REFLECTIVE ROOF COATING HAVING REDUCED TITANIUM DIOXIDE

Abstract

A reflective coating that is substantially or fully absent of TiO.sub.2, and which coating is capable of meeting the ASTM D6083 specification for acrylic roof coatings, and which coating has suitable hide to achieve an average resulting solar reflectively of at least 60% or an SRI of at least 60.

Claims

1. A method of forming a roofing and/or siding material comprising: a) providing a substrate member that forms at least part of a roofing system of a structure or is configured to subsequently be used as at least part of a roofing system of a structure; said substrate member has a top surface; and b) applying a layer of coating material to said top surface of said substrate member; said coating material including a water-based coating, a solvent-based coating, a latex-based coating, an acrylic-based coating, a vinyl-acrylic based coating, a polyurethane base coating, a polyurea-based coating, a silicone-based coating, a silicon hybrid based coating, polyvinyl alcohol-based coating, polydimethylsiloxane-based coating, PMMA-based coating, PUMA-based coating, SEBS elastomeric based coating, alkyd-based coating, epoxy-based coating, or a polyvinylidene fluoride (PVDF) based coating; said coating material includes less than 10 wt. % titanium dioxide; said coating material satisfies the requirements under ASTM D6083; said coating material has an average resulting reflectively in a dried state of at least 60% or an SRI of at least 60; said coating material includes a pigment and a pigment extender; said pigment includes of BaSO.sub.4, ZnO, and/or ZnS; said pigment extender includes microspheres.

2. The method as defined in claim 1, wherein said coating material includes a fire retardant; said fire retardant includes antimony trioxide (Sb.sub.2O.sub.3), aluminum trihydrate (ATH), and/or ammonium polyphosphate (NH.sub.4PO.sub.3).

3. The method as defined in claim 1, wherein a top surface of said substrate member and/or a top surface of said coating material includes granules or slag.

4. The method as defined in claim 1, wherein said substrate material is a prefabricated material.

5. The method as defined in claim 1, wherein said BaSO.sub.4, ZnO, and/or ZnS constitutes 50-100 wt. % of said pigment.

6. The method as defined in claim 1, wherein said pigment includes BaSO.sub.4 and ZnO at a weight ratio of 9:1 to 1:9.

7. The method as defined in claim 1, wherein said pigment includes BaSO.sub.4 and ZnS at a weight ratio of 9:1 to 1:9.

8. The method as defined in claim 1, wherein said pigment includes BaSO.sub.4, ZnO and ZnS; a weight ratio of BaSO.sub.4 to the combined weight of ZnO and ZnS is 9:1 to 1:9; and a weight ratio of ZnO and ZnS is 100:1 to 1:100.

9. The method as defined in claim 1, wherein coating material includes a secondary pigment that includes one or more of CaCO.sub.3, SiO.sub.2, Al.sub.2O.sub.3, MgO, YAlO.sub.3, CaO, MgAl.sub.2O.sub.4, Al(OH).sub.3, and/or LaAlO.sub.3.

10. The method as defined in claim 9, wherein a weight ratio of the combined weight percent of BaSO.sub.4, ZnO, and ZnS to a combined weight percent of CaCO.sub.3 SiO.sub.2, Al.sub.2O.sub.3, MgO, YAlO.sub.3, CaO, MgAl.sub.2O.sub.4, Al(OH).sub.3, and LaAlO.sub.3 is 9:1 to 1:5.

11. The method as defined in claim 9, wherein said secondary pigment has an average particle size of 1 nanometer to 500 nanometers.

12. The method as defined in claim 1, wherein said pigment constitutes at least 0.5 wt. % of said coating material.

13. The method as defined in claim 1, wherein said pigment has an average particle size of 1 nanometer to 500 nanometers.

14. The method as defined in claim 2, wherein said fire retardant includes antimony trioxide (Sb.sub.2O.sub.3).

15. The method as defined in claim 1, wherein said coating material includes by weight percent: TABLE-US-00004 Component Weight Percent Water 5-30 Glycol 0-15 Thickener 0-5 Defoamer 0-5 Dispersing Agent 0-5 pH Adjuster 0-2 BaSO4, ZnO and/or ZnS 0.5-50 Secondary Pigment 0-35 Polymer Base 20-65 Fire Retardant 0-55 Biocide 0-8 Polymer Dispersion 0-15 Pigment Extender 0.1-20 Coalescent Solvent 0-10 Filler 0.1-25.

16. The method as defined in claim 1, wherein said coating materials includes by weight percent: TABLE-US-00005 Component Weight Percent Water 8-25 Glycol 0.5-5.sup. Thickener 0-2 Defoamer 0-2 Dispersing Agent 0-2 pH Adjuster 0-1 BaSO4, ZnO and/or ZnS 0.1-30 Secondary Pigment that includes 0-25 one or more of CaCO.sub.3, SiO.sub.2, Al.sub.2O.sub.3, MgO, YAlO.sub.3, CaO, MgAl.sub.2O.sub.4, Al(OH).sub.3, and/or LaAlO.sub.3 Acrylic or Acrylic Blend 20-60 Fire Retardant 0.05-30.sup. Biocide 0-6 Polymer Dispersion 2-12 Pigment Extender that includes 1-9 microspheres Coalescent Solvent 0-5 Filler .sup.0-15.

