WO2014043643A2 - Matériau de couverture avec traitement de surface et zone d'ombre - Google Patents

Matériau de couverture avec traitement de surface et zone d'ombre Download PDF

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Publication number
WO2014043643A2
WO2014043643A2 PCT/US2013/059994 US2013059994W WO2014043643A2 WO 2014043643 A2 WO2014043643 A2 WO 2014043643A2 US 2013059994 W US2013059994 W US 2013059994W WO 2014043643 A2 WO2014043643 A2 WO 2014043643A2
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WO
WIPO (PCT)
Prior art keywords
granules
coating
roofing material
shingles
roofing
Prior art date
Application number
PCT/US2013/059994
Other languages
English (en)
Other versions
WO2014043643A3 (fr
Inventor
Kirk M. Bailey
Jeffrey T. HOLMAN
Original Assignee
Cool Angle LLC
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Cool Angle LLC filed Critical Cool Angle LLC
Publication of WO2014043643A2 publication Critical patent/WO2014043643A2/fr
Publication of WO2014043643A3 publication Critical patent/WO2014043643A3/fr

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Classifications

    • 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
    • E04D1/28—Roofing elements comprising two or more layers, e.g. for insulation
    • 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
    • E04D5/12—Roof covering by making use of flexible material, e.g. supplied in roll form specially modified, e.g. perforated, with granulated surface, with attached pads
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D7/00—Roof covering exclusively consisting of sealing masses applied in situ; Gravelling of flat roofs
    • E04D7/005—Roof covering exclusively consisting of sealing masses applied in situ; Gravelling of flat roofs characterised by loose or embedded gravel or granules as an outer protection of the roof covering
    • 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
    • E04D2001/005—Roof covering by making use of tiles, slates, shingles, or other small roofing elements the roofing elements having a granulated surface
    • 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
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02A—TECHNOLOGIES FOR ADAPTATION TO CLIMATE CHANGE
    • Y02A30/00—Adapting or protecting infrastructure or their operation
    • Y02A30/24—Structural elements or technologies for improving thermal insulation
    • Y02A30/254—Roof garden systems; Roof coverings with high solar reflectance
    • 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
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02B—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO BUILDINGS, e.g. HOUSING, HOUSE APPLIANCES OR RELATED END-USER APPLICATIONS
    • Y02B80/00—Architectural or constructional elements improving the thermal performance of buildings
    • 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.]
    • Y10T428/24752—Laterally noncoextensive components

