SURFACING MEDIA WITH FLAME RETARDING EFFECTS AND HIGH SOLAR REFLECTANCE, AND METHOD OF MAKING SAME

• US 20080248242A1
• Filed: 03/31/2008
• Published: 10/09/2008
• Est. Priority Date: 04/03/2007
• Status: Abandoned Application

• Current Assignee: CertainTeed Corp. (Compagnie De Saint-Gobain)
• Original Assignee: CertainTeed Corp. (Compagnie De Saint-Gobain)
• Inventors: Jacobs, Gregory F., Shiao, Ming Liang, McDonough, Barbara A.
• Application Number:
  US12/059,194
• Publication Number:
  US 20080248242A1
• Time in Patent Office: Days
• US Class Current: 428/141
• CPC Class Codes: B05D 2601/00 Inorganic fillers
• CPC Class Codes: B05D 5/00 Processes for applying liquids or other fluent materials to surfaces to obtain special surface effects, finishes or structures
• CPC Class Codes: B05D 5/02 to obtain a matt or rough surface
• CPC Class Codes: B05D 7/52 Two layers
• CPC Class Codes: E04D 1/20 of plastics; of asphalt; of fibrous materials
• CPC Class Codes: E04D 11/02 Build-up roofs, i.e. consisting of two or more layers bonded together in situ, at least one of the layers being of watertight composition gravelling of flat roofs E04D7/00; venting or ventilation E04D13/17
• CPC Class Codes: E04D 2001/005 the roofing elements having a granulated surface
• CPC Class Codes: E04D 5/10 by making use of compounded or laminated materials, e.g. metal foils or plastic films coated with bitumen
• CPC Class Codes: E04D 5/12 specially modified, e.g. perforated, with granulated surface, with attached pads
• 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 428/24355 Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
• CPC Class Codes: Y10T 428/2989 Microcapsule with solid core [includes liposome]

Abstract

A roofing material includes a fire-retardant particulate material on its upper surface. A solar-reflective surface coating encapsules the fire-retardant particulate.

Claims

1. A solar-reflective, fire-retardant roofing material comprising:

(a) a base material having an upper surface;

(b) a fire-retardant particulate material applied to the upper surface of the base material; and

(c) a solar-reflective surface coating, the solar reflective surface coating at least partially encapsulating the fire-retardant particulate material.

2. A roofing material according to claim 1 wherein the fire-retardant particulate material is partially embedded in and partially protruding from the solar reflective surface coating.

3. A roofing material according to claim 1 wherein the fire-retardant particulate material is fully encapsulated in the solar reflective surface coating.

4. A roofing material according to claim 1 wherein the fire-retardant material is selected from the group consisting of hydrated metal silicates, alumina hydrates, antimony-containing compounds, phosphorous-containing compounds, and halogenated compounds.

5. A roofing material according to claim 1 wherein the solar reflective coating is formed from a solar-reflective coating composition including at least one solar-reflective pigment.

7. A roofing material according to claim 5 wherein the solar reflective coating composition comprises at least one binder material selected from the group consisting of metal silicate compositions, silicas, phosphates, and polymeric binder compositions.

6. (canceled)

8. (canceled)

9. A method of making solar-reflective, fire-retardant roofing materials, the method comprising:

(a) providing a base material having an upper surface;

(b) applying a solar-reflective surface coating composition to the upper surface of the base material;

(c) depositing a fire-retardant particulate material on the upper surface of the base material in the solar-reflective surface coating composition; and

(d) curing the solar-reflective surface coating composition to at least partially encapsulate the fire-retardant particulate material.

10. A method according to claim 9 wherein the fire-retardant material is selected from the group consisting of hydrated metal silicates, alumina hydrates, antimony-containing compounds, phosphorous-containing compounds, and halogenated compounds.

11. A method according to claim 9 wherein the solar-reflective coating composition includes at least one solar-reflective pigment.

13. A method according to claim 9 wherein the solar reflective coating composition comprises at least one binder material selected from the group consisting of metal silicate compositions, silicas phosphates, and polymeric binder compositions.

12. (canceled)

14. (canceled)

15. A method of making solar-reflective, fire-retardant roofing materials, the method comprising:

(a) providing a fire-retardant particulate material;

(b) applying a solar-reflective surface coating composition to fire-retardant particulate material;

(c) curing the solar-reflective surface coating composition to at least partially encapsulate the fire-retardant particulate material with a solar-reflective surface coating; and

(d) depositing the encapsulated fire-retardant particulate material on the upper surface of the base material.

16. A method according to claim 15 wherein the fire-retardant material is selected from the group consisting of hydrated metal silicates, alumina hydrates, antimony-containing compounds, phosphorous-containing compounds, and halogenated compounds.

17. A method according to claim 16 wherein the solar reflective coating is formed from a solar-reflective coating composition including at least one solar-reflective pigment.

19. A method according to claim 15 wherein the solar reflective coating composition comprises at least one binder material selected from the group consisting of metal silicate compositions, silicas phosphates, and polymeric binder compositions.

18. (canceled)

20. (canceled)

21. A method of coating a substrate surface, the method comprising:

(a) providing a substrate surface;

(b) applying a liquid surface coating composition to the substrate surface;

(c) depositing a fire-retardant particulate material on an upper surface of the liquid surface coating;

(d) at least partially encapsulating the fire-retardant particulate material; and

(e) causing the liquid surface coating to cure to a solid state;

whereby a tack-free time of a thusly coated substrate surface is shorter than the tack-free time of a coated substrate surface cured without the fire-retardant particulate material deposited thereon.

22. A method according to claim 21 wherein the substrate surface comprises a roofing material.

23. A method according to claim 21 wherein the liquid surface coating composition is a solar-reflective coating composition in a cured state.

24. A method according to claim 23 wherein the solar reflective coating composition includes at least one solar-reflective pigment.

25. A method according to claim 21 wherein the fire-retardant particulate material is selected from the group consisting of intumescent and non-intumescent fire-retardant materials.

26. A granular particulate material for surfacing roofing materials, the particulate comprising fire-retardant material at least partially encapsulated in a solar-reflective coating.

27. A granular particulate material according to claim 26 wherein the fire-retardant material is selected from the group consisting of hydrated metal silicates, alumina hydrates, antimony-containing compounds, phosphorous-containing compounds, and halogenated compounds.

28. A granular particulate material according to claim 26 wherein the fire-retardant material is selected from the group consisting of intumescent and non-intumescent fire retardant materials.

29. A granular particulate material according to claim 26 wherein the solar reflective coating is formed from a solar-reflective coating composition including at least one solar-reflective pigment.

31. A granular particulate material according to claim 29 wherein the at least one solar reflective pigment has an integrated reflectance of at least about 50% over the wavelength range from 700 to 2500 nm.

32. A granular particulate material according to claim 29 wherein the solar reflective coating composition comprises at least one binder material selected from the group consisting of metal silicate compositions, silicas, phosphates, and polymeric binder compositions.

30. (canceled)

33. (canceled)