U.S. patent application number 14/638180 was filed with the patent office on 2015-09-17 for energy efficient shingles.
The applicant listed for this patent is Marwa Mohamed Hassan, Micah Joel Kiletico. Invention is credited to Marwa Mohamed Hassan, Micah Joel Kiletico.
Application Number | 20150259920 14/638180 |
Document ID | / |
Family ID | 54068344 |
Filed Date | 2015-09-17 |
United States Patent
Application |
20150259920 |
Kind Code |
A1 |
Hassan; Marwa Mohamed ; et
al. |
September 17, 2015 |
Energy Efficient Shingles
Abstract
A novel energy efficient shingle is disclosed. The shingle is
layered with the top layer comprising recycled glass cullet coated
with a reflecting material such as TiO.sub.2. The novel shingle
provides significant improvement in the Solar Reflectance Index
(SRI).
Inventors: |
Hassan; Marwa Mohamed;
(Baton Rouge, LA) ; Kiletico; Micah Joel; (Belle
Chasse, LA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Hassan; Marwa Mohamed
Kiletico; Micah Joel |
Baton Rouge
Belle Chasse |
LA
LA |
US
US |
|
|
Family ID: |
54068344 |
Appl. No.: |
14/638180 |
Filed: |
March 4, 2015 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61952515 |
Mar 13, 2014 |
|
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|
Current U.S.
Class: |
428/148 |
Current CPC
Class: |
E04D 1/20 20130101; Y02B
80/34 20130101; B32B 5/02 20130101; Y02A 30/255 20180101; B32B
2262/101 20130101; B32B 2419/06 20130101; Y02B 80/00 20130101; E04D
1/16 20130101; E04D 1/28 20130101; B32B 11/02 20130101; Y02A 30/254
20180101; Y10T 428/24413 20150115 |
International
Class: |
E04D 1/16 20060101
E04D001/16; E04D 1/20 20060101 E04D001/20 |
Claims
1. A roof covering comprising a substrate mat, an asphalt binder
backdust, and white pigment coated glass cullet.
2. A roof covering according to claim 1 wherein the white pigment
is selected from a group consisting of Sb.sub.2O.sub.3, BaSO.sub.4,
PbCO.sub.3.Pb(OH).sub.2, TiO.sub.2, and ZnO.
3. A roof covering according to claim 1 wherein the white pigment
comprises TiO.sub.2.
4. A roof covering according to claim 1 wherein the mat is selected
from a group consisting of organic felt and fiberglass; wherein
said mat has a density of between 0.15 and 0.30 pounds per square
foot.
5. A roof covering according to claim 1, wherein the mat is
fiberglass.
6. A roof covering according to claim 1 that is a plurality of
shingles.
7. A shingle according to claim 6, wherein the shingle comprises:
a. A mat impregnated with an asphalt binder comprising air blown
asphalt and glass cullet wherein the mat has a top side and a
bottom side, and b. wherein the top side of the mat is imbedded
with TiO.sub.2 coated glass cullet, and c. wherein the bottom side
of the mat is imbedded with backdust comprising glass cullet; and
d. wherein the shingle is oriented so that the top side of the
shingle faces the atmosphere and the bottom side of the shingle is
placed against the roof.
8. An asphalt binder according to claim 7 wherein the air blown
asphalt is between 30% and 40% by weight of the glass cullet.
9. An asphalt binder according to claim 8 wherein the glass cullet
is sized between 35 .mu.m to 200 .mu.m.
10. A TiO.sub.2 coated glass cullet according to claim 7 wherein
the TiO.sub.2 is between 7% and 11% by weight of the glass
cullet.
11. A glass cullet according to claim 10 wherein the glass cullet
is sized between 500 .mu.m and 3.0 mm.
12. A glass cullet used for backdust according to claim 7 wherein
the glass cullet is sized between 70 .mu.m and 600 .mu.m.
13. A shingle according to claim 7 wherein the surface of the
bottom layer of the mat is covered with glass cullet at coverage of
about 0.3 g/sq.in. to about 1.3 g/sq.in. of recycled glass
cullet.
14. A shingle according to claim 7 wherein the surface of the top
surface of the mat is covered with coated glass cullet at coverage
of about 1.5 g/sq.in. to about 2.5 g/sq.in.
Description
[0001] The present application claims the benefit of U.S.