Definitions

  • Asphalt shingles are by far the most commonly used in the U.S. for residential sloped-roof applications. Asphalt shingles are constructed of a felt or fiberglass mat that is saturated with asphalt and covered with granules which are adhered to the mat. Advantages of this type of roofing include its low cost, durability, aesthetic variety (colors, shading, layers, and textures), as well as ease of installation and repair.
  • the granules of asphalt shingles are generally derived from a hard mineral base rock such as slate, basalt, or nephelite, and are typically ground to a particle size of about 10 to 35 US mesh. Granules are typically coated prior to being applied to shingles to achieve a variety of desired properties. This has been done for many years as illustrated by U.S. Patent 2,379,358 (1945) to Jewett.
  • Patent 6,698,151 (2004) to Elliott.
  • U.S. Patents 7,638,164 (2009) to Aschenbeck and 4,583,486 (1986) to Miller describe methods for accurate granule placement in complex patterns to achieve desired aesthetics. Darker and multi-toned shingles remain preferred in the market place.
  • the visual appearance of a material is strongly influenced by the surface properties, including color, tone, reflectivity, and surface irregularities and their orientation. The resulting properties of all tailoring for visual effect are referred to herein as "tailored aesthetic properties.”
  • the thermal response of a material to incident radiation is determined by the surface radiation properties. These include the reflectivity, absorptivity, transmissivity, and emissivity. Methods described in the prior art to improve the thermal response to solar incidence do so by incorporating features that effect the surface radiation properties. In particular, treatments that increase the surface reflectivity are commonly used.
  • the resulting properties of any such tailoring, including the use of reflective granules, coatings, paints, powders, or other means designed to alter the radiation properties in order to improve thermal performance is referred to herein as "tailored radiation properties.”
  • the granules can be replaced with a more reflective material such as the metal flakes described in U.S. Patent Application Publication 2009/0117329.
  • This method can result in improved reflectivity, but requires deviation from the established, efficient, and low-cost process of producing rock- based granule-coated shingles.
  • this method does not take advantage of the extensive availability of aesthetic choices for typical granule -based shingles.
  • Wood shake shingles are very thin at the uppermost end tapering to considerably thicker at the lower, exposed end.
  • Tile shingles have a variety of curved or flat shapes with interlocking features at interfaces designed to prevent water penetration of the shingle system. While there are a variety of shapes of popular shingles, none of the current art designs capitalize on shape to accomplish directional properties. More particularly, there have been no attempts to create shingles with large scale surfaces that face the sun direction and others that face the viewing direction to facilitate directional tailoring for desired properties.
  • the roofing material includes a plurality of laminate layers and a surface treatment.
  • the plurality of laminate layers includes a top laminate layer which at least partially overlaps a bottom laminate layer.
  • the surface treatment is on portions of the top and bottom laminate layers.
  • a shadow area is created on a top surface of the bottom laminate layer, adjacent to the top laminate layer, that is void of the surface treatment. This shadow area has a distinct visual appearance from the other portions of the top and bottom laminate layers that are subjected to the surface treatment.
  • Other embodiments of the roofing material are also described.
  • Fig. 1 depicts a schematic diagram of one embodiment of the "sun-direction" and the "view-direction” for a typical roof.
  • Fig. 2 depicts a schematic diagram of one embodiment of a cross-section of an asphalt shingle with the dark granules and substrate coated with a material of high reflectivity in the sun-direction.
  • Fig. 3 depicts a schematic diagram of one embodiment of a section of a black asphalt shingle with three types of surface conditions viewed from the sun-direction.
  • Fig. 4 depicts a schematic diagram of one embodiment of a section of a black asphalt shingle with three types of surface conditions viewed from the view-direction.
  • Fig. 5 depicts a schematic diagram of one embodiment of a cross-section of an asphalt shingle with reflective granules and substrate coated with a dark material in the view- direction.
  • Fig. 6 depicts a schematic diagram of one embodiment of a cross-section of an asphalt shingle with generic granules and substrate coated with a material of high reflectivity in the sun-direction and a dark material in the view-direction.
  • Fig. 7 depicts a schematic diagram of one embodiment of a cross-section of an asphalt shingle with granules of bimodal size distribution with large dark granules and small reflective granules.
  • Fig. 8 depicts a schematic diagram of one embodiment of a cross-section of an asphalt shingle with granules of bimodal size distribution.
  • Fig. 9 depicts a schematic diagram of one embodiment of a stepped shingle tailored to have high reflectivity in the sun-direction and pleasing aesthetics in the view- direction.
  • Fig. 10A depicts a schematic diagram of one embodiment of a controlled pattern of separate coatings.
  • Fig. 10B depicts a schematic diagram of another embodiment of a controlled pattern of separate coatings.
  • Fig. 11 A depicts a cross- sectional view of one embodiment of various incident angles from which different coatings may be applied to a roofing material.
  • Fig. 1 IB depicts a plan view of another embodiment of various incident angles from which different coatings may be applied to a roofing material.
  • Fig. 12 depicts a schematic diagram of a system for treating a roofing material to have a coating of material of high reflectivity in the sun-direction and a dark material in the view-direction.
  • Fig. 13A depicts a cross- sectional view of one embodiment of a roofing material with directionally toned triangular granules applied to a base material.
  • Fig. 13B depicts a graph of a reflectivity response of the roofing material of Fig. 13A.
  • Fig. 14A depicts a cross- sectional view of another embodiment of a roofing material with directionally toned triangular granules with asymmetrical shapes.
  • Fig. 14B depicts a graph of a reflectivity response of the roofing material of Fig. 14A.
  • Fig. 15A depicts a cross- sectional view of another embodiment of a roofing material with directionally toned triangular granules with asymmetrical shapes.
  • Fig. 15B depicts a graph of a reflectivity response of the roofing material of Fig.
  • FIGs. 16A-B depict different views of one embodiment of a laminate shingle with a band of granules that is not subject to a directional coating.
  • Fig 1 illustrates the two directions for an application on a sloped roof.
  • a typical building 20 has a roof 22 that is subjected to incident radiation loads from the sun 24.
  • This incident radiation is in the form of both direct and diffuse radiation; direct passing directly through the atmosphere thereby maintaining its direction, diffuse having been scattered by the atmosphere thereby losing its directional orientation. While the direction of incident radiation is not fixed, it is predominantly coming from directions above the roof, and in particular those directed toward the sun and sky. For any point on the roof 26, local incidence is then predominantly associated with vectors passing through the upper portion of a hemisphere 28 centered on the point. These directions are transient due to the changing position of the sun, but they are predominantly upward.
  • This collection of upward directions is denoted here as the "sun-direction" 30.
  • the sun direction is predominantly from the upward (or sky) directions
  • a viewer 32 predominantly observes the roof from the downward (or ground) directions.
  • These directions are variable due to, for example, elevation changes in the local terrain, but they are predominantly from the downward directions.
  • the collection of vectors passing from these prominent viewing directions through the lower portion of the hemisphere to a point on the surface makes up the "view- direction" 34.
  • the thermal response of a material to incident radiation is determined by the surface radiation properties. These include the reflectivity, absorptivity, transmissivity and emissivity.
