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

• US 8,997,427 B2
• Filed: 01/23/2014
• Issued: 04/07/2015
• 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:
  US14/162,160
• Publication Number:
  US 20140134400A1
• Time in Patent Office: 439 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, 428/141, 106/493, 427/214, 427/212
• US Class Current: 52/518
• 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 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 roofing product, comprising:

a substrate having an exposure zone and a headlap zone;

a bitumen layer on the substrate;

first granules on the bitumen layer in the exposure zone, the first granules having a solar reflectance greater than 35;

an adhesive on only some portions on tops of the first granules, such that the first granules have an open portion that is free of the adhesive; and

an overlay of second granules that are non-white in color on the adhesive, such that the overlay of second granules and the adhesive form raised structures that are distributed substantially across the exposure zone above a plane of the first granules.

2. The roofing product of claim 1, wherein the roofing product is planar and flexible.

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

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

5. The roofing product of claim 1, wherein the raised structures provide 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 roofing product of claim 1, wherein the substrate is a fiberglass web, and the adhesive is an organic polymer or a bituminous adhesive.

7. The roofing product of claim 1, wherein the first granules have a solar reflectance greater than 50.

8. The roofing product of claim 1, wherein the second granules have a solar reflectance greater than about 30.

9. The roofing product of claim 1, wherein the raised structures are continuous.

10. The roofing product of claim 1, wherein at least two of the raised structures intersect.

11. The roofing product of claim 1, wherein the raised structures are discontinuous.

12. The roofing product of claim 1, wherein the raised structures are parallel to one another.

13. The roofing product of claim 1, wherein the raised structures have a wavy shape.

14. The roofing product of claim 1, wherein the raised structures vary in a crossweb position in a downweb direction.

15. The roofing product of claim 1, wherein the raised structures have a shape selected from the group of consisting of circles, ellipsoids, polygons, squares, checks, rectangles, parallelograms, chevrons, triangles, and trapezoids.

16. The roofing product of claim 1, wherein the raised structures vary in shape.

17. The roofing product of claim 1, wherein the raised structures vary in size.

18. The roofing product of claim 1, wherein the raised structures cover less than about 50 percent of the exposure zone.

19. The roofing product of claim 1, wherein the raised structures have a width between about 8 mm and about 40 mm.

20. The roofing product of claim 1, wherein the raised structures have a height between about 1 mm and about 5 mm.

21. The roofing product of claim 1, wherein the raised structures vary in height.

22. A roofing product, comprising:

a sheet having an exposure portion and a non-exposure portion;

a coating of an adhesive on the sheet, the adhesive coated sheet having a front surface and a rear surface;

a front layer of first granules adhered to the front surface of the exposure portion of the sheet comprising a first granule coated front surface, and the first granules have a solar reflectance greater than 50;

an overlay adhesive coating adhered to at least a first zone on top of the first granule coated front surface of the exposure portion;

a second zone of the first granule coated front surface of the exposure portion that is free of the overlay adhesive coating; and

an overlay layer of second granules adhered to the first zone of the overlay adhesive coating such that the overlay layer of the second granules and the overlay adhesive coating comprise a raised structure above a plane of the exposure portion, and the second granules have a non-white color.

23. The roofing product of claim 22, wherein the sheet comprises a material selected from the group consisting of asphalt, metal, plastic and fiberglass or a combination thereof.

24. The roofing product of claim 22, wherein at least one of the adhesive layer or the overlay adhesive coating comprises an organic polymer or a bituminous material.