17. The method as defined in claim 1, wherein said coating materials includes by weight percent: TABLE-US-00006 Component Weight Percent Water 5-30 Glycol 0-10 Thickener 0-4 Defoamer 0-2 Dispersing Agent 0-1 pH Adjuster .sup.0-0.5 BaSO4, ZnO and/or ZnS 0.2-20 Secondary Pigment that includes one or more of CaCO.sub.3, SiO.sub.2, Al.sub.2O.sub.3, MgO, YAlO.sub.3, CaO, MgAl.sub.2O.sub.4, Al(OH).sub.3, and/or LaAlO.sub.3 Acrylic or Acrylic Blend 20-65 Fire Retardant that includes 0.05-40.sup. antimony trioxide Biocide 0-5 Polymer Dispersion 0-15 Pigment Extender that includes 1-12 microspheres Coalescent Solvent 0-6 Filler .sup.0-20.

18. The method as defined in claim 1, wherein said coating materials includes by weight percent: TABLE-US-00007 Component Weight Percent Water 9-16 Glycol 1.5-2.5 Thickener .sup.0-0.6 Dispersant 0.1-0.4 Defoamer 0.1-0.3 Dispersing Agent 0.1-0.9 pH Adjuster 0.01-0.04 BaSO4, ZnO and/or ZnS 0.5-15 Secondary Pigment that includes one or more of CaCO.sub.3, SiO.sub.2, Al.sub.2O.sub.3, MgO, YAlO.sub.3, CaO, MgAl.sub.2O.sub.4, Al(OH).sub.3, and/or LaAlO.sub.3 Acrylic or Acrylic Blend 30-35 Fire Retardant that includes 10-35 antimony trioxide Biocide 0.5-3.5 Polymer Dispersion 1-9 Pigment Extender that includes 1-10 hollow polymeric microspheres Coalescent Solvent 0.2-3.sup. Filler .sup.0-12.

19. A roofing material and/or siding material comprising a substrate member that has a top surface and a layer of coating material on said top surface; said coating material including a water-based coating, a solvent-based coating, a latex-based coating, an acrylic-based coating, a vinyl-acrylic based coating, a polyurethane base coating, a polyurea-based coating, a silicone-based coating, a silicon hybrid based coating, polyvinyl alcohol-based coating, polydimethylsiloxane-based coating, PMMA-based coating, PUMA-based coating, SEBS elastomeric based coating, alkyd-based coating, epoxy-based coating, or a Polyvinylidene Fluoride (PVDF) based coating, and the like; said coating material includes less than 10 wt. % titanium dioxide; said coating material satisfies the requirements under ASTM D6083; said coating material has an average resulting reflectively in a dried state of at least 60% or an SRI of at least 60; said coating material includes a pigment and a pigment extender; said pigment includes of BaSO.sub.4, ZnO, and/or ZnS; said pigment extender includes microspheres.

20. The roofing material and/or siding material as defined in claim 19, wherein said coating material includes a fire retardant; said fire retardant includes antimony trioxide (Sb.sub.2O.sub.3), aluminum trihydrate (ATH), and/or ammonium polyphosphate (NH.sub.4PO.sub.3).

21. The roofing material and/or siding material as defined in claim 19, wherein a top surface of said substrate member and/or a top surface of said coating material includes granules or slag.

22. The roofing material and/or siding material as defined in claim 19, wherein said roofing and/or siding material is a prefabricated material.

23. The roofing material and/or siding material as defined in claim 19, wherein said BaSO.sub.4, ZnO, and/or ZnS constitutes 50-100 wt. % of said pigment.

24. The roofing material and/or siding material as defined in claim 19, wherein said pigment includes BaSO.sub.4 and ZnO at a weight ratio of 9:1 to 1:9.

25. The roofing material and/or siding material as defined in claim 19, wherein said pigment includes BaSO.sub.4 and ZnS at a weight ratio of 9:1 to 1:9.

26. The roofing material and/or siding material as defined in claim 19, wherein said pigment includes BaSO.sub.4, ZnO and ZnS; a weight ratio of BaSO.sub.4 to the combined weight of ZnO and ZnS is 9:1 to 1:9; and a weight ratio of ZnO and ZnS is 100:1 to 1:100.

27. The roofing material and/or siding material as defined in claim 19, wherein coating material includes a secondary pigment that includes one or more of CaCO.sub.3, SiO.sub.2, Al.sub.2O.sub.3, MgO, YAlO.sub.3, CaO, MgAl.sub.2O.sub.4, Al(OH).sub.3, and/or LaAlO.sub.3.

28. The roofing material and/or siding material as defined in claim 27, wherein a weight ratio of the combined weight percent of BaSO.sub.4, ZnO, and ZnS to a combined weight percent of CaCO.sub.3, SiO.sub.2, Al.sub.2O.sub.3, MgO, YAlO.sub.3, CaO, MgAl.sub.2O.sub.4, Al(OH).sub.3, and LaAlO.sub.3 is 9:1 to 1:5.

29. The roofing material and/or siding material as defined in claim 27, wherein said secondary pigment has an average particle size of 1 nanometer to 500 nanometers.

30. The roofing material and/or siding material as defined in claim 19, wherein said pigment constitutes at least 0.5 wt. % of said coating material.

31. The roofing material and/or siding material as defined in claim 19, wherein said pigment has an average particle size of 1 nanometer to 500 nanometers.

32. The roofing material and/or siding material as defined in claim 19, wherein said fire retardant includes antimony trioxide (Sb.sub.2O.sub.3).

33. The roofing material and/or siding material as defined in claim 19, wherein said coating material includes by weight percent: TABLE-US-00008 Component Weight Percent Water 5-30 Glycol 0-15 Thickener 0-5 Defoamer 0-5 Dispersing Agent 0-5 pH Adjuster 0-2 BaSO4, ZnO and/or ZnS 0.5-50 Secondary Pigment 0-35 Polymer Base 20-65 Fire Retardant 0-55 Biocide 0-8 Polymer Dispersion 0-15 Pigment Extender 0.1-20 Coalescent Solvent 0-10 Filler 0.1-25.