  • the effective directional dependence is strongly influenced by surface properties and orientation. The same properties also influence the visual appearance of a material; that is, surface irregularities and surface radiation properties. All of the methods described in the prior art to improve the thermal response to solar incidence do so by incorporating features that effect the surface radiation properties. In particular, treatments that increase the surface reflectivity are commonly used.
  • tailored radiation properties The results of any tailoring to achieve desired aesthetics are referred to here as “tailored aesthetics.” This includes tailoring such as that described in the prior art including the use of colors, texturing, shading, layering or any other means of achieving desired visual effects.
  • the predominant payoff of tailored radiation properties is associated with surface properties in the sun-direction since the largest fraction of solar incidence is associated with that direction.
  • the predominant payoff of tailored aesthetics is associated with properties in the view-direction since the surface is predominantly viewed in that direction.
  • What is lacking in the prior art is directionally dependent tailored radiation properties and tailored aesthetics, and in particular tailored radiation properties in the sun-direction and tailored aesthetics in the view-direction. That deficiency is addressed in the following embodiments which provide tailored radiation properties in the sun-direction and tailored aesthetics in the view-direction.
  • a line depicting demarcation 36 between the two collections of directions making up the sun-direction 30 and the view-direction 34 is shown in Fig 1. However, there need not be a distinct demarcation between the two directions. Any fraction of all possible directions may be tailored for reflectivity from the sun-direction and aesthetics from the view-direction so long as tailoring of both has been achieved.
  • Various embodiments provide roofing materials with tailored radiation properties in the sun-direction and tailored aesthetics in the view-direction.
  • High reflectivity of solar radiation in the sun-direction is desirable to extend the service life of the shingles and to reduce heating loads for the building.
  • Visual properties with favorable aesthetics are desired in the view-direction to enhance the attractiveness of the roof.
  • These tailored properties are accomplished by providing directional treatments on irregular surfaces of the roofing materials.
  • the irregular surfaces can be inherently provided by materials common to the current art such as granule-coated asphalt shingles. Asphalt shingles have granules that vary in size, shape and orientation resulting in an irregular surface.
  • the irregular surfaces can also be accomplished through the creation of surface shapes specifically designed to provide orientations in the sun-direction and view- direction.
  • Fig 2 depicts the first embodiment wherein shingle granules with tailored aesthetics 38 are adhered to an asphalt-impregnated substrate such as felt or fiberglass 40.
  • the granules are then directionally coated with material with tailored radiation properties in the form of high reflectivity 42 on the surfaces of the shingles facing the sun-direction. This can easily be accomplished by applying the coating at a consistent predetermined angle with the proper application equipment and settings.
  • the aesthetics of the view-direction are maintained by excluding that direction from high reflectivity treatment.
  • Fig 3 provides a photograph of a section of a black asphalt shingle 44 with three different surface conditions; one that remains black 46, one uniformly coated with high reflectivity white coating 48, and one treated with directionally applied high reflectivity white coating 50.
  • the shingles are photographed from within the sun-direction.
  • the white 48 and the directionally treated 50 surfaces look similar indicating that the two will have similar reflective properties on surfaces facing the sun-direction.
  • Fig 4 shows a photograph of the same shingle 44 section taken from within the view-direction.
  • the directionally treated surface 50 appears similar to the untreated black surface 46, illustrating that the two have similar aesthetics from the view- direction.
  • Fig 5 depicts another embodiment wherein the rock granules 52 have high reflectivity prior to being adhered to an asphalt-impregnated substrate such as felt or fiberglass 40.
  • the irregular surface of the shingle is directionally treated with a coating 54 to enhance aesthetics on the surfaces of the shingle facing the view-direction.
  • the surfaces facing the sun-direction are unchanged thereby maintaining their high reflectivity in that direction. This can easily be accomplished by applying the coating at a consistent predetermined angle with the proper application equipment and settings.
  • Fig 6 depicts another embodiment wherein generic granules 56 are adhered to an asphalt-impregnated substrate such as felt or fiberglass 40.
  • the granules are then modified with different coatings in the two directions.
  • the irregular surface of the shingle is directionally treated with a coating 54 to enhance aesthetics on the surfaces of the shingle facing the view-direction.
  • the granules are also directionally coated with material with tailored radiation properties in the form of high reflectivity 42 on the surfaces of the shingles facing the sun-direction. This can easily be accomplished by applying the coatings at consistent predetermined angles with the proper application equipment and settings.
  • the coating applied to the roofing material has a thermal reflectivity value of at least approximately 0.6.
  • the granules forming the non-planar surface of the roofing material have a thermal value of at least approximately 0.6.
  • the directionally dependent conditions of enhanced reflectivity in the sun- direction and enhanced aesthetics in the view direction may also be achieved in another embodiment with a multi-modal size distribution of granules are adhered to an asphalt- impregnated substrate such as felt or fiberglass.
  • a bimodal example of such an embodiment is illustrated in Fig 7.
  • Granules in the smaller size modes 58 are tailored to have highly reflective surfaces.
  • Granules of larger modes have enhanced aesthetics 38. This results in improved reflectivity in the sun-direction since the smaller reflective particles are not blocked from views from above. The smaller reflective particles are somewhat obscured from view in the view-direction by the larger aesthetic particles, resulting in favorable aesthetics in that direction.
  • Various size distributions and proportions can be used to achieve the desired effect.
  • Patterning of the granules can range from random distribution to horizontal stripping with intermittent rows of large and small particles.
  • the effectiveness of this embodiment would be determined by many factors shown in Fig 8 including the roof angle 60, view direction 62, view angle 64, sizes of the granules 66 and 68, and the distance between the granules 70.
  • roofing embodiments are not limited to the familiar asphalt shingle.
  • shingles constructed of any composition such as slate, metal, fibrous cement, ceramics, wood, and concrete are possible by shaping and tailoring the surface properties for reflectivity in one direction and aesthetics in another.
  • a metal, plastic, or other type of roofing panel may be physically altered or treated to yield a surface texture that will take the treatment described below.
  • the panel may be crimped, stamped, embossed, etched, or otherwise altered to provide a patterned or random arrangement of raised and/or depressed portions that extend away from a primary surface of the panel.
  • Other embodiments may use other types of roofing material.
  • Fig 9 illustrates a material of a stepped shape 72 with the faces of the steps facing in different directions tailored to have different properties.
  • the steps facing in the sun-direction are directionally coated with a high reflectivity coating 42 in the sun-direction and have a directionally applied coating with tailored aesthetics 54 applied in the view-direction.
  • some of the embodiments provide a roofing material with both tailored radiation properties and tailored aesthetics. More importantly, these
  • embodiments allow for a product with directionally specific tailoring of these two properties in order to reduce the inevitable compromise between the two.
