Roofing Materials with Synthetic Roofing Granules and Methods of Making Thereof

This application claims the priority of U.S. provisional application Ser. No. U.S. 63/161,483, entitled “Roofing Materials With Synthetic Roofing Granules And Methods of Making Thereof” filed Mar. 16, 2021, which is incorporated herein by reference in its entirety for all purposes.

This invention relates to roofing materials having synthetic roofing granules and methods of making these roofing materials. By preparing roofing materials such as, e.g., shingles, using synthetic or non-mineral based roofing granules, these roofing materials can exhibit superior properties of, for example, reduced weight, improved or higher solar reflectance, reduced staining, improved color saturation and/or gloss, as compared to roofing materials having traditional, mineral-based roofing granules.

Traditional roofing materials, such as, e.g., shingles, are based upon a glass or felt mat that is coated and impregnated with an asphalt-based composition that is coated with granules. These granules, which are typically mineral-based particles, are applied to the surface of the shingles to protect the shingle, while also providing additional coloring and/or textures to thus, enhance the aesthetics of the shingle. Generally, the mineral-based particles are mined from rock that is dense, which results in a significant increase in the weight of the shingle. Additionally, the mineral-based particles are typically dark in color for the necessary UV opacity to protect the asphaltic materials of the shingle from degradation over time, while also having a rough surface as a result of crushing the material to size. As a result, these dark-color, rough granules have a tendency to absorb high levels of solar radiation, while the rough surfaces decrease reflectivity of the granules. This absorption of high levels of solar radiation, as well as the decreased reflectivity of the granules can result in a “hot roof,” which can lead to an increase in the cooling energy needed to keep the indoor air comfortable during summer seasons.

As discussed above, roofing granules comprising mineral-based particles can significantly increase the weight of the shingle, such that the shingles become heavy to handle and/or the design of multiple layers of shingles is limited due to the heavy weight of the final shingle product. Also, the mineral-based roofing granules have a tendency to absorb oils from the asphalt of the shingles, which results in an undesirable “stained” or “darkened” color of the shingle.

There is thus a need for synthetic or non-mineral based roofing granules for preparing roofing materials that exhibit reduced weight, improved solar reflectance, reduced staining, improved color and/or gloss, as compared to roofing materials having traditional, mineral-based roofing granules.

One embodiment of this invention pertains to a roofing material comprising (a) a coated substrate having a top surface and a back surface, and (b) a plurality of roofing granules applied to the top surface of the coated substrate. The plurality of roofing granules comprises from 50% to 100% of unitary, uncoated, non-mineral based particles.

In one embodiment, the substrate comprises one of a fiberglass mat, a polyester mat, a scrim, a coated scrim, or a combination thereof.

In one embodiment, the roofing material is one of a roofing shingle and a roofing tile.

In one embodiment, the roofing material is one of (i) an asphaltic shingle, (ii) a non-asphaltic shingle, and (ii) a polymer-modified asphalt shingle.

In some embodiments, each roofing granule of the plurality of roofing granules has a density of 1.2 g/cmto 2.5 g/cm.

In one embodiment, the non-mineral based particles comprise a synthetic particle.

In one embodiment, the non-mineral based particles comprise at least one of a thermoplastic polymer, filled polymers, filled rubbers, filled plastics, a polymer-sand composite, a rubber particle, a recycled material, a wood filled polymer, a bio-based particle, a thermoset material, a fiber-reinforced polymer, and combinations thereof.

In one embodiment, the non-mineral based particles have an aspect ratio of from 1.5 to 50. In another embodiment, the non-mineral based particles have an aspect ratio of from 5 to 30.

In one embodiment, the non-mineral based particles have a particle size of #8 US mesh to #60 US mesh.

In one embodiment, less than 1% by weight of the plurality of roofing granules have a particle size of greater than #100 US mesh.

In an embodiment, the roofing material exhibits a lower weight per thickness as compared to a roofing material prepared with roofing granules comprising a majority of mineral based particles.

In one embodiment, the roofing material exhibits a weight per thickness of 1 to 3 g/mil/ft.

In one embodiment, the roofing material exhibits an improved staining resistance as compared to a roofing material prepared with roofing granules comprising a majority of mineral based particles.

In an embodiment, the roofing granules exhibit a total solar reflectance (TSR) of 0.2 to 0.8 according to ASTM C1549.

In one embodiment, the roofing granules exhibit a higher color saturation as compared to roofing granules comprising mineral based particles.

