U.S. patent application number 17/487095 was filed with the patent office on 2022-04-21 for roofing granules with high solar reflectance, roofing products with high solar reflectance, and processes for producing same.
The applicant listed for this patent is CertainTeed LLC. Invention is credited to Keith C. Hong, Ming Liang Shiao, Walter T. Stephens.
Application Number | 20220119309 17/487095 |
Document ID | / |
Family ID | 1000006062213 |
Filed Date | 2022-04-21 |
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United States Patent
Application |
20220119309 |
Kind Code |
A1 |
Shiao; Ming Liang ; et
al. |
April 21, 2022 |
Roofing Granules with High Solar Reflectance, Roofing Products with
High Solar Reflectance, and Processes for Producing Same
Abstract
Solar reflective roofing granules include a binder and inert
mineral particles, with solar reflective particles dispersed in the
binder. An agglomeration process preferentially disposes the solar
reflective particles at a desired depth within or beneath the
surface of the granules.
Inventors: |
Shiao; Ming Liang;
(Collegeville, PA) ; Hong; Keith C.; (Lilitz,
PA) ; Stephens; Walter T.; (Cleveland, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
CertainTeed LLC |
Malvern |
PA |
US |
|
|
Family ID: |
1000006062213 |
Appl. No.: |
17/487095 |
Filed: |
September 28, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16358672 |
Mar 19, 2019 |
11130708 |
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17487095 |
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15211085 |
Jul 15, 2016 |
10246879 |
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16358672 |
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12601169 |
Mar 31, 2010 |
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PCT/US2008/064676 |
May 23, 2008 |
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15211085 |
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60939989 |
May 24, 2007 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
C04B 2235/3232 20130101;
Y02B 80/00 20130101; C04B 35/62821 20130101; C04B 18/023 20130101;
C04B 35/62695 20130101; C04B 35/6316 20130101; C04B 33/04 20130101;
C04B 2235/3427 20130101; Y10T 428/2982 20150115; C04B 35/636
20130101; C04B 2235/349 20130101; C04B 2235/48 20130101; Y10T
428/2993 20150115; Y02A 30/254 20180101; E04D 2001/005 20130101;
C04B 2235/9646 20130101; E04D 5/12 20130101; C04B 18/021 20130101;
C04B 2235/656 20130101; E04D 7/005 20130101; C04B 35/64 20130101;
C04B 33/14 20130101; C04B 2111/80 20130101; C04B 2111/00586
20130101; C04B 35/6365 20130101 |
International
Class: |
C04B 18/02 20060101
C04B018/02; C04B 33/04 20060101 C04B033/04; C04B 33/14 20060101
C04B033/14; C04B 35/626 20060101 C04B035/626; C04B 35/628 20060101
C04B035/628; C04B 35/63 20060101 C04B035/63; C04B 35/636 20060101
C04B035/636; E04D 7/00 20060101 E04D007/00; C04B 35/64 20060101
C04B035/64; E04D 5/12 20060101 E04D005/12 |
Claims
1-14. (canceled)
15. Solar reflective roofing granules, each comprising (a) a
granule body comprising inert mineral particles or ceramic
particles bound by an inorganic binder, the granule body having an
exterior surface; and (b) solar reflective particles, the solar
reflective particles being adhered to the granule body only at or
proximate to the exterior surface of the granule.
16. Solar reflective roofing granules according to claim 15 wherein
the solar reflective particles are mechanically adhered to the
exterior surface of the granule bodies.
17. Solar reflective roofing granules according to claim 15 wherein
the solar reflective particles are selected from the group
consisting of titanium dioxides, metal pigments, titanates, and
metal reflective pigments.
18. Solar reflective roofing granules according to claim 15 wherein
the granule body comprises inert mineral particles.
19. Solar reflective roofing granules according to claim 18 wherein
the inert mineral particles have an average particle size from
about 0.1 micrometers to about 40 micrometers.
20. Solar reflective roofing granules according to claim 15 wherein
the granule body comprises ceramic particles.
21. Solar reflective roofing granules according to claim 15 wherein
the binder is selected from the group consisting of silicate,
silica, phosphate, titanate, zirconate, and aluminate binders, and
mixtures thereof.
22. Solar reflective roofing granules according to claim 21 wherein
the binder further comprises aluminosilicate or kaolin clay.
23. Solar reflective roofing granules according to claim 15,
wherein each granule further comprises a coloring pigment.
24. Solar reflective roofing granules according to claim 15 having
a solar reflectance of at least about 60%.
25. A roofing product comprising solar reflective roofing granules
according to claim 15.
26. The roofing product according to claim 25, wherein the roofing
product is in the form of a shingle comprising a bituminous
substrate having the solar reflective roofing granules adhered to a
surface thereof.
27. Solar reflective roofing granules, each granule comprising a
granule body comprising ceramic particles and solar reflective
particles homogeneously dispersed with one another and bound by an
inorganic binder, the granule body having an exterior surface, a
plurality of the solar reflective particles being located at or
proximate to the exterior surface of the granule.
28. Solar reflective roofing granules according to claim 27 wherein
the solar reflective particles are selected from the group
consisting of titanium dioxides, metal pigments, titanates, and
metal reflective pigments.
29. Solar reflective roofing granules according to claim 27 wherein
the binder is selected from the group consisting of silicate,
silica, phosphate, titanate, zirconate, and aluminate binders, and
mixtures thereof.
30. Solar reflective roofing granules according to claim 29 wherein
the binder further comprises an inorganic material selected from
the group consisting of aluminosilicate and kaolin clay.
31. Solar reflective roofing granules according to claim 27 having
a solar reflectance of at least about 60%.
32. Solar reflective roofing granules according to claim 27,
wherein each granule body further comprises a coloring pigment
bound together with the ceramic particles and the solar reflective
particles by the binder.
33. A roofing product comprising solar reflective roofing granules
according to claim 27.
34. The roofing product according to claim 33, wherein the roofing
product is in the form of a shingle comprising a bituminous
substrate having the solar reflective roofing granules adhered to a
surface thereof.
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a division of pending U.S. patent
application Ser. No. 12/601,169, having a 371 date of Mar. 31,
2010, which was a national phase of International Application No.
PCT/US2008/064676, filed May 23, 2008, which claimed the priority
of U.S. Provisional Patent Application Ser. No. 60/939,989 filed
May 24, 2007.
BACKGROUND OF THE INVENTION
1. Field of the Invention
[0002] The present application relates to roofing granules and
roofing products including roofing granules, such as roofing
shingles.
2. Brief Description of the Prior Art
[0003] Asphalt shingles are conventionally used in the United
States and Canada as roofing and siding materials. Roofing granules
are typically distributed over the upper or outer face of such
shingles. The roofing granules, in general are formed from mineral
materials, and serve to provide the shingle with durability. They
protect the asphalt from the effects of the solar radiation (in
particular from the degradative effects of ultraviolet rays) and of
the environment (wind, precipitation, pollution, and the like), and
contribute to better reflection of incident radiation. The granules
moreover are typically colored, naturally or artificially by way of
the application of pigments, to meet the aesthetic requirements of
the user.
[0004] Roofing granules typically comprise crushed and screened
mineral materials, which are subsequently coated with a binder
containing one or more coloring pigments, such as suitable metal
oxides. The binder can be a soluble alkaline silicate that is
subsequently insolubilized by heat or by chemical reaction, such as
by reaction between an acidic material and the alkaline silicate,
resulting in an insoluble colored coating on the mineral particles.
