CONSTRUCTION MATERIALS COMPRISING AGGLOMERATED PARTICLES

Abstract

Roofing granules comprise agglomerated inorganic material, and construction materials such as roofing tiles include these granules. By manufacturing roofing granules from agglomerated inorganic material, it is possible to tailor the particle size distribution to provide optimal tile surface coverage, thereby reducing tile weight and raw material usage. Additionally, the agglomeration process allows for the use of byproducts from conventional granule production processes.

Description

CONSTRUCTION MATERIALS COMPRISING AGGLOMERATED PARTICLES Field of Invention The invention relates to construction materials (such as roofing tiles) that include roofing granules comprising agglomerated inorganic material. The invention also relates to roofing granules comprising agglomerated inorganic material. By manufacturing roofing granules from agglomerated inorganic material, it is possible to tailor the particle size distribution to provide better surface coverage for roofing products, thereby reducing the weight of the roofing product and the use of raw materials. Additionally, the use of agglomeration allows for the use of byproducts from conventional granule production processes. Background of the Invention Roofing products are an important category of building materials. They are often divided into three main groups: roofing tiles, roofing felt, and underlayment. Roofing tiles have been widely used in residential buildings as roof coverings due to their aesthetic appeal, ease of installation, water drainage, and excellent performance over a long period. ζζα^ηη / Lznz / E / YiAi Ref. 317334 Traditional roofing shingles consist of a fiberglass or felt mat coated and impregnated with an asphalt-based composition, which is then coated with roofing granules. Roofing shingles can be single-ply strip shingles, laminated shingles with two or more layers, interlocking shingles, and large individual shingles in a variety of weights and colors. Such laminated asphalt shingles are also often referred to as composite shingles, architectural shingles, or dimensional shingles. The fiberglass mat or felt shingle serves as a matrix to support the other components and gives the shingle the strength required to withstand manufacturing, handling, installation, and service in the intended environment. An asphalt coating formulated for the particular service application is often applied to the base material to provide the desired long-term weather resistance and stability in extreme temperatures. Roofing granules applied to roofing shingles or roofing rolls are typically size-graded stone particles. Different sizes of roofing granules can be applied to different areas of the shingle surface (e.g., back surface, top flap, bottom flap, etc.) depending on the required properties of a given area. For example, roofing granules can protect the asphalt layer of the shingles from UV and impact damage, provide aesthetic effects on exposed surfaces, and impart fire resistance. Minimizing the weight of roofing granules applied to roofing shingles or rolls is beneficial to reduce (a) roof load; (b) shipping costs; (c) raw material usage; and (d) facilitate installation. Reducing raw material costs by utilizing byproducts from other processes, such as rock fines, is also advantageous. Therefore, there is a need for roofing granules that provide optimal surface coating of roofing rolls or tiles and that can be manufactured from waste materials such as rock fines. Summary of the Invention In one aspect, the invention relates to a method comprising: obtaining (a) at least one of a rock, mineral, or a combination thereof and (b) a binder; mixing (a) the at least one of a rock, mineral, or a combination thereof and (b) the binder to produce agglomerated particles; and applying the agglomerated particles to a sheet to form a roofing product. In another aspect, the invention relates to a method comprising: (1) obtaining (a) at least one of a rock, mineral, or combination thereof and (b) a binder, wherein the at least one of a rock, mineral, or combination thereof has a particle size that passes through a 40 mesh US filter; (2) mixing (a) the at least one of a rock, mineral, or combination thereof and (b) the binder to produce unsintered agglomerated particles; and (3) applying the unsintered agglomerated particles to a sheet to form a roofing product. In another aspect, the roofing product is a roofing tile or roll. In another aspect, the binder is present in the agglomerated particles in an amount of 1% by weight to 10% by weight with respect to a total weight of the agglomerated particles. In yet another aspect, the binder is present in the agglomerated particles in an amount of approximately 2% to 10% by weight. In another aspect, the binder is present in the agglomerated particles in an amount of approximately 6% to 10% by weight. In another aspect, at least one of a rock, a mineral or a combination thereof comprises one or more of basalt, metabasalt, andesite and rhyolite. In another aspect, the binder is at least one of ζζα^ηη / Lznz / E / YiAi sodium silicate, gypsum or a combination thereof. In another aspect, at least one of a rock, a mineral, or a combination thereof comprises metabasalt. In another aspect, the binder comprises sodium silicate. In another aspect, the agglomerated particles have a coating comprising silicate and clay. In another aspect, the mixing uses a needle mixer. In another aspect, the method also includes pelletizing the agglomerated particles. In another aspect, the method also includes drying the agglomerated particles. In another aspect, the invention relates to a method comprising: (1) obtaining (a) at least one of a rock, mineral, or a combination thereof and (b) a binder; (2) mixing the at least one of a rock, mineral, or a combination thereof and the binder to produce agglomerated particles; and (3) applying the agglomerated particles to a sheet to form a tile, wherein, when evaluating the weight percent with respect to a total weight of the agglomerated particles, (A) the agglomerated particles have a particle size distribution comprising (1) at least approximately 10% by weight retained by 50 mesh US after passing through the 40 mesh US filter, (2) at least