Colored roofing granules with increased solar heat reflectance, solar heat-reflective shingles, and process for producing same

• US 8,535,803 B2
• Filed: 12/09/2011
• Issued: 09/17/2013
• Est. Priority Date: 10/06/2003
• Status: Active Grant

• Current Assignee: Certainteed, LLC (Compagnie de Saint-Gobain SA)
• Original Assignee: CertainTeed Corp. (Compagnie De Saint-Gobain)
• Inventors: Shiao, Ming Liang, Kalkanoglu, Husnu M., Hong, Keith C.
• Primary Examiner(s): KILIMAN, LESZEK B
• Application Number:
  US13/316,115
• Publication Number:
  US 20120094076A1
• Time in Patent Office: 648 Days
• Field of Search: 428402-407, 106/493, 252/587, 427/212
• US Class Current: 428/403
• CPC Class Codes: C01P 2006/62 L* (lightness axis)
• CPC Class Codes: E04D 1/00 Roof covering by making use of tiles, slates, shingles, or other small roofing elements roofing supports or underlayers E04D12/00
• CPC Class Codes: E04D 1/26 Strip-shaped roofing elements simulating a repetitive pattern, e.g. appearing as a row of shingles
• CPC Class Codes: E04D 2001/005 the roofing elements having a granulated surface
• 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 428/2438 Coated
• CPC Class Codes: Y10T 428/24388 Silicon containing coating
• CPC Class Codes: Y10T 428/25 Web or sheet containing structurally defined element or component and including a second component containing structurally defined particles
• CPC Class Codes: Y10T 428/2982 Particulate matter [e.g., sphere, flake, etc.]
• 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 428/2996 Glass particles or spheres
• CPC Class Codes: Y10T 428/2998 including synthetic resin or polymer

Abstract

Solar-reflective roofing granules having deep-tone colors are formed by coating base mineral particles with a coating composition including an infrared-reflective pigment. Color is provided by colored infrared pigment, light-interference platelet pigment, or a metal oxide.

Claims

1. Colored infrared-reflective roofing granules comprising base particles comprising inert mineral particles coated with a cured first coating composition comprising including a base particle binder and at least one colorant selected from the group consisting of uv-stabilized dyes and granule coloring pigments, the base particles being coated with a cured second coating composition comprising a coating binder and at least one infrared-reflective functional pigment.

2. Colored infrared-reflective roofing granules according to claim 1 wherein the at least one colorant is selected from the group consisting of pearlescent pigments, light-interference platelet pigments, ultramarine blue, ultramarine purple, cobalt chromite blue, cobalt aluminum blue, chrome titanate, nickel titanate, cadmium sulfide yellow, cadmium sulfoselenide orange, and organic pigments selected from the group consisting of phthalo blue, phthalo green, quinacridone red, diarylide yellow, and dioxazine purple.

3. Colored infrared reflective roofing granules according to claim 1 wherein the at least one colorant is selected from the group consisting of metal oxide pigments.

4. Colored infrared-reflective roofing granules according to claim 1 wherein the at least one colorant is selected from the group consisting of PC-9415 Yellow, PC-9416 Yellow, PC-9158 Autumn Gold, PC-9189 Bright Golden Yellow, V-9186 Iron-Free Chestnut Brown, V-780 Black, V0797 IR Black, V-9248 Blue, PC-9250 Bright Blue, PC-5686 Turquoise, V-13810 Red, V-12600 Camouflage Green, V12560 IR Green, V-778 IR Black, and V-799 Black.

5. Colored infrared-reflective roofing granules according to claim 1 wherein the at least one infrared-reflective functional pigment is selected from the group consisting of light-interference platelet pigments including mica, light-interference platelet pigments including titanium dioxide, mirrorized silica pigments based upon metal-doped silica, and alumina.

6. Colored infrared-reflective roofing granules according to claim 1, the colored infrared-reflective roofing granules having an L* value of less than 55.

