System, method and apparatus for increasing average reflectance of a roofing product for sloped roof

• US 8,673,427 B2
• Filed: 07/25/2012
• Issued: 03/18/2014
• Est. Priority Date: 08/18/2011
• Status: Active Grant

• Current Assignee: CertainTeed Corp. (Compagnie De Saint-Gobain)
• Original Assignee: CertainTeed Corp. (Compagnie De Saint-Gobain)
• Inventors: Kalkanoglu, Husnu M., Jacobs, Gregory F., Snyder, Richard A.
• Primary Examiner(s): Nguyen, Chi Q
• Application Number:
  US13/558,069
• Publication Number:
  US 20130042561A1
• Time in Patent Office: 601 Days
• Field of Search: 525/18, 428/40.1, 428/212, 428/142, 428/402, 428/403, 428/404, 428/405, 428/406, 428/407, 428/143, 106/493, 427/214
• US Class Current: 428/143
• CPC Class Codes: B05D 5/061 Special surface effect
• CPC Class Codes: B05D 5/065 having colour interferences or colour shifts or opalescent looking, flip-flop, two tones
• CPC Class Codes: E04D 1/20 of plastics; of asphalt; of fibrous materials
• CPC Class Codes: E04D 13/16 Insulating devices or arrangements in so far as the roof covering is concerned, e.g. characterised by the material or composition of the roof insulating material or its integration in the roof structure
• CPC Class Codes: E04D 2001/005 the roofing elements having a granulated surface
• CPC Class Codes: Y02A 30/254 Roof garden systems; Roof coverings with high solar reflectance
• CPC Class Codes: Y02B 10/20 Solar thermal
• CPC Class Codes: Y02B 80/00 Architectural or constructional elements improving the thermal performance of buildings
• CPC Class Codes: Y10T 428/14 Layer or component removable to expose adhesive
• CPC Class Codes: Y10T 428/24355 Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
• CPC Class Codes: Y10T 428/24372 Particulate matter
• CPC Class Codes: Y10T 428/2982 Particulate matter [e.g., sphere, flake, etc.]
• CPC Class Codes: Y10T 428/2996 Glass particles or spheres

Abstract

A roofing product and method includes coating a substrate with bitumen to yield a bitumen coated substrate having an exposure zone. First granules are adhered to the exposure zone to yield a first granule coating. The first granules have a solar reflectance greater than 35. An adhesive is adhered to at least a portion of the first granule coating. An open portion of the first granule coating that is free of the adhesive is maintained. An overlay of non-white second granules is adhered to the adhesive, such that the overlay of second granules and the adhesive provide a raised structure above a plane of the first granule coating.

Claims

1. A method of making a roofing product, comprising:

(a) providing a substrate;

(b) coating the substrate with bitumen to yield a bitumen coated substrate having an exposure zone;

(c) adhering first granules to the exposure zone to yield a first granule coating, the first granules having a solar reflectance greater than 35;

(d) adhering an adhesive to at least a portion of the first granule coating;

(e) maintaining an open portion of the first granule coating that is free of the adhesive; and

(f) adhering an overlay of second granules that are non-white in color to the adhesive, such that the overlay of second granules and the adhesive provide a raised structure that is distributed substantially across the exposure zone above a plane of the first granule coating.

2. The method of claim 1, wherein the roofing product is a shingle.

3. The method of claim 1, wherein the roofing product is a roll roofing product.

4. The method of claim 1, wherein at least a portion of the raised structure is positioned closer to an exposed edge of the substrate than the open portion of the first granule coating.

5. The method of claim 1, wherein the raised structure provides a dominant component of a color of the roofing product when viewed from a down roof position at an angle of at least 70°

off normal.

6. The method of claim 1, wherein the adhesive is an organic polymer or a bituminous adhesive.

7. A method of making a roofing product, comprising;

(a) providing a web;

(b) coating the web with bitumen to yield a bitumen coated web having an exposure zone and a headlap zone;

(c) adhering first granules to the exposure zone, the first granules having a solar reflectance greater than about 50;

(d) adhering second granules to the headlap zone;

(e) applying an adhesive to at least a portion of the first granules in the exposure zone;

(f) maintaining an open portion of the first granules that is free of the adhesive; and

(g) adhering an overlay of third granules to the adhesive such that the overlay of third granules and the adhesive provide at least one raised structure above a plane of the first granules in the exposure zone, and the third granules have a non-white color.

8. The method of claim 7, wherein the raised structure is positioned on the web such that in an installed condition of the roofing product on a roof, at least some of the raised structure is down roof from at least some of the open portion.

9. The method of claim 8, wherein the raised structure provides a dominant component of a color of the roofing product when viewed from a down roof position at an angle of at least 60°

off normal.

10. The method of claim 7, wherein the third granules have a solar reflectance greater than about 25.

11. The method of claim 7, wherein the exposure portion has a predetermined lateral direction and a vertical direction with respect to a down roof direction when the roofing product is installed on a roof.

12. The method of claim 11, wherein the third granules vary in color in the lateral direction.

13. The method of claim 7, wherein the at least one raised structure comprises a plurality of raised structures.

14. The method of claim 13, wherein the raised structures cover less than about 50 percent of the exposure zone.

15. The method of claim 13, wherein the raised structures have a width between about 8 mm and about 40 mm.

16. The method of claim 13, wherein the raised structures have a height between about 1 mm and about 5 mm.

17. A method of making a layer of roofing product, the method comprising the steps of:

(a) providing a sheet;

(b) coating the sheet with an adhesive to yield an adhesive coated sheet having a front surface and a rear surface;

(c) denoting an exposure portion and a non-exposure portion of the sheet;

(d) adhering a front layer of first granules to the front surface of the exposure portion of the sheet to yield a first granule coated front surface;

(e) adhering an overlay adhesive coating to at least a first zone of the first granule coated front surface of the exposure portion;

(f) maintaining at least a second zone of the first granule coated front surface of the exposure portion free of the overlay adhesive coating; and

,

(g) adhering an overlay layer of second granules to the first zone of the overlay adhesive coating such that the overlay layer of the second granules and the overlay adhesive coating provide a raised structure above a plane of the exposure portion;

wherein

(h) the first granules have a solar reflectance greater than 50; and

the second granules have a non-white color.