approximately 5% by weight retained by 60 mesh US after passing through the 50 mesh US filter, and (3) at least approximately 5% by weight retained by 100 mesh US after passing through the 70 mesh US filter;or (B) the agglomerated particles have a particle size distribution comprising (1) at least approximately 40% by weight retained by 16 US mesh after passing through the 12 US mesh filter, (2) at least approximately 30% by weight retained by 20 US mesh after passing through the 16 US mesh filter, and (3) at least approximately 20% by weight retained by 30 US mesh after passing through the 20 US mesh filter; or (C) the agglomerated particles have a particle size distribution comprising (1) at least approximately 1% by weight retained by 20 US mesh after passing through the 16 US mesh filter, (2) at least approximately 40% by weight retained by 30 US mesh after passing through the 20 US mesh filter, and (3) at least approximately 2% by weight retained by 40 US mesh after passing through the 30 US mesh filter. In another respect, the agglomerated particles have a particle size distribution comprising (1) at least approximately 20% by weight retained by 50 mesh US after passing through the 40 mesh US filter, (2) at least approximately 10% by weight retained by 60 mesh US after passing through the 50 mesh US filter, and (3) at least approximately 10% by weight retained by 100 mesh US after passing through the 70 mesh US filter. In another respect, the agglomerated particles have a particle size distribution comprising (1) at least approximately 30% by weight retained by 50 mesh US after passing through the 40 mesh US filter, (2) at least approximately 20% by weight retained by 60 mesh US after passing through the 50 mesh US filter, and (3) at least approximately 20% by weight retained by 100 mesh US after passing through the 70 mesh US filter. In another respect, the agglomerated particles have a particle size distribution comprising (1) at least approximately 40% by weight retained by 16 mesh US after passing through the 12 mesh US filter, (2) at least approximately 30% by weight retained by 20 mesh US after passing through the 16 mesh US filter, and (3) at least approximately 20% by weight retained by 30 mesh US after passing through the 20 mesh US filter. In another respect, the agglomerated particles have a particle size distribution comprising (1) at least approximately 2% by weight retained by 20 mesh US after passing through the 16 mesh US filter, (2) at least approximately 50% by weight retained by 30 mesh US after passing through the 20 mesh US filter, and (3) at least approximately 10% by weight retained by 40 mesh US after passing through the 30 mesh US filter. In another respect, the agglomerated particles have a particle size distribution comprising (1) at least approximately 5% by weight retained by 20 mesh US after passing through the 16 mesh US filter, (2) at least approximately 60% by weight retained by 30 mesh US after passing through the 20 mesh US filter, and (3) at least approximately 20% by weight retained by 40 mesh US after passing through the 30 mesh US filter. In another aspect, the binder is present in the agglomerated particles in an amount of 1% by weight to 10% by weight with respect to a total weight of the agglomerated particles. In another aspect, the binder is present in the agglomerated particles in an amount of approximately 6% to 10% by weight. In yet another aspect, the binder is at least one of sodium silicate, gypsum, or a combination thereof. In another aspect, the agglomerated particles have a coating comprising silicate and clay. In another aspect, the mixing uses a needle mixer. In another aspect, the method also includes pelletizing the agglomerated particles. In another aspect, the method also includes drying the agglomerated particles. In another aspect, the invention relates to a roofing tile or roll comprising agglomerated particles comprising (a) at least one of a rock, a mineral, or a combination thereof and (b) a binder, wherein, when evaluated as a weight percent relative to the total weight of the agglomerated particles, (A) the agglomerated particles have a particle size distribution comprising (1) at least approximately 10% by weight retained by 50 mesh US after passing through the 40 mesh US filter, (2) at least approximately 5% by weight retained by 60 mesh US after passing through the 50 mesh US filter, and (3) at least approximately 5% by weight retained by 100 mesh US after passing through the 70 mesh US filter;or (B) the agglomerated particles have a particle size distribution comprising (1) at least approximately 40% by weight retained by 16 US mesh after passing through the 12 US mesh filter, (2) at least approximately 30% by weight retained by 20 US mesh after passing through the 16 US mesh filter, and (3) at least approximately 20% by weight retained by 30 US mesh after passing through the 20 US mesh filter; or (C) the agglomerated particles have a particle size distribution comprising (1) at least approximately 1% by weight retained by 20 US mesh after passing through the 16 US mesh filter, (2) at least approximately 40% by weight retained by 30 US mesh after passing through the 20 US mesh filter, and (3) at least approximately 2% by weight retained by 40 US mesh after passing through the 30 US mesh filter. ζζα^ηη / Lznz / E / YiAi Among the benefits and improvements described, other objects and advantages of this invention will become apparent from the following description. Detailed embodiments of the invention are described herein; however, it should be understood that the embodiments described are merely illustrative of the invention, which can be implemented in various ways. Furthermore, each of the examples given in connection with the various embodiments of the invention is intended to be illustrative and not restrictive. In the description and claims, the following expressions have the meanings explicitly given to them herein, unless the context clearly indicates otherwise. The phrases "in one embodiment" and "in some embodiments," as used herein, do not necessarily refer to the same embodiments, although they may. Likewise, the phrases "in another embodiment" and "in some additional embodiments," as used herein, do not necessarily refer to a different