US20100095618A1 - Roofing Materials with Metallic Appearance - Google Patents

Roofing Materials with Metallic Appearance Download PDF

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Publication number
US20100095618A1
US20100095618A1 US12/582,203 US58220309A US2010095618A1 US 20100095618 A1 US20100095618 A1 US 20100095618A1 US 58220309 A US58220309 A US 58220309A US 2010095618 A1 US2010095618 A1 US 2010095618A1
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Prior art keywords
metallic
roofing material
reflective
effect pigment
roofing
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US12/582,203
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English (en)
Inventor
Michael Edison
Gregory R. Coughlin
Doreen C. Becker
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BASF Corp
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BASF Corp
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Priority to US12/582,203 priority Critical patent/US20100095618A1/en
Publication of US20100095618A1 publication Critical patent/US20100095618A1/en
Assigned to BASF CORPORATION reassignment BASF CORPORATION ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: COUGHLIN, GREGORY R., EDISON, MICHAEL
Priority to US13/668,810 priority patent/US20130065021A1/en
Abandoned legal-status Critical Current

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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B32B27/20—Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/302—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising aromatic vinyl (co)polymers, e.g. styrenic (co)polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/304—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/30—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers
    • B32B27/308—Layered products comprising a layer of synthetic resin comprising vinyl (co)polymers; comprising acrylic (co)polymers comprising acrylic (co)polymers
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
    • B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D1/00—Roof covering by making use of tiles, slates, shingles, or other small roofing elements
    • E04D1/12—Roofing elements shaped as plain tiles or shingles, i.e. with flat outer surface
    • E04D1/20—Roofing elements shaped as plain tiles or shingles, i.e. with flat outer surface of plastics; of asphalt; of fibrous materials
    • E04D1/205—Roofing elements shaped as plain tiles or shingles, i.e. with flat outer surface of plastics; of asphalt; of fibrous materials of wood
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D5/00—Roof covering by making use of flexible material, e.g. supplied in roll form
    • E04D5/10—Roof covering by making use of flexible material, e.g. supplied in roll form by making use of compounded or laminated materials, e.g. metal foils or plastic films coated with bitumen
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2264/00—Composition or properties of particles which form a particulate layer or are present as additives
    • B32B2264/10—Inorganic particles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/304—Insulating
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/30—Properties of the layers or laminate having particular thermal properties
    • B32B2307/306—Resistant to heat
    • B32B2307/3065—Flame resistant or retardant, fire resistant or retardant
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B32B2307/402—Coloured
    • B32B2307/4026—Coloured within the layer by addition of a colorant, e.g. pigments, dyes
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/40—Properties of the layers or laminate having particular optical properties
    • B32B2307/416—Reflective
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2307/00—Properties of the layers or laminate
    • B32B2307/70—Other properties
    • B32B2307/71—Resistive to light or to UV
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2419/00—Buildings or parts thereof
    • B32B2419/06—Roofs, roof membranes
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24355—Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
    • Y10T428/24372—Particulate matter
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24355—Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
    • Y10T428/24372—Particulate matter
    • Y10T428/24421—Silicon containing

Definitions

  • roofing materials having a unique appearance, and in particular a metallic appearance.
  • the materials have increased solar reflectance properties.
  • roofing materials that are the basis of roofing structures come from many different varieties. Since the roof is directly exposed on the top surface of the building structure, one needs to carefully consider the composition of the roofing materials. Although man has been making roofs out of all kinds of materials, from palm fronds to ancient quarried slates, since the earliest days of civilization, certain roofing materials impart qualities suitable for various environmental challenges and climate conditions. For example, in less developed countries, straw roofing may be used. But in geographies where it may vary in weather conditions and seasons, more solid and heat absorbing/reflecting materials may be more appropriate. In certain areas, the multi-billion dollar roofing industry may find it particularly useful and environmentally friendly to employ roofing materials of other desirable features.
