or ceramic [i.e., fired or glazed clay, cement, etc.] [porcelain, quartz, etc.]
• CPC Class Codes: Y10T 428/259 : Silicic material
• CPC Class Codes: Y10T 428/2991 : Coated
• CPC Class Codes: Y10T 428/2993 : Silicic or refractory material containing [e.g., tungsten oxide, glass, cement, etc.]
• CPC Class Codes: Y10T 428/2995 : Silane, siloxane or silicone coating
• CPC Class Codes: Y10T 428/31 : Surface property or characteristic of web, sheet or block

Abstract

Dark colored roofing granules include an inert base particle coated with a composition including a metal silicate, a non-clay latent heat reactant, and a dark colored but solar reflective pigment.

Claims

1. A plurality of dark-colored roofing granules, each of the dark-colored roofing granules comprising:

an inert base particle; and

a cured coating disposed about the inert base particle, the cured coating being a reaction product of a coating composition comprising;

an alkali metal silicate;

at least one non-clay latent heat reactant; and

at least one inorganic solar heat-reflective pigment, each of the at least one inorganic solar heat-reflective pigments having an L* less than 30 and a solar reflectance greater than 20 percent, and wherein the coating composition comprises at least about 5 percent to 25 percent of the at least one solar heat-reflective pigment,

wherein

the plurality of dark-colored roofing granules has an L* less than 30 and a solar reflectance greater than 20, and

wherein each of the dark-colored roofing granules lacks a light-colored base coat disposed between the inert base particle and the cured coating.

2. A plurality of dark-colored roofing granules according to claim 1, wherein in the coating composition the at least one non-clay latent heat reactant is selected from the group consisting of Portland cement, aluminum fluoride, ammonium silicofluoride, alkali metal silicofluorides, and alkaline earth metal silicofluorides.

3. A plurality of dark-colored roofing granules according to claim 1, wherein in the coating composition the at least one non-clay latent heat reactant comprises Portland cement, aluminum fluoride and at least one alkali metal silicofluoride.

4. A plurality of dark-colored roofing granules according to claim 3, wherein in the coating composition the at least one alkali metal silicofluoride is sodium silicofluoride.

5. A plurality of dark-colored roofing granules according to claim 3, wherein in the coating composition wherein the at least one non-clay latent heat reactant comprise from about 3 to 15 weight percent of the coating composition of aluminum fluoride, from about 0.5 to 5 weight percent of the coating composition of sodium silicofluoride, and from about 0.5 to 5 weight percent of the coating composition of Portland cement.

6. A plurality of dark-colored roofing granules according to claim 1, wherein in the coating composition wherein the at least one inorganic solar heat-reflective pigment is selected from the group consisting of Arctic Black 10C909 (chromium green-black), Black 411 (chromium iron oxide), Brown 12 (zinc iron chromite), Brown 8 (iron titanium brown spinel), and Yellow 193 (chrome antimony titanium), 56, Eclipse Black 10201, Forest Green 10241, Eclipse Black 10202, Eclipse Black 10203, and H IR Green V-12650.

7. A plurality of dark-colored roofing granules of claim 1 wherein in each of the dark-colored roofing granules the cured coating comprises a first layer including a first metal silicate binder and a first inorganic solar heat-reflective pigment and a second layer including a second metal silicate binder and a second inorganic solar heat-reflective pigment.

8. A plurality of dark-colored roofing granules of claim 7 wherein in each of the dark-colored roofing granules the second inorganic solar heat-reflective pigment is identical to the first inorganic solar heat-reflective pigment.

9. A plurality of dark-colored roofing granules of claim 8 wherein in each of the dark-colored roofing granules the first and second inorganic solar heat-reflective pigments are selected from the group consisting of Arctic Black 10C909 (chromium green-black), Black 411 (chromium iron oxide), Brown 12 (zinc iron chromite), Brown 8 (iron titanium brown spinel), and Yellow 193 (chrome antimony titanium), Brown 10364, Eclipse Black 10201, Forest Green 10241, Eclipse Black 10202, Eclipse Black 10203, and H IR Green V-12650.