embodiment, although they may. Therefore, as described below, several embodiments of the invention may easily be combined without departing from the scope or spirit of the invention. Detailed Description of the Invention One modality refers to a roofing tile that includes roofing granules composed of agglomerated particles. The agglomerated particles may be applied to the back surface, bottom flap, and / or top flap of the tile. In one modality, the agglomerated particles applied to the back surface, bottom flap, and / or top flap of the tile have different particle size distributions. The choice of particle size distribution for a tile surface may be influenced by the balance between surface coverage, tile weight, degree of smoothness, and required impact resistance. The tile may be a single-layer tile or a laminated tile. Examples of sheets that can be used to make the shingle are as follows. In one embodiment, the shingle can be formed from a fiberglass mat with an asphalt coating on both sides. In another embodiment, the shingle can be formed from organic felt or other types of base material, including synthetic mats or glass / hybrid mats with an appropriate coating. Non-exhaustive examples of coatings include asphalt and modified bituminous coatings based on atactic polypropylene (APP), styrene-butadiene-styrene (SBS), styrene-ethylene-butadiene-styrene (SEBS), amorphous alpha-alpha-olefin (APAO), thermoplastic polyolefin (TPO), synthetic rubber, or other asphaltic modifiers. In one embodiment, two or more shingles are installed on a roof deck in a roofing system such that the shingles are in a row from left to right and the side edges of the shingles in the row are contiguous to each other, i.e., their side edges are adjacent. Each row represents a course, and the shingles are laid in overlapping courses on the roof deck, where the lower overlap portion of a subsequent course is placed over the upper overlap portion of a preceding course. In one embodiment, the upper overlap portion of the shingle is at least as wide as the lower overlap portion of the shingle so that when the shingles are installed on a roof deck in overlapping courses, the entire lower overlap portion of a subsequent course has upper overlaps beneath it. In one embodiment, one edge of the shingle has a plurality of dragon's teeth with openings between them.In one type of laminated shingle, a backing strip is provided beneath the dragon teeth, with portions of the backing strip exposed through the openings between the dragon teeth. In one type of single-layer shingle, when the shingle is installed on a roof deck, the dragon teeth of a second layer of shingles are positioned on the top flap of a previously installed layer of shingles, so that portions of the top flap region are exposed through the openings between the dragon teeth. One modality refers to a roofing system comprising one or more tiles comprising the agglomerated particles. A. Agglomerated particles —Composition In one embodiment, the agglomerated particles comprise binder and inorganic material. In one embodiment, the inorganic material comprises rock and / or mineral fragments (i.e., fragments of (a) rock and / or (b) mineral). In one embodiment, the rock and / or mineral fragments comprise larger and / or finer particle sizes. In one scenario, the rock and / or mineral fragments have a particle size such that they pass through a 40-mesh US filter. In other scenarios, the rock and / or mineral fragments have a particle size such that they pass through a 50-mesh US, or 60-mesh US, or 70-mesh US, or 100-mesh US, or 120-mesh US, or 140-mesh US, or 200-mesh US, or 230-mesh US, or 270-mesh US, or 325-mesh US filter. Ranges based on any of the above are also considered; for example, the rock and / or mineral fragments may have particle sizes that pass through a 40-mesh US filter but are retained by a 270-mesh US filter. Non-exhaustive examples of binders include sodium silicate, gypsum, or other cementitious binders. Non-exhaustive examples of rock and / or mineral materials include igneous rocks such as basalt, andesite, and rhyolite; amphibolite produced from the metamorphism of basaltic parent rock such as metabasalt; or combinations thereof, e.g., basalt and metabasalt; basalt and andesite. In one embodiment, the binder content of the agglomerated particles is at least approximately 1% by weight, at least approximately 2% by weight, at least approximately 3% by weight, at least approximately 5% by weight, or at least approximately 10% by weight. In one embodiment, the binder content of the agglomerated particles is approximately 1% to approximately 10% by weight. In one embodiment, the binder content of the agglomerated particles is approximately 1% to approximately 8% by weight. In one embodiment, the binder content of the agglomerated particles is approximately 1% to approximately 6% by weight. In one embodiment, the binder content of the agglomerated particles is approximately 1% to approximately 3% by weight. In one embodiment, the binder content of the agglomerated particles is approximately 1% to approximately 2% by weight. In one embodiment, the binder content of the agglomerated particles is approximately 2% to approximately 10% by weight. In one embodiment, the binder content of the agglomerated particles is approximately 4% to approximately 10% by weight. In one embodiment, the binder content of the agglomerated particles is approximately 6% to approximately 10% by weight. In one embodiment, the binder content of the agglomerated particles is approximately 8% to approximately 10% by weight. In one embodiment, the binder content of the agglomerated particles is approximately 2% to approximately 8% by weight. In one embodiment, the binder content of the agglomerated particles is approximately 3% to approximately 6% by weight. In one embodiment, the binder content of the agglomerated particles is approximately 2% to approximately 3% by weight. In one embodiment, the binder content of the agglomerated particles is approximately 3.5% by weight. In one embodiment, the binder content of the agglomerated particles is approximately 3% by weight. In one embodiment, the binder content of the agglomerated particles is approximately 2.5% by weight. In one embodiment, the binder content of