  • roofing materials such as wood, slate, or metal can be coated or covered by using various means such as shingling or paint.
  • a metallic composition or look can be advantageous due to reflective properties and heat shielding ability, among other insulative properties.
  • Useful desired insulative properties can include low thermal conductivity and delayed build-up of heat. However, the most ideal results are not usually obtained using metals themselves.
  • Effect pigments also known as nacreous pigments and pearlescent pigments, are lustrous specialty chemical products that are widely used in a variety of high-end applications such as automotive finishes. Effect pigments simulate pearly luster or have effects that range from silky sheen to metallic luster as disclosed in L. M. Greenstein, “Nacreous (Pearlescent) Pigments and Interference Pigments”, T HE P IGMENT H ANDBOOK , Volume 1, Properties & Economics, Second Edition, Edited by Peter A. Lewis, John Wiley & Sons, Inc. (1988).
  • One of the attributes of the effect pigments is that they can generate a range of optical effects depending on the angle at which they are viewed.
  • Pearlescent or nacreous pigments simulate the effect of natural pearl and are composed of thin platelets which are transparent in the visible region of the spectrum.
  • the platelets are very smooth and part of the light which strikes the platelets is reflected and part is transmitted through the platelets. That part of the light that is transmitted is subsequently reflected by other layers of platelets. The result is that multiple reflections from many layers occur and this results in depth of sheen since the eye cannot focus on one particular layer.
  • the reflection that occurs in these types of pigments is specular in that the angle of incidence equals the angle of reflection.
  • the amount of light reflected at non-specular angles is small and the amount of light reflected diminishes very quickly as the specular angle is passed.
  • the result is that pearlescent pigments are extremely sensitive to viewing angle.
  • the platelets In order for the maximum amount of light to be reflected, the platelets must be extremely smooth. Any surface roughness causes light to be scattered in a non-specular manner and diminishes the lustrous effect.
  • the platelets must be aligned parallel to each other and to the substrate for maximum reflectivity. If not so aligned, light will be reflected randomly and again, luster will diminish. The amount of light that is reflected depends on the index of refraction. As the index of refraction increases, the amount of reflected light increases.
  • effect materials have a lesser degree of hiding power than desired.
  • a variety of materials have been incorporated in effect pigment formulations.
  • Effect pigments are often based on platelet shaped particles. Because the optical effect is the result of multiple reflections and transmission of light, it is desirable to provide particles that will align in the medium in which they are found and to optimize the desired effect. The presence of either misaligned particles or particles of an additive, or both, interferes with this objective and diminishes the optical effect of the pigment. It is therefore generally considered to be desirable for any additive being used for increased hiding to be somehow bound to the platelets rather than present as part of a physical mixture.
  • Effect pigments have long been used in automotive top coats in order to achieve a colored metallic effect, among other reasons. That metallic effect can be characterized by the flip-flop of light to dark as the viewing angle is changed. In the case of mica pigments, that flip-flop is from the reflection color of the mica to dark.
  • most automotive top coats are required to be opaque to ultraviolet light and also to visible light when applied at a conventional thickness of about 0.5 to 1.2 mils (about 12.7-30.5 microns) for a variety of reasons.
  • One “mil” equals 1/1000 inch (a thickness unit of film). It has been a challenge to maintain the “face” or reflection color which is contributed by the mica pigment while at the same time developing hiding in that it is known that opaque pigments greatly reduce the color/effect of the mica pigments.
  • Metallic flake pigments such as aluminum are opaque to light, i.e., no light is transmitted. Because of the preceding property, metallic flake pigments cover well and thus, the substrate over which they are coated can be completed hidden. This property is known as hiding power.
  • Blends of aluminum metal pigments with mica pigments are well known for diverse applications.