34. The roofing material and/or siding material as defined in claim 19, wherein said coating materials includes by weight percent: TABLE-US-00009 Weight Percent Component Weight Water 8-25 Glycol 0.5-5.sup. Thickener 0-2 Defoamer 0-2 Dispersing Agent 0-2 pH Adjuster 0-1 BaSO4, ZnO and/or ZnS 0.1-30 Secondary Pigment that includes 0-25 one or more of CaCO.sub.3, SiO.sub.2, Al2O.sub.3, MgO, YAlO.sub.3, CaO, MgAl.sub.2O.sub.4, Al(OH).sub.3, and/or LaAlO.sub.3 Acrylic or Acrylic Blend 20-60 Fire Retardant 0.05-30.sup. Biocide 0-6 Polymer Dispersion 2-12 Pigment Extender that includes 1-9 microspheres Coalescent Solvent 0-5 Filler .sup.0-15.

35. The roofing material and/or siding material as defined in claim 19, wherein said coating materials includes by weight percent: TABLE-US-00010 Component Weight Percent Water 5-30 Glycol 0-10 Thickener 0-4 Defoamer 0-2 Dispersing Agent 0-1 pH Adjuster .sup.0-0.5 BaSO4, ZnO and/or ZnS 0.2-20 Secondary Pigment that includes 0-20 one or more of CaCO.sub.3, SiO.sub.2, Al.sub.2O.sub.3, MgO, YAlO.sub.3, CaO, MgAl.sub.2O.sub.4, Al(OH).sub.3, and/or LaAlO.sub.3 Acrylic or Acrylic Blend 20-65 Fire Retardant that includes 0.05-40.sup. antimony trioxide Biocide 0-5 Polymer Dispersion 0-15 Pigment Extender that includes 1-12 microspheres Coalescent Solvent 0-6 Filler .sup.0-20.

36. The roofing material and/or siding material as defined in claim 19, wherein said coating materials includes by weight percent: TABLE-US-00011 Component Weight Percent Water 9-16 Glycol 1.5-2.5 Thickener .sup.0-0.6 Dispersant 0.1-0.4 Defoamer 0.1-0.3 Dispersing Agent 0.1-0.9 pH Adjuster 0.01-0.04 BaSO4, ZnO and/or ZnS 0.5-15 Secondary Pigment that includes 0-12 one or more of CaCO.sub.3, SiO.sub.2, Al.sub.2O.sub.3, MgO, YAlO.sub.3, CaO, MgAl.sub.2O.sub.4, Al(OH).sub.2, and/or LaAlO.sub.3 Acrylic or Acrylic Blend 30-35 Fire Retardant that includes 10-35 antimony trioxide Biocide 0.5-3.5 Polymer Dispersion 1-9 Pigment Extender that includes 1-10 hollow polymeric microspheres Coalescent Solvent 0.2-3.sup. Filler .sup.0-12.

37. A roofing material and/or siding material comprising a substrate member that has a top surface and a layer of coating material on said top surface; said coating material is selected from the group consisting of an acrylic-based coating and a vinyl-acrylic based coating; said coating material includes less than 5 wt. % titanium dioxide; said coating material satisfies the requirements under ASTM D6083 for a Type I and/or a Type II acrylic coating; said coating material has an average resulting reflectively in a dried state of at least 60% or an SRI of at least 60; said coating material includes pigment, pigment extender and fire retardant; said pigment includes of BaSO.sub.4, ZnO, and/or ZnS; said pigment constitutes 0.1-50 wt. % of said coating material; said pigment extender includes microspheres; a combined weight percent of said pigment and said pigment extender in said coating material is 0.2-65 wt. %; said fire retardant includes antimony trioxide (Sb.sub.2O.sub.3), aluminum trihydrate (ATH), and/or ammonium polyphosphate (NH.sub.4PO.sub.3); said fire retardant constitutes 1-40 wt. % of said coating material.

38. The roofing material and/or siding material as defined in claim 37, wherein said BaSO.sub.4, ZnO, and/or ZnS constitutes 50-100 wt. % of said pigment.

39. The roofing material and/or siding material as defined in claim 37, wherein coating material includes a secondary pigment; said secondary pigment includes one or more of CaCO.sub.3, SiO.sub.2, Al.sub.2O.sub.3, MgO, YAlO.sub.3, CaO, MgAl.sub.2O.sub.4, Al(OH).sub.3, and/or LaAlO.sub.3; said pigment has an average particle size of 1 nanometer to 500 nanometers; said secondary pigment has an average particle size of 1 nanometer to 500 nanometers.

40. The roofing material and/or siding material as defined in claim 38, wherein coating material includes a secondary pigment; said secondary pigment includes one or more of CaCO.sub.3, SiO.sub.2, Al.sub.2O.sub.3, MgO, YAlO.sub.3, CaO, MgAl.sub.2O.sub.4, Al(OH).sub.3, and/or LaAlO.sub.3; said pigment has an average particle size of 1 nanometer to 500 nanometers; said secondary pigment has an average particle size of 1 nanometer to 500 nanometers.