For example, U.S. Pat. No. 1,898,345 to Deming discloses coating a
granular material with a coating composition including a sodium
silicate, a coloring pigment, and a colloidal clay, and heating
below the fusing temperature of sodium silicate, and subsequently
treating with a solution, such as a solution of calcium or
magnesium chloride, or aluminum sulphate, that will react with the
sodium silicate to form an insoluble compound. Similarly, U.S. Pat.
No. 2,378,927 to Jewett discloses a coating composition for roofing
granules consisting of sodium silicate, and clay or another
aluminum-bearing compound such as sodium aluminate, or cryolite or
other insoluble fluorides such as sodium silicofluoride, and a
color pigment. The coating is then heat cured at a temperature
above the dehydration temperature of the coating materials but
below the fusion temperature at which the combination of materials
fuses, thus producing a non-porous, insoluble weather-resistant
cement. Roofing granules are typically produced using inert mineral
particles with metal-silicate binders and clays as a latent heat
reactant at an elevated temperature, for example, such as those
described in U.S. Pat. No. 2,981,636. The granules are employed to
provide a protective layer on asphaltic roofing materials such as
shingles, and to add aesthetic values to a roof.
[0005] Pigments for roofing granules have usually been selected to
provide shingles having an attractive appearance, with little
thought to the thermal stresses encountered on shingled roofs.
However, depending on location and climate, shingled roofs can
experience very challenging environmental conditions, which tend to
reduce the effective service life of such roofs. One significant
environmental stress is the elevated temperature experienced by
roofing shingles under sunny, summer conditions, especially roofing
shingles coated with dark colored roofing granules. Although such
roofs can be coated with solar reflective paint or coating
material, such as a composition containing a significant amount of
titanium dioxide pigment, in order to reduce such thermal stresses,
this utilitarian approach will often prove to be aesthetically
undesirable, especially for residential roofs.
[0006] Mineral surfaced asphalt shingles, such as those described
in ASTM D225 or D3462, are generally used in steep-sloped roofs to
provide water-shedding function while adding aesthetically pleasing
appearance to the roofs. The asphalt shingles are generally
constructed from asphalt-saturated roofing felts and surfaced by
pigmented color granules, such as those described in U.S. Pat. No.
4,717,614. Asphalt shingles coated with conventional roofing
granules are known to have low solar heat reflectance, and hence
will absorb solar heat especially through the near infrared range
(700 nm-2500 nm) of the solar spectrum. This phenomenon is
increased as the granules covering the surface become dark in
color. For example, while white-colored asphalt shingles can have
solar reflectance in the range of 25-35%, dark-colored asphalt
shingles can only have solar reflectance of 5-15%. Furthermore,
except in the white or very light colors, there is typically only a
very small amount of pigment in the conventional granule's color
coating that reflects solar radiation well. As a result, it is
common to measure temperatures as high as 77.degree. C. on the
surface of black roofing shingles on a sunny day with 21.degree. C.
ambient temperature. Absorption of solar heat may result in
elevated temperatures at the shingle's surroundings, which can
contribute to the so-called heat-island effects and increase the
cooling load to its surroundings. It is therefore advantageous to
have roofing shingles that have high solar reflectivity in order to
reduce the solar heat absorption. The surface reflectivity of an
asphalt shingle largely depends on the solar reflectance of the
granules that are used to cover the bitumen.
[0007] In recent years, the state of California has implemented a
building code requiring the low-sloped roofs to have roof coverings
with solar reflectance greater than 70%. To achieve such high level
of solar reflectance, it is necessary to coat the roof with a
reflective coating over granulated roofing products, since the
granules with current coloring technology are not capable of
achieving such high levels of solar reflectance. However, polymeric
coatings applied have only a limited amount of service life and
will require re-coat after certain years of service. Also, the cost
of adding such a coating on roof coverings can be relatively
high.
[0008] In order to reduce the solar heat absorption, one may use
light colored roofing granules which are inherently more reflective
towards the solar radiation. White pigment containing latex
coatings have been proposed and evaluated by various manufacturers.
However, consumers and homeowners often prefer darker or earth tone
colors for their roof. In recent years, there have been
commercially available roofing granules that feature a reflective
base coat (i.e., a white coat) and a partially coated top color
coat allowing the reflective base coat to be partially revealed to
increase solar reflectance. Unfortunately, these granules have a
"washed-out" color appearance due to the partially revealed white
base coat.
[0009] Other manufactures have also proposed the use of
exterior-grade coatings that were colored by infrared-reflective
pigments for deep-tone colors and sprayed onto the roof in the
field. U.S. Patent Application Publication No. 2003/0068469 A1
discloses an asphalt-based roofing material comprising mat
saturated with an asphalt coating and a top coating having a top
surface layer that has a solar reflectance of at least 70%. U.S.
Patent Application Publication No. 2003/0152747 A1 discloses the
use of granules with solar reflectance greater than 55% and
hardness greater than 4 on the Moh's scale to enhance the solar
reflectivity of asphalt based roofing products. However, there is
no control of color blends and the novel granules are typically
available only in white or buff colors. U.S. Patent Application
Publication No. 2005/0074580 A1 discloses a non-white construction
surface comprising a first reflective coating and a second
reflective coating with total direct solar reflectance of at least
20%.
[0010] Also, there have been attempts in using special
near-infrared reflective pigments in earth-tone colors to color
roofing granules for increased solar reflectance. However, the
addition of kaolin clays, which are used to make the metal-silicate
binder durable through heat curing, inevitably reduce the color
strength or the color intensity of the pigment.
[0011] Colored roofing granules can also be prepared using a metal
silicate binder without adding clay and curing the binder at
temperatures greater than glass sintering temperature, or through a
"pickling" process by applying acid. However, these alternatives
require either very high temperatures, or the use of corrosive
chemicals, and in many cases could result in loss of color due to
pigment degradation by the acid.
[0012] In the alternative, a non-silicate binder, such as a
synthetic polymeric binder, can be used to coat the inert mineral
materials in order to produce roofing granules with dark colors and
high solar reflectance. However, the long-term durability and cost
for polymeric coatings are not as advantageous as the silicate
binders.
[0013] Another approach is provided by solar control films that
contain either thin layer of metal/metal oxides or dielectric
layers through vacuum deposition, and which have been commercially
available for use in architectural glasses.
[0014] There is a continuing need for roofing materials, and
especially asphalt shingles, that have improved resistance to
thermal stresses while providing an attractive appearance.
SUMMARY OF THE INVENTION
[0015] The present invention provides roofing granules, which have
high solar reflectance, such as at least 70 percent, as well as
roofing products such as shingles provided with such solar
reflective roofing granules. The present invention also provides a
process for preparing solar reflective roofing granules. In one
presently preferred embodiment, the process of the present
invention comprises providing a binder, inert mineral particles,
and solar reflective particles, dispersing the inert mineral
particles and the solar reflective particles in the binder to form
a mixture, forming the mixture into uncured granules; and curing
the binder to form cured roofing granules. Preferably, the process
of the present invention includes selecting the solar reflective
particles to provide granules having greater than about 60 percent,
and more preferably greater than about 70 percent solar
reflectance.