  • U.S. Pat. No. 6,503,965 teaches an ink which can contain a non-fluorescent pigment alone or a mixture of two or more non-fluorescent pigments which can be selected from a long list of such pigments, including aluminum flake pigments (with thickness ranging from about 0.1 to about 2 microns) and TiO 2 - and Fe 2 O 3 -coated mica pigments.
  • U.S. Pat. No. 2,278,970 teaches that thin mica flakes are suitable for use as an inert filler in combination with aluminum flake pigment to extend the covering quality of the latter.
  • 6,331,326 teaches coating a primer and/or a first metallic paint containing a non-leafing type aluminum flake, and then applying a second metallic paint containing small thin flakes.
  • the primer can be blended with a flat pigment, such as the thin aluminum flakes as well as flaky mica, to increase hiding power or hiding sand scratches on the substrate.
  • U.S. Pat. No. 6,306,931 teaches the use of preferred aluminum flake pigments that have median particle size of about 100 microns or less or especially 10 microns or less for incorporation into a coating.
  • U.S. Pat. No. 6,398,861 teaches the use of an aluminum flake pigment having a diameter range of 6 microns to 600 microns for coatings.
  • Silberline.com advertises that its vacuum metallized aluminum flake can be used in cosmetics to achieve a smooth, mirror-like metallic effect and to deliver highly reflective, brilliant finishes.
  • Blends of aluminum with non-effect materials are also known.
  • U.S. Pat. No. 4,937,274 teaches mixing aluminum flake pigments with ultrafine materials such as titanium dioxide.
  • This coating composition does not include any interference (effect) mica pigments but is said to be still capable of providing an effect like those coatings containing the interference mica pigments and aluminum flake.
  • metallic flake pigments may not be appropriate or desirable in all applications, such as in roof coverings.
  • a non-metallic, yet metallic appearing pigment would be more suitable.
  • a roofing material comprising at least two layers of polymeric materials, a top layer exposed to the environment and a bottom layer contacting the roof structure, the top layer having incorporated therein an amount of effect pigment material that imparts a metallic appearance.
  • the polymeric materials include thermoplastic olefin resins, polyvinyl chloride resins, EPDM, acrylonitrile-styrene-acrylate (ASA), or other materials. Additionally, the polymeric materials contain UV stabilizers.
  • a roofing material comprising a shingle having at least two layers of polymeric materials, a capstock layer exposed to the environment and a bottom layer contacting the roof structure, the top layer including an amount of metallic appearing effect pigment material sufficient to impart a metallic appearance.
  • a roofing material comprising a shingle having a capstock layer exposed to the environment.
  • the capstock layer can include an amount of metallic appearing effect pigment material sufficient to impart a metallic appearance.
  • the polymeric materials contain flame retardants and a smoke suppressant.
  • a reflective polymer membrane includes at least one layer of polymeric material including an amount of metallic appearing effect pigment material sufficient to impart a metallic appearance.
  • the effect pigment can be used in an amount of about 0.5% by weight to about 3.0% by weight based on the total weight of the reflective polymeric membrane.
  • polymeric membranes prepared according to the Examples using suitable effects pigments as described herein would be have good total solar reflectance (TSR) in a range of about 20% to about 80%, among other thermal properties.
  • TSR total solar reflectance
  • polymeric membranes prepared according to the Examples using suitable effects pigments would show delayed heat build-up over time via solar reflectance and lowered thermal conductivity.
  • the polymeric membranes prepared as described therein are expected to provide better insulative properties when compared to known roofing materials.
  • a process for preparing a reflective polymeric membrane comprising melting of a plastic resin, adding a flame retardant material to the melted resin, adding a metallic appearing effect pigment material sufficient to impart a metallic appearance, and thereby forming the polymeric membrane by low shear extrusion and/or calendaring.
  • the effect pigment material can be added in an amount of about 0.5% by weight to about 3.0% by weight based on the total weight of the reflective polymeric membrane.
  • FIG. 1 depicts a TSR graph of an embodiment of PVC films using metallic appearing effect pigment materials at a level of 1% by weight based on the total weight of the film, measured according to ASTM method E-891.