the agglomerated particles is approximately 1% by weight. In terms of modalities, the agglomerated particles comprise the binder content of any of the modalities detailed herein with the rock and / or mineral fragments that form the remainder. In one embodiment, the agglomerated particles are coated. In one embodiment, the coating is semi-ceramic. In one embodiment, the semi-ceramic coating comprises silicate and clay. In one embodiment, the coating imparts color to the agglomerated particles. In one embodiment, the coated agglomerated particles are applied to the lower flap of the tile. In one embodiment, the agglomerated particles consist essentially of, or consist of, (a) the rock and / or mineral fragments and (b) the binder, or (a) the rock and / or mineral fragments, (b) the binder and (c) the coating. B. Agglomerated particles—Particle size distribution In one modality, the agglomerated particles have a particle size distribution. In one modality, the particle size distribution is unimodal, bimodal, or multimodal. That is, the agglomerated particles can have one, two, or multiple modal sizes. In one embodiment, the particle size distribution of the agglomerated particles applied to the back surface of the tile comprises at least approximately 10% by weight of 50 mesh US particles, at least approximately 20% by weight of 50 mesh US particles, at least approximately 30% by weight of 50 mesh US particles, or at least approximately 40% by weight of 50 mesh US particles. In one embodiment, the particle size distribution of the agglomerated particles applied to the back surface of the tile comprises at least approximately 5% by weight of 60 mesh US particles, at least approximately 10% by weight of 60 mesh US particles, at least approximately 20% by weight of 60 mesh US particles, or at least approximately 30% by weight of 60 mesh US particles.In one embodiment, the particle size distribution of the agglomerated particles applied to the back surface of the tile comprises at least approximately 5% by weight of 100 mesh US particles, at least approximately 10% by weight of 100 mesh US particles, at least approximately 20% by weight of 100 mesh US particles, or at least approximately 30% by weight of 100 mesh US particles. In one embodiment, the particle size distribution of the agglomerated particles applied to the top flap of the tile comprises at least approximately 20% by weight of 16 mesh US particles, at least approximately 30% by weight of 16 mesh US particles, at least approximately 40% by weight of 16 mesh US particles, or at least approximately 50% by weight of 16 mesh US particles. In one embodiment, the particle size distribution of the agglomerated particles applied to the top flap of the tile comprises at least approximately 10% by weight of 20 mesh particles. US, at least approximately 20% by weight of 20 mesh US particles, at least approximately 30% by weight of 20 mesh US particles, or at least approximately 40% by weight of 20 mesh US particles. In one embodiment, the particle size distribution of the agglomerated particles applied to the top flap of the tile comprises at least approximately 5% by weight of 30 mesh US particles, at least approximately 10% by weight of 30 mesh US particles, at least approximately 20% by weight of 30 mesh US particles, or at least approximately 30% by weight of 30 mesh US particles. In another embodiment, the particle size distribution of the agglomerated particles applied to the upper flap of the tile comprises at least approximately 1% by weight of 20 mesh US particles, at least approximately 2% by weight of 20 mesh US particles, at least approximately 5% by weight of 20 mesh US particles, at least approximately 10% by weight of 20 mesh US particles, at least approximately 20% by weight of 20 mesh US particles, or at least approximately 30% by weight of 20 mesh US particles.In one embodiment, the particle size distribution of the agglomerated particles applied to the top flap of the tile comprises at least approximately 40% by weight of 30 mesh US particles, at least approximately 50% by weight of 30 mesh US particles, at least approximately zza^nn / Lznz / E / YiAi % by weight of 30 mesh US particles, at least approximately 70% by weight of 30 mesh US particles, or at least approximately 80% by weight of 30 mesh US particles.In one embodiment, the particle size distribution of the agglomerated particles applied to the top flap of the tile comprises at least approximately 2% by weight of 40 mesh US particles, at least approximately 4% by weight of 40 mesh US particles, at least approximately 10% by weight of 40 mesh US particles, at least approximately 20% by weight of 40 mesh US particles, at least approximately 30% by weight of 40 mesh US particles, or at least approximately 40% by weight of 40 mesh US particles. C. Method for Manufacturing Agglomerated Particles One embodiment of this invention relates to a method for manufacturing agglomerated particles for application to roof tiles. In one embodiment, rock and / or mineral fragments are combined with a liquid or dry binder in a needle mixer. In the needle mixer, needles or rods attached to a horizontal rotating shaft mix the components and produce agglomerated particles by the action of centrifugal force. In one embodiment, the agglomerated particles produced by the needle mixer are substantially spherical. In another embodiment, the agglomerated particles produced by the needle mixer can be dried and used directly. The agglomerated particles produced by the needle mixer can be applied to the back surface or the top flap of a roof tile. In another embodiment, the agglomerated particles produced by the needle mixer are combined with an additional liquid binder in a disc or tray pelletizer. The agglomerated particle size increases due to bulk growth and centrifugal force. The agglomerated particle size can be controlled by varying the disc angle and rotation speed, and by modulating the properties of the feed particles and the liquid binder. Once the desired agglomerated particle size is achieved, the agglomerated particles can be dried. The disc or tray pelletizer further increases the agglomerated particle size and produces agglomerated particles that can be applied to the underside of a tile. In one embodiment, the