[0016] In another presently preferred embodiment, the present
invention provides a process for preparing solar reflective roofing
granules comprising providing a binder and inert mineral particles
to form a mixture, forming the mixture into uncured granule bodies
having an exterior surface, adhering solar reflective particles to
the exterior surface of the uncured granule bodies, and curing the
binder. In one aspect of this embodiment of the process of the
present invention, the solar reflective particles are mechanically
adhered to the exterior surface of the uncured granule bodies. In
another aspect of this embodiment of the process of the present
invention, the process further comprises mixing the solar
reflective particles with a fluid carrier to form a paste or
coating and adhering the solar reflective particles to the exterior
surface of the granule bodies by applying the paste to the exterior
surface of the granule bodies.
[0017] Preferably, the process further comprises sizing the uncured
granules by screening. In one presently preferred embodiment of the
process of the present invention, the uncured granules are heated
to cure the binder. In one aspect, the present process further
comprises surface treating the cured roofing granules. In one
presently preferred embodiment of the process of the present
invention, the inert mineral particles comprise uncalcined kaolin,
the binder comprises metal silicate, and the binder is cured by
heating the uncured granules at from about 500 degrees C. to 800
degrees C.
[0018] The present invention also provides solar reflective roofing
granules comprising a binder, inert mineral particles, and solar
reflective particles, with the inert mineral particles and the
solar reflective particles being dispersed in the binder.
Preferably, the solar reflective particles are selected from the
group consisting of titanium dioxides, metal pigments, titanates,
and metal reflective pigments. Preferably, the inert mineral
particles have an average particle size from about 0.1 micrometers
to 40 micrometers, and more preferably from about 0.25 micrometers
to 20 micrometers. Preferably, the solar reflective roofing
granules themselves have an average particle size from about 0.1 mm
to 3 mm, and more preferably from about 0.5 mm to 1.5 mm.
Preferably, the binder is selected from the group consisting of
silicate, silica, phosphate, titanate, zirconate, and aluminate
binders, and mixtures thereof. In one aspect, the binder preferably
further comprises an inorganic material selected from the group
consisting of aluminosilicate and kaolin clay.
[0019] In another aspect, the present invention also provides a
process for preparing solar reflective roofing granules, in which
the process comprises providing ceramic particles; forming the
ceramic particles into uncured granule bodies having an exterior
surface; adhering solar reflective particles to the exterior
surface of the uncured granule bodies; and sintering the uncured
granule bodies to form solar reflective roofing granules.
Preferably, the solar reflective particles are mechanically adhered
to the exterior surface of the uncured granule bodies. In this
aspect, the present process further preferably comprises providing
a sintering binder and mixing the sintering binder with the ceramic
particles to form a mixture and subsequently forming the mixture
including the ceramic particles into uncured granule bodies. In
this aspect, the present invention also provides solar reflective
roofing granules having an exterior surface, the roofing granules
comprising sintered ceramic particles; and solar reflective
particles; wherein at least some of the solar reflective particle
are proximate the exterior surface of the solar reflective
particles. Preferably, the solar reflective particles are selected
from the group consisting of titanium dioxides, metal pigments,
titanates, and metal reflective pigments.
[0020] The present invention also provides roofing products, such
as bituminous roofing shingles, including solar reflective roofing
granules according to the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0021] FIG. 1 is a schematic sectional elevational representation
of a roofing granule according to a first embodiment of the present
invention.
[0022] FIG. 2 is a schematic sectional elevational representation
of a roofing granule according to a second embodiment of the
present invention.
[0023] FIG. 3 is a schematic sectional elevational representation
of a roofing granule according to a third embodiment of the present
invention.
[0024] FIG. 4 is a schematic sectional elevational representation
of a roofing granule according to a fourth embodiment of the
present invention.
[0025] FIG. 4a is a partial fragmentary schematic sectional
elevational representation of the roofing granule of FIG. 4.
[0026] FIG. 5 is a partial fragmentary schematic sectional
elevational representation according to a fifth embodiment of the
present invention.
DETAILED DESCRIPTION
[0027] As used in the present specification and claims, "solar
reflective," and "solar heat-reflective" refer to reflectance in
the near infrared range (700 to 2500 nm) of the electromagnetic
spectrum, and "high solar reflectance" means having an average
reflectance of at least about 70 percent over the near infrared
range (700 to 2500 nm) of the electromagnetic spectrum.
[0028] As used in the present specification and claims, "solar
reflective particle" means a particulate material having a solar
reflectance of at least 60 percent, and preferably at least about
70 percent.
[0029] As used in the present specification and claims, "solar
reflective functional pigment" denotes a 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,
metal flake pigments, metal oxide coated flake pigments, and
alumina. As used in the present specification and claims, "granule
coloring pigment" denotes a conventional metal oxide-type pigment
employed to color roofing granules.
[0030] Preferably, the present invention provides highly
reflective, solid, durable, and crush-resistance granules suitable
for roofing applications with the sizes ranging from -10 to +40
U.S. mesh.
[0031] Preferably, the solar reflective roofing granules according
to the present invention have a solar reflectance of at least about
60 percent, and more preferably at least about 70 percent.
[0032] Roofing granules according to the present invention can be
made by synthetically forming a "green" or uncured granule body,
adhering highly solar reflective particles to the uncured granule
body, and curing the uncured granule body.
[0033] The mineral particles employed in the process of the present
invention are preferably chemically inert materials. The mineral
particles preferably have an average particle size of from about
0.1 micrometers to about 40 micrometers, and more preferably from
about 0.25 micrometers to about 20 micrometers. Stone dust can be
employed as the source of the mineral particles in the process of
the present invention. Stone dust is a natural aggregate produced
as a by-product of quarrying, stone crushing, machining operations,
and similar operations. In particular, dust from talc, slag,
limestone, granite, marble, syenite, diabase, greystone, quartz,
slate, trap rock, basalt, greenstone, andesite, porphyry, rhyolite,
greystone, and marine shells can be used, as well as manufactured
or recycled manufactured materials such as ceramic grog, proppants,
crushed bricks, concrete, porcelain, fire clay, and the like.
Ceramic materials, such as silicon carbide and aluminum oxide of
suitable dimensions can also be used. Preferably, the mineral
particles are manufactured from crushing naturally occurring rocks
with low free silica into suitable sizes for their UV opacity and
protection to asphalt when the roofing granules according to the
present invention are employed to protect bituminous roofing
materials such as asphalt shingles. Such silica-deficient rocks are
generally dark in color and have low solar reflectance in the range
around 8 to 15 percent. Conventionally, it is necessary to coat
granules prepared from these naturally-derived rocks with heavy
coatings or multiple coats in order to significantly increase the
solar reflectance. Even so, the highest achievable solar
reflectance is only limited to about 60%. Although one may reduce
the particle sizes to further increase the solar reflectance, the
surface coverage and the exposure of asphalt can be affected.
[0034] Advantageously, the process of the present invention can
produce highly reflective granules that do not require additional
coatings to achieve high solar reflectance, such as 70 percent
solar reflectance, while providing particle size distributions
similar to conventional #11-grade roofing granules.
[0035] Thus, the present invention provides a process for preparing
solar reflective roofing granules. In one aspect, the process of
the present invention comprises providing a binder, inert mineral
particles, and solar reflective particles; dispersing the inert
mineral particles and the solar reflective particles in the binder
to form a mixture; forming the mixture into uncured or "green"
granules or granule bodies; and curing the binder.
[0036] The granules can be formed by the methods disclosed in
United States Patent Publication 2004/0258835 A1, incorporated
herein by reference.
[0037] The "green" or uncured granules can be formed by using
relatively low-cost raw materials, such as clay and/or granule dust
from the waste stream of granule crushing, and adding water and/or
a suitable binder followed by a suitable granulation or
agglomeration process to form the uncured granules.