41. The roofing material and/or siding material as defined in claim 37, wherein said coating material includes by weight percent: TABLE-US-00012 Component Weight Percent Water 5-30 BaSO4, ZnO and/or ZnS 0.2-20.sup. Secondary Pigment that includes 0-20 one or more of CaCO.sub.3, SiO.sub.2, Al.sub.2O.sub.3, MgO, YAlO.sub.3, CaO, MgAl.sub.2O.sub.4, Al(OH).sub.3, and/or LaAlO.sub.3 Acrylic or Acrylic Blend 20-65 Fire Retardant 1-40.

42. The roofing material and/or siding material as defined in claim 40, wherein said coating material includes by weight percent: TABLE-US-00013 Component Weight Percent Water 5-30 BaSO4, ZnO and/or ZnS 0.2-20.sup. Secondary Pigment that includes 0-20 one or more of CaCO.sub.3, SiO.sub.2, Al.sub.2O.sub.3, MgO, YAlO.sub.3, CaO, MgAl.sub.2O.sub.4, Al(OH).sub.3, and/or LaAlO.sub.3 Acrylic or Acrylic Blend 20-65 Fire Retardant 1-40.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0047] Reference may now be made to the drawings which illustrate various non-limiting embodiments that the disclosure may take in physical form and in certain parts and arrangement of parts wherein:

[0048] FIG. 1 is a side sectional view of a roofing and/or siding system illustrating a layer of coating material in accordance with the present disclosure applied to the roofing and/or siding system.

[0049] FIG. 2 is a side sectional view of another roofing and/or siding system illustrating a layer solid material applied onto the layer of coating material in accordance with the present disclosure applied to the roofing and/or siding system.

[0050] FIG. 3 is a side sectional view of still another roofing and/or siding system illustrating a layer solid material applied onto the layer of coating material in accordance with the present disclosure applied to the roofing and/or siding system.

DETAILED DESCRIPTION OF NON-LIMITING EMBODIMENTS

[0051] Although specific terms are used in the following description for the sake of clarity, these terms are intended to refer only to the particular structure of the embodiments selected for illustration in the drawings and are not intended to define or limit the scope of the disclosure. In the drawings and the following description below, it is to be understood that like numeric designations refer to components of like function.

[0052] The singular forms a, an, and the include plural referents unless the context clearly dictates otherwise.

[0053] As used in the specification and in the claims, the term comprising may include the embodiments consisting of and consisting essentially of. The terms comprise(s), include(s), having, has, can, contain(s), and variants thereof, as used herein, are intended to be open-ended transitional phrases, terms, or words that require the presence of the named ingredients/steps and permit the presence of other ingredients/steps. However, such description should be construed as also describing compositions or processes as consisting of and consisting essentially of the enumerated ingredients/steps, which allows the presence of only the named ingredients/steps, along with any unavoidable impurities that might result therefrom, and excludes other ingredients/steps.

[0054] Numerical values in the specification and claims of this application should be understood to include numerical values which are the same when reduced to the same number of significant figures and numerical values which differ from the stated value by less than the experimental error of conventional measurement technique of the type described in the present application to determine the value.

[0055] All ranges disclosed herein are inclusive of the recited endpoint and independently combinable (for example, the range of from 2 grams to 10 grams is inclusive of the endpoints, 2 grams and 10 grams, and all the intermediate values).

[0056] The terms about and approximately can be used to include any numerical value that can vary without changing the basic function of that value. When used with a range, about and approximately also disclose the range defined by the absolute values of the two endpoints, e.g., about 2 to about 4 also discloses the range from 2 to 4. Generally, the terms about and approximately may refer to plus or minus 10% of the indicated number.

[0057] Percentages of elements should be assumed to be percent by weight of the stated element, unless expressly stated otherwise.

[0058] The inventors have conceived of novel technology that, for the purpose of illustration, is disclosed herein as applied in the context of an apparatus and method for metal treatment analysis. While the disclosed applications of the inventors' technology satisfy a long-felt but unmet need in the art of metal treatment analysis, it should be understood that the inventors' technology is not limited to being implemented in the precise manners set forth herein, but could be implemented in other manners without undue experimentation by those of ordinary skill in the art in light of this disclosure. Accordingly, the examples set forth herein should be understood as being illustrative only, and should not be treated as limiting.

[0059] Referring now to the drawings wherein the showings are for the purpose of illustrating a non-limiting embodiments of the present disclosure only and not for the purpose of limiting same, FIG. 1 illustrates a shingle, cap sheet roll roofing material or modified bitumen roofing material 200. The roofing material 200 is configured to be secured to a roof, roof substrate (e.g., base sheets), or subroof by any suitable arrangement.

[0060] The roofing material 200 includes a bitumen- or asphalt-based material 202, 204, a reinforcement material 206 therebetween, and layer of granules or slag 208. The reinforcement material 206 is typically a felt or fiberglass material that is commonly used in the art; however, other materials can be used. The reinforcement material 206 is shown as fully embedded in the bitumen- or asphalt-based material 202; however, this is not required. The granules or slag 208 are illustrated as partially embedded and secured in the bitumen- or asphalt-based material 202. The granules or slag can be typical granules or slag used in roofing materials or highly reflective granules or slag. The granules are generally derived from a mineral base rock such as greenstone, greystone, nephylene syenite, gravel slate, gannister, granite, quartzite, andosite, rhyolite and the like. The granules may be coated to color the granules and/or provide the granules with antimicrobial resistance. The granules can be spherical and have the same size; however, this is not required. In practice, the granules have a variety of different shapes. One common size of granules used on shingles is No. 11 grade particles. No. 11 grade particles are known in the industry to have a particle range of about 840 US mesh having an average mesh size of about 19 US mesh (i.e., 937 mm sieve designation). The slag can have a particle size distribution of between 50 mesh and 20 mesh.