agglomerated particles are dried after leaving the needle mixer or the disc or tray pelletizer. In another embodiment, the agglomerated particles are dried in a fluidized bed drying system.In a fluidized bed drying system, hot air flows through a perforated plate, drying the agglomerated particles and moving them through the apparatus. In one embodiment, the fluidized bed drying system comprises multiple heating zones and a final cooling zone. D. Method of applying agglomerated particles to a roofing tile In some embodiments, the invention relates to the method of applying the agglomerated particles to a tile. In some embodiments, the method includes applying the agglomerated particles to at least one of the back surfaces, the lower flap, or the upper flap of the tile. The manufacture of the tile includes applying agglomerated particles to asphalt-coated sheets. The asphalt sheet is then pressed in a press roll unit so that the agglomerated particles become embedded in the asphalt coating. The asphalt sheet is then cut to the desired shape on a machine line. In some embodiments, the invention includes the method of manufacturing the agglomerated particles and applying the agglomerated particles to a tile as detailed herein. In one embodiment, the agglomerated particles are not sintered before use. In other words, the agglomerated particles are used, without sintering, to manufacture a roofing material, such as a shingle or roofing roll. As used herein, sintering is the process of compacting and forming a solid mass of material by means of heat or pressure without melting it to the point of liquefaction. E. Examples Specific embodiments of the invention will now be demonstrated with reference to the following examples. It should be understood that these examples are described by way of illustration of the invention and should not be taken in any way as a limitation of the scope of the invention. Examples Example 1 Table 1 gives an example particle size distribution of the agglomerated particles applied to the back surface of a tile. ζζα^ηη / Lznz / E / YiAi Table 1 Tyler Scale Mesh US Mesh % by weight retained 30 28 0-0 40 35 0-5 50 48 20-32 60 60 10-20 70 65 6-15 100 100 15-25 140 150 7-17 200 200 4-10 Tray Tray 2-11 Table 2 provides additional example particle size distributions of agglomerated particles applied to the back surface of a tile. Table 2 ζζα^ηη / Lznz / E / YiAi Mesh US Tyler Scale Mesh % by Weight Retained Range 30 28 0.0-0.0 40 35 3.1-4.8 50 48 19.9-21.6 60 60 13.3-13.8 70 65 9.5-10.8 100 100 19.5-21.6 140 150 13.2-14.4 200 200 8.8-9.0 Tray Tray 7.3-9.3 Table 3 gives an example particle size distribution of the agglomerated particles applied to the top flap of a tile. Table 3 Tyler Scale Mesh US Mesh % by weight retained 8 8 0-0 12 10 4-10 16 14 30-45 20 20 25-35 30 28 14-24 40 35 2-9 Tray Tray 0-2 Table 4 gives an additional example particle size distribution of the agglomerated particles applied to the top flap of a tile. zza^nn / Lznz / E / YiAi Table 4 Tyler Scale Mesh US Mesh % by weight retained 12 10 0-0 16 14 0-6 20 20 2-26 30 28 48-76 40 35 4-32 Tray Tray 0-6 The choice of particle size distribution selected for a tile may be influenced by the balance between surface coverage, tile weight, degree of smoothness, and required impact resistance. For reference, Table 5 below shows the correspondence between US mesh, Tyler scale US mesh, and sieve opening size in inches and micrometers: Table 5 ISO Standard Sieve Size Standard Mesh Opening mm or µm as indicated inches (n) Approximate Equivalent mm Mesh US Tyler Scale Mesh 5.60 mm 0.2230 5.600 3.5 3.5 4.75 mm 0.1870 4.750 4 4 4.00 mm 0.1570 4.000 5 5 ISO Standard Sieve Size Standard Mesh Opening mm or pm as indicated Approximate equivalent inches (in) mm Mesh US Tyler Scale Mesh 3.35 mm 0.1320 3.350 6 6 2.80 mm 0.1100 2.800 7 7 2.36 mm 0.0937 2.360 8 8 2.00 mm 0.0787 2.000 10 9 1.70 mm 0.0661 1.700 12 10 1.40 mm 0.0555 1.400 14 12 1.18 mm 0.0469 1.180 16 14 1.00 mm 0.0394 1.000 18 16 850 pm 0.0331 0.850 20 20 710 pm 0.0278 0.710 25 24 600 pm 0.0234 0.600 30 28 500 pm 0.0197 0.500 35 32 425 pm 0.0165 0.425 40 35 355 pm 0.0139 0.355 45 42 300 pm 0.0117 0.300 50 48 250 pm 0.0098 0.250 60 60 212 pm 0.0083 0.212 70 65 180 pm 0.0070 0.180 80 80 150 pm 0.0059 0.150 100 100 125 pm 0.0049 0.125 120 115 106 pm 0.0041 0.106 140 150 90 pm 0.0035 0.090 170 170 75 pm 0.0029 0.075 200 200 63 pm 0.0025 0.063 230 250 53 pm 0.0021 0.053 270 270 zzafrnn / Lznz / E / γΐΛΐ ISO Standard Sieve Size Standard Mesh Opening mm or pm as indicated Approximate equivalent inches (in) mm Mesh US Tyler Scale Mesh 45 pm 0.0017 0.045 325 325 38 pm 0.0015 0.038 400 400 32 pm 0.0012 0.032 450 25 pm 0.0010 0.025 500 20 pm 0.0008 0.020 635 As discussed earlier, an example of the rock and / or mineral is basalt; however, metabasalt (which is an amphibolite produced from the metamorphism of basaltic parent rock) may be used in addition to basalt or instead of it. In other words, when modalities use the term basalt, it should be understood as describing the use of basalt, metabasalt, or a combination of basalt and metabasalt. Conclusion Although these instructions have been described in conjunction with various modalities and examples, they are not intended to be limited to such modalities or examples. On the contrary, these instructions cover various alternatives, modifications, and equivalents, as those skilled in the art will appreciate. Although various embodiments have been described and illustrated herein, those skilled in the art will readily conceive of various alternative means and / or structures for performing the function and / or obtaining the results and / or one or more of the advantages described herein, and each such variation and / or modification will be considered within the scope of the embodiments described herein. More generally, those skilled in the art will readily recognize that all parameters, dimensions, materials, and configurations described herein are intended as examples and that the actual parameters, dimensions, materials, and / or configurations will depend upon the specific application or applications for which the indications of the invention are used. Those skilled in the art will recognize many equivalents to the specific embodiments described