10. A plurality of dark-colored roofing granules of claim 8 wherein in each of the dark-colored roofing granules the first coating layer comprises at least about 30 percent to about 40 percent of the first inorganic solar heat-reflective pigment, and wherein the second coating layer comprises at least about 30 percent to about 40 percent of the second inorganic solar heat-reflective pigment.

11. A plurality of dark-colored roofing granules of claim 7 wherein in each of the dark-colored roofing granules the first and second coating layers form from about 4 percent by weight of the inert base particle to about 10 percent by weight of the inert base particle.

12. A plurality of dark-colored roofing granules of claim 7 wherein each of the dark-colored roofing granules further comprises a third coating layer, the third coating layer being identical to the second coating layer and the first coating layer.

13. A plurality of dark-colored roofing granules of claim 7 wherein in each of the dark-colored roofing granules the second inorganic solar heat-reflective pigment is different from the first inorganic solar heat-reflective pigment.

14. A plurality of dark-colored roofing granules of claim 13 wherein in each of the dark-colored roofing granules the first inorganic solar heat-reflective pigment is selected from the group consisting of Arctic Black 10C909 (chromium green-black), Black 411 (chromium iron oxide), Brown 12 (zinc iron chromite), Brown 8 (iron titanium brown spinel), and Yellow 193 (chrome antimony titanium), Brown 10364, Eclipse Black 10201, Forest Green 10241, Eclipse Black 10202, Eclipse Black 10203, and H IR Green V-12650.

15. A plurality of dark-colored roofing granules of claim 13 wherein in each of the dark-colored roofing granules the second inorganic solar heat -reflective pigment is selected from the group consisting of Arctic Black 10C909 (chromium green-black), Black 411 (chromium iron oxide), Brown 12 (zinc iron chromite), Brown 8 (iron titanium brown spinel), and Yellow 193 (chrome antimony titanium), Brown 10364, Eclipse Black 10201, Forest Green 10241, Eclipse Black 10202, Eclipse Black 10203, and H IR Green V-12650.

16. A plurality of dark-colored roofing granules of claim 13 wherein in each of the dark-colored roofing granules the second layer further comprises an inorganic solar-reflective functional pigment.

17. A plurality of dark-colored roofing granules of claim 16 wherein in each of the dark-colored roofing granules the solar-reflective functional pigment is selected from the group consisting of mirrorized silica flakes, metal flake pigments, and metal oxide coated flake pigments.

18. A plurality of dark-colored roofing granules of claim 16 wherein in each of the dark-colored roofing granules the second coating layer comprises at least about 1 percent to about 60 percent of the solar-reflective functional pigment.

19. A plurality of dark-colored roofing granules of claim 16 wherein in each of the dark-colored roofing granules the second coating layer comprises at least about 1 percent to about 60 percent of the second solar heat-reflective pigment.

20. A plurality of dark-colored roofing granules of claim 1, wherein in each of the dark-colored roofing granules the inert base particle is an inert mineral particle and the cured coating is disposed directly on the inert mineral particle.

21. A plurality of dark-colored roofing granules of claim 1, wherein in each of the dark-colored roofing granules the coating composition further includes aluminum oxide having a particle size in the range of 0.1 to 5 micrometers.

22. A plurality of dark-colored roofing granules of claim 1, wherein in each of the dark-colored roofing granules the coating composition is free of kaolin clay.

23. A plurality of dark-colored roofing granules of claim 1, wherein in each of the dark-colored roofing granules the at least one inorganic solar heat-reflective pigment is a metal oxide pigment.

24. A plurality of dark-colored roofing granules of claim 1, wherein in each of the dark-colored roofing granules the at least one inorganic pigment is the only pigment in the coating composition.

25. A plurality of dark-colored roofing granules of claim 1, wherein in each of the dark-colored roofing granules the inorganic solar heat-reflective pigments does not comprise a white pigment coated with a near infrared-absorbing colorant.

26. An asphalt shingle having a surface coated with the plurality of dark-colored roofing granules of claim 1, the shingle having an L* less than 55 and a solar reflectance of greater than 20 percent.

27. An asphalt shingle having a surface coated with the plurality of dark-colored roofing granules of claim 1, the shingle having an L* less than 30 and a solar reflectance of greater than 20 percent.