IP Library Granted Patent US 9,303,407
Granted Patent B2
US 9,303,407 · App. 14/506,570 · Granted Apr 5, 2016

Highly reflective roofing system

Inventors: Eric L. Sexauer (Camarillo, CA); Matthew W. Kolb (Camarillo, CA)
Assignee: National Coatings Corporation
E04D7/005E04D5/12Y02B80/34Y10T428/2443Y10T428/24388Y10T428/249982Y10T428/249985Y10T428/25Y10T428/252
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Quick Facts
Patent No.
US 9,303,407
App. No.
14/506,570
Granted
Apr 5, 2016
Kind
B2
Abstract

A cool roofing system includes highly reflective calcined kaolin particles having a solar reflectance of 80% to 92%. When applied to a roofing substrate, the highly reflective kaolin particles produce a roofing system having a solar reflectance greater than or equal to 70%.

Claims (33)

1. A cool roofing system comprising:

at least one asphalt layer and at least one granular layer directly adhered to a top surface of the asphalt, wherein the granular layer comprises a plurality of highly reflective calcined bright white crushed kaolin particles having a solar reflectance ranging from about 80% to about 92% prior to any added surface treatment, wherein the surface treated, bright white crushed kaolin particles comprise crushed kaolin chamotte particles;

wherein the surface treated highly reflective, calcined, bright white crushed kaolin particles have a surface treatment consisting of a clear coating,

wherein, when the highly reflective calcined, surface treated, bright white crushed kaolin particles are applied to the asphalt layer used for roofing materials, the highly reflective calcined, surface treated, bright white crushed kaolin particles have a resultant reflectance between about 70-82% substantially covering the surface of the asphalt layer in the cool roofing system providing a minimum solar reflectance of 70% or more; and

wherein the clear coating is selected from the group consisting of silanes, siloxanes, polysiloxanes, organo-siloxanes, silicates, organic silicates, silicone resins, acrylics, urethanes, polyurethanes, glycol ethers and mixtures thereof.

2. The cool roofing system according to claim 1 , wherein the clear coating comprises a solventless emulsion comprising silanes and siloxanes.

3. The cool roofing system according to claim 1 , wherein the clear coating improves adherence to the highly reflective calcined, surface treated, bright white crushed kaolin particles.

4. A cool roofing system comprising:

a roofing substrate,

at least one layer of spray polyurethane foam applied to the roofing substrate,

an elastomeric coating layer applied over and adhered to the spray polyurethane foam layer,

a granular layer directly adhered to the elastomeric coating layer,

wherein the granular layer comprises a plurality of highly reflective calcined bright white crushed kaolin particles having a solar reflectance ranging from about 80% to about 92% prior to any added surface treatment, wherein the surface treated, bright white crushed kaolin particles comprise crushed kaolin chamotte particles

wherein the surface treated highly reflective, calcined, bright white crushed kaolin particles have a surface treatment consisting of a clear coating,

wherein, when the highly reflective calcined, surface treated, bright white crushed kaolin particles are applied to the elastomeric layer used for roofing materials, the highly reflective calcined, surface treated, bright white crushed kaolin particles have a resultant reflectance between about 70-82% adhered to the elastomeric layer in the cool roofing system providing a minimum solar reflectance of 70% or more; and

wherein the clear coating is selected from the group consisting of silanes, siloxanes, polysiloxanes, organo-siloxanes, silicates, organic silicates, silicone resins, acrylics, urethanes, polyurethanes, glycol ethers and mixtures thereof.

5. The cool roofing system according to claim 4 , wherein a thickness of the spray polyurethane foam layer ranges from about 1 inch to about 3 inches.

6. The cool roofing system according to claim 4 , wherein the elastomeric coating layer comprises any one of an acrylic, urethane or silicone.

7. The cool roofing system according to claim 4 , wherein the clear coating comprises an emulsion of silanes and siloxanes.

8. The cool roofing system according to claim 7 , wherein the clear coating improves adherence of the highly reflective calcined, surface treated, bright white crushed kaolin particles.

9. A cool roofing system consisting of an asphalt layer and a granular layer directly adhered to a top surface of the asphalt layer, wherein the granular layer comprises a plurality of highly reflective calcined, bright white crushed kaolin particles having a solar reflectance ranging from about 80% to about 92% prior to any added surface treatment, wherein the highly reflective, calcined, bright white crushed kaolin particles comprise crushed kaolin chamotte particles, wherein the highly reflective, calcined, bright white crushed kaolin particles are surface treated with a clear coating, and wherein, when the highly reflective, calcined, surface treated, bright white crushed kaolin particles are applied to the asphalt layer used for roofing materials, the resultant solar reflectance of the cool roofing system is between about 70-82%.