herein.Therefore, it should be understood that the embodiments described herein are presented by way of example only and that, within the scope of the appended and equivalent claims, the embodiments may be implemented in a manner different from that specifically described and claimed. The embodiments of the present description relate to each individual feature, system, article, material, kit, and / or method described herein. Furthermore, any combination of two or more such features, systems, articles, materials, kits, and / or methods is included within the scope of the present description, provided that the features, systems, articles, materials, kits, and / or methods are not mutually inconsistent. zza^nn / Lznz / E / YiAi All definitions, as defined and used herein, shall be understood to supersede dictionary definitions, definitions in documents incorporated by reference, and / or common meanings of the terms defined. It should be understood that the indefinite articles "a" and "one," as used herein and in the claims, unless clearly stated otherwise, mean at least one. Otherwise, in the description, the meanings of "a," "one," "an," "the," and "the" include plural references. All intervals cited herein are inclusive. The meaning of "en" includes "en" and "sobre". The expressions substantially, approximately, and around used in the description and claims generally mean plus or minus 10% of the stated value, e.g., around 100 would include from 90 to 110. Therefore, as used herein, the expression around X means X plus or minus 10%. For example, around 10% by weight means from 9% to 11% by weight. The phrase "and / or," as used herein in the description and claims, should be understood to mean either or both of the elements thus joined, i.e., elements that are present in conjunction in some cases and in disjunction in others. Several elements listed with "and / or" should be interpreted in the same way, i.e., one or more of the elements joined in this manner. Optionally, there may be other elements present in addition to those specifically identified by the "and / or" clause, whether or not they are related to the specifically identified elements.Therefore, as a non-exhaustive example, a reference to A and / or B, when used in conjunction with an open-sense language such as that which it comprises, may refer, in one modality, to only A (optionally including elements other than B); in another modality, to only B (optionally including elements other than A); in yet another modality, to both A and B (optionally including other elements); etc. It should be understood that "or," as used herein and in the claims, has the same meaning as "and / or," as defined above. Otherwise, as used herein, the term "or" is an inclusive "or" operator and is equivalent to the phrase "and / or," unless the context clearly indicates otherwise. For example, when items are separated in a list, "o" and "or" shall be construed as inclusive, meaning the inclusion of at least one, but also the inclusion of more than one, of a number or list of items, and optionally additional items not included in the list. Only terms clearly indicated to the contrary, such as "only one of" or "exactly one of" or, when used in the claims, "consisting of," shall refer to the inclusion of exactly one item from several or a list of items.In general, the term "or," as used herein, shall only be construed as indicating exclusive alternatives (i.e., one or the other, but not both) when preceded by terms of exclusivity, such as "any," "one of," "only one of," or "exactly one of." "Consisting essentially of," when used in the claims, shall have its usual meaning. As used in the description and claims, the expression "at least one," in reference to a list of one or more elements, should be understood to mean at least one element selected from any one or more of the elements in the list of elements, but does not necessarily include at least one of each and every element specifically indicated within the list of elements and does not exclude any combination of elements in the list of elements. This definition also allows for elements to be optionally present other than the elements specifically identified within the list of elements to which the phrase "at least one" refers, whether or not they are related to the specifically identified elements ζζα^ηη / Lznz / E / YiAi.Therefore, as a non-exhaustive example, at least one of A and B (or, equivalently, at least one of A or B or, equivalently, at least one of A and / or B) may refer, in one modality, to at least one, optionally including more than one, A, without any B present (and optionally including elements other than B); in another modality, to at least one, optionally including more than one, B, without any A present (and optionally including elements other than A); in another additional modality, to at least one, optionally including more than one, A, and at least one, optionally including more than one, B (and optionally including other elements); etc. The expression "based on" is not exclusive and allows for reliance on additional factors not described, unless the context clearly indicates otherwise. As used herein, % by weight refers to percentage by weight. The terms roofing tile and tile are used interchangeably. In the claims, as well as in the preceding description, all transitional phrases, such as comprising, including, bearing, having, containing, implying, supporting, composed of, and the like, should be understood in an open sense, that is, meaning including, but not exhaustively. Only the transitional phrases consisting of and essentially consisting of will be considered closed or semi-closed transitional phrases, respectively. The claims shall not be construed as being limited to the order or elements described unless expressly stated. It shall be understood that a person skilled in the art may make various changes in form and detail without departing from the spirit and scope of the appended claims. All embodiments that fall within the spirit and scope of the following claims and their equivalents are claimed. It is hereby stated that, as of this date, the best method known to the applicant for putting the aforementioned invention into practice is the one that is clear from the present description of the invention.