  • the effect pigment substrate may be mica based, alumina based, metallic based, synthetic mica based and borosilicate based. This listing is provided as exemplary and is not intended to be limiting.
  • the effect pigment substrate is optionally coated, blended, or combined with metal oxide, such as, for example, titanium dioxide, iron oxide, aluminum oxide, and mixtures thereof, to impart a metallic appearance in the thermoplastic membranes.
  • metal oxide such as, for example, titanium dioxide, iron oxide, aluminum oxide, and mixtures thereof.
  • the thermoplastic membranes containing the effect pigment have the appearance of a metallic-based material.
  • the metallic appearing pigments functions as a pigment additive in the roofing materials.
  • Useful effect pigments are further described in U.S. Pat. No. 7,507,285, which is herein incorporated by reference in its entirety.
  • Exemplary amounts of effect pigments relative to the entire roofing material, that is, relative to the polymeric layer or membrane, can range from about 0.5% to 3.55%. In an embodiment, the amount of effect pigments is 0.75% to 3.0% relative to the entire roofing composition, that is, relative to the polymeric layer or membrane.
  • a roofing material that is made up of two or more layers of polymeric membrane materials, the top layer being exposed to the environment (the capstock layer) containing metallic or metallic appearing effect pigment materials.
  • the cap stock layer contains the bulk of the UV stabilizers.
  • the capstock layer contains metal oxides, effect pigments and fire retardants.
  • the roofing material may be made of an upper thermoplastic layer over a bottom thermoplastic layer.
  • the roofing material may be made of one or several upper thermoplastic layers and one or more bottom thermoplastic layers, with supporting layers in between, for example, a scrim, in between two thermoplastic layers.
  • thermoplastic layers have a depth of 20 to 120 mils.
  • the thermoplastic resin layer can be between 20 to 120 mils thick and the capstock layer can be typically between 20-80 mils.
  • the roofing membrane is comprised of polymeric membranes.
  • the polymer's membrane is a thermoplastic olefin resin (TPO).
  • the polymeric membrane may be a polyvinyl chloride-based resin (PVC).
  • roofing materials may include EPDM (a rubber, ethylene propylene diene monomer rubber), asphalt, shingles, tiles, metal and coated metal, terra cotta, and clay. Additional roofing materials known to the skilled artisan are also contemplated.
  • the roofing membrane can preferably contain UV stabilizers.
  • the UV stabilizer may be a hindered amine light stabilizer (HALS), UV absorbers (organics or inorganics), antioxidants, and temperature stabilizers. Other UV stabilizers are known to those skilled in the art.
  • the UV stabilizer is used in the capstock layer. Lower levels of UV stabilizer may also be present in base stock layers. Examples of UV stabilizers are commercially available from BASF Corporation (Florham Park, New Jersey).
  • At least the capstock membrane layer contains IR reflective materials to minimize heat build and effect pigment material to impart metallic appearance.
  • the roofing material further contains a flame retardant and smoke suppressant.
  • a flame retardant and smoke suppressant for example, in an embodiment, magnesium hydroxide can be used.
  • Other flame retardants and smoke suppressants are known to the skilled artisan.
  • the metallic appearing effect pigment material may not be incorporated in the TPO/PVC layer itself. Instead, the metallic appearing effect pigment material can be coated on the top or bottom of the TPO/PVC layer as a separate layer.
  • the UV stabilizer can be melt compounded into the polymeric materials, as a part of the thermoplastic resin.
  • it can be used (melt compounded in at 0.1-2.5%) in the capstock layer.
  • UVINUL® materials available from BASF Corporation, are the UV stabilizers.
  • a three layer roofing material is produced.
  • optional non-pigment additives including optional flame retardant and UV stabilizing additives, are added to the compounding of the thermoplastic in an extruder.