10. The cool roofing system according to claim 9 , wherein the clear coating is selected from the group consisting of silanes, siloxanes, polysiloxanes, organo-siloxanes, silicates, organic silicates, silicone resins, acrylics, urethanes, polyurethanes, glycol ethers and mixtures thereof.

11. The cool roofing system according to claim 10 , wherein the surface clear coating comprises a solventless emulsion comprising silanes and siloxanes.

12. The cool roofing system according to claim 11 , wherein the clear coating improves adherence of the highly reflective calcined, surface treated, bright white crushed kaolin particles.

13. A cool roofing system consisting of:

a roofing substrate;

at least one layer of spray polyurethane foam applied to the roofing substrate;

an elastomeric coating layer applied over and adhered to the spray polyurethane foam layer; and

a granular layer directly adhered to the elastomeric coating layer;

wherein the granular layer comprises a plurality of highly reflective calcined, bright white crushed kaolin particles having a solar reflectance ranging from about 80% to about 92% prior to any added surface treatment, wherein the highly reflective, calcined, bright white crushed kaolin particles are surface treated with a clear coating, and wherein, when the highly reflective calcined, surface treated, bright white crushed kaolin particles are applied to the elastomeric layer used for roofing materials, the highly reflective calcined, surface treated, bright white crushed kaolin particles have a resultant reflectance between about 70-82% adhered to the elastomeric layer in the cool roofing system providing a minimum solar reflectance of 70% or more.

14. The cool roofing system according to claim 13 , wherein the clear coating is selected from the group consisting of silanes, siloxanes, polysiloxanes, organo-siloxanes, silicates, organic silicates, silicone resins, acrylics, urethanes, polyurethanes, glycol ethers and mixtures thereof.

15. The cool roofing system according to claim 14 , wherein the clear coating comprises a solventless emulsion comprising silanes and siloxanes.

16. A cool roofing system comprising: at least one asphalt layer and a granular layer directly adhered to a top surface of the asphalt layer, wherein the granular layer comprises a plurality of highly reflective calcined, bright white crushed kaolin particles having a solar reflectance ranging from about 80% to about 92% prior to any added surface treatment, wherein the highly reflective, calcined, bright white crushed kaolin particles comprise crushed kaolin chamotte particles, wherein the highly reflective, calcined, bright white crushed kaolin particles have a surface treatment consisting of clear coating, and wherein, when the highly reflective calcined, surface treated, bright white crushed kaolin particles are applied to the asphalt layer used for roofing materials, the highly reflective, calcined, bright white crushed kaolin particles have a resultant solar reflectance between about 70-82% substantially covering the surface of the asphalt layer in the cool roofing system providing a minimum solar reflectance of 70% or more, and wherein the clearing coating comprises a solventless emulsion comprising silanes and siloxanes.

Assignments (5)
RELEASE OF SECURITY INTEREST Recorded Aug 1, 2024
From: BNP PARIBAS, AS COLLATERAL AGENT
To: U.S. SILICA COMPANY
Reel/Frame 068155/0034 →
NOTICE OF GRANT OF SECURITY INTEREST IN INTELLECTUAL PROPERTY (FIRST LIEN) Recorded Jul 31, 2024
From: U.S. SILICA COMPANY
To: WILMINGTON TRUST, NATIONAL ASSOCIATION, AS COLLATERAL AGENT
Reel/Frame 068307/0349 →
SECURITY INTEREST Recorded Sep 19, 2017
From: U.S. SILICA COMPANY
To: BNP PARIBAS
Reel/Frame 043619/0793 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Jun 5, 2017
From: NATIONAL COATINGS CORPORATION
To: U.S. SILICA COMPANY
Reel/Frame 042601/0431 →
ASSIGNMENT OF ASSIGNOR'S INTEREST Recorded Mar 3, 2016
From: SEXAUER, ERIC L.; KOLB, MATTHEW W.
To: NATIONAL COATINGS CORPORATION
Reel/Frame 037888/0663 →
Continuity (3)
Continuation 12857948 · Aug 17, 2010
Provisional Application 61248285 · Oct 2, 2009
Related Publication 20150259922A1 · Sep 17, 2015