Solar heat reflective roofing membrane and process for making the same

• US 10,245,816 B2
• Filed: 05/06/2015
• Issued: 04/02/2019
• Est. Priority Date: 09/07/2005
• Status: Active Grant

• Current Assignee: Certainteed, LLC (Compagnie de Saint-Gobain SA)
• Original Assignee: CertainTeed Corp. (Compagnie De Saint-Gobain)
• Inventors: Kalkanoglu, Husnu M., Shiao, Ming Liang, Jacobs, Gregory F.
• Primary Examiner(s): Zhao, Xiao S
• Application Number:
  US14/705,403
• Publication Number:
  US 20150266280A1
• Time in Patent Office: 1,427 Days
• CPC Class Codes: B32B 11/10 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 2255/02 on fibrous or filamentary layer
• CPC Class Codes: B32B 2255/26 Polymeric coating
• CPC Class Codes: B32B 2260/021 Fibrous or filamentary layer
• CPC Class Codes: B32B 2260/046 Synthetic resin
• CPC Class Codes: B32B 2262/02 Synthetic macromolecular fibres
• CPC Class Codes: B32B 2262/101 Glass fibres
• CPC Class Codes: B32B 2264/102 Oxide or hydroxide
• CPC Class Codes: B32B 2307/304 Insulating
• CPC Class Codes: B32B 2307/416 Reflective
• CPC Class Codes: B32B 2307/552 Fatigue strength
• CPC Class Codes: B32B 2307/554 Wear resistance
• CPC Class Codes: B32B 2307/712 Weather resistant
• CPC Class Codes: B32B 2419/06 Roofs, roof membranes
• CPC Class Codes: B32B 25/10 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 25/20 comprising silicone rubber
• CPC Class Codes: B32B 27/00 Layered products comprising a layer of synthetic resin fibrous or filamentary layer made of a synthetic resin B32B5/02; particulate layer made of a synthetic resin B32B5/16; foamed layer made of a synthetic resin B32B5/18
• CPC Class Codes: B32B 27/12 next to a fibrous or filamentary layer
• CPC Class Codes: B32B 27/304 comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
• CPC Class Codes: B32B 27/308 comprising acrylic (co)polymers
• CPC Class Codes: B32B 37/04 : characterised by the partial melting of at least one layer
• CPC Class Codes: B32B 5/022 : Non-woven fabric
• CPC Class Codes: E04D 5/08 : by making use of other materials
• CPC Class Codes: Y02A 30/254 : Roof garden systems; Roof coverings with high solar reflectance
• CPC Class Codes: Y02B 80/00 : Architectural or constructional elements improving the thermal performance of buildings
• CPC Class Codes: Y10T 428/31511 : Of epoxy ether
• CPC Class Codes: Y10T 428/3154 : Of fluorinated addition polymer from unsaturated monomers
• CPC Class Codes: Y10T 428/31725 : Of polyamide
• CPC Class Codes: Y10T 428/31786 : Of polyester [e.g., alkyd, etc.]
• CPC Class Codes: Y10T 428/31815 : Of bituminous or tarry residue
• CPC Class Codes: Y10T 428/31935 : Ester, halide or nitrile of addition polymer
• CPC Class Codes: Y10T 428/31938 : Polymer of monoethylenically unsaturated hydrocarbon

Abstract

A roofing membrane with high solar heat reflectance includes a bituminous base sheet, a tie-layer with a reinforcement material, and a solar heat-reflective upper layer.

Claims

1. A process for preparing a roofing membrane with solar heat-reflectance, the process comprising:

laminating a tie-layer to a bituminous base sheet to form an intermediate sheet, the bituminous base sheet comprising a continuous substrate sheet of fibrous material, the continuous substrate sheet being saturated with a bituminous material and coated on at least one side with a bituminous material;

depositing a solar heat-reflective polymeric coating composition directly on the intermediate sheet;

curing the solar heat-reflective polymeric coating composition to form a solar heat-reflective coating; and

depositing an upper coating composition directly on the solar heat-reflective coating to form an upper coating layer;

wherein the tie-layer is laminated to the bituminous base sheet by heating the surface of the base sheet to above the softening temperature of the bituminous material, and adhering the tie-layer to the base sheet by contacting the base sheet with the tie-layer and permitting the bituminous material to partially saturate the tie-layer.

2. A process according to claim 1 wherein the solar heat-reflective polymeric coating composition is deposited by curtain coating.

