Algae resistant roofing granules with controlled algaecide leaching rates, algae resistant shingles, and process for producing same

1. An algae-resistant roofing shingle, the shingle comprising a shingle stock material and algae-resistant roofing granules adhered to a shingle stock material, each of the algae-resistant roofing granules comprising:

(a) a porous, inert base particle comprising agglomerated particles of stone dust having an average particle size in the range of 0.1 microns to 40 microns, bound by a binder, each base particle comprising a plurality of pores exposed at an exterior surface of the base particle and a porosity in the range of 3-30%; and

(b) at least one inorganic algaecide disposed within pores of the base particle.

2. An algae-resistant roofing shingle according to claim 1 wherein the binder comprises an aluminosilicate material.

3. An algae-resistant roofing shingle according to claim 1 wherein the at least one inorganic algaecide is selected from the group consisting of copper materials, zinc materials, and mixtures thereof.

4. An algae-resistant roofing shingle according to claim 3 wherein the at least one inorganic algaecide includes cuprous oxide or zinc oxide.

5. An algae-resistant roofing shingle according to claim 3 wherein the at least one inorganic algaecide is disposed in pores in the base particles in the absence of a binder.

6. An algae-resistant roofing shingle according to claim 5 wherein the at least one inorganic algaecide includes cuprous oxide.

7. An algae-resistant roofing shingle according to claim 3 wherein the at least one inorganic algaecide is provided in the base particles together with a binder.

8. An algae-resistant roofing shingle according to claim 7 wherein the at least one inorganic algaecide includes cuprous oxide.

9. An algae-resistant roofing shingle according to claim 2 wherein each of the algae-resistant roofing granules further comprises a colorant composition disposed on the base particle.

10. An algae-resistant roofing shingle according to claim 1 , wherien the shingle stock includes a non-woven base coated with one or more layers of a bituminous material.

11. An algae-resistant roofing shingle, the shingle comprising a shingle stock material and algae-resistant roofing granules adhered to a shingle stock material, each of the algae-resistant roofing comprising stone dust having an average particle size in the range of 0.1 microns to 40 microns and at least one inorganic algaecide, the stone dust and the at least one inorganic algaecide being bound by a binder, the particles having a porosity in the range of 3-30%.

12. An algae-resistant roofing shingle according to claim 11 wherein the at least one inorganic algaecide is selected from the group consisting of copper materials, zinc materials, and mixtures thereof.

13. An algae-resistant roofing shingle according to claim 12 wherein the at least one inorganic algaecides include one or more of cuprous oxide and zinc oxide.

14. An algae-resistant roofing shingle according to claim 11 , wherein the binder comprises an aluminosilicate material.

15. An algae-resistant roofing shingle according to claim 11 , wherein the algaecide is a first algaecide, and wherein each of the algae-resistant roofing granules further comprises a second algaecide disposed in pores of the base particle, the second algaecide being less soluble than the first algaecide.

16. A method for making algae-resistant roofing granules, the method comprising:

(a) providing porous, inert base particles, each of the base particles comprising agglomerated particles of stone dust having an average particle size in the range of 0.1 microns to 40 microns, bound by a binder, each base particle comprising a plurality of pores exposed at an exterior surface of the base particle and having a porosity in the range of 3-30%; and

(b) disposing at least one inorganic algaecide within pores of the base particles to form algaecide-bearing particles.

17. A method according to claim 16 , wherein providing the porous, inert base particles comprises providing a mixture of stone dust and binder, forming the mixture into formed particles, the firing the formed particles to provide the porous, inert base particles.

18. A method according to claim 17 , wherein forming the mixture into formed particles is performed by a forming process selected from press molding, cast molding, injection molding, extrusion, spray granulation, gel casting, pelletizing, compaction and agglomeration.

19. A method according to claim 17 , wherein the mixture of stone dust and binder further include an additive, and wherein the firing of the form particles causes the additive to burn off or produce gaseous products to form pores of the porous, inert base particles.

20. A method according to claim 16 , wherein the at least one inorganic algaecide is disposed in pores in the base particles in the absence of a binder, wherein the at least one inorganic algaecide is provided in pores the base particles after the base particles are fired by a method comprising providing a solution comprising an algaecide-forming compound dissolved in a fluid, and drawing the solution into pores of the base particles by capillary action to form solution-laden particles, then subsequently treating the solution-laden particles to convert the algaecide-forming compound to an inorganic algaecide.

21. A method according to claim 16 , wherein the at least one inorganic algaecide is provided in the base particles together with a binder, wherein the at least one inorganic algaecide is provided in pores the base particles after the base particles are fired by a method comprising providing a slurry comprising an algaecide-forming compound and a binder dispersed in a fluid, and drawing the slurry into pores of the base particles by capillary action to form slurry-laden particles, then subsequently treating the slurry-laden particles to convert the algaecide-forming compound to an inorganic algaecide.