[0038] The solar reflective particles can be directly incorporated
into the uncured granules by blending with other starting raw
materials, or the solar reflective particles can be added during a
later stage of the granulation/agglomeration step. In the
alternative, the solar reflective particles can be added to the
surface of the formed uncured granules either by blending the solar
reflective particles in the form of a dry powder with the still
moist, uncured granules, or coating the uncured granules in a form
of a paste or coating.
[0039] In one aspect of the process of the present invention,
"green" or uncured granules can be formed from a mixture of mineral
particles, solar reflective particles and binder, ranging from
about 95% by weight binder to less than about 10% by weight binder,
and the uncured solar reflective roofing granules preferably are
formed from a mixture that includes from about 10% to 40% by weight
binder.
[0040] The binder can be a binder selected from the group
consisting of silicate, silica, phosphate, titanate, zirconate, and
aluminate binders, and mixtures thereof. The binder can further
comprise an inorganic material selected from the group consisting
of aluminosilicate and kaolin clay. In one aspect of the present
invention, the binder is a soluble alkali metal silicate, such as
aqueous sodium silicate or aqueous potassium silicate. The soluble
alkali metal silicate is subsequently insolubilized by heat or by
chemical reaction, such as by reaction between an acidic material
and the alkali metal silicate, resulting in cured solar reflective
granules. The binder may also include additives for long term
outdoor durability and functionality.
[0041] When an alkali metal-silicate binder such as sodium silicate
is employed in the preparation of solar reflective roofing
granules, the binder can include a heat-reactive aluminosilicate
material, such as clay, for example, kaolin clay. Alternatively, it
is possible to insolubilize the metal silicate binder chemically by
reaction with an acidic material, for example, ammonium chloride,
aluminum chloride, hydrochloric acid, calcium chloride, aluminum
sulfate, and magnesium chloride, such as disclosed in U.S. Pat.
Nos. 2,591,149, 2,614,051, 2,898,232 and 2,981,636, or other acidic
material such as aluminum fluoride. The binder can also be a
controlled release sparingly water soluble glass such as a
phosphorous pentoxide glass modified with calcium fluoride, such as
disclosed in U.S. Pat. No. 6,143,318. The most commonly used binder
for conventional granule coating is a mixture of an alkali metal
silicate and an alumino-silicate clay material.
[0042] The mixture of mineral particles, solar reflective particles
and binder can be formed into uncured solar reflective roofing
granules, using a forming process such as press, molding, cast
molding, injection molding, extrusion, spray granulation, gel
casting, pelletizing, compaction, or agglomeration. Preferably, the
resulting uncured solar reflective roofing granules have sizes
between about 50 micrometer and 5 mm, more preferably between about
0.1 mm and 3 mm, and still more preferably between about 0.5 mm and
1.5 mm. The uncured solar reflective roofing granules can be formed
using a conventional extrusion apparatus. For example, aqueous
sodium silicate, kaolin clay, mineral particles, and solar
reflective particles and water (to adjust mixability) can be
charged to a hopper and mixed by a suitable impeller before being
fed to an extrusion screw provided in the barrel of the extrusion
apparatus, such as disclosed, for example, in United States Patent
Publication 2004/0258835 A1. Alternatively, the ingredients can be
charged to the extruder continuously by gravimetric feeds. The
screw forces the mixture through a plurality of apertures having a
predetermined dimension suitable for sizing roofing granules. As
the mixture is extruded, the extrudate is chopped by suitable
rotating knives into a plurality of uncured solar reflective
roofing granules, which are subsequently fired at an elevated
temperature to sinter or densify the binder.
[0043] When the formed granules are fired, such as in a rotary
kiln, at an elevated temperature, such as at least 800 degrees C.,
and preferably at 1,000 to 1,200 degrees C., and the binder
densifies to form solid, durable, and crush-resistance
granules.
[0044] Examples of clays that can be employed in the process of the
present invention include kaolin, other aluminosilicate clays,
Dover clay, bentonite clay, etc.
[0045] Suitable solar reflective particles include titanium
dioxides such as rutile titanium dioxide and anatase titanium
dioxide, metal pigments, titanates, and mirrorized silica
pigments.
[0046] Examples of mirrorized silica pigments that can be employed
in the process of the present invention include pigments such as
Chrom Brite.TM. CB4500, available from Bead Brite, 400 Oser Ave,
Suite 600, Hauppauge, N.Y. 11788.
[0047] Examples of rutile titanium dioxide and anatase titanium
dioxide that can be employed in the solar reflective roofing
granules of the present invention include R-101 which are available
from Du Pont de Nemours, P.O. Box 8070, Wilmington, Del. 19880.
[0048] Examples of metal pigments that can be employed in the solar
reflective roofing granule of the present invention include
aluminum flake pigment, copper flake pigments, copper alloy flake
pigments, and the like. Metal pigments are available, for example,
from ECKART America Corporation, Painesville, Ohio 44077. Suitable
aluminum flake pigments include water-dispersible lamellar aluminum
powders such as Eckart RO-100, RO-200, RO-300, RO-400, RO-500 and
RO-600, non-leafing silica coated aluminum flake powders such as
Eckart STANDART PCR-212, PCR 214, PCR 501, PCR 801, and PCR 901,
and STANDART Resist 211, STANDART Resist 212, STANDART Resist 214,
STANDART Resist 501 and STANDART Resist 80; silica-coated
oxidation-resistant gold bronze pigments based on copper or
copper-zinc alloys such as Eckart DOROLAN 08/0 Pale Gold, DOROLAN
08/0 Rich Gold and DOROLAN 10/0 Copper.
[0049] Examples of titanates that can be employed in the solar
reflective roofing granules of the present invention include
titanate pigments such as colored rutile, priderite, and
pseudobrookite structured pigments, including titanate pigments
comprising a solid solution of a dopant phase in a rutile lattice
such as nickel titanium yellow, chromium titanium buff, and
manganese titanium brown pigments, priderite pigments such as
barium nickel titanium pigment; and pseudobrookite pigments such as
iron titanium brown, and iron aluminum brown. The preparation and
properties of titanate pigments are discussed in Hugh M. Smith,
High Performance Pigments, Wiley-VCH, pp. 53-74 (2002).
[0050] Examples of near IR-reflective pigments available from the
Shepherd Color Company, Cincinnati, Ohio, include Arctic Black
10C909 (chromium green-black), Black 411 (chromium iron oxide),
Brown 12 (zinc iron chromite), Brown 8 (iron titanium brown
spinel), and Yellow 193 (chrome antimony titanium).
[0051] Aluminum oxide, preferably in powdered form, can be used as
solar-reflective additive in the color coating formulation to
improve the solar reflectance of colored roofing granules without
affecting the color. The aluminum oxide should have particle size
less than #40 mesh (425 micrometers), preferably between 0.1
micrometers and 5 micrometers. More preferably, the particle size
is between 0.3 micrometers and 2 micrometers. The alumina should
have a percentage of aluminum oxide greater than 90 percent, more
preferably greater than 95 percent. Preferably the alumina is
incorporated into the granule so that it is concentrated near
and/or at the outer surface of the granule.