3. A process according to claim 1 wherein the solar heat-reflective polymeric coating composition is deposited by electrostatic spray coating.

4. A process according to claim 1 wherein the upper coating composition is formulated to provide exterior durability.

5. A process according to claim 4 wherein the upper coating composition comprises at least one of a fluoropolymer, a UV-curable coating, an acrylic latex based coating, or a silicone emulsion.

6. A process according to claim 1 wherein the tie-layer is formed from a reinforcement material.

7. A process according to claim 6 wherein the reinforcement material is selected from the group consisting of non-woven glass fiber mats, non-woven polyester mats, composite non-woven mats of various fibers, composite woven fabrics of various fibers, industrial fabrics such as papermaker'"'"'s forming fabrics and papermaker'"'"'s canvasses, polymer netting, screen, and mineral particles.

8. A process according to claim 1 wherein the tie-layer has a thickness of from about 0.001 cm to about 0.1 cm.

9. A process for preparing a roofing membrane with solar heat-reflectance, the process comprising:

depositing a solar heat-reflective polymeric coating composition directly on a tie-layer to form an intermediate sheet;

curing the solar heat-reflective polymeric coating composition to form a solar heat-reflective coating on top of the tie-layer;

laminating the tie-layer of the intermediate sheet directly to a bituminous base sheet, the bituminous base sheet comprising a continuous substrate sheet of fibrous material, the continuous substrate sheet being saturated with a bituminous material and coated on at least one side with a bituminous material; and

depositing an upper polymeric coating composition directly on the solar heat-reflective coating to form an upper coating layer;

wherein the tie-layer is laminated to the bituminous base sheet by heating the surface of the base sheet to above the softening temperature of the bituminous material, and adhering the tie-layer to the base sheet by contacting the base sheet with the tie-layer and permitting the bituminous material to partially saturate the tie-layer.

10. A process according to claim 9 wherein the solar heat-reflective polymeric coating composition is deposited by curtain coating.

11. A process according to claim 9 wherein the upper polymeric coating composition is deposited by curtain coating.

12. A process according to claim 9 wherein the solar heat-reflective polymeric coating composition is deposited by electrostatic spray coating.

13. A process according to claim 9 wherein the upper polymeric coating comprises at least one of a fluoropolymer, a UV-curable coating, an acrylic latex based coating, or a silicone emulsion.

14. A process according to claim 9 wherein the tie-layer is formed from a reinforcement material selected from the group consisting of non-woven glass fiber mats, non-woven polyester mats, composite non-woven mats of various fibers, composite woven fabrics of various fibers, industrial fabrics such as papermaker'"'"'s forming fabrics and papermaker'"'"'s canvasses, polymer netting, screen, and mineral particles.

15. A process according to claim 9 wherein the tie-layer has a thickness of from about 0.001 cm to about 0.1 cm.

16. A method of constructing a roof having solar heat reflectance, the method comprising adhering to a roofing deck a roofing membrane with solar heat reflectance, the roofing membrane comprising:

a bituminous base sheet comprising a continuous substrate sheet of fibrous material, the continuous substrate sheet being saturated with a bituminous material and coated on at least one side with a bituminous material;

a tie-layer comprising a reinforcement material laminated directly to the bituminous base sheet;

a solar heat-reflective layer deposited directly onto the tie-layer; and

a protective top coating deposited directly onto the solar heat-reflective layer;

wherein the tie-layer is laminated to the bituminous base sheet by heating the surface of the base sheet to above the softening temperature of the bituminous material, and adhering the tie-layer to the base sheet by contacting the base sheet with the tie-layer and permitting the bituminous material to partially saturate the tie-layer.

17. A process according to claim 16 wherein the solar-heat reflective layer is deposited by spray coating.

18. A process according to claim 16 wherein the solar-heat reflective layer is deposited by electrostatic spray coating.

19. A process according to claim 16 wherein the protective top coating comprises at least one of a fluoropolymer, a UV-curable coating, an acrylic latex based coating, or a silicone emulsion.

20. A process according to claim 16 wherein the tie-layer is formed from a reinforcement material selected from the group consisting of non-woven glass fiber mats, non-woven polyester mats, composite non-woven mats of various fibers, composite woven fabrics of various fibers, industrial fabrics such as papermaker'"'"'s forming fabrics and papermaker'"'"'s canvasses, polymer netting, screen, and mineral particles.