Provisional Patent Application No. 61/952,515, filed on 13 Mar.
2014, which is hereby incorporated by reference herein in its
entirety including, but not limited to, those portions that
specifically appear herein.
[0002] This invention pertains to novel energy efficient
shingles.
BACKGROUND OF THE INVENTION
[0003] Significant sources of urban heating are heat islands,
wherein roofs of buildings absorb heat and then dissipate absorbed
heat into the buildings or into the atmosphere in the vicinity of
the heat islands. For buildings with dark, non-reflective surfaces
the problem is worse.
[0004] Heat islands may increase outdoor air temperature by about 2
to 8 degrees Fahrenheit within a specific area, or "island."
[0005] Current single roofing technologies that are used to reduce
building thermal loads and reduce "heat island" effects are based
on a concept called "cool roofs." A cool roof is designed to
reflect solar heat flux instead of allowing the solar heat flux
from penetrating through the roof into a building. Further,
energy-efficient shingles should allow heat within a house to
dissipate in the evenings when the sun is down.
[0006] There are three main methods for constructing solar
reflecting roofs; (1) use of highly reflective material, for
example, white polyvinyl coverings; (2) coating a roof with a
highly reflective coating; and (3) the use of green roofs or living
roofs, which is a roof of a building that is partially or
completely covered with vegetation and a growing medium, planted
over a waterproofing membrane.
[0007] A highly reflective roof typically has a solar reflectance
index (SRI) (ASTM E1980), (which is the best tool to measure heat
reflectance as it incorporates both reflectance and emittance in a
single value representing a materials temperature in the sun) of
78% or higher.
[0008] Conventional tar and gravel roofs typically have a SRI value
of between 3% and 10% due to the non-reflective nature of these
surfaces.
[0009] From this discussion, it is noted that none of the available
techniques have produced energy efficient roofing that is
affordable.
BRIEF DESCRIPTION OF INVENTION
[0010] The invention described herein is a novel cost-effective
shingle that used recycled glass coated with a white pigment for
the top layer of the shingle.
[0011] Waste glass, such as food and beverage containers, light
bulbs, and broken glassware, may be obtained from construction and
demolish waste sites ("C&D"). This waste glass is called "glass
cullet."
[0012] Typically, glass cullet obtained from a C&D facility
contains glass particle that are too large. Thus, before use, the
glass cullet was ground so that the particles were smaller than
about 2.5 mm.
[0013] The invention described herein used recycled glass cullet as
a top surface for asphalt-based shingles.
[0014] The glass cullet was coated with a white pigment before
attaching to the top surface of the asphalt-based shingles to
increase reflection of the shingles.
[0015] This invention also provided a new use for waste, broken
glass. With the increases in energy costs and the gradual depletion
of natural resources, there is a need to conserve energy and
recycle waste. The United States Environmental Protection Agency
estimates that about 11.5 to 12.8 million tons of glass waste is
generated annually. Broken and crushed glass is plentiful and may
be recycled into a new and useful product.
[0016] Glass cullet was isolated by color, including green and
clear.
[0017] The novel shingles disclosed herein were effective at
reflecting sunlight and thus will be effective at reducing heat
islands in urban areas.
[0018] The novel energy efficient shingles disclosed comprise three
layers; an interior base mat layer with a bottom side and a top
side, impregnated with an asphalt-filler material; a backdust layer
on the bottom side of the asphalt-impregnated mat; and a reflective
layer on the top side of the asphalt-impregnated mat.
[0019] The mat may be selected from a group containing organic felt
and fiberglass.
[0020] The asphalt-filler material comprises air blown asphalt and
recycled glass cullet, wherein the glass cullet was sized to be
between about 45 .mu.m and 150 .mu.m.
[0021] The backdust layer comprises recycled glass cullet, wherein
the glass cullet was sized to be between about 70 .mu.m and 600
.mu.m.
[0022] The reflective layer comprises recycled glass cullet, coated
with a white pigment, whereas the coated glass cullet was sized to
be between about 600 .mu.m and 3.00 mm.
[0023] A white pigment was selected from the group of white
pigments consisting of Sb.sub.2O.sub.3, BaSO.sub.4,
PbCO.sub.3.Pb(OH).sub.2, TiO.sub.2, and ZnO.
