Roofing granule including a base particle and a layer covering the base particle, a process of forming the same, and a roofing product including the roofing granule

Patent metadata

Field	Value
Publication number	US-9670677-B2
Application number	US-201314023151-A
Country	US
Kind code	B2
Filing date	Sep 10, 2013
Priority date	Sep 14, 2012
Publication date	Jun 6, 2017
Grant date	Jun 6, 2017

Abstract

A roofing granule can include a base particle having a base material and a layer covering the base particle of the roofing granule. The layer can has a first material and a second material that includes a metal carbonate, wherein the first and second materials include a same metal element, and the base material is different from the first material. In a process of forming the roofing granule, the layer can have pores. The process can include infiltrating a fluid into the pores of the layer while the base particle is present and adjacent to the layer, wherein the fluid includes a carbonate. The process can further include reacting the carbonate with a metal compound within the layer to form a metal carbonate within the layer. The roofing granules can be used in roofing products.

First claim

What is claimed is:

1. A roofing granule comprising:
a base particle having an unreacted base material, the base particle having an average diameter of up to approximately 2.4 mm; and
a first layer covering the base particle of the roofing granule, wherein:
the first layer has a first material and a second material that includes a metal carbonate;
the first and second materials include a same metal element; and
the unreacted base material is different from the first material, wherein the base particle has an open porosity not greater than 50% of an open porosity of the first layer, wherein the first and the second materials have a D 90 particle size of at least 0.7 microns and the base material has an average particle size not greater than 90% of the average particle size of the first and second materials.

2. The roofing granule of claim 1 , wherein the first layer further comprises an organic colorant or an inorganic colorant.

3. The roofing granule of claim 1 , wherein the base particle occupies a base volume, the first layer occupies a first volume, and a ratio of the base volume to the first volume is at least approximately 1.1:1, at least approximately 1.5:1, at least approximately 2:1, at least approximately 3:1, at least approximately 5:1, at least approximately 9:1, at least approximately 14:1, or at least approximately 20:1.

4. The roofing granule of claim 1 , wherein the first layer further comprises an antimicrobial agent, wherein the first material and the antimicrobial agent include a same metal element.

5. The roofing granule of claim 1 , further comprising an interphase compound between the base particle and the first layer, wherein the interphase compound includes a base constituent from the base material and a first constituent from the first material.

6. The roofing granule of claim 1 , wherein the base particle further comprises a particular metal carbonate, wherein the base material and the particular metal carbonate comprise a same metal element.

7. The roofing granule of claim 1 , wherein a solubility of the metal carbonate in water at 20° C. is less than about 0.05, less than about 0.004, less than about 0.001, or less than about 0.0008 grams per 100 grams of water.

8. A roofing product comprising roofing granules including the roofing granule of claim 1 .

9. The roofing product of claim 8 , wherein the roofing product comprises a roofing shingle.

Assignees

• Shiao Ming Liang
• Jacobs Gregory F
• Certain Teed Corp

Inventors

• Shiao Ming Liang
• Jacobs Gregory F

Classifications

• E04D1/28 Primary

  Roofing elements comprising two or more layers, e.g. for insulation · CPC title

• B05D7/52

  Two layers · CPC title

• Y10T428/2438

  Coated · CPC title

• E04D2001/005

  the roofing elements having a granulated surface · CPC title

• Y10T428/2991

  Coated · CPC title