[0061] As illustrated in FIG. 1 much of the top surface of bitumen- or asphalt-based material 202 is covered by granules or slag 208. Generally, a majority of the surface of the bitumen- or asphalt-based material 202 is covered by granules or slag 208. Typically, about 90-98% of the exposed surface of bitumen- or asphalt-based material 202 is covered by granules or slag 208. The coverage provided by the granules or slag reduces the amount of exposed black surface from the bitumen- or asphalt-based material 202, thus non-black granules or slag, when used, can result in the increase the resulting or effective reflectivity or SRI of roofing material 200.

[0062] Referring again to FIG. 1, roofing material 200 includes one or more layers of a coating material 210. The coating material 210 can be applied in a single application or by multiple applications. The coating material 210 can be applied in many different ways such as, but not limited to, spray coating, dipping, pouring and subsequently spreading, etc. If more than a single application is used to apply the coating material 210, the process for applying each coating material 210 can be the same or different.

[0063] The coating material 210 is a reflective material that has a reflectivity of at least about 70% and/or a SRI of at least 70 when dry. Typically, the coating material 210 color is white; however, this is not required. The coating material 210 is shown to be applied after granules or slag 208 have been applied to the surface of bitumen- or asphalt-based material 202. The coating material 210 can be applied over the granules or slag on the jobsite after installation of the roofing material 200.

[0064] As illustrated in FIG. 1, the layer of coating material 210 at least partially coats many of granules or slag 208 and at least partially fills in the spaces between granules or slag 208. Typically, a majority of granules or slag 208 are at least partially coated with the coating material 210 and a majority of the spaces between the granules or slag are at least partially filled in by the coating material 210. The coating material 210 layer not only increases the resulting reflectivity of the roofing material, the coating material 210 layer facilitates in the binding of the granules or slag to the roofing material, increases the strength and/or durability of the roofing material, positively affects the aesthetic properties of the roofing material, and/or positively affects other properties of the roofing material.

[0065] As illustrated in FIG. 1, the thickness of the coating material 210 layer is thinner on the top surfaces of granules or slag 208 than the thickness of the coating layer between the granules or slag; however, this is not required. This varying of thickness is due in part to the viscosity of the coating material 210. FIG. 1 also illustrates that the thickness of the coating material 210 layer between granules or slag 208 is less than the height of granules or slag 208 that are extending above the surface of the bitumen- or asphalt-based material 202; however, this is not required. As such, the roofing material maintains a non-smooth texture. However, the filling of the spaces by the coating material 210 does form a smoother top surface of the roofing material. As can be appreciated, the amount of coating material 210 applied to the top of the roofing material can be controlled to a) form a smooth top surface wherein the coating material 210 layer in the spaces between the granules or slag equals or exceeds the height of granules or slag 208 that are extending above the surface of the bitumen- or asphalt-based material 202, or b) form a textured surface as shown in FIG. 1. The degree of roughness of the roofing material can be in part controlled by the thickness of the coating material 210 layer. It has been found that smoother the top surfaces of the roofing material which include a partially exposed reflective coating material 210 layer have a greater resulting or effective reflectivity than less smooth top surfaces. The thickness of the wet coating material 210 layer is typically at least about 0.5 mils (approximately 0.03 gal./100 ft.sup.2). Typically, the wet coating material 210 layer is less than about 50 mils (approximately 3.13 gal./100 ft.sup.2); however, this is not required. In one non-limiting example, the thickness of the wet coating material 210 layer from a coating material 210 having a reflectivity of at least about 70% to form a roofing material having a resulting reflectivity that exceeds about 60% is about 5-25 mils. The thickness of the dried coating material 210 layer generally depends on the amount of solids in the coating material 210.

[0066] This reflective roofing material can be formed by a manufacturing process at a site that is remote to the site that the roofing materials are to be installed. As can be appreciated, the one or more layers of coating material 210 can be applied on site just prior to or after the roof material is applied to the roof substrate. As can be appreciated, the roofing material formed by an off-site manufacturing process (e.g., prefabrication process) can be formed without having to further treat the surface of the roofing material.

[0067] The type of coating used on the roofing material is limited only to the ability of the coating material 210 to properly bind to the bitumen- or asphalt-based material 202 and/or granules or slag 208. The coating material 210 can be a water-based coating, a solvent-based coating, a latex-based coating, an acrylic-based coating, a vinyl-acrylic based coating, a polyurethane base coating, a polyurea-based coating, a silicone-based coating, a silicon hybrid based coating, polyvinyl alcohol-based coating, polydimethylsiloxane-based coating, PMMA-based coating, PUMA-based coating, SEBS elastomeric based coating, alkyd-based coating, epoxy-based coating, or a Polyvinylidene Fluoride (PVDF) based coating, and the like. Typically, the color of the coating material 210 is white or extra white; however, this is not required.

[0068] As described so far above, the roofing material is a shingle, cap sheet roll roofing material or modified bitumen roofing material. It will be appreciated that the broad concept of the present disclosure can be applied to other types of roofing systems. As can be appreciated, the concept of the present disclosure can also be used on wood, plastic or metal roofing systems. The reflective coating material 210 can be applied prior to and/or after the granules or slag are applied to the wood, plastic or metal roofing system to obtain a highly reflective roof material. This roofing material could be manufactured off-site (e.g., prefabricated). Other types of roofing systems can in the reflective coating material, namely foam roofing, built-up roofing (BUR), flood coat and gravel systems, and wood roofing and/or siding, etc.