  • IR reflective or transparent pigments are added at the feed throat of the extruder as well as some of the special effect pigment.
  • Effect pigment materials are optionally added later in the process, for example, in downstream feeder, to minimize residence time in order to prevent their destruction by the shear forces of the calendar or extruder equipment which can cause stripping of the optical coating from the substrate resulting in washed out appearance or less of a special effect.
  • the resulting product forms the upper or outer layer of the thermoplastic membrane.
  • TPO resin 49.4 49.4 49.4 49.4 49.4 49.5 1 Mearlin ®, Lumina ®, and MagnaPearl ® effect pigments are products available from BASF Corp. 2 Meteor ® Plus inorganic pigment is available from BASF Corp.
  • the prepared polymeric membrane materials exhibit unexpectedly enhanced TSR values when compared to metal target. It is notable that the polymeric membrane materials prepared as in Table 1, Example 2 are generally non-metallic materials, and the effect pigments themselves are non-metallic materials. However, a metallic look or appearance is provided, which is amply demonstrated by the TSR value results.
  • the TPO resin was melt compounded using a single screw, twin screw, buss co kneader, internal mixer or other plastic mixing or compounding equipment.
  • the additives and the pigment can be added at the feed throat of the extruder or even more desirable using a side or downstream feed port. Care was taken to minimize shear and residence time during processing to ensure that the effect pigments remain intact. This was effected by low shear extrusion screws, processing aids, or other means to minimize destruction of effect pigments during processing.
  • the resin contains the magnesium hydroxide FR (flame retardant) and the UV stabilizing additives, or these additives. In some cases, these additives are introduced earlier via a concentrate or compound production.
  • compositions comprises:
  • additives include: processing aids, process stabilizers, heat stabilizer/antioxidant, and other additives typically used in polymeric membrane roofing applications.
  • the membranes are made using film/membrane production equipment such as a calendaring operation. To minimize shear, single layer or co-extrusion process are used.
  • polymeric membranes prepared according to the Examples using other suitable effects pigments as described above would be have good total solar reflectance (TSR) in a range of about 20% to about 80%, among other thermal properties.
  • TSR total solar reflectance
  • polymeric membranes prepared according to the Examples using suitable metallic effects pigments, as described above would show delayed heat build-up over time via solar reflectance and lowered thermal conductivity.
  • the polymeric membranes prepared as described therein are expected to provide better insulative properties when compared to known roofing materials.
  • a reflective polymeric membrane containing metallic appearing effect pigment material can have a TSR ranging from about 20% to about 80%. In another exemplary embodiment, the reflective polymeric membrane containing metallic appearing effect pigment material can have a TSR ranging from about 40% to about 80%. In yet another embodiment, the reflective polymeric membrane containing metallic appearing effect pigment material can have a TSR ranging from about 50% to about 80%.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Wood Science & Technology (AREA)
  • Compositions Of Macromolecular Compounds (AREA)
  • Laminated Bodies (AREA)
US12/582,203 2008-10-20 2009-10-20 Roofing Materials with Metallic Appearance Abandoned US20100095618A1 (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
US12/582,203 US20100095618A1 (en) 2008-10-20 2009-10-20 Roofing Materials with Metallic Appearance