Another embodiment of this invention pertains to a method of preparing a roofing material. The method includes (a) obtaining a coated substrate, (b) obtaining a plurality of roofing granules, wherein the plurality of roofing granules comprises from 50% to 100% of unitary, uncoated, non-mineral based particles, and (c) applying the plurality of roofing granules to a surface of the coated substrate to form a roofing material.

In one embodiment, the step of applying the plurality of roofing granules to the surface of the coated substrate is conducted to achieve an average surface coverage amount of the roofing granules of greater than 80%.

In one embodiment, the substrate comprises one of a fiberglass mat, a polyester mat, a scrim, a coated scrim, or a combination thereof.

In some embodiments, the roofing material is one of a roofing shingle and a roofing tile.

In some embodiments, each roofing granule of the plurality of roofing granules has a density of 1.2 g/cmto 2.5 g/cm.

In one embodiment, the non-mineral based particles comprise a synthetic particle.

In one embodiment, the non-mineral based particles comprise at least one of a thermoplastic polymer, filled polymers, filled rubbers, filled plastics, a polymer-sand composite, a rubber particle, a recycled material, a wood filled polymer, a bio-based particle, a thermoset material, a fiber-reinforced polymer, and combinations thereof.

Among those benefits and improvements that have been disclosed, other objects and advantages of this disclosure will become apparent from the following description taken in conjunction with the accompanying figures. Detailed embodiments of the present disclosure are disclosed herein; however, it is to be understood that the disclosed embodiments are merely illustrative of the disclosure that may be embodied in various forms. In addition, each of the examples given regarding the various embodiments of the disclosure are intended to be illustrative, and not restrictive.

Throughout the specification and claims, the following terms take the meanings explicitly associated herein, unless the context clearly dictates otherwise. The phrases “in one embodiment,” “in an embodiment,” and “in some embodiments” as used herein do not necessarily refer to the same embodiment(s), though they may. Furthermore, the phrases “in another embodiment” and “in some other embodiments” as used herein do not necessarily refer to a different embodiment, although they may. All embodiments of the disclosure are intended to be combinable without departing from the scope or spirit of the disclosure.

As used herein, the term “based on” is not exclusive and allows for being based on additional factors not described, unless the context clearly dictates otherwise. In addition, throughout the specification, the meaning of “a,” “an,” and “the” include plural references. The meaning of “in” includes “in” and “on.”

As used herein, terms such as “comprising,” “including,” and “having” do not limit the scope of a specific claim to the materials or steps recited by the claim.

As used herein, terms such as “consisting of” and “composed of” limit the scope of a specific claim to the materials and steps recited by the claim.

All prior patents, publications, and test methods referenced herein are incorporated by reference in their entireties.

As used herein, the term “coated substrate” means a substrate that is coated on one side (upper surface or lower surface) or both sides (upper surface and lower surface) with a coating that includes, for example, an asphaltic coating, a non-asphaltic coating, and/or a polymer-modified asphalt coating. According to one embodiment, the “coated substrate” can also include a modified bitumen roll(s), a roll(s) of non-asphaltic roofing, metal shingles and/or tiles, and any other roofing tiles or elements where a granulated surface is desired.

As used herein, the term “weight percent” or “% by weight” means the percentage by weight of the roofing granules based upon a total weight of the roofing granules applied to the roofing material.

As used herein, the term “a majority of” means greater than 50% by weight.

As used herein, the term “roofing material” includes, but is not limited to, shingles, waterproofing membranes, underlayment, and tiles.

One embodiment of this invention pertains to a roofing material comprising (a) a coated substrate having a top surface and a back surface, and (b) a plurality of roofing granules applied to the top surface of the coated substrate. The plurality of roofing granules comprises from 50% to 100% of unitary, uncoated, non-mineral based particles.

illustrates a roofing material (e.g., shingle)according to an embodiment of the invention. In this embodiment, the roofing materialincludes a coated substratehaving a front or top surfaceand a back surface. The roofing materialfurther includes an upper portion or headlap portionand a lower portion or buttlap portion. The buttlap portionincludes a series of cut-outsleaving a plurality of tabs. The edgeof the buttlap portionwill be the lowermost or bottom edge of the roofing materialwhen installed onto a roof. Attached and/or laminated to the back surfaceof the roofing materialis a backer strip. As shown in, the upper surface of the backer stripis visible between the tabsof the buttlap portionof the coated substrateof the roofing material.