[0069] Referring now to FIG. 2, another embodiment of roofing material 200 is illustrated. In this embodiment, the structure of the roofing material is similar to the roofing material illustrated in FIG. 1, but includes an additional layer of granules or slag 212. The upper surface of the top layer of bitumen- or asphalt-based material 202 includes two different sizes of granules or slag 208, 212. A majority of the granules or slag 208 are partially embedded in layer 202; however, this is not required. As stated above, the coating material 210 can be applied in a single application or by multiple applications. The coating material 210 can be applied in many different ways such as, but not limited to, spray coating, dipping, pouring and subsequently spreading, etc. If more than a single application is used to apply the coating material 210, the process for applying each layer can be the same or different. The coating material 210 is a reflective coating as described above. The coating material 210 is shown to be applied after granules or slag 208 have been applied to the surface of bitumen- or asphalt-based material 202. As can be appreciated, a layer of coating material 210 can additionally or alternatively be applied to the bitumen- or asphalt-based material 202 prior to applying the layer of granules or slag 208. If the coating material 210 is applied to the bitumen- or asphalt-based material 202 prior to applying the layer of granules or slag 208, the granules or slag are typically applied to the coating material 210 prior to the coating layer fully drying so as to facilitate in the adhesion of the granules or slag to the surface of the roofing material; however, this is not required. Indeed, if the granules or slag are applied after the coating material 210 has substantially or fully dried, a binder can be used to facilitate in the adhesion of the granules or slag to the top surface of the roofing material.

[0070] As illustrated in FIG. 2, the layer of coating material 210 at least partially coats many of granules or slag 208 and at least partially fills in the spaces between granules or slag 208. Typically, a majority of granules or slag 208 are at least partially coated with the coating material 210 and a majority of the spaces between the granules or slag are at least partially filled in by the coating material 210. The coating material 210 layer not only increases the resulting reflectivity and/or SRI of the roofing material, the coating material 210 facilitates in the binding of the granules or slag to the roofing material, increases the strength and/or durability of the roofing material, positively affects the aesthetic properties of the roofing material, and/or positively affects other properties of the roofing material.

[0071] As illustrated in FIG. 2, granules or slag 212 are partially embedded and/or secured in the upper surface coating material 210. As can be appreciated, some of granules or slag 212 may be fully embedded in the coating material 210 and/or not embedded in the coating material 210 to meet the desired end use of roofing material 200. Typically, granules or slag 212 are applied to coating material 210 prior to the coating material 210 fully drying; however, this is not required. When granules or slag 212 are applied prior to the coating material 210 becoming fully dried, the non-fully dried coating material 210 facilitates in the adhesion of the granules or slag to the surface of the roofing material. Indeed, if granules or slag 212 are applied after the coating material 210 has substantially or fully dried, a binder can be used to facilitate in the adhesion of the granules or slag to the top surface of the roofing material.

[0072] The inclusion of granules or slag 212 on the surface of coating material 210 provides additional overage for the roofing material. As such, the addition of granules or slag 212 assist in reflecting more sunlight off the roofing material by at least partially covering the black bitumen- or asphalt-based material 202 that still may be exposed after application of granules or slag 208 and coating material 210. These smaller granules or slag also occupy the spaces between larger granules or slag 208, thereby increasing the amount of coverage by the granules or slag of the upper surface of the roofing material. This increased amount of granule coverage not only can increase the resulting reflectivity of the roofing material, but also forms a more uniform surface of the roofing material, positively affects the physical properties of the roofing material, reduce the rate of degradation of the roofing material, reduce the surface temperature of the roofing material, extend the life of the roofing material, and/or positively affects the aesthetics of the roofing material. The increased coverage provided by granules or slag 212 can results in a 1-5% or more increase in resulting and/or effective reflectivity of the roofing material. As can be appreciated, some or all of the granules or slag that are applied to the top surface of the coating material 210 can be the same size or larger than the previously applied granules or slag; however, this is not required.

[0073] Referring now to FIG. 3, another embodiment of roofing material 200 is illustrated. In this embodiment, the structure of the roofing material is similar to the roofing material illustrated in FIGS. 1 and 2, but includes a layer of reflective coating material 207 that has been applied to the top surface of the bitumen- or asphalt-based material 202 prior to the application of granules or slag 208 and 212. The upper surface of the coating material 207 includes two different sizes of granules or slag 208, 212; however, this is not required. A majority of the granules or slag 208 are partially embedded in coating material 207; however, this is not required. As stated above, the coating material 207 can be applied in a single application or by multiple applications. The coating material 207 can be applied in many different ways such as, but not limited to, spray coating, dipping, pouring and subsequently spreading, etc. If more than a single application is used to apply the coating material 207, the process for applying each layer can be the same or different.

[0074] The material that forms coating material 207 is a reflective coating as described above with regard to coating material 210 in FIGS. 1 and 2. As can be appreciated, a layer of coating material 207 can additionally be applied after one or more granules or slag coatings have been applied to the roofing material. As can also be appreciated, the roofing material illustrated in FIGS. 1-3 can be absent granules, and the reflective coating can be used to form the top layer of the roofing material.