[0052] In addition, granule coloring pigments such as iron oxide,
white pigments such as lithopone, zinc sulfide, zinc oxide, and
lead oxide, void pigments such as spherical styrene/acrylic beads
(Ropaque.RTM. beads, Rohm and Haas Company), and/or hollow glass
beads having pigmentary size for increased light scattering, can
also be mixed with the solar reflective particles and mineral
particles and binder to form the uncured granules, or with the
solar reflective particles to be adhered to the exterior surface of
the uncured granules. In the case where an organic polymeric void
pigment is employed, a lower temperature cycle is desirable to
avoid alteration of or damage to such pigment.
[0053] A colored, infrared-reflective pigment can also be employed
in preparing the solar reflective roofing granules of the present
invention. Preferably, the colored, infrared-reflective pigment
comprises a solid solution including iron oxide, such as disclosed
in U.S. Pat. No. 6,174,360, incorporated herein by reference. The
colored infrared-reflective pigment can also comprise a near
infrared-reflecting composite pigment such as disclosed in U.S.
Pat. No. 6,521,038, incorporated herein by reference. Composite
pigments are composed of a near-infrared non-absorbing colorant of
a chromatic or black color and a white pigment coated with the
near-infrared non-absorbing colorant. Near-infrared non-absorbing
colorants that can be used in the present invention are organic
pigments such as organic pigments including azo, anthraquinone,
phthalocyanine, perinone/perylene, indigo/thioindigo, dioxazine,
quinacridone, isoindolinone, isoindoline, diketopyrrolopyrrole,
azomethine, and azomethine-azo functional groups. Preferred black
organic pigments include organic pigments having azo, azomethine,
and perylene functional groups. When organic colorants are
employed, a low temperature cure process is preferred to avoid
thermal degradation of the organic colorants.
[0054] The solar-reflective roofing granules of the present
invention can include conventional coatings pigments. Examples of
coatings pigments that can be used include those provided by the
Color Division of Ferro Corporation, 4150 East 56th St., Cleveland,
Ohio 44101, and produced using high temperature calcinations,
including 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.
[0055] The solar reflective roofing granules of the present
invention can also include light-interference platelet pigments.
Light-interference platelet pigments are known to give rise to
various optical effects when incorporated in coatings, including
opalescence or "pearlescence."
[0056] Examples of light-interference platelet pigments that can be
employed in the process of the present invention include pigments
available from Wenzhou Pearlescent Pigments Co., Ltd., No. 9 Small
East District, Wenzhou Economical and Technical Development Zone,
Peoples Republic of China, such as Taizhu TZ5013 (mica, rutile
titanium dioxide and iron oxide, golden color), TZ5012 (mica,
rutile titanium dioxide and iron oxide, golden color), TZ4013 (mica
and iron oxide, wine red color), TZ4012 (mica and iron oxide, red
brown color), TZ4011 (mica and iron oxide, bronze color), TZ2015
(mica and rutile titanium dioxide, interference green color),
TZ2014 (mica and rutile titanium dioxide, interference blue color),
TZ2013 (mica and rutile titanium dioxide, interference violet
color), TZ2012 (mica and rutile titanium dioxide, interference red
color), TZ2011 (mica and rutile titanium dioxide, interference
golden color), TZ1222 (mica and rutile titanium dioxide, silver
white color), TZ1004 (mica and anatase titanium dioxide, silver
white color), TZ4001/600 (mica and iron oxide, bronze appearance),
TZ5003/600 (mica, titanium oxide and iron oxide, gold appearance),
TZ1001/80 (mica and titanium dioxide, off-white appearance),
TZ2001/600 (mica, titanium dioxide, tin oxide, off-white/gold
appearance), TZ2004/600 (mica, titanium dioxide, tin oxide,
off-white/blue appearance), TZ2005/600 (mica, titanium dioxide, tin
oxide, off-white/green appearance), and TZ4002/600 (mica and iron
oxide, bronze appearance).
[0057] Examples of light-interference platelet pigments that can be
employed in the process of the present invention also include
pigments available from Merck KGaA, Darmstadt, Germany, such as
Iriodin.RTM. pearlescent pigment based on mica covered with a thin
layer of titanium dioxide and/or iron oxide; Xirallic.TM. high
chroma crystal effect pigment based upon Al2O3 platelets coated
with metal oxides, including Xirallic T 60-10 WNT crystal silver,
Xirallic T 60-20 WNT sunbeam gold, and Xirallic F 60-50 WNT
fireside copper; ColorStream.TM. multi color effect pigments based
on SiO2 platelets coated with metal oxides, including ColorStream F
20-00 WNT autumn mystery and ColorStream F 20-07 WNT viola fantasy;
and ultra interference pigments based on titanium dioxide and
mica.
[0058] The amount of solar reflective particles added is preferably
such that the resultant solar reflective roofing granules have a
solar reflectance of at least about 60 percent, and preferably at
least about 70 percent, while not unduly adversely affecting
granulation.
[0059] In one presently preferred embodiment uncalcined kaolin can
be employed as the source of mineral particles and metal-silicates
can be employed as binder to form uncured granules. In this case,
it is preferred that the kaolin can be formed into granule body by
a suitable granulation or agglomeration process and permitted to
dry to an uncured green body either by simple rotary dryer, in a
fluidized bed drier, or by drying in an oven in a suitable tray or
on a continuous belt. The reflective pigments can then be
incorporated into sodium silicate and the resultant mixture can
then be soaked into the green body of kaolin clay due to its high
porosity and capillary forces. Advantageously, the resultant
uncured granules can be heat cured at a temperature ranging from
about 500 to 800 degrees C. to react the kaolin and the sodium
silicate, which can be handled by simple kiln or dryer to further
reduce manufacturing cost, to form durable, hard granules suitable
for roofing applications.
[0060] The resultant granules can also be surface treated with
siliconates or suitable oils to enhance its adhesion to asphalt and
also to reduce their staining potentials.
[0061] Other methods of forming a granular body and incorporating
solar reflective particles during the formation of the said body
will become apparent to those who are skilled in the art.
[0062] In yet another aspect of the present invention, the binder
comprises a chemically bonded cement, preferably, a chemically
bonded phosphate cement. It is preferred in this aspect that the
binder comprise a chemically bonded phosphate cement prepared from
a cementitious exterior coating composition including at least one
metal oxide or a metal hydroxide slightly soluble in an acidic
aqueous solution to provide metal cations and a source of phosphate
anions. Preferably, the relative quantities of the at least one
metal oxide or metal hydroxide and at least one source of phosphate
anion are selected to provide a cured coating having a neutral pH,
the coating composition being cured by the acid-base reaction of
the at least one metal oxide or hydroxide and the source of
phosphate anions. Preferably, in this aspect the binder comprises
at least one metal oxide or metal hydroxide as a source of metal
cations and at least one phosphate. Preferably, at least one metal
oxide or metal hydroxide comprises at least one clay. Preferably,
the binder further includes colloidal silica.
[0063] Preferably, the at least one metal oxide or metal hydroxide
is selected from the group consisting of alkali earth metal oxides,
alkaline earth hydroxides, aluminum oxide, oxides of first row
transition metals, hydroxides of first row transition metals,
oxides of second row transition metals, and hydroxides of second
row transition metals. More preferably, the at least one metal
oxide or metal hydroxide is selected from the group consisting of
magnesium oxide, calcium oxide, iron oxide, copper oxide, zinc
oxide, aluminum oxide, cobalt oxide, zirconium oxide and molybdenum
oxide. Preferably, the at least one metal oxide or metal hydroxide
is sparingly soluble in an acidic aqueous solution. In addition, it
is preferred that the at least one metal oxide or metal hydroxide
comprise from about 10 to 30% by weight of the binder.