  • This provides a material that is marketable due to its tailored aesthetics and at the same time has a high reflectivity so that service temperatures are reduced. This results in increased effective service life and a reduction in cooling loads for the building.
  • some embodiments of the shingles manufactured with directionally dependant properties have the following additional advantages:
  • roofing materials with directionally dependent properties are coated or otherwise finished to have varying finish properties. Similar to conventional shingles which may include a mixture of surface granules to achieve color variation in the look of installed shingles; multiple coatings may be directionally applied to achieve some variation in the color and/or performance properties of the roofing material. In some embodiments, the multiple coatings may be applied at substantially the same time as a mixture of different coatings. Alternatively, the multiple coatings may be applied one at a time, so that each coating material does not mix with other coating materials. The coating materials may be applied to generate a substantially random pattern. In another embodiment, the coating materials may be applied according to a specific coating process in order to achieve a substantially controlled pattern on the surface of the roofing material.
  • Fig. 10A depicts a schematic diagram of one embodiment of a controlled pattern of separate coatings 42 that may be achieved on granules 38 of an asphalt shingle 40 by sequentially applying the different coatings at different application angles. Some of the coatings may be applied specifically for visual appeal, while other coatings may be applied specifically for energy efficiency performance, while still other coatings may be applied to achieve some combination of visual appeal and energy efficiency.
  • a first coating (shown as solid white lines) with first visual and/or performance properties is applied at a first incident angle relative to the normal of the roofing material.
  • a second coating (shown as dashed black lines) with second visual and/or performance properties is applied at a second incident angle relative to the normal of the roofing material.
  • the second incident angle is greater than the first incident angle so that less of the granule surface is coated by the second coating, and at least some of the first coating remains exposed.
  • the second coating may have higher reflectivity characteristics, or other improved thermal or energy efficiency characteristics, relative to the first coating.
  • a third coating (shown as solid black lines) with third visual and/or performance properties is applied at a third incident angle relative to the normal of the roofing material.
  • the third incident angle may be even greater than the second incident angle so that at least some of the second coating remains exposed, and the third coating may have even higher energy efficiency
  • the use of two or more coatings with different visual and/or performance properties can be applied in a controlled manner in order to achieve more precise patterns of coatings on the roofing material.
  • the cross-sectional view provided in Fig. 10A only shows variation in the coating locations relative to one direction (e.g., up-down) of the shingle. In some embodiments, similar variations (random or patterned) also may be achieved in other directions (e.g., side-to-side or left- to-right).
  • Fig. 10B depicts a schematic diagram of another embodiment of a controlled pattern of separate coatings.
  • the base coating (shown in white) is applied to substantially the entire non-planar surface of the base material and the granules.
  • the base coating is applied in a substantially uniform manner to the non- planar surface.
  • the top coating is then applied directionally, so that less than all of the surface of the granules is covered.
  • Fig. 11 A depicts a cross- sectional view of one embodiment of various incident angles from which different coatings may be applied to a roofing material.
  • the incident angles vary between about 75-85 degrees from the normal (about 5- 15 degrees from the parallel of the underlying surface). In other embodiments, the incident angles may vary more or less (e.g., between about 60-90 degrees) from the normal.
  • Fig. 1 IB depicts a plan view of another embodiment of various incident angles from which different coatings may be applied to a roofing material.
  • different incident angles and/or coating patterns may be achieved by locating different nozzles or other coating emitters at different physical locations relative to the shingles.
  • different incident angles may be achieved in part by using nozzles or other coating emitters which have different emission patterns (e.g., wide angle, fan, etc.).
  • the angle of the spray relative to the direction of travel of the shingle may be dependent on one or more operating factors.
  • the angle of the spray may take into account the direction and speed of the shingle in a particular direction.
  • the angle of the spray may be established to result in relatively equal amounts of spray on any pairs of vertical surfaces (e.g., vertical surfaces of any cutout portions of the substrate).
  • the angle of the spray may be
  • the vertical angle, the pressure, the nozzle opening, or any other operating parameter may be controlled independently, or in combination with other parameters, based on the speed of the shingle. In this way, the coating parameters may be changed to match the speed of the shingles through the production line.
  • a detector such as an electronic eye (or a combination of detectors) may be used to provide feedback on the quality, locations, thickness, or other characteristics of the coating that is actually applied.
  • a controller may reference some or all of this feedback data, in addition to line speed data, to dynamically fine tune the coating application. Additionally, the detector(s) and controller may be used to provide reporting data to production operators.
  • the coating process uses a fine mist of paint or other coating falling gently like rain instead of at high velocity right out of a spray nozzle.
  • An atomizer at the top of a tall booth may be implemented to emit droplets of coating material(s) that fall slowly onto the shingle at a particular angle or angles.
  • the angle of the shingle relative to the atomizer may be changed to allow different coatings to be applied at different angles.
  • different coatings are applied by different atomizers at different angles within the booth by slightly rotating or twisting the shingles as they pass under each of the atomizers.
  • Other methods of application may also be used. For example, an electrical charge based system, a gravity coating system, a chemical deposition, or spin coating system may be used.
  • the tones of different coatings are all very light and, therefore, quite reflective. This would go a long way in keeping the roof looking "normal” and would mask the color change due to perspective or roof viewing angle. As one example, this could be done with simple 3 tab shingles by varying the spray direction along the shingle (a very simple way to make 3-tab look more architectural) or with architectural grade much as they do now by mixing the pieces prior to bonding.
  • the order in which coatings might be applied can be established so that coatings with higher energy efficiency properties are applied last and, hence, are substantially exposed to sunlight or other sources of energy.
  • the relative quantities of coatings may be set so that higher quantities of more efficient coatings are used.
  • the way that the granules are applied to the asphalt- saturated felt base of the shingle may be varied in order to achieve different visual and/or energy efficiency performance properties.
  • the granules are pressed into the asphalt- saturated felt base at a decreased depth relative to conventional shingles. This may allow the granules to be exposed more at the end of the manufacturing process and, consequently, receive more directional coating than if the granules were pressed further into the asphalt- saturated felt base.
  • an additional heating stage may be added to the manufacturing process.
  • the shingle is then exposed to a heating stage in order to raise the granules some distance out of the asphalt- saturated felt base.
  • the raised granules then may be coated to a greater extent than if the granules were pressed further into the asphalt- saturated felt base.
  • some or all of the granules may be directionally coated prior to being pressed into the base material.
  • an additional coating (or constituent of the color coating) may be used to decrease adhesion of the asphalt material of the base to the surface of the granule that is coated with a color or material that has a reflectivity that is different from the reflectivity of the asphalt.