[0075] The reflective coating is substantially or fully absent TiO.sub.2 (e.g., 0-2 wt. % of the reflective coating and all values and ranges therebetween). The reflective coating generally has a) a resulting reflectivity of 60-99% (and all values and ranges therebetween) as determined by the test methods in accordance with one or more of ASTM C1549-16; ASTM E903 (spectrometer); ASTM C1549 (reflectometer); ASTM E1918 (pyranometer); and ASTM E892; and/or b) a Solar Reflectance Index (SRI) of at least 60 in accordance with ASTM E1980. The reflective coating can be a solvent-based coating, a latex-based coating, an acrylic-based coating, a vinyl-acrylic based coating, a polyurethane base coating, a polyurea-based coating, a silicone-based coating, a silicon hybrid based coating, polyvinyl alcohol-based coating, polydimethylsiloxane-based coating, PMMA-based coating, PUMA-based coating, SEBS elastomeric based coating, alkyd-based coating, epoxy-based coating, or a Polyvinylidene Fluoride (PVDF) based coating. In one non-limiting formulation, the reflective coating is an acrylic-based coating. In another non-limiting formulation, the reflective coating is an acrylic-based coating that meets one or more or all of the ASTM D6083 standard for liquid applied acrylic coating. In one non-limiting formulation, the reflective coating includes a) a pigment that includes BaSO.sub.4, ZnO, and/or ZnS, b) pigment extender, and c) fire retardant. In another non-limiting formulation, the reflective coating includes a) BaSO.sub.4, b) pigment extender that includes microspheres, and c) fire retardant that includes antimony trioxide (Sb.sub.2O.sub.3). In another non-limiting formulation, the reflective includes a) a pigment that includes BaSO.sub.4, and wherein the BaSO.sub.4 constitutes 0.1-5 wt. % (and all values and ranges therebetween) of the reflective coating, b) pigment extender that includes microspheres, and wherein the microspheres constitute 1-15 wt. % (and all values and ranges therebetween) of the reflective coating, and wherein the microspheres have an average particle size of 5-50 m, and c) fire retardant that includes antimony trioxide (Sb.sub.2O.sub.3), and wherein the antimony trioxide (Sb.sub.2O.sub.3) constitutes 1-15 wt. % (and all values and ranges therebetween) of the reflective coating. In another non-limiting formulation, the weight percent ratio in the reflective coating of the pigment that is substantially or fully absent TiO.sub.2 (e.g., BaSO.sub.4, ZnO, and/or ZnS) to the pigment extender that includes microspheres is 0.08:1 to 0.4:1 (and all values and ranges therebetween). In another non-limiting formulation, the weight percent ratio in the reflective coating of the pigment that is substantially or fully absent TiO.sub.2 (e.g., BaSO.sub.4) to the microspheres is 0.09:1 to 0.35:1 (and all values and ranges therebetween). In another non-limiting formulation, the weight percent ratio in the reflective coating of antimony trioxide (Sb.sub.2O.sub.3) to the pigment extender that includes microspheres is 0.3:1 to 1:0.3 (and all values and ranges therebetween). In another non-limiting formulation, the weight percent ratio in the reflective coating of antimony trioxide (Sb.sub.2O.sub.3) to the microspheres is 0.35:1 to 1:0.35 (and all values and ranges therebetween). In another non-limiting formulation, the combined weight percent of BaSO.sub.4, microspheres and antimony trioxide (Sb.sub.2O.sub.3) in the reflective coating is 5-30 wt. % (and all values and ranges therebetween). In another non-limiting formulation, the reflective coating that includes 0-1 wt. % TiO.sub.2 (and all values and ranges therebetween) in weight percent:

TABLE-US-00003 Ex. A Ex. B Component wt. % wt. % Water 5-20 7-15 Glycol 0-9 0-3 Thickener 0-5 .sup.0-1.5 Defoamer .sup.0-2.5 .sup.0-0.6 Dispersing Agent .sup.0-2.5 .sup.0-0.9 pH Adjuster .sup.0-0.6 0-0.15 BaSO.sub.4 0.15-5.5 0.35-1.8 Secondary Pigment (e.g., CaCO.sub.3, 0-9 0-4 Al.sub.2O.sub.3, MgO, CaO, and/or MgAl.sub.2O.sub.4) Acrylic or Acrylic Blend 21-59 30-55 Fire Retardant (e.g., Sb.sub.2O.sub.3, ATH, 1-38 10-34 and/or NH.sub.4PO.sub.3) Biocide .sup.0-4.5 0-3 Polymer Dispersion 0-15 0-7 Pigment Extender 1-15 2-9 (e.g., Microspheres, etc.) Coalescent Solvent 0-7 0-2 Filler 0-12 0-7

[0076] One non-limiting manufacturing process for forming a reflective shingle, cap sheet, or modified bitumen is described below. The reflective coating material 207 can be applied as a restoration coating to an existing fastened new or aged roof. The existing roof may or may not have a granule or slag surface. The existing roof may or may not already be coated with a previously applied reflective or non-reflective coating. The previously applied coating does not need to be of the same chemical make up as the reflective coating material 207. Once it is determined that the existing roof is a candidate to be coated with the restoration reflective coating, the coating material 207 can be applied in many different ways such as, but not limited to, spray coating, dipping, pouring and subsequently spreading, etc. Application can be in a single coat or multiple coats applied either the same way or with different application methods.

[0077] In another non-limiting manufacturing process for forming a reflective shingle, cap sheet roll roofing or modified bitumen is described below. Reinforcement material is passed through a coater containing liquid asphalt-bituminous composition to at least partially or fully impregnate the reinforcement material. The speed at which the reinforcement material is moved is about 1-100 ft./min., and typically about 20-60 ft./min; however, other speeds can be used. As the reinforcement material is passed through a coater 230, the reinforcement material is guided by one or more guide rollers, and a continuous hot asphalt-bituminous coated strip is formed. As can be appreciated, other processes can be used to coat the reinforcement material with the asphalt-bituminous composition. As can also be appreciated, more than one coating of asphalt-bituminous composition can be applied to the reinforcement material. The coated strip can optionally be passed beneath a hopper which applies granules or slag (primary granules or slag) on the upper surface of the coated strip. As can be appreciated, many different types of devices can be used to control the spread pattern and/or amount of granules or slag being applied to the coated strip, when granules or slag are used. The amount of granules or slag deposited on the upper surface of the coated strip is typically selected to cover most of the upper surface of the coated strip; however, this is not required. The coverage of granules or slag on the upper surface of the coated strip is generally represented by the coverage of granules or slag 208 in FIG. 1. For instance, when No. 11 grade granules are used, the coverage provided by the granules or slag is typically about 90-98% (ASTM D6225).