The roofing materialof the embodiment offurther includes a plurality of roofing granulesdisposed on the top surfaceof the headlap portion, the plurality of tabs, and the backer strip. In an embodiment, the plurality of roofing granules comprises from 50% to 100% of unitary, uncoated, non-mineral based particles. In an embodiment, the plurality of roofing granules comprises from 60% to 100% of unitary, uncoated, non-mineral based particles. In an embodiment, the plurality of roofing granules comprises from 70% to 100% of unitary, uncoated, non-mineral based particles. In an embodiment, the plurality of roofing granules comprises from 75% to 100% of unitary, uncoated, non-mineral based particles. In an embodiment, the plurality of roofing granules comprises from 80% to 100% of unitary, uncoated, non-mineral based particles. In an embodiment, the plurality of roofing granules comprises from 85% to 100% of unitary, uncoated, non-mineral based particles. In an embodiment, the plurality of roofing granules comprises from 90% to 100% of unitary, uncoated, non-mineral based particles. In an embodiment, the plurality of roofing granules comprises from 95% to 100% of unitary, uncoated, non-mineral based particles. In an embodiment, the plurality of roofing granules comprises from 50% to 90% of unitary, uncoated, non-mineral based particles. In an embodiment, the plurality of roofing granules comprises from 60% to 90% of unitary, uncoated, non-mineral based particles. In an embodiment, the plurality of roofing granules comprises from 70% to 90% of unitary, uncoated, non-mineral based particles. In an embodiment, the plurality of roofing granules comprises from 80% to 90% of unitary, uncoated, non-mineral based particles. In an embodiment, the plurality of roofing granules comprises from 50% to 80% of unitary, uncoated, non-mineral based particles. In an embodiment, the plurality of roofing granules comprises from 60% to 80% of unitary, uncoated, non-mineral based particles. In an embodiment, the plurality of roofing granules comprises from 70% to 80% of unitary, uncoated, non-mineral based particles. In an embodiment, the plurality of roofing granules comprises from 50% to 70% of unitary, uncoated, non-mineral based particles. In an embodiment, the plurality of roofing granules comprises from 60% to 70% of unitary, uncoated, non-mineral based particles. In an embodiment, the plurality of roofing granules comprises from 50% to 60% of unitary, uncoated, non-mineral based particles.

In an embodiment, the substrate (e.g., coated substrate) comprises one of a fiberglass mat, a polyester mat, a scrim, a coated scrim, or a combination thereof. In some embodiments, the substrate or mat includes nano-fibrillated cellulose fibers.

In an embodiment, the roofing material (e.g., roofing material) is one of a roofing shingle and a roofing tile. In some embodiments, the roofing material is one of (i) an asphaltic shingle, (ii) a non-asphaltic shingle, and (ii) a polymer-modified asphalt shingle. According to one embodiment, the roofing material is a roofing shingle that is one of (i) a single layer shingle or (ii) a laminated shingle having two or more layers.

In an embodiment, each roofing granule of the plurality of roofing granules has a density of 1 g/cmto 3 g/cm. In an embodiment, each roofing granule of the plurality of roofing granules has a density of 1.2 g/cmto 3 g/cm. In an embodiment, each roofing granule of the plurality of roofing granules has a density of 1.5 g/cmto 3 g/cm. In an embodiment, each roofing granule of the plurality of roofing granules has a density of 1.6 g/cmtog/cm. In an embodiment, each roofing granule of the plurality of roofing granules has a density of 1.8 g/cmto 3 g/cm. In an embodiment, each roofing granule of the plurality of roofing granules has a density of 2 g/cmto 3 g/cm. In an embodiment, each roofing granule of the plurality of roofing granules has a density of 2.2 g/cmto 3 g/cm. In an embodiment, each roofing granule of the plurality of roofing granules has a density of 2.5 g/cmto 3 g/cm. In an embodiment, each roofing granule of the plurality of roofing granules has a density of 2.8 g/cmto 3 g/cm. In an embodiment, each roofing granule of the plurality of roofing granules has a density of 1 g/cmto 2.5 g/cm. In an embodiment, each roofing granule of the plurality of roofing granules has a density of 1.2 g/cmto 2.5 g/cm. In an embodiment, each roofing granule of the plurality of roofing granules has a density of 1.5 g/cmto 2.5 g/cm. In an embodiment, each roofing granule of the plurality of roofing granules has a density of 1.6 g/cmto 2.5 g/cm. In an embodiment, each roofing granule of the plurality of roofing granules has a density of 1.8 g/cmto 2.5 g/cm. In an embodiment, each roofing granule of the plurality of roofing granules has a density of 2 g/cmto 2.5 g/cm. In an embodiment, each roofing granule of the plurality of roofing granules has a density of 2.2 g/cmto 2.5 g/cm. In an embodiment, each roofing granule of the plurality of roofing granules has a density of 1 g/cmto 2 g/cm. In an embodiment, each roofing granule of the plurality of roofing granules has a density of 1.2 g/cmto 2 g/cm. In an embodiment, each roofing granule of the plurality of roofing granules has a density of 1.5 g/cmto 2 g/cm. In an embodiment, each roofing granule of the plurality of roofing granules has a density of 1.6 g/cmto 2 g/cm. In an embodiment, each roofing granule of the plurality of roofing granules has a density of 1.8 g/cmto 2 g/cm. In an embodiment, each roofing granule of the plurality of roofing granules has a density of 1 g/cmto 1.6 g/cm. In an embodiment, each roofing granule of the plurality of roofing granules has a density of 1.2 g/cmto 1.6 g/cm. In an embodiment, each roofing granule of the plurality of roofing granules has a density of 1.5 g/cmto 1.6 g/cm.