[0064] Preferably, the at least one phosphate is selected from the
group consisting of phosphoric acid and acid phosphate salts. More
preferably, the at least phosphate is selected from the group
consisting of phosphoric acid, and acid salts of phosphorous oxo
anions, and especially salts including at least one cation selected
from the group consisting of ammonium, calcium, sodium, potassium,
and aluminum cations. In particular, it is preferred that the at
least one phosphate be selected from the group consisting of
phosphoric acid, ammonium hydrogen phosphate, ammonium dihydrogen
phosphate, potassium hydrogen phosphate, potassium dihydrogen
phosphate, potassium phosphate, calcium hydrogen phosphate, calcium
dihydrogen phosphate, magnesium hydrogen phosphate, sodium hydrogen
phosphate, sodium dihydrogen phosphate, aluminum hydrogen
phosphate, aluminum dihydrogen phosphate, and mixtures thereof.
Commercial grades of calcium phosphate salts, such "NSP" (normal
super phosphate) and "TSP" (triple super phosphate) can also be
used. Potassium dihydrogen phosphate ("monopotassium phosphate"),
aluminum hydrophosphate (AlH.sub.3(PO.sub.4).2H.sub.2O),
monoaluminum phosphate (Al(H.sub.2PO.sub.4).sub.3) and magnesium
dihydrogen phosphate are especially preferred. Preferably, the at
least one phosphate comprises from about 10 to 60% by weight of the
binder.
[0065] In this aspect of solar reflective roofing granules
according to the present invention, the cure of the binder depends
on the composition of the chemically bonded cement. A broad range
of cure conditions, ranging from rapid room temperature curing to
low energy cures at moderately elevated temperatures to high energy
cures at more elevated temperatures can be attained by varying the
metal oxide or hydroxide and the phosphate. Optionally, the
reactivity of the metal oxide or hydroxide can be reduced by
calcining the metal oxide or metal hydroxide prior to preparing the
binder. In addition, the pot life of the binder can be extended by
the optional addition of a retardant such as boric acid.
[0066] In another aspect, the solar reflective roofing granules
according to the present invention can include an inert mineral
core material, covered with a layer of mineral particles, solar
reflective particles, and binder.
[0067] The inert mineral core material can be a suitably sized
mineral particle such as described above, or in the alternative,
the mineral core material can be a solid or hollow glass spheres.
Solid and hollow glass spheres are available, for example, from
Potters Industries Inc., P. O. Box 840, Valley Forge, Pa.
19482-0840, such as SPHERIGLASS.RTM. solid "A" glass spheres
product grade 1922 having a mean size of 0.203 mm, product code
602578 having a mean size of 0.59 mm, BALLOTTINI impact beads
product grade A with a size range of 600 to 850 micrometers (U.S.
sieve size 20-30), and QCEL hollow spheres, product code 300 with a
mean particle size of 0.090 mm. Glass spheres can be coated or
treated with a suitable coupling agent if desired for better
adhesion to the binder of the coating composition.
[0068] In another aspect of the present invention, solar reflective
roofing granules are produced by an accretion process such as
disclosed in U.S. Pat. No. 7,067,445, incorporated herein in its
entirety by reference. The starting materials employed are mineral
particles and binder, and optionally solar reflective particles.
The starting materials are preferably ground, if necessary, by ball
milling or another attrition process, to form particles having a
mean particle size of about 20 microns or less, more preferably,
about 15 microns or less, and most preferably about 10 microns or
less, expressed in terms of particle diameter (or average diameter
for non-spherical particles). The ground starting materials are
combined with a liquid, such as water, and mixed in an intensive
mixer, such as an Eirich mixer (Eirich Machines Inc., Gurnee, Ill.
60031) having a rotatable confinement vessel having a rotatable
table, or pan, and a rotatable impacting impeller. In an intensive
mixer the rotatable table and impeller rotate in opposite
directions. Sufficient water or other liquid is added to cause
essentially spherical pellets of the starting material mixture to
be formed (about 15 to 40 weight percent water based on the
starting materials). After such pellets have formed, a second
mixture is added, and the mixture is further operated to cause
accretion of the added material to the pellets being formed. The
second mixture includes solar reflective particles and binder, and
optionally mineral particles and colorant material particles. The
second mixture preferable comprises up to 25 percent, and more
preferably, from about 5 to 15 percent by weight, of the starting
materials. The pellet so formed are then dried to a moisture
content of less than about 10 weight percent, for example, in a
drier at a temperature between about 100 degree C. and 300 degrees
C. to form "green" roofing granules. The "green" roofing granules
so formed are subsequently cured. Depending on the nature of the
binder, the "green" granules can be cured by heating at an elevated
temperature to cure the binder. For example, when the binder
comprises aqueous sodium silicate and kaolin clay, the "green"
granules can be cured by heating at a temperature between about 400
degrees C. and 800 degrees C. to solidify the binder.
[0069] In another aspect of the present invention, solar reflective
roofing granules are produced by an accretion process similar to
that disclosed in U.S. Pat. No. 7,067,445. In this aspect of the
present invention, the starting materials employed are ceramic
particles and a sinter binder, and optionally solar reflective
particles.
[0070] Suitable ceramic particles include oxides, such as aluminum
oxides, such as alumina, silicon oxides, such as silica, and
mixtures thereof. Preferably, the ceramic particles comprise silica
and alumina, and comprise at least 80 percent by weight of the
starting materials, expressed in terms of the calcined (essentially
anhydrous) weight, and more preferably, at least about 90 percent
of the calcined weight.
[0071] "Calcined" as used herein refers to a heating process to
which a material has been subjected to release water and other
volatiles from the material, such as organic materials and
chemically bound water such water of hydration. Ore materials that
have been fully calcined exhibit very low loss on ignition ("LOI")
and moisture content, for example, about 1 to 2 percent by weight
or less. Uncalcined ore materials such as bauxites and clays can
contain from about 10 to about 40 percent volatiles. "Partially
calcined" material typically exhibit total volatiles (LOI and
moisture content) of about 5 to 8 percent. Typical calcination
temperatures are usually less than 1000 degrees C.
[0072] The ceramic particles can be clays (predominantly hydrated
alumina) such as kaolin, diaspore clay, burley clay, flint clay,
bauxitic clays, nature or synthetic bauxites, mixtures thereof and
the like. The ceramic particles can be calcined or partially
calcined. The ceramic particles are preferably formed from oxides,
aluminates, and silicates, such as magnesium silicates, and
preferably comprise up to 50 percent by weight, more preferably at
least 90 percent by weight, and most preferably at least 90 percent
by weight of the starting materials.
[0073] The starting materials can also include various sintering
aids, such as bentonite clay, iron oxide, boron, boron carbide,
aluminum diboride, boron nitride, boron phosphide, other boron
compounds, or fluxes such as sodium carbonate, lithium carbonate,
titania, calcium carbonate, and sodium silicate, which materials
can be added in amounts up to about 10 percent by weight to aid in
sintering.
[0074] In addition, a sintering binder, such as wax, a starch, or
resin, such as gelatinized cornstarch, polyvinyl alcohol, or
mixture thereof, can be added to the initial mixture to aid in
pelletizing the mixture and increase the green strength of the
pellets prior to sintering. The sintering binder can be added in an
amount of about 0 to 6 percent by weight of the starting
materials.
