Hybrid coating for roof applications

Patent metadata

Field	Value
Publication number	US-11466174-B2
Application number	US-202016785791-A
Country	US
Kind code	B2
Filing date	Feb 10, 2020
Priority date	Aug 30, 2017
Publication date	Oct 11, 2022
Grant date	Oct 11, 2022

Abstract

Embodiments may include a coated granule for roofing systems. The coated granule may include an aluminum silicate granule and a coating disposed on the aluminum silicate granule. The coating may include a copolymer and a siloxane-based or a silane-based compound. The copolymer may be a cationic fluorinated (meth)acrylic copolymer. The aluminum silicate granule may have a particle size in a range from 0.2 mm to 2.4 mm. The aluminum silicate granule may have a 65% or greater reflectivity. The coated granule may repel oil and maintain its reflectivity better than with other techniques.

First claim

What is claimed is:

1. A method of manufacturing a roofing system, the method comprising:
coating a plurality of aluminum silicate granules with a mixture comprising:
a copolymer, and
a siloxane-based or silane-based compound, wherein the siloxane-based or silane-based compound is 60 wt. % or more of the coating;

drying the coating on the plurality of aluminum silicate granules to form a plurality of coated granules; and
affixing the plurality of coated granules to a waterproof layer,
wherein:
the copolymer is a cationic fluorinated (meth)acrylic copolymer,
the plurality of aluminum silicate granules has a particle size in a range from 0.2 mm to 2.4 mm, and
the plurality of aluminum silicate granules has a 65% or greater reflectivity.

2. The method of claim 1 , wherein the plurality of coated granules have an oil repellency effective to prevent greater than 98% of the plurality of coated granules from sinking in a naphthenic oil bath after 28 days.

3. The method of claim 1 , wherein the coating on the plurality of coated granules is effective to maintain at least 91% of the reflectivity of the coated granule after 28 days of being aged in an oven at 80° C. after affixing the plurality of coated granules to the waterproof layer.

4. The method of claim 1 , further comprising mixing the copolymer and the siloxane-based or the silane-based compound.

5. The method of claim 1 , wherein the mixture is not applied to the waterproof layer.

6. The method of claim 1 , wherein the waterproof layer is an asphalt-based membrane.

7. The method of claim 1 , wherein coating the plurality of aluminum silicate granules with the mixture comprises direct spraying the mixture onto the plurality of aluminum silicate granules.

8. The method of claim 1 , wherein coating the plurality of aluminum silicate granules with the mixture comprises dip coating the mixture onto the plurality of aluminum silicate granules.

9. The method of claim 1 , wherein drying the coating on the plurality of aluminum silicate granules to form the plurality of coated granules comprises drying the coating on the plurality of aluminum silicate granules in an oven.

10. The method of claim 1 , further comprising prior to affixing the plurality of coated granules to the waterproof layer, applying a second coating of the mixture to the plurality of aluminum silicate granules to form the plurality of coated granules.

11. The method of claim 1 , wherein affixing the plurality of coated granules to the waterproof layer comprises:
providing the waterproof layer in a molten state;
placing the plurality of coated granules in the waterproof layer in the molten state; and
cooling the waterproof layer in the molten state to couple the plurality of coated granules to the waterproof layer.

12. The method of claim 1 , wherein affixing the plurality of coated granules to the waterproof layer comprises coupling the plurality of coated granules to the waterproof layer with an adhesive.

13. The method of claim 1 , wherein the siloxane-based or silane-based compound is 75 wt. % or more of the coating.

14. The method of claim 1 , wherein the coating comprises from 0.001 wt. % to 3.0 wt. % on a dry basis of the plurality of aluminum silicate granules.

15. A method of manufacturing a roofing system, the method comprising:
coating a plurality of aluminum silicate granules with a hybrid coating, wherein the hybrid coating comprises:
a copolymer comprising a cationic fluorinated (meth)acrylic copolymer, wherein the cationic fluorinated (meth)acrylic copolymer reduces absorption of asphaltic chemical by the aluminum silicate granules; and
a siloxane-based or silane-based compound, wherein the siloxane-based or silane-based compound:
is 60 wt. % or more of the coating; and
comprises at least one of polydimethylsiloxane or organosiloxane,

wherein the hybrid coating, when coated onto an uncoated aluminum silicate granule, comprises from 0.001% to 3.0% by weight of the uncoated aluminum silicate granule;

drying the coating on the plurality of aluminum silicate granules to form a plurality of coated granules; and
affixing the plurality of coated granules to a waterproof layer,
wherein:
the plurality of aluminum silicate granules has a particle size in a range from 0.2 mm to 2.4 mm,
and the plurality of aluminum silicate granules has a 65% or greater reflectivity.

16. The method of claim 15 , wherein the cationic fluorinated (meth)acrylic copolymer comprises at least one fluorinated alkyl chain.

17. The method of claim 15 , wherein the cationic fluorinated (meth)acrylic copolymer comprises a silane containing monomer, wherein the silane containing monomer comprises is methacryloxypropyltrimethoxysilane.

Assignees

• Johns Manville

Inventors

• Shen Changqing
• Hazy Joel
• Metz Julian
• Wang Lance

Classifications

• E04D5/12

  specially modified, e.g. perforated, with granulated surface, with attached pads · CPC title

• E04D5/10

  by making use of compounded or laminated materials, e.g. metal foils or plastic films coated with bitumen · CPC title

• C08K9/04

  Ingredients treated with organic substances {(treated with macromolecular compounds C08K9/08)} · CPC title

• C04B20/1033

  obtained by reactions only involving carbon-to-carbon unsaturated bonds · CPC title

• E04D11/02

  Build-up roofs, i.e. consisting of two or more layers bonded together in situ, at least one of the layers being of watertight composition (gravelling of flat roofs E04D7/00; venting or ventilation E04D13/17) · CPC title