Claims

Having described the invention as above, the following claims are claimed as property:

1. A method, characterized in that it comprises: obtaining (a) a plurality of fragments of at least one of a rock, a mineral, or a combination thereof and (b) a binder, wherein the plurality of fragments of at least one of a rock, a mineral, or a combination thereof comprises fragments having a particle size that passes through 100 mesh US, but is retained by 270 mesh US;and mixing (a) the plurality of fragments of at least one of a rock, a mineral, or a combination thereof and (b) the binder to produce an unsintered agglomerated particle formed by agglomerating together the plurality of fragments and the binder, the unsintered agglomerated particle being configured to be applied to a sheet to form a roofing product, wherein the at least one of a rock, a mineral, or a combination thereof comprises at least one of basalt, metabasalt, andesite, rhyolite, or a combination thereof, wherein the unsintered agglomerated particle is substantially spherical, and wherein the binder is present in the unsintered agglomerated particle in an amount of 2% by weight to 8% by weight.

2. The method according to claim 1, characterized in that the roofing product is a roofing tile or roll.

3. The method according to claim 1, characterized in that the binder is at least one of sodium silicate, gypsum, or a combination thereof.

4. The method according to claim 1, characterized in that the agglomerated particle has a coating comprising silicate and clay.

5. The method according to claim 1, characterized in that the mixture uses a needle mixer.

6. The method according to claim 1, characterized in that it further comprises granulating the agglomerated particle.

7. The method according to claim 1, characterized in that it further comprises drying the agglomerated particle.

8. A method, characterized in that it comprises: obtaining (a) a plurality of fragments of at least one of a rock, a mineral, or a combination thereof and (b) a binder, wherein the plurality of fragments of at least one of a rock, a mineral, or a combination thereof comprises fragments having a particle size that passes through 100 mesh US, but is retained by 270 mesh US; and mixing, using a needle mixer, the plurality of fragments of at least one of a rock, a mineral, or a combination thereof and the binder to produce an agglomerated particle formed by agglomerating together the plurality of fragments and the binder, the agglomerated particle being configured to be applied in non-sintered form to a sheet to form a roofing product, wherein the at least one of a rock, a mineral, or a combination thereof comprises at least one of basalt, metabasalt, andesite, rhyolite,or a combination thereof, wherein the binder is present in the agglomerated particle in an amount of 2% by weight to 8% by weight, and wherein the agglomerated particle is substantially spherical, wherein a plurality of the agglomerated particles are obtained by the method, and wherein, when evaluated as % by weight with respect to a total weight of the agglomerated particles, (A) the agglomerated particles have a particle size distribution comprising (1) at least approximately 10% by weight retained by 50 mesh US after passing through 40 mesh US, (2) at least approximately 5% by weight retained by 60 mesh US after passing through 50 mesh US, and (3) at least approximately 5% by weight retained by 100 mesh US after passing through 70 mesh US; or (B) the agglomerated particles have a particle size distribution comprising (1) at least approximately 40% by weight retained by 16 mesh US after passing through 12 mesh US,(2) at least approximately 30% by weight retained by 20 mesh US after passing through 16 mesh US, and (3) at least approximately 20% by weight retained by 30 mesh US after passing through 20 mesh US; or (C) the agglomerated particles have a particle size distribution comprising (1) at least approximately 1% by weight retained by 20 mesh US after passing through 16 mesh US, (2) at least approximately 40% by weight retained by 30 mesh US after passing through 20 mesh US, and (3) at least approximately 2% by weight retained by 40 mesh US after passing through 30 mesh US.

9. The method according to claim 8, characterized in that the agglomerated particles have a particle size distribution comprising (1) at least approximately 20% by weight retained by 50 mesh US after passing through 40 mesh US, (2) at least approximately 10% by weight retained by 60 mesh US after passing through 50 mesh US, and (3) at least approximately 10% by weight retained by 100 mesh US after passing through 70 mesh US.

10. The method according to claim 8, characterized in that the agglomerated particles have a particle size distribution comprising (1) at least approximately 30% by weight retained by 50 mesh US after passing through 40 mesh US, (2) at least approximately 20% by weight retained by 60 mesh US after passing through 50 mesh US, and (3) at least approximately 20% by weight retained by 100 mesh US after passing through 70 mesh US.

11. The method according to claim 8, characterized in that the agglomerated particles have a particle size distribution comprising (1) at least approximately 40% by weight retained by 16 mesh US after passing through 12 mesh US, (2) at least approximately 30% by weight retained by 20 mesh US after passing through 16 mesh US, and (3) at least approximately 20% by weight retained by 30 mesh US after passing through 20 mesh US.

12. The method according to claim 8, characterized in that the agglomerated particles have a particle size distribution comprising (1) at least approximately 2% by weight retained by 20 mesh US after passing through 16 mesh US, (2) at least approximately 50% by weight retained by 30 mesh US after passing through 20 mesh US, and (3) at least approximately 10% by weight retained by 40 mesh US after passing through 30 mesh US.

13. The method according to claim 8, characterized in that the agglomerated particles have a particle size distribution comprising (1) at least approximately 5% by weight retained by 20 mesh US after passing through 16 mesh US, (2) at least approximately 60% by weight retained by 30 mesh US after passing through 20 mesh US, and (3) at least approximately 20% by weight retained by 40 mesh US after passing through 30 mesh US.

14. The method according to claim 8, characterized in that the binder is at least one of sodium silicate, gypsum, or a combination thereof.

15. The method according to claim 8, characterized in that the agglomerated particle has a coating comprising silicate and clay.

16. The method according to claim 8, characterized in that it further comprises drying the agglomerated particles.

17. The method according to claim 8, characterized in that at least one of a rock, mineral, or a combination thereof comprises metabasalt.

18. The method according to claim 1, characterized in that at least one of a rock, a mineral, or a combination thereof comprises basalt.

19. The method according to claim 1, characterized in that at least one of a rock, mineral, or a combination thereof comprises metabasalt.

20. The method according to claim 1, characterized in that at least one of a rock, a mineral, zza^nn / Lznz / E / YiAi or a combination thereof comprises andesite.

21. The method according to claim 1, characterized in that at least one of a rock, a mineral, or a combination thereof comprises rhyolite.

22. The method according to claim 1, characterized in that the binder comprises gypsum.

23. The method according to claim 1, characterized in that the agglomerated particle has a coating comprising silicate and clay, and wherein at least one of a rock, mineral, or combination thereof is basalt.

24. The method according to claim 1, characterized in that the binder is present in the unsintered agglomerated particle in an amount of 2% by weight to 6% by weight.

25. The method according to claim 11, characterized in that the binder is present in the unsintered agglomerated particle in an amount of 2% by weight to 6% by weight.