[0024] The bottom side layer of the novel shingle was placed in
contact with the roof, and the top side layer of the novel shingle
was faced to the atmosphere.
[0025] Recycled glass cullet collected from C&D processing
plants was reduced in size by placing it in a high performance
mixer. Fragments were sieved and separated by size.
[0026] The ground recycled glass was used in place of traditional
materials in the manufacture of shingles, including calcium
limestone.
BRIEF DESCRIPTION OF DRAWINGS
[0027] FIG. 1. A top view of a layered shingle with each layer
shown in an exploded view.
[0028] FIG. 2. A side view of a layered shingle with each layer
shown from the bottom to the top.
DETAILED DESCRIPTION OF THE INVENTION
[0029] The novel energy efficient shingles (50) disclosed comprise
three layers as shown in FIG. 1; an interior base mat layer (30)
with a bottom side and a top side, impregnated with an
asphalt-filler material (20); a backdust layer (40) on the bottom
side of the asphalt-impregnated mat; and a reflective layer (10) on
the top side of the asphalt-impregnated mat. FIG. 2 shows the novel
shingle viewed from the side. A bottom dustback layer (40) is
beneath the asphalt-filler layer (20). Between the asphalt-filler
layers (20), a matting layer (30) is shown. Above the matting layer
(30) and the asphalt-filler layer (20) is a reflective layer
(10).
[0030] Fiberglass matting (30), wherein the matting weight was
15-30 lb per 100 square foot area, was used as the base mat layer
(30), wherein the mat was fully impregnated with an asphalt-filler
mix (20). An asphalt-filler mix for conventional shingles was
calcium carbonate mixed with air blown asphalt. The asphalt-filler
layer (20) for the novel shingle comprised air blown asphalt and
recycled glass cullet.
[0031] The asphalt-filler mix (20) for novel shingles had a ratio
of air blown asphalt to glass cullet between about 30:60 to 40:70.
The glass cullet used for the asphalt-filler mix (20) was sized to
be between 45 .mu.m and 150 .mu.m.
[0032] The bottom backdust layer (40) was bound to the
asphalt-filler mix (20) on the mat (30) wherein the surface of the
bottom layer was covered with about 0.3 g/sq.in. to about 1.3
g/sq.in. of recycled glass cullet. The glass cullet used for
backdust (40) was sized to be between about 75 .mu.m to about 600
.mu.m. The bottom layer was bonded to the mat by the asphalt-filler
mixture (20). The overall thickness of the shingle (50) was about
the same as the thickness of current asphalt shingles being used in
the market.
[0033] For the top layer (10), a white pigment, for example,
TiO.sub.2, was coated onto the surface of recycled glass cullet.
Between about 5% and 10% by weight TiO.sub.2, and more preferably
about 8% by weight TiO.sub.2, was mixed with the glass cullet to
prepare the top, reflective layer of the shingles. The mix of glass
cullet and TiO.sub.2 was submerged under water for 2-5 minutes,
after which the mixture dried at 110.degree. C. to constant mass.
Then the dried TiO.sub.2 coated glass cullet was added to the
shingle's top surface. The coated glass cullet was added to the top
of the shingle so that the top surface (10) of the
asphalt-impregnated mat (30) contained about 1.5 g/sq.in. to about
2.5 g/sq.in. of the coated glass cullet. The glass cullet used for
the top-reflective layer (10) was sized to be between about 600
.mu.m to about 3.0 mm.
[0034] A novel shingle (50), when placed on a roof, would be
oriented so that the top reflective layer (10) is the outer layer
and the backdust layer (40) would be in contact with the roof.
[0035] The invention can be applied to all types of asphalt
shingles including strip shingles, 3-tab asphalt shingles, and
laminated asphalt shingles. It can also be extended to be used with
other types of roofing systems including roll up asphalt roofs,
single ply rubberized asphalt, Multi-ply (built-up) roof systems
and Ballasted Roofs.
[0036] The invention may also use other type matting than
fiberglass, including organic felt.
Example 1
Prototype Shingle
[0037] The filler mixture was prepared with air blown asphalt with
a viscosity of 33,500 cP (centipoise) (the viscosity was measured
at 135.degree. C.). The air blown asphalt was heated to 204.degree.