[0075] The starting materials are preferably ground, if necessary,
by ball milling or another attrition process, to form particles
having a mean particle size of about 20 microns or less, more
preferably, about 15 microns or less, and most preferably about 10
microns or less, expressed in terms of particle diameter (or
average diameter for non-spherical particles). The ground starting
materials are combined with a liquid, such as water, and mixed in
an intensive mixer. Sufficient water or other liquid is added to
cause essentially spherical pellets of the starting material
mixture to be formed (about 15 to 40 weight percent water based on
the starting materials). After such pellets have formed, a second
mixture is added, and the mixture is further operated to cause
accretion of the added material to the pellets being formed. The
second mixture includes solar reflective particles and sintering
binder, and optionally ceramic particles, sintering aid, and
colorant material particles. The second mixture preferable
comprises up to 25 percent, and more preferably, from about 5 to 15
percent by weight, of the starting materials. The pellet so formed
are then dried to a moisture content of less than about 10 weight
percent, for example, in a drier at a temperature between about 100
degree C. and 300 degrees C. to form "green" roofing granules.
[0076] The "green" roofing granules so formed are subsequently
sintered in a furnace at a sintering temperature until a specific
gravity of from about 2.1 to 4.1 grams per cubic centimeter is
obtained, depending on the composition of the starting materials,
and the desired specific gravity of the roofing granules. Sintering
generally causes a reduction of up to about 20 percent in pellet
size as well as an increase in specific gravity. Suitable sintering
temperatures are generally about 1150 degrees C. and above, more
preferably at about 1300 degrees C., still more preferably about
1500 degrees C., although sintering temperatures can be as high as
1600 degrees C.
[0077] In another aspect, roofing granule core particles are
prepared by a sintering process as described above, and are
subsequently treated to provide a surface layer with a desired
functionality, such as solar reflectivity, biocidal activity, or
other functionality. The surface coating can include solar
reflective particles and a binder curable at temperatures below the
sintering range. In this case, the solar reflective particles can
optionally be omitted from the core particles. Thus, in this aspect
the surface coating can be formed from a coating composition
including a binder selected from the group consisting of silicate,
silica, phosphate, titanate, zirconate, and aluminate binders, and
mixtures thereof, and the binder can further comprise an inorganic
material selected from the group consisting of aluminosilicate and
kaolin clay.
[0078] Referring now to the drawings, in which like reference
numerals refer to like elements in each of the several views, there
are shown schematically in FIGS. 1, 2, and 3 examples of solar
reflective roofing granules according to the present invention.
[0079] FIG. 1 is a schematic cross-sectional representation of a
first embodiment of solar reflective roofing granule 10 according
to the present invention. The solar reflective roofing granule 10
comprises a plurality of inert mineral particles 12 and solar
reflective particles 14 dispersed in a binder 16. The solar
reflective roofing granule 10 has an exterior surface 18. Solar
reflectance is provided to the solar reflective roofing granule 10
by virtue of the solar reflective particles 14 provided at or
proximate the exterior surface 18 of the solar reflective roofing
granule 10. The solar reflective roofing granule 10 can be formed
by extrusion, agglomeration, roll compaction or other forming
techniques. While the solar reflective roofing granule 10 is shown
schematically as a sphere in FIG. 1, solar reflective roofing
granules according to the present invention can assume any regular
or irregular shape. After formation, depending on binder chemistry
and the nature of the colorant, the solar reflective roofing
granule 10 can be fired at 250 degrees C. or higher (or less, in
the case of organic colorants), preferably from 500 degrees C. to
800 degrees C., to insolubilize the binder 16. The particle size of
the solar reflective roofing granule 10 preferably ranges from
about 0.1 mm to 3 mm, and more preferably from about 0.5 mm to 1.5
mm. The inert mineral particles 12 are minute particulates or dust,
such as for example, particulates of rhyolite, syenite, bauxite and
other rock sources formed as a byproduct from quarry, crushing and
similar operations. The inert mineral particles 12 preferably have
a particle size ranging from about 0.1 micrometer to 40
micrometers, and more preferably from about 0.25 micrometer to 20
micrometers. The binder 16 is preferably selected from the group
consisting of silicate, silica, phosphate, titanate, zirconate and
aluminate binders, and mixtures thereof. The binder content of the
solar reflective roofing granule 10 preferably ranges from 10% to
90% by weight. In addition, aluminosilicate, kaolin clay and other
inorganic materials can be added to the binder 16 to improve the
mechanical, chemical, or physical properties of the solar
reflective roofing granule 10.
[0080] FIG. 2 is a schematic cross-sectional representation of a
second embodiment of solar reflective roofing granule 20 according
to the present invention. The solar reflective roofing granule 20
comprises a plurality of inert mineral particles 22 dispersed in a
binder 26, and solar reflective particles 24 adhered to the
exterior surface 28 of the solar reflective roofing granule 20. The
solar reflective granules 20 of this second embodiment can be
prepared by mixing the inert mineral particles 22 with the binder
26 and forming uncured granule bodies (not shown) from the mixture
by granulation, agglomeration or another technique. The mixture is
preferably prepared so that the binder remains somewhat tacky or
adhesive after the uncured granule bodies have been formed. The
uncured granule bodies are then dusted with the solar reflective
particles 24 so that the solar reflective particles mechanically
adhere to the exterior surface of the uncured granule bodies to
form uncured roofing granules (not shown). The uncured roofing
granules are then subjected to elevated temperature to cure the
binder to form the solar reflective roofing granules 20.
[0081] FIG. 3 is a schematic cross-sectional representation of a
third embodiment of a solar reflective roofing granule 30 according
to the present invention. The solar reflective roofing granule 30
comprises a plurality of inert mineral particles 32 dispersed in a
binder 36 to form an inert composite mineral body or granule body
35 having an exterior surface 38, covered with a plurality of solar
reflective particles 34 dispersed in an exterior binder 40. Solar
reflective activity is provided to the solar reflective roofing
granule 30 by virtue of the solar reflective particles 34 provided
at or proximate the exterior surface 39 of the solar reflective
roofing granule 30. The solar reflective roofing granules 30 of
this third embodiment can be prepared by mixing the inert mineral
particles 32 with the binder 36 and forming uncured granule bodies
(not shown) from the mixture by granulation or another technique.
The uncured granule bodies are then covered with a slurry of the
solar reflective particles 34 dispersed in another binder material
40 so that the slurry of solar reflective particles 34 adheres to
the exterior surface of the uncured granule bodies to form uncured
roofing granules (not shown). The uncured roofing granules are then
subjected to elevated temperature to cure the binder to form the
solar reflective roofing granules 30. The binder 40 employed to
form the slurry of solar reflective particles 34 can be the same as
that employed to form the uncured granule bodies, or a different
binder can be employed.
[0082] FIG. 4 is a schematic cross-sectional representation of a
fourth embodiment of a solar reflective roofing granule 40
according to the present invention. The solar reflective roofing
granule 40 comprises a plurality of inert mineral particles 42 and
dispersed in a binder 46 as well as an exterior layer 50 of solar
reflective particles 44 dispersed in binder 46 proximate the
surface of the roofing granule 40, and formed by a particle
accretion process in an intensive mixer. The exterior layer 50 can
have a thickness of from about 20 micrometers to 200 micrometers.
The exterior layer 50 can also include particulate colorants 49 or
dyes, better seen in the partial fragmentary view of FIG. 4a.
