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

• US 8,628,850 B2
• Filed: 10/11/2012
• Issued: 01/14/2014
• 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:
  US13/649,321
• Publication Number:
  US 20130034696A1
• Time in Patent Office: 460 Days
• Field of Search: 428402-407, 106/493, 252/587
• US Class Current: 428/402
• 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 a colored infrared pigment, a light-interference platelet pigment, or a metal oxide.

Claims

1. A roofing product comprising colored infrared reflective roofing granules selected from the group consisting of

(a) 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;

(b) granules comprising base particles comprising inert mineral particles coated with a cured first coating composition including a base particle binder and at least one reflective white pigment, the base particles being coated with a cured second coating composition including a coating binder, and at least one colorant selected from the group consisting of pigments with near infrared transparency;

(c) granules comprising inert base particles with size passing #8 mesh and retaining on #70 mesh coated with a cured coating composition comprising a coating binder and at least one colored, infrared-reflective pigment;

(d) granules comprising base particles with size passing #8 mesh and retaining on #70 mesh coated with a cured coating composition comprising a coating binder and at least one colored, infrared-reflective pigment wherein the base particles comprise mineral particles coated with a cured base coating composition including a base particle binder, and at least one reflective white pigment;

(e) granules comprising base particles comprising inert mineral particles coated with a cured first coating composition including a base particle binder and at least one reflective white pigment, the base particles being coated with a cured second coating composition including a coating binder, and at least one colorant selected from the group consisting of uv-stabilized dyes and granule coloring pigments;

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

(g) combinations thereof.

2. A roofing product according to claim 1, wherein the roofing product comprises a shingle.

3. A roofing product according to claim 1, wherein the roofing product comprises a roll good.

4. A roofing product according to claim 1, wherein the roofing product comprises a membrane.

5. A roofing product according to claim 1, wherein the roofing product comprises a bituminous roofing product.

6. A roofing product according to claim 1, wherein the roofing product comprises a bituminous coating material.

7. A roofing product according to claim 1, wherein the roofing granules are adhered to a shingle stock material.

8. A roofing product according to claim 1, wherein the roofing product has an L* of less than 55.

9. A roofing product according to claim 1, wherein the roofing product has a solar reflectance great than 25%.

12. A process according to claim 1, wherein the roofing product comprises a shingle.

10. A process for preparing a roofing product, the process comprising:

(a) providing colored infrared reflective roofing granules selected from the group consisting of;

(1) granules comprising case 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) granules comprising base particles comprising inert mineral particles coated with a cured first coating composition including a base particle binder and at least one reflective white pigment, the base particles being coated with a cured second coating composition including a coating binder, and at least one colorant selected from the group consisting of pigments with near infrared transparency;

(3) granules comprising inert base particles with size passing #8 mesh and retaining on #70 mesh coated with a cured coating composition, a coating binder and at least one colored, infrared-reflective pigment;

(4) granules comprising base particles with size passing #8 mesh and retaining on #70 mesh coated with a cured coating composition comprising a coating binder and at least one colored, infrared-reflective pigment wherein the base parti9cles comprise mineral particles coated with a cured base coating composition including a base particle binder, and at least one reflective white pigment;

(5) granules comprising base particles comprising inert mineral particles coated with a cured first coating composition including a base particle binder and at least one reflective white pigment, the base particles being coated with a cured second coating composition including a coating binder, and at least one colorant selected from the group consisting of uv-stabilized dyes and granule coloring pigments;

(6) granules comprising inert mineral particles coated with a cured firs coating composition including a base particle binder and at least one colorant selected from the group consisting of uv-stabilized dyes and granule coloring pigments to form base particles, the base particles being coated with a cured second coating composition including a coating binder and at least one infrared-reflective functional pigment 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; and

(7) combinations thereof; and

(b) adhering the granules to a shingle stock material.

11. A process according to claim 10, wherein the step of providing colored infrared roofing granules comprises:

(a) coating colored roofing granules with a coating composition including a coating binder and at least one infrared-reflective functional pigment 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; and

(b) curing the coating binder to provide the colored infrared reflective roofing granules.

13. A process according to claim 10, wherein the roofing product comprises a roll good.

14. A process according to claim 10, wherein the roofing product comprises a membrane.

15. A process according to claim 10, wherein the shingle stock material comprises a bituminous roofing product.

16. A process according to claim 10, wherein the shingle stock material comprises a bituminous coating material.

17. A process according to claim 10, wherein the roofing product has an L* of less than 55.

18. A process according to claim 11, wherein the roofing product has a solar reflectance great than 25%.

19. A process according to claim 10, wherein the roofing product has a solar reflectance greater than 25%.

20. A process according to claim 19, wherein the roofing product has an L* of less than 55.