In an embodiment, the non-mineral based particles comprise a synthetic particle. In some embodiments, the non-mineral based particles comprise at least one of a thermoplastic polymer, filled polymers, filled rubbers, filled plastics, highly filled polymer particles, composite particles of non-mineral materials, such as a polymer-sand composite, a rubber particle, a recycled material, a wood filled polymer, a bio-based particle, a thermoset material, a fiber-reinforced polymer, and combinations thereof. According to one embodiment, the particles can be highly filled with mineral fillers, including, e.g., sands, stone fines, granule fines, calcium carbonates, clays, fly ashes, and combinations thereof. According to an embodiment, the particles can be filled with mineral fillers by up to 75% by weight.

In an embodiment, the non-mineral based particles can contain functional fillers to improve processability, impact resistance, fire resistance, UV resistance, UV blocking, oxidation resistance, color stability, algae resistance, and combinations thereof, as well as fillers able to remove and/or trap a targeted chemical compound (such as, e.g., NOx, CO, etc.). Also, according to an embodiment, the particles can have highly reflective pigments, such as, e.g., pigments comprising TiO, metal oxides, graphene, perylene, transitional metal oxides, metallic pigments, pearlescent pigments, thin film coated pigments, solar reflective colorants, solar reflective fillers, opacifiers, voids, or their combinations to increase the total solar reflectance of the particles.

According to an embodiment, the non-mineral based particles can be obtained via a number of processes, including, but not limited to, extrusion, co-extrusion, blending or mixing at elevated temperatures, or any agglomeration process to form the initial mass, followed by particle forming methods such as, e.g., crushing, impact-crushing, hammer mills, cryogenic crushing or grinding, roller mills, chopping or cutting after extrusion strand forming, injection molding, compression molding, encapsulations, and combinations thereof.

According to an embodiment, the non-mineral based particles can have other structures such as, e.g., a core-shell structure to have different layers that can provide different functionalities and/or to have a low-cost core covered with a durable, weatherable outer layer. Also, according to an embodiment, the non-mineral based particles can include a biocide or algaecide to help to control the roof algae growth and/or to maintain the aesthetics. Furthermore, according to an embodiment, the non-mineral based particles can have an adhesive promoter, a surface for promoting adhesion to asphalt, and/or a surface treated via plasma or flame or the like to promote its adhesion to an asphaltic coating.

According to an embodiment, the non-mineral based particles comprise one or more shapes, including, for example, round shapes, flat circles, squares, cylinders (including, e.g., flat cylinders, disk-shapes, rod shapes, and/or pancakes), flat rectangles (including, e.g., coasters), etc., and combinations thereof.