26. An agglomerated particle characterized in that it comprises: (a) a plurality of fragments of at least one of a rock, a mineral, or a combination thereof; and (b) a binder, wherein the plurality of fragments of at least one of a rock, mineral, or combination thereof comprises fragments having a particle size passing through 100 mesh US, but retained by 270 mesh US, wherein the agglomerated particle is an unsintered agglomerated particle configured to be applied to a sheet to form a roofing product, wherein the at least one of a rock, mineral, or combination thereof comprises at least one of basalt, metabasalt, andesite, rhyolite, or a combination thereof, wherein the agglomerated particle is substantially spherical, and wherein the binder is present in the agglomerated particle in an amount of 2% by weight to 8% by weight.

27. The agglomerated particle according to claim 26, characterized in that the roofing product is a roofing tile or roll.

28. The agglomerated particle according to claim 26, characterized in that the binder is at least one of sodium silicate, gypsum, or a combination thereof.

29. The agglomerated particle according to claim 26, characterized in that the binder comprises sodium silicate.

30. The agglomerated particle according to claim 26, characterized in that the binder comprises gypsum.

31. The agglomerated particle according to claim 26, characterized in that the agglomerated particle is coated with a coating comprising silicate and clay.

32. The agglomerated particle according to claim 26, characterized in that at least one of a rock, mineral, or a combination thereof comprises metabasalt.

33. The agglomerated particle according to claim 26, characterized in that at least one of a rock, mineral, or a combination thereof comprises andesite.

34. The agglomerated particle according to claim 26, characterized in that at least one of a rock, mineral, or a combination thereof comprises rhyolite.

35. The agglomerated particle according to claim 26, characterized in that the agglomerated particle is coated with a coating comprising silicate and clay, and wherein at least one of a rock, mineral, or combination thereof is basalt.

36. The agglomerated particle according to claim 26, characterized in that the binder is present in the agglomerated particle in an amount of 2% by weight to 6% by weight.

37. A roofing product characterized in that it comprises: a plurality of agglomerated particles, wherein each of the plurality of agglomerated particles comprises: (a) a plurality of fragments of at least one of a rock, a mineral, or a combination thereof and (b) a binder, wherein the plurality of fragments of at least one of a rock, a mineral, or a combination thereof comprises fragments having a particle size passing through 100 mesh US, but retained by 270 mesh US, wherein the agglomerated particle is an unsintered agglomerated particle, wherein the at least one of a rock, a mineral, or a combination thereof comprises at least one of basalt, metabasalt, andesite, rhyolite, or a combination thereof, wherein the agglomerated particle is substantially spherical, and wherein the binder is present in the agglomerated particle in an amount of 2% by weight to 8% by weight.

38. The roofing product according to claim 37, characterized in that the binder is at least one of sodium silicate, gypsum, or a combination thereof.

39. The roofing product according to claim 37, characterized in that the agglomerated particle is coated with a coating comprising silicate and clay.

40. The roofing product according to claim 37, characterized in that at least one of a rock, mineral, or combination thereof comprises metabasalt.

41. The roofing product according to claim 37, characterized in that at least one of a rock, mineral, or combination thereof comprises basalt.

42. The roofing product according to claim 37, characterized in that the agglomerated particle is coated with a coating comprising silicate and clay, and wherein at least one of a rock, mineral, or combination thereof is basalt.

43. The roofing product according to claim 37, characterized in that the binder is present in the agglomerated particle in an amount of 2% by weight to 6% by weight.

44. The roofing product according to claim 37, characterized in that the roofing product is a roofing tile or roll.

45. A method, characterized in that it comprises: obtaining an agglomerated particle, the agglomerated particle comprising (a) a plurality of fragments of at least one of a rock, mineral, or a combination thereof and (b) a binder, agglomerated together to form the agglomerated particle, wherein the plurality of fragments of at least one of a rock, mineral, or a combination thereof comprises fragments having a particle size passing through 100 mesh US but retained by 270 mesh US, wherein the agglomerated particle is an unsintered agglomerated particle, wherein the at least one of a rock, mineral, or a combination thereof comprises at least one of basalt, metabasalt, andesite, rhyolite, or a combination thereof, wherein the agglomerated particle is substantially spherical, and wherein the binder is present in the agglomerated particle in an amount of 2% by weight to 8% by weight;and apply the agglomerated particle to a sheet to form a roofing product.

46. ​​The method according to claim 45, characterized in that the roofing product is a roofing tile or roll.

47. The method according to claim 45, characterized in that the qualifier is at least one of sodium silicate, gypsum, or a combination thereof.

48. The method according to claim 45, characterized in that the binder comprises sodium silicate.

49. The method according to claim 45, characterized in that the binder comprises gypsum.

50. The method according to claim 45, characterized in that the agglomerated particle is coated with a coating comprising silicate and clay.

51. The method according to claim 45, characterized in that at least one of a rock, mineral, or a combination thereof comprises metabasalt.

52. The method according to claim 45, characterized in that at least one of a rock, a mineral, or a combination thereof comprises andesite.

53. The method according to claim 45, characterized in that at least one of a rock, a mineral, or a combination thereof comprises rhyolite.

54. The method according to claim 45, characterized in that the agglomerated particle is coated with a coating comprising silicate and clay, and wherein at least one of a rock, mineral, or combination thereof is basalt.

55. The method according to claim 45, characterized in that the binder is present in the agglomerated particle in an amount of 2% by weight to 6% by weight.

56. The method according to claim 45, characterized in that the roofing product is an asphalt tile.

57. The method according to claim 45, characterized in that the sheet comprises a fiberglass mat, and wherein the application of the agglomerated particle to a sheet to form a roofing product comprises applying the agglomerated particle to the fiberglass mat that was coated with asphalt.