  • This anti-adhesion coating may be applied on top of a colored coating or in combination with a colored coating.
  • the anti-adhesion coating is mixed with the color coating prior to application of the color coating.
  • the anti-adhesion coating is applied at
  • the anti-adhesion coating may be applied on top of the color coating after the color coating has sufficiently dried or cured to substantially prevent mixing.
  • tailored shapes and/or sizes (or mix of shape and/or sizes) of granules may be used.
  • multiple granule applications may be implemented so that some granules are added and pressed into the asphalt- saturated felt base during a first stage, and then other granules are added and pressed into the asphalt- saturated felt base at a different depth.
  • the granules of the different pressing stages could be different sizes, generally.
  • the second pressing stage may be implemented with larger granules so that the larger granules are more exposed after the second pressing stage. Any number of pressing stages may be implemented.
  • At least one of the pressing stages may be implemented with a rubber roller (or other material with a soft exterior or variable firmness) so that the larger granules create a threshold for how far smaller granules might be pressed into the asphalt- saturated felt base.
  • granules may be bonded differently (e.g., using better adhesives) to the asphalt- saturated felt base in order to eliminate the need for pressing.
  • enhanced versions of asphalt that are more flexible and stronger than conventional asphalt may be used to bond granules to the asphalt- saturated felt base.
  • granules are coated with an absorbing material that serves as a bonding agent to facilitate bonding the directional coating(s) to the granule and, in some embodiments, substantially prevent bleeding or flow of the coating onto unintended locations or sides of the granules.
  • bonding agents or absorbing materials include, but are not limited to, porous ceramic materials, clear or substantially transparent primers, and colored primers which match one or more of the colors of the coating material(s).
  • the coatings may be produced with minimal or relatively low levels of surfactant(s) in order to minimize or substantially prevent back-side bleeding of the coating on the granules.
  • airless or other application techniques may be used to apply the coating(s) to the granules.
  • coating the shingles before applying them to a roof eliminates the problem of sealing the interface between the shingles at the lower edge of each shingle that allows water to run out from under the shingle as designed (sometimes voiding shingle warranties).
  • coating the shingles before applying them to a roof eliminates the problem of sealing the interface between the shingles at the lower edge of each shingle that allows water to run out from under the shingle as designed (sometimes voiding shingle warranties).
  • instead of using conventional techniques to roll or spray coatings onto roofing surfaces in a manner that seals adjacent rows of shingles together, preventing air or fluid flow between the adjacent shingles at least some of the embodiments described herein avoid inadvertently sealing adjacent rows of shingles together because the application angle prevents application of the coating(s) at the interface between the adjacent rows of shingles.
  • an applicator e.g., sprayer nozzle
  • a mounting device which maintains the applicator at an acceptable angle of incidence (or within an acceptable range) relative to the roofing material.
  • the applicator and/or mounting device use a running rail to guide the applicator and/or the mounting device along different rows of shingles.
  • the running rail may be secured to a location on the roof such as a "hook" or other implement to mount the rail relative to the roof peak. Other devices may clamp to a particular row of shingles or other roofing equipment.
  • the applicator may be automated or semi- automated to travel at a particular speed.
  • multiple applicators may be used to apply a variety of coating materials at the same time, or at different times, and at the same or different incident angles.
  • a shield or other device may be used to cover up lower rows of shingles which otherwise might receive overspray.
  • the applicator may move horizontally across the roof.
  • the applicator may move vertically up and down the roof.
  • the applicator may follow other patterns for application to an existing roof. [0074]
  • various testing approaches may be used.
  • an appropriately shaped spacer may be placed between test samples and the instrument to accomplish various angles while minimizing or substantially preventing unnecessary light leakage.
  • angled spacers may be used to align test equipment with shingles to be tested. Some of the angled spacers may include reflective surfaces to allow reflected light to eventually be redirected to the test equipment.
  • Fig. 12 depicts a schematic diagram of a system 100 for treating a roofing material 102 to have a coating of material of high reflectivity in the sun-direction and a dark material in the view-direction.
  • the roofing material 102 passes over a roller 104.
  • the roofing material 102 is deformed as it moves over the roller 104.
  • the roofing material may be bent at an angle 106 of various degrees.
  • a nozzle 108 creates a spray pattern 110 of surface treatment or coating material that adheres to the roofing material 102.
  • the application area 112 for the system 100 is defined at least in part by an overspray guard 114 and an underspray or drip guard 116.
  • the guards 114 and 116 prevent unwanted application of the coating material to the roofing material 102.
  • the roofing material 102 is a felt, fiberglass, or mesh based shingle. Other embodiments may include metal, plastic, cloth, wood, or other type of roofing material that can be flexed without breaking or exhibiting purely plastic deformation after passing over the roller 104.
  • the roofing material 102 is a stepped material (see Fig. 9).
  • the roller 104 may have a patterned surface to improve the tracking of the roofing material 102 across the roller 104.
  • the roller 104 may be stationary with a smooth surface to allow the roofing material 102 to pass over the roller 104.
  • the roller 104 rotates to facilitate a controlled rate of movement of the roofing material 102 through the system 100.
  • the roller 104 may includes multiple channels or tracks to carry multiple feeds of roofing material 102 through the system 100 simultaneously.
  • the roller 104 has a geometry to cause the roofing material 102 to bend at a slight angle 106. In other embodiments, the roller 104 is such that the roofing material is deformed heavily at a more dramatic angle 106. Other embodiments may incorporate other degrees of angle 106 bends into the system 100 to achieve different textures, patterns, saturations, coverages, stiffnesses, geometries, surface features, or other qualities of the roofing material 102 or coating.
  • the nozzle 108 pressure sprays the coating onto the roofing material 102. In other embodiments, the nozzle 108 applies a charge to the coating to electrically apply the coating to the roofing material 102. In this embodiment, a
  • corresponding charge may be applied to the roofing material 102 to attract the coating.
  • the illustrated system 100 is rotated ninety degrees so that the nozzle 108 is directed straight down and the coating is directed to the roofing material 102 by the force of gravity.
  • the system 100 may be oriented to allow the nozzle 108 to spray straight up to apply the coating to the roofing material 102.
  • the roofing material 102 passes across the underside of the roller 104 and the nozzle 108 sprays the coating onto the roofing material. In this embodiment, the amount of overspray and inaccuracy of the application of the coating may be reduced because gravity will cause the excess coating to fall away from the roofing material 102.
  • the nozzle 108 forms a spray pattern 110 of the coating.
  • the nozzle 108 may be configured to spray at several angles, dispositions, or rates.
  • the spray pattern 110 may be constant or may vary with time or location within the spray pattern 110 or location or angle relative to the roofing material 102.
  • the pressure behind the nozzle 108 may be varied or constant and controlled by a separate system (not shown).
  • the spray pattern 110 may sweep back and forth across the application area 112 or may be static and provide coverage to the entire breadth of the roofing material 102.