According to an embodiment, the non-mineral based particles have an aspect ratio, meaning a ratio between the smallest dimension to the largest dimension of the particles (e.g., a ratio of the thickness to the diameter of, for example, a disk-shaped particle and/or a ratio of the thickness to the length of, for example, a rod shaped particle), of from 1.5 to 50. According to another embodiment, the non-mineral based particles have an aspect ratio of from 2 to 50. According to an embodiment, the non-mineral based particles have an aspect ratio of from 3 to 50. According to an embodiment, the non-mineral based particles have an aspect ratio of from 5 to 50. According to an embodiment, the non-mineral based particles have an aspect ratio of from 10 to 50. According to an embodiment, the non-mineral based particles have an aspect ratio of from 15 to 50. According to an embodiment, the non-mineral based particles have an aspect ratio of from 20 to 50. According to an embodiment, the non-mineral based particles have an aspect ratio of from 25 to 50. According to an embodiment, the non-mineral based particles have an aspect ratio of from 30 to 50. According to an embodiment, the non-mineral based particles have an aspect ratio of from 40 to 50. According to an embodiment, the non-mineral based particles have an aspect ratio of from 1.5 to 40. According to an embodiment, the non-mineral based particles have an aspect ratio of from 2 to 40. According to an embodiment, the non-mineral based particles have an aspect ratio of from 3 to 40. According to an embodiment, the non-mineral based particles have an aspect ratio of from 5 to 40. According to an embodiment, the non-mineral based particles have an aspect ratio of from 10 to 40. According to an embodiment, the non-mineral based particles have an aspect ratio of from 15 to 40. According to an embodiment, the non-mineral based particles have an aspect ratio of from 20 to 40. According to an embodiment, the non-mineral based particles have an aspect ratio of from 25 to 40. According to an embodiment, the non-mineral based particles have an aspect ratio of from 30 to 40. According to an embodiment, the non-mineral based particles have an aspect ratio of from 1.5 to 30. According to an embodiment, the non-mineral based particles have an aspect ratio of from 2 to 30. According to an embodiment, the non-mineral based particles have an aspect ratio of from 3 to 30. According to an embodiment, the non-mineral based particles have an aspect ratio of from 5 to 30. According to an embodiment, the non-mineral based particles have an aspect ratio of from 10 to 30. According to an embodiment, the non-mineral based particles have an aspect ratio of from 15 to 30. According to an embodiment, the non-mineral based particles have an aspect ratio of from 20 to 30.

According to an embodiment, the non-mineral based particles have an aspect ratio of from 25 to 30. According to an embodiment, the non-mineral based particles have an aspect ratio of from 1.5 to 25. According to an embodiment, the non-mineral based particles have an aspect ratio of from 2 to 25. According to an embodiment, the non-mineral based particles have an aspect ratio of from 3 to 25. According to an embodiment, the non-mineral based particles have an aspect ratio of from 5 to 25. According to an embodiment, the non-mineral based particles have an aspect ratio of from 10 to 25. According to an embodiment, the non-mineral based particles have an aspect ratio of from 15 to 25. According to an embodiment, the non-mineral based particles have an aspect ratio of from 20 to 25. According to an embodiment, the non-mineral based particles have an aspect ratio of from 1.5 to 20. According to an embodiment, the non-mineral based particles have an aspect ratio of from 2 to 20. According to an embodiment, the non-mineral based particles have an aspect ratio of from 3 to 20. According to an embodiment, the non-mineral based particles have an aspect ratio of from 5 to 20. According to an embodiment, the non-mineral based particles have an aspect ratio of from 10 to 20. According to an embodiment, the non-mineral based particles have an aspect ratio of from 15 to 20. According to an embodiment, the non-mineral based particles have an aspect ratio of from 1.5 to 15. According to an embodiment, the non-mineral based particles have an aspect ratio of from 2 to 15. According to an embodiment, the non-mineral based particles have an aspect ratio of from 3 to 15. According to an embodiment, the non-mineral based particles have an aspect ratio of from 5 to 15. According to an embodiment, the non-mineral based particles have an aspect ratio of from 10 to 15. According to an embodiment, the non-mineral based particles have an aspect ratio of from 1.5 to 10. According to an embodiment, the non-mineral based particles have an aspect ratio of from 2 to 10. According to an embodiment, the non-mineral based particles have an aspect ratio of from 3 to 10. According to an embodiment, the non-mineral based particles have an aspect ratio of from 5 to 10. According to an embodiment, the non-mineral based particles have an aspect ratio of from 1.5 to 5. According to an embodiment, the non-mineral based particles have an aspect ratio of from 2 to 5. According to an embodiment, the non-mineral based particles have an aspect ratio of from 3 to 5. According to an embodiment, the non-mineral based particles have an aspect ratio of from 1.5 to 3. According to an embodiment, the non-mineral based particles have an aspect ratio of from 2 to 3. According to an embodiment, the non-mineral based particles have an aspect ratio of from 1.5 to 2. According to an embodiment, the non-mineral based particles have an aspect ratio of from 1 to 1.