7. Colored infrared-reflective roofing granules according to claim 1, the colored infrared-reflective roofing granules having an infrared reflectance of at least 25%.

8. A bituminous roofing product comprising a substrate sheet of a fibrous material saturated with a bituminous coating material and colored infrared-reflective roofing granules comprising base particles comprising inert mineral particles coated with a cured first coating composition comprising including a base particle binder and at least one colorant selected from the group consisting of uv-stabilized dyes and granule coloring pigments, the base particles being coated with a cured second coating composition comprising a coating binder and at least one infrared-reflective functional pigment.

9. A bituminous roofing product according to claim 8 having an L* value of less than 55.

10. A bituminous roofing product according to claim 8 having an infrared reflectance of at least 25%.

11. A bituminous roofing product according to claim 8 wherein the at least one colorant is selected from the group consisting of pearlescent pigments, light-interference platelet pigments, ultramarine blue, ultramarine purple, cobalt chromite blue, cobalt aluminum blue, chrome titanate, nickel titanate, cadmium sulfide yellow, cadmium sulfoselenide orange, and organic pigments selected from the group consisting of phthalo blue, phthalo green, quinacridone red, diarylide yellow, and dioxazine purple.

12. A bituminous roofing product according to claim 8 wherein the at least one colorant is selected from the group consisting of metal oxide pigments.

13. A bituminous roofing product according to claim 8 wherein the at least one colorant is selected from the group consisting of PC-9415 Yellow, PC-9416 Yellow, PC-9158 Autumn Gold, PC-9189 Bright Golden Yellow, V-9186 Iron-Free Chestnut Brown, V-780 Black, V0797 IR Black, V-9248 Blue, PC-9250 Bright Blue, PC-5686 Turquoise, V-13810 Red, V-12600 Camouflage Green, V12560 IR Green, V-778 IR Black, and V-799 Black.

14. A bituminous roofing product according to claim 8 wherein the at least one infrared-reflective functional pigment is selected from the group consisting of light-interference platelet pigments including mica, light-interference platelet pigments including titanium dioxide, mirrorized silica pigments based upon metal-doped silica, and alumina.

15. A method for preparing colored infrared-reflective roofing granules, the method comprising:

(a) providing inert mineral particles;

(b) coating the inert mineral particles with first coating composition comprising including a base particle binder and at least one colorant selected from the group consisting of uv-stabilized dyes and granule coloring pigments,

(c) curing the first coating composition to provide base particles;

(d) coating the base particles with a second coating composition comprising a coating binder and at least one infrared-reflective functional pigment; and

(e) curing the second coating composition.

16. A method according to claim 15 wherein the at least one colorant is selected from the group consisting of pearlescent pigments, light-interference platelet pigments, ultramarine blue, ultramarine purple, cobalt chromite blue, cobalt aluminum blue, chrome titanate, nickel titanate, cadmium sulfide yellow, cadmium sulfoselenide orange, and organic pigments selected from the group consisting of phthalo blue, phthalo green, quinacridone red, diarylide yellow, and dioxazine purple.

17. A method according to claim 15 wherein the at least one colorant is selected from the group consisting of metal oxide pigments.

18. A method according to claim 15 wherein the at least one colorant is selected from the group consisting of PC-9415 Yellow, PC-9416 Yellow, PC-9158 Autumn Gold, PC-9189 Bright Golden Yellow, V-9186 Iron-Free Chestnut Brown, V-780 Black, V0797 IR Black, V-9248 Blue, PC-9250 Bright Blue, PC-5686 Turquoise, V-13810 Red, V-12600 Camouflage Green, V12560 IR Green, V-778 IR Black, and V-799 Black.

19. A method according to claim 15 wherein the at least one infrared-reflective functional pigment is selected from the group consisting of light-interference platelet pigments including mica, light-interference platelet pigments including titanium dioxide, mirrorized silica pigments based upon metal-doped silica, and alumina.

20. A method according to claim 15 wherein the at least one colorant is selected to provide colored infrared-reflective roofing granules having an L* value of less than 55.