  • the spray pattern 110 may have varied degrees of saturation depending on the location within the spray pattern 110. Other qualities of the spray pattern 110 may facilitate other patterns, coverage rates, coverage thicknesses, or other aspects of the coating or application process.
  • the illustrated embodiment also includes one or more flanges 118 to hold a leading edge of the roofing material 102 in place relative to the roller 104.
  • the use of one or more flanges 118 may facilitate directing the leading edge of the roofing material 102 below the guard 114, which is described in more detail below.
  • a single 118 flange may run substantially the length of the leading edge of the roofing material 102.
  • multiple small, thin flanges 118 e.g., wires, brackets, etc.
  • Minimal obstruction refers to using a flange design that is no larger than is sufficient, within a reasonable design tolerance, to mechanically hold the leading of the roofing material 102 in place relative to the roller 104.
  • one or more additional rollers 120 may be included.
  • the roller 104 or any of the additional rollers 120 may be powered or passive. In some embodiments, at least one of the rollers 104, 120 is powered to advance the roofing material 102 through the system 100. In another
  • the rollers 104, 120 are all passive, and the roofing material 102 is advance through the system 100 under an external force from another feeding mechanism (not shown).
  • the roofing material 102 is passed over multiple rollers 104 for application of multiple types of surface coatings.
  • the multiple coatings may mix during or after applications.
  • the individual coatings may be allowed to dry or cure prior to application of a subsequent coating.
  • embodiments may include other application mechanics or schemes.
  • multiple coatings may be applied in such a manner as to vary the optical appearance of the coatings.
  • the coatings may be applied at several dispositions/angles or quantities.
  • Other embodiments may incorporate other patterns or color schemes to improve the aesthetic and/or functional aspects of the roofing material 102 relative to the angle of viewing/impingement.
  • the application area 112 is the area of the roofing surface 102 that is exposed to the spray from the nozzle 108. In the illustrated embodiment, the application area 112 is at least partially defined by the guards 114 and 116. In some embodiments, the roofing material 102 is bent through the entirety of the application area 112. In other embodiments, the application area 112 also includes a relatively flat portion of the roofing material 102 before it contacts the roller 104 or after it breaks contact with the roller 104.
  • the guards 114 and 116 are oriented to shield portions of the system 100 from the coating emitted from the nozzle 108. In some embodiments, the guards 114 and 116 prevent coating material from adhering to the roofing material 102 in an uncontrolled manner, such as overspray or dripping. In some embodiments, the guards 114 and 116 are coupled to a reclamation system (not shown) to recover coating material that did not adhere to the roofing material 102. In some embodiments, the guards 114 and 116 are simple panels or plates. Other embodiments of the guards may be screens, cloths, plastic sheets, or a directed air flow.
  • overspray guard 114 may be a strong directed flow of air that travels up the right side of the roofing material and carries overspray material away from the surface of the roofing material 102.
  • Other embodiments of the guards 114 and 116 may include other means for preventing or reducing unwanted application of the coating to the roofing material 102.
  • Fig. 13A depicts a cross- sectional view of one embodiment of a roofing material 130 with directionally toned triangular granules 132 applied to a base material 134.
  • Fig. 13B depicts a graph 132 of a reflectivity response of the roofing material 130 of Fig. 13A.
  • This graph 132 is based on a model in which the white side of the granules 132 is about 95% reflective and the dark side of the granules 132 is about 5% reflective.
  • stepped structures e.g., stepped metal roofing
  • embossed structures e.g., embossed metal panels
  • This graph is also based on an assumption of perfect color separate without overspray during application of one or more coatings.
  • Fig. 14A depicts a cross- sectional view of another embodiment of a roofing material 140 with directionally toned triangular granules 142 with asymmetrical shapes.
  • the granules 142 are applied to a base material 144.
  • the light side is at approximately 70 degrees
  • the dark side is at approximately 135 degrees.
  • Other embodiments may have other slopes.
  • Fig. 14B depicts a graph 146 of a reflectivity response of the roofing material 140 of Fig. 14A.
  • Fig. 15A depicts a cross- sectional view of another embodiment of a roofing material 150 with directionally toned triangular granules 152 with asymmetrical shapes.
  • the granules 152 are applied to a base material 154.
  • the light side is at approximately 70 degrees
  • the dark side is at approximately 110 degrees.
  • Fig. 15B depicts a graph 156 of a reflectivity response of the roofing material 150 of Fig. 15A.
  • a removable sacrificial layer may be used as an undercoating prior to applying one of the reflective coatings.
  • the removable sacrificial coating may be any mixture that temporarily adheres to the roofing material, but which subsequently can be washed off or otherwise removed from the roofing material.
  • sugar-water may be used.
  • a solution of soap and water may be used.
  • Other embodiments may use other types of sacrificial coatings. The sacrificial coating is applied to surfaces which ultimately will not have the reflective coating (e.g., the bottom half of the granules that are visible from the viewing direction).
  • the reflective coating is applied to surfaces which are intended to remain reflective. Any overspray of the reflective coating will deposit on the sacrificial coating. By subsequently removing the sacrificial coating, the overspray droplets of the reflective coating will be removed (e.g., washed off) with the sacrificial coating.
  • this process of using a preliminary sacrificial layer may be referred to as a pre- coating process and a removal or dissolving process.
  • overspray can be removed using a more abrasive removal technique such as grit-blasting (e.g., sand-blasting).
  • grit-blasting e.g., sand-blasting
  • overspray droplets may be removed from the impacted surfaces of the roofing material without damaging the granules or other surfaces of the roofing material.
  • the grit characteristics and blasting parameters are sufficient to remove overspray droplets of the reflective coating, without damaging the underlying roofing material. Any remaining grit which falls onto the roofing material may be disposed of by, for example, washing off the surface of the roofing material.
  • a specialized grit-blasting device may be implemented to maintain the grit- blasting nozzle at a desired angle relative to the roofing material while the grit-blasting device is moved along (up-and-down or side-to-side) an existing sloped roof.
  • the grit- blasting device also may include one or more shield to substantially contain the grit that is used in the blasting process.
  • the grit-blasting device also may include a vacuum to suction some or all of the grit from the roofing material and, in some instances, reuse at least some of the suctioned grit in further blasting processes. For convenience, this process of using grit- blasting to touch up an existing coating may be referred to as a coat-and-blast process.
  • manufactured shingles may be obtained and modified to achieve directional reflectivity.
  • manufactured shingles refers to shingles that are manufactured to a finished state by a conventional shingle manufacturer. These shingles include an assembled arrangement of backing material (e.g., fiberglass, paper, etc.), an adhesive material (e.g., asphalt), and granules which are pressed into the adhesive material.
  • manufactured shingles may be modified by removing some or all of the granules and/or the adhesive material from the backing material. The shingle may be heated to make the adhesive material softer to work with so that the adhesive material can be more easily scraped off of the backing material.
  • a new layer of adhesive material (e.g., tar, asphalt, mastic, etc.) may be applied to the surface of the backing material. Once the new layer of adhesive material is applied to the backing material, the granules are then applied to the new layer of adhesive material. In another embodiment, only some of the existing adhesive material and/or granules are removed, and the new layer of adhesive material is applied over the residual existing adhesive layer and/or granules. Alternatively, the new layer of adhesive material may be applied without removing any of the existing adhesive material or granules.