US13/668,810 US20130065021A1 (en) 2008-10-20 2012-11-05 Roofing Materials with Metallic Appearance

Applications Claiming Priority (3)

Application Number Priority Date Filing Date Title
US10670908P 2008-10-20 2008-10-20
US15006809P 2009-02-05 2009-02-05
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US20100160190A1 (en) * 2008-12-19 2010-06-24 Kuvshinnikova Olga I Weatherable colored resinous composition and method
US20110223410A1 (en) * 2010-03-12 2011-09-15 Imet Corporation Waterproof, Thermal insulating radiant reflective roofing laminate
US8715819B2 (en) * 2010-03-12 2014-05-06 Imet Corporation Waterproof, thermal insulating radiant reflective roofing laminate
WO2013078467A1 (en) * 2011-11-23 2013-05-30 Building Materials Investment Corporation Tpo batten system
US8769903B2 (en) 2011-11-23 2014-07-08 Building Materials Investment Corporation TPO batten system
US11065843B2 (en) 2017-06-07 2021-07-20 Novelis Inc. Multi-layered finishes for can ends
WO2020182975A1 (en) * 2019-03-13 2020-09-17 Sika Technology Ag A weathering stable thermochromic membrane
EP3708356A1 (en) * 2019-03-13 2020-09-16 Sika Technology Ag A weathering stable thermochromic roofing membrane
US12051990B2 (en) 2020-01-22 2024-07-30 GAF Energy LLC Integrated photovoltaic roofing shingles, methods, systems, and kits thereof
US11876480B2 (en) 2020-06-04 2024-01-16 GAF Energy LLC Photovoltaic shingles and methods of installing same
US11843067B2 (en) 2020-07-22 2023-12-12 GAF Energy LLC Photovoltaic modules
US11870227B2 (en) 2020-09-03 2024-01-09 GAF Energy LLC Building integrated photovoltaic system
US11996797B2 (en) 2020-12-02 2024-05-28 GAF Energy LLC Step flaps for photovoltaic and roofing shingles
US11965335B2 (en) 2021-01-19 2024-04-23 GAF Energy LLC Watershedding features for roofing shingles
US12095415B2 (en) 2021-03-29 2024-09-17 GAF Energy LLC Electrical components for photovoltaic systems
US11869997B2 (en) 2021-05-06 2024-01-09 GAF Energy LLC Photovoltaic module with transparent perimeter edges
US12100775B2 (en) 2021-06-02 2024-09-24 GAF Energy LLC Photovoltaic module with light-scattering encapsulant providing shingle-mimicking appearance
US20230203815A1 (en) * 2021-06-03 2023-06-29 GAF Energy LLC Roofing module system
US12009781B2 (en) 2021-07-06 2024-06-11 GAF Energy LLC Jumper module for photovoltaic systems
US12009773B2 (en) 2021-09-01 2024-06-11 GAF Energy LLC Photovoltaic modules for commercial roofing
US11824486B2 (en) 2022-01-20 2023-11-21 GAF Energy LLC Roofing shingles for mimicking the appearance of photovoltaic modules
US12013153B2 (en) 2022-02-08 2024-06-18 GAF Energy LLC Building integrated photovoltaic system
US12126301B2 (en) 2022-07-11 2024-10-22 GAF Energy LLC Roof mounted photovoltaic system and method for wireless transfer of electrical energy
US12034089B2 (en) 2022-09-01 2024-07-09 GAF Energy LLC Anti-reflective photovoltaic shingles and related methods
US12123194B2 (en) 2022-09-12 2024-10-22 GAF Energy LLC System of roofing and photovoltaic shingles and methods of installing same
US12051996B2 (en) 2022-09-13 2024-07-30 GAF Energy LLC Sensing roofing system and method thereof
US12015374B2 (en) 2022-09-26 2024-06-18 GAF Energy LLC Photovoltaic modules integrated with building siding and fencing
US12031332B2 (en) 2022-10-25 2024-07-09 GAF Energy LLC Roofing materials and related methods
US12009782B1 (en) 2023-04-04 2024-06-11 GAF Energy LLC Photovoltaic systems with wireways

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JP2012506504A (ja) 2012-03-15
CN102272393A (zh) 2011-12-07
WO2010048187A1 (en) 2010-04-29
EP2347063A1 (en) 2011-07-27
KR20110086086A (ko) 2011-07-27
CA2740780A1 (en) 2010-04-29
AU2009307732A1 (en) 2010-04-29
MX2011004277A (es) 2011-05-25
BRPI0919936A2 (pt) 2016-02-16
US20130065021A1 (en) 2013-03-14

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