[0078] After granules or slag have been deposited on the upper surface of the asphalt-bituminous coated strip, one or more layers of a reflective coating material 208 is applied by one or more sprayers on the top surface of the coated strip. As can be appreciated, the coating material 208 can be applied to the coated strip by other processes. The coating material 208 can optionally be fast drying coating that typically takes less than 60 minutes to dry to touch; however, this is not required. A heating or drying mechanism (e.g., air blower, oven, heating coils, etc.) can optionally be used to obtain faster dry times for the coating material 208. The thickness of the one or more wet coating material 208 is generally about 0.5-100 mils (0.3-60 mils dry), and typically about 3-40 mils (1.5-24 mils dry).

[0079] After the coating material 208 is applied to the coated strip, secondary granules or slag can be optionally deposited on the surface of the coating material 208 as illustrated in FIG. 2. Typically, the granules or slag are applied to the coating material 208 prior to the coating material 208 being fully dried so as to facilitate in the adhesion of the granules or slag to the roofing material. The secondary granules or slag, when used, can optionally have a smaller average particle size than the particle size of the primary granules or slag.

[0080] After the granules or slag are deposited on the roofing material, the coated strip is typically passed around a drum; however, this is not required. As the coated strip travels about drum, some or all of the granules or slag can be at least partially pressed into the coating material 208; however, this is not required. The drum can be a heated drum to facilitate in the dry of the coating layer; however, this is not required. After the coated strip passes around drum, the coated strip can be guided by one or more guide rollers to a cooling section and/or pressing section. The cooling process is not required. One or more press rollers can be used to at least partially press granules or slag into the coating material 208 for improved adhesion of granules or slag to the roofing material; however, this is not required. After the coated strip is cooled and/or pressed, the coated strip can be rolled up and/or formed into shingles. The process steps of cooling, pressing, rolling, and shingle formation are well known in the art, thus will not be described herein.

[0081] In another non-limiting manufacturing process, the reinforcement material can be partially or fully impregnated with an asphalt-bituminous composition as discussed above. After the one or more coatings of asphalt-bituminous composition are applied to the reinforcement material, one or more layers of a reflective coating material 207 is applied by one or more sprayers on the top surface of the coated strip to form a coated strip as illustrated in FIG. 3. This application of a layer of coating material 207 on the top of the asphalt-bituminous composition is an optional process. As can be appreciated, the reflective coating material 207 can be applied to the coated strip by other processes. The coating layer can be atomized during the spraying process obtain a more uniform coating; however, this is not required. After the one or more coatings of the coating material 207 has been applied to the top surface of the asphalt-bituminous composition, the coated strip can optionally be passed beneath a hopper which optionally applies granules or slag on the upper surface of the coated strip. The strip can optionally be further processed by drying, passed about a drum, passed through press rollers, cooled, etc. as discussed above. After granules or slag have been deposited on the upper surface of the coated strip, one or more layers of a reflective coating material 207 can optionally be applied by one or more sprayers on the top surface of the coated strip.

[0082] After the coated strip is cooled and/or pressed, the asphalt-bituminous coated strip is rolled up and/or formed into shingles. The process steps of cooling, pressing, rolling, and shingle formation are well known in the art, thus will not be described herein.

[0083] Although the operations of exemplary embodiments of the disclosed method may be described in a particular, sequential order for convenient presentation, it should be understood that disclosed embodiments can encompass an order of operations other than the particular, sequential order disclosed. For example, operations described sequentially may in some cases be rearranged or performed concurrently. Further, descriptions and disclosures provided in association with one particular embodiment are not limited to that embodiment, and may be applied to any embodiment disclosed.

[0084] The description sometimes uses terms such as produce and provide to describe the disclosed method. These terms are abstractions of the actual operations that can be performed. The actual operations that correspond to these terms can vary depending on the particular implementation and are, based on this disclosure, readily discernible by one of ordinary skill in the art.

[0085] It will thus be seen that the objects set forth above, among those made apparent from the preceding description, are efficiently attained, and since certain changes may be made in the constructions set forth without departing from the spirit and scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. The invention has been described with reference to preferred and alternate embodiments. Modifications and alterations will become apparent to those skilled in the art upon reading and understanding the detailed discussion of the invention provided herein. This invention is intended to include all such modifications and alterations insofar as they come within the scope of the present invention. It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described and all statements of the scope of the invention, which, as a matter of language, might be said to fall there between. The invention has been described with reference to the preferred embodiments. These and other modifications of the preferred embodiments as well as other embodiments of the invention will be obvious from the disclosure herein, whereby the foregoing descriptive matter is to be interpreted merely as illustrative of the invention and not as a limitation. It is intended to include all such modifications and alterations insofar as they come within the scope of the appended claims.

[0086] To aid the Patent Office and any readers of this application and any resulting patent in interpreting the claims appended hereto, applicants do not intend any of the appended claims or claim elements to invoke 35 U.S.C. 112 (f) unless the words means for or step for are explicitly used in the particular claim.