  • adhesive material e.g., tar, asphalt, mastic, etc.
  • the granules may be applied to the new layer of adhesive material in various ways.
  • the adhesive material is applied in a liquid or viscous state, and the granules are applied before the adhesive material solidifies.
  • the adhesive material may be a liquid adhesive at room temperature and allowed to dry over time after the granules have been applied.
  • the adhesive material may be heated, applied, and allowed to cool once the granules have been applied.
  • the granules may be applied after the adhesive layer is allowed to solidify or otherwise dry/cool to the point where the granules at room temperatures would not adhere well to the adhesive material.
  • the granules may be heated to a temperature which is maintained for a time while the granules are applied to the at least partially solidified adhesive material. Upon contact of the granules at the adhesive material, the granules transfer heat to the adhesive material, thereby melting a portion of the adhesive material and allowing the granules to become embedded within the adhesive material.
  • the acceptable temperature range of the granules will vary depending on several factors including, but not limited to, the heat coefficients of the granule material and/or the adhesive material, the melting point of the adhesive material, the thickness of the layer of adhesive material, the size(s) of the granules, the intended depth of embedding the granules, and so forth.
  • this heated- granule approach may be used in the initial manufacturing process of the manufactured shingles. Additionally, this heated-granule approach may be used to add another layer of granules to manufactured shingles, without the use of an additional layer of adhesive material. In this embodiment, the heated granules may be heated to a temperature sufficient to become embedded in the original layer of adhesive material (e.g., asphalt). In further embodiments, heated granules may be applied in two or more stages.
  • a first stage may include applying granules of a first size
  • a second stage may include applying granules of a second size.
  • the granules used in the different stages may be heated to the same or different temperatures. Additionally, the granules may be applied from various directions. In one embodiment, heated granules are dropped onto an exposed surface of the adhesive layer. In other embodiment, the granules are mechanically propelled towards the surface of the adhesive material. In other embodiment, the granules are maintained in a relatively stationary position such as on a heated or insulated platform, and the base material with the applied adhesive material is inverted and moved into contact with the granules. This process may facilitate very specific arrangements of the granules for application to the adhesive material. In some embodiments, the surface of the platform may be resistant to the adhesive material.
  • Additional rolling techniques also may be implemented to provide a mechanical force to the granules to facilitate embedding the granules into the adhesive material.
  • the roller may have a surface which is resistant to the adhesive material. Additionally, the surface of the roller may have characteristics such as dimples or other depth-variable features which facilitate a variation in the depth at which the granules are embedded into the adhesive material.
  • rolling, pressing, or other mechanical forces may be applied to the back side of the backing material, rather than on the side to which the adhesive material and/or granules are applied.
  • the rolling or other force may be applied to the back side of the backing material.
  • the backing material is subsequently removed from the platform, some or all of the granules previously disposed or arranged on the platform will be adhered to the adhesive material on the backing material.
  • embodiments described herein may be applied to "strip” shingles (also referred to as “3-tab” shingles). As another example, embodiments described herein may be applied to “laminate” shingles (also referred to as “architectural” shingles). In the case of laminate shingles, which have multiple layers of shingles, some or all of the operations described herein may be applied individually to each layer before the multiple layers are assembled together. For example, a directional coating may be applied to the granules of each layer, and then the multiple layers may be assembled into a single structure. In another example, the directional coating may be applied, or other operations may be implemented, after the individual layers are assembled together.
  • Shingles which have multiple base layers, or substrates, that are already laminated together when a directional coating is applied may have a resulting band of granules that is not subject to the directional coating.
  • Figs. 16A-B depict different views of one embodiment of a laminate shingle 160 with a band 166 of granules that is not subject to a directional coating.
  • the laminate shingle 160 includes a headlap portion 162, and a tab portion 164.
  • a nailing strip (not shown) may be located approximately between the headlap portion 162 and the tab portion 164.
  • the tab portion 164 includes a top layer 174 with die-cut tabs (or tabs formed in another manner) that overlap a lower layer 176 in an arrangement which gives the appearance of two layers of offset tabs.
  • a directional coating is applied to the tab portion 164 of the shingle 160.
  • Various methods of applying a directional coating are described herein.
  • Fig. 16B illustrates one embodiment of a system with a nozzle 108 or other applicator to dispose the directional coating on the shingle 160 from an angle. By placing the nozzle 108 at a certain angle relative to the top layer 174 and the bottom layer 176 of the shingle 160, a portion 178 of the surface area on the top surface of the bottom layer 176 can be maintained free from the directional coating. This portion 178 corresponds to the band 166 shown in Fig. 16A.
  • this band 166 also may be referred to as a shadow area because it is in the "shadow" of the top layer 174 relative to the incident coating from the nozzle 108.
  • the width 180 of the shadow area is dependent on the angle of incidence of the coating, as well as the height 182 of the top layer 174.
  • the presence of the band 166 or shadow area on the shingle 160 may serve an aesthetic function to present the appearance of more depth, or thickness, to the shingle 160.
  • the perception of increased depth can add to the perceived value or quality of the shingle 160. Also, the perception of increased depth may help to mimic certain other shingle materials.
  • the band 166 may be formed by using a separate coating, applying different thicknesses of coatings, applying different quantities of coating layers, or otherwise varying the parameters that will impact the visual appearance of the band 166 relative to other portions of the shingle 160.
  • a specific coating or surface treatment can be applied just to the shadow area to make the shadow area have a darker appearance, or otherwise visually distinguish the shadow area from other surface portions of the shingle.
  • this type of band 166 may be produced at the overlapping intersection of separate shingles, for example, if a coating is applied to shingles that are already installed on a roof. Additionally, this type of approach to generating a band 166 of a distinct visual appearance may be applicable to other types of roofing materials.
  • directional coatings may be applied to shingles or other roofing materials without significantly sacrificing the visual appearance of the shingle or other roofing materials.
  • By applying one or more coatings at a variety of intensities, tones, and/or angles, such shingles or roofing materials may achieve improved energy efficiency and performance while retaining a resemblance to conventional shingles with varying tones and color schemes.
  • an infrared (IR) coating is applied to the shingles.
  • IR coatings may have reflective properties that are optimized or predominantly effective in or near the IR wavelengths to reflect IR energy that is incident on the IR coating.
  • the IR coating is applied to some or all of the granules, in addition to a separate directional coating.
  • the IR coating is applied as a directional coating by itself or in combination with other directional coatings.