[0083] FIG. 5 is a fragmentary schematic cross-sectional
representation of a fifth embodiment of a solar reflective roofing
granule 60 according to the present invention. The solar reflective
roofing granule 60 comprises a plurality of sintered ceramic
particles 62 and an exterior layer 70 of solar reflective particles
64 sintered to the ceramic particles 62 proximate to the surface
the roofing granule 60, and formed by a particle accretion process
in an intensive mixer to form green pellets, followed by sintering
at an elevated temperature. The exterior layer 70 can have a
thickness of from about 20 micrometers to 200 micrometers. The
exterior layer 90 can also include particulate colorants 69,
sintered to the ceramic particles 62 and/or solar reflective
particles 64.
[0084] The solar reflective roofing granules of the present
invention can be employed in the manufacture of roofing products,
such as asphalt shingles and bituminous membranes, using
conventional roofing production processes. Typically, bituminous
roofing products are sheet goods that include a non-woven base or
scrim formed of a fibrous material, such as a glass fiber scrim.
The base is coated with one or more layers of a bituminous material
such as asphalt to provide water and weather resistance to the
roofing product. One side of the roofing product is typically
coated with mineral granules to provide durability, reflect heat
and solar radiation, and to protect the bituminous binder from
environmental degradation. The solar reflective roofing granules of
the present invention can be mixed with conventional roofing
granules, and the granule mixture can be embedded in the surface of
such bituminous roofing products using conventional methods.
Alternatively, the solar reflective roofing granules of the present
invention can be substituted for conventional roofing granules in
manufacture of bituminous roofing products.
[0085] Bituminous roofing products are typically manufactured in
continuous processes in which a continuous substrate sheet of a
fibrous material such as a continuous felt sheet or glass fiber mat
is immersed in a bath of hot, fluid bituminous coating material so
that the bituminous material saturates the substrate sheet and
coats at least one side of the substrate. The reverse side of the
substrate sheet can be coated with an anti-stick material such as a
suitable mineral powder or a fine sand. Roofing granules are then
distributed over selected portions of the top of the sheet, and the
bituminous material serves as an adhesive to bind the roofing
granules to the sheet when the bituminous material has cooled. The
sheet can then be cut into conventional shingle sizes and shapes
(such as one foot by three feet rectangles), slots can be cut in
the shingles to provide a plurality of "tabs" for ease of
installation and aesthetic effect, additional bituminous adhesive
can be applied in strategic locations and covered with release
paper to provide for securing successive courses of shingles during
roof installation, and the finished shingles can be packaged. More
complex methods of shingle construction can also be employed, such
as building up multiple layers of sheet in selected portions of the
shingle to provide an enhanced visual appearance, or to simulate
other types of roofing products. Alternatively, the sheet can be
formed into membranes or roll goods for commercial or industrial
roofing applications.
[0086] The bituminous material used in manufacturing roofing
products according to the present invention is derived from a
petroleum-processing by-product such as pitch, "straight-run"
bitumen, or "blown" bitumen. The bituminous material can be
modified with extender materials such as oils, petroleum extracts,
and/or petroleum residues. The bituminous material can include
various modifying ingredients such as polymeric materials, such as
SBS (styrene-butadiene-styrene) block copolymers, resins,
flame-retardant materials, oils, stabilizing materials, anti-static
compounds, and the like. Preferably, the total amount by weight of
such modifying ingredients is not more than about 15 percent of the
total weight of the bituminous material. The bituminous material
can also include amorphous polyolefins, up to about 25 percent by
weight. Examples of suitable amorphous polyolefins include atactic
polypropylene, ethylene-propylene rubber, etc. Preferably, the
amorphous polyolefins employed have a softening point of from about
130 degrees C. to about 160 degrees C. The bituminous composition
can also include a suitable filler, such as calcium carbonate,
talc, carbon black, stone dust, or fly ash, preferably in an amount
from about 10 percent to 70 percent by weight of the bituminous
composite material.
Example
[0087] Particles with high solar reflectance are prepared by
agglomerating the appropriate materials in an Eirich RV02 mixer
using the following procedure. A quantity of the kaolin material
(Calcined Plastic Fireclay by Christy Minerals) and a drilling
starch binder were disposed into an Eirich mixer and dry mixed for
30 seconds. De-ionized water was then added over a 30 second period
as the mixer continued to rotate and spheres of base material were
formed. After approximately four minutes of mixing the base
material, binder and water, the TiO.sub.2 pigment material (CR-826,
available from Tronox, Okla. City, Okla.) was slowly added over 3
to 5 minutes to the mass of rotating spherically shaped bases by
sprinkling (also known as "dusting in") the layer material on top
of the bases as they were moving in the mixer until uniform
distribution of the TiO.sub.2 pigment on particle surface was
observed. Samples contain various amounts of kaolin material and
TiO.sub.2 pigments which total a constant 15 lbs. The formed
particles were then spread on a tray and dried in a forced air oven
and were then fired to sinter in a static kiln at various
temperatures to form solar reflective particles. The amount of
TiO.sub.2 pigments and the firing temperatures are listed in Table
1, along with the color reading, solar reflectance (ASTM C-1549
method), and the UV opacity (ARMA Granule Test Manual Test Method
#9) of the resultant particles. In Table 2, the particle size data
of the resultant particles are listed. As one can see, the
particles have high solar reflectance with suitable sizes for
roofing applications.
TABLE-US-00001 TABLE 1 Firing TiO2 Temp. Color Reading Solar % UV
wt % .degree. C. L* a* b* Reflectance Opacity 0 900 82.38 5.55 9.18
0.697 NA 0 1200 88.05 1.47 7.21 0.746 93 0 1450 87.91 0.82 11.49
0.78 94.9 20 900 84.86 2.14 9.62 0.725 NA 20 1200 81.71 2.49 18.14
0.712 92 20 1450 70.67 8.04 27.52 0.623 97 30 900 86.57 1.74 9.25
0.749 NA 30 1200 82 2.05 17.13 0.719 99 30 1450 68.95 8.42 27.08
0.625 99 40 900 87.63 0.74 7.1 0.749 NA 40 1200 81.51 1.38 15.07
0.708 100 40 1450 68.25 8.21 26.08 0.628 100
TABLE-US-00002 TABLE 2 Firing TiO2 Temp. Sieve Analysis, wt %
retaining on US mesh size wt % .degree. C. #8 #12 #16 #20 #30 #40
Pan 0 900 5.54 17.52 48.66 23.43 3.03 0.27 1.41 0 1200 6.42 16.08
46.62 25.03 4.24 0.43 1.19 0 1450 2.39 8.15 37.54 39.97 9.55 1.89
0.05 20 900 14.59 25.2 34.31 18.49 5.02 1.27 1.12 20 1200 11.97
20.23 33.78 24.52 7.32 1.8 0.38 20 1450 7.87 15.46 31.13 29.18
11.44 3.89 1.03 30 900 2.45 15.4 46.42 30.74 4.52 0.29 0.18 30 1200
1.61 8.19 35.57 41.67 11.28 1.53 0.15 30 1450 1.22 7.26 30.91 44.35
13.83 2.3 0.13 40 900 1.74 21.38 46.6 25.875 4.04 0.34 0.1 40 1200
0.64 11.95 44.28 36.99 5.54 0.13 0 40 1450 0.21 7.85 36.85 40.9
11.8 2.14 0.25
[0088] Various modifications can be made in the details of the
various embodiments of the processes, compositions and articles of
the present invention, all within the scope and spirit of the
invention and defined by the appended claims.
* * * * *