C. to lower the viscosity and allow for better mixing with the
recycled glass. The recycled glass (with size ranging from 53 .mu.n
to 75 .mu.m) was heated to a 100.degree. C. The recycled glass is
added to the binder according to the measurements shown in Table 1
and mixed thoroughly. The viscosity of the mixture was measured at
204.degree. C. and 150.degree. C. and was found to be 20,000 cP and
33,940 cP. The mixture was placed back in the oven and heated to
230.degree. C. For a sample of 3''.times.3'', 14.7 g air blown
asphalt and 27.3 g recycled glass (35:65 ratio) was used for layer
two.
TABLE-US-00001 TABLE 1 ANATOMY OF SHINGLE SAMPLE BY WEIGHT PERCENT
(Grams) BY WEIGHT Fiberglass Matting (3'' .times. 3'') 2.0 4%
Filler Mixture 36.0 68% Asphalt (35%) 12.6 24% Glass Cullet (65%)
23.4 44% Top Surface Glass Cullet 13.0 24% Backdust Glass Cullet
2.20 4% Total Shingle Sample 53.2 100%
[0038] Several 3'.times.3'' fiberglass mats were placed into a hot
metal mold. The filler mixture was then poured over the fiberglass
mats to allow the filler mixture to impregnate the mats. The mold
was then placed in an oven heated to 230.degree. C. where it
remained for 15-20 minutes to allow for full penetration of the
filler mixture into the mats.
[0039] Top surface glass cullet sized between 0.814 mm to 2.83 mm
were coated with TiO.sub.2 by submerging a mixture of TiO.sub.2 and
glass cullet in water, thoroughly mixing and then heating the
mixture to a 110.degree. C. at which temperature to dry the mixture
to constant mass.
[0040] TiO.sub.2 coated glass cullet was added to the top of the
molten asphalt mixture that had been impregnated into the mats so
that the top surface was completely covered with the TiO.sub.2
coated glass cullet. The mold was then cooled to room
temperature.
[0041] Once cooled, the prototype shingles were removed from the
mold.
[0042] The prototype shingles were turned so that the bottom side
of the shingle was available. Heat was applied to surface of the
bottom side of the shingle to melt the surface of the asphalt
binder located on the bottom surface. Backdust made from glass
cullet sized between about 75 .mu.m and 600 .mu.m then was added to
the heated bottom surface. Then the prototype shingles were allowed
to cool to room temperature.
[0043] Different types of glass cullet were used, including green
glass and clear glass.
Example 2
Solar Reflectance Index (SRI)
[0044] SRI incorporates both solar reflectance and emittance into a
single value and is a measure of the constructed surface's ability
to stay cool in the sun by reflecting solar radiation and emitting
thermal radiation. It is defined such that a standard black surface
(initial solar reflectance 0.05, initial thermal emittance 0.90)
has an initial SRI of 0, and a standard white surface (initial
solar reflectance 0.80, initial thermal emittance 0.90) has an
initial SRI of 100. Materials with the highest SRI values are the
coolest choices for roofing.
[0045] Table 2 displays the SRI of conventional asphalt
shingles.
TABLE-US-00002 TABLE 2 SOLAR REFLECTANCE INDEX OF CONVENTIONAL
ASPHALT SHINGLES TYPE OF THE TYPE OF THE ASPHALT SHINGLE SRI
ASPHALT SHINGLE SRI White 21 Black 1 Gray 4 Weathered Wood 4 Green
18 Dark Brown 4 Antique Silver 19 Beachwood Sand 19
[0046] Table 3 displays the SRI of the novel asphalt shingle.
TABLE-US-00003 TABLE 3 SOLAR REFLECTANCE INDEX OF NOVEL ASPHALT
SHINGLES Material Composition ID Top Surface Filler SRI X1 Control
1: Ceramic Coated Granules Limestone 0 X2 Control 2: Ceramic Coated
Granules Clear Glass 1 0 A Green Glass Limestone 3 B Clear Glass 1
Limestone 5 C Green Glass Green Glass 3 D Clear Glass 1 Clear Glass
1 5 C1 Green Glass & Pigments Green Glass 28 D1 Clear Glass 1
& Pigments Clear Glass 1 27 G1 Clear Glass 2 & Pigments
Clear Glass 2 30
[0047] As can be seen from a comparison of the SRI for the novel
shingle and conventional shingles, the novel shingle will reflect
more solar energy than those shingles currently available.
* * * * *