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Finishing Walls (AREA)
  • Roof Covering Using Slabs Or Stiff Sheets (AREA)

Abstract

L'invention porte sur un matériau de couverture qui comprend une pluralité de couches stratifiées et un traitement de surface. La pluralité de couches stratifiées comprennent une couche stratifiée supérieure qui chevauche au moins partiellement une couche stratifiée inférieure. Le traitement de surface se trouve sur les parties des couches stratifiées supérieure et inférieure. Une zone d'ombre est créée sur une surface supérieure de la couche stratifiée inférieure, à proximité de la couche stratifiée supérieure, qui est exempte du traitement de surface. Cette zone d'ombre présente un aspect visuel distinct de celui des autres parties des couches stratifiées supérieure et inférieure qui sont soumises au traitement de surface.
PCT/US2013/059994 2012-09-14 2013-09-16 Matériau de couverture avec traitement de surface et zone d'ombre WO2014043643A2 (fr)

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
US201261700980P 2012-09-14 2012-09-14
US61/700,980 2012-09-14
US201361856591P 2013-07-19 2013-07-19
US61/856,591 2013-07-19

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US20150059283A1 (en) * 2013-09-05 2015-03-05 Garrick David Brown Method of roof repair

Citations (5)

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Publication number Priority date Publication date Assignee Title
US6692608B2 (en) * 2000-06-30 2004-02-17 Owens Corning Fiberglas Technology, Inc. Method of making simulated wood shake shingle having vertical shadow lines
US6698151B2 (en) * 1999-10-29 2004-03-02 Owens Corning Fiberglas Technology, Inc. Shingle for optically simulating a tiled roof
US20040123543A1 (en) * 2002-12-31 2004-07-01 Elliott Bert W. Shingle with a rendered shadow design
US20100313512A1 (en) * 2004-02-12 2010-12-16 Building Materials Investment Corporation Roofing Shingle
US20120088071A1 (en) * 2010-10-06 2012-04-12 Cool Angle LLC Roofing material with directionally dependent properties and method of making the same

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6698151B2 (en) * 1999-10-29 2004-03-02 Owens Corning Fiberglas Technology, Inc. Shingle for optically simulating a tiled roof
US6692608B2 (en) * 2000-06-30 2004-02-17 Owens Corning Fiberglas Technology, Inc. Method of making simulated wood shake shingle having vertical shadow lines
US20040123543A1 (en) * 2002-12-31 2004-07-01 Elliott Bert W. Shingle with a rendered shadow design
US20100313512A1 (en) * 2004-02-12 2010-12-16 Building Materials Investment Corporation Roofing Shingle
US20120088071A1 (en) * 2010-10-06 2012-04-12 Cool Angle LLC Roofing material with directionally dependent properties and method of making the same

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