Solar Reflective Polymer Rubber Composite Shingles
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Solution Overview
Problem
Conventional roofing shingles have low solar reflectance due to the exposed black asphalt substrate and poor adhesion of ceramic granules, which leads to limited reuse of waste vulcanizates and high manufacturing costs.
Innovation Solution
Development of solar reflective shaped articles using thermoplastic polymer encapsulated vulcanizates, such as ground tire rubber, with colored or uncolored fluidizable particles and roofing granules, which are dispersed or adhered to a composite layer to enhance solar reflectance and thermal emissivity, while utilizing conventional processing equipment and minimizing layers.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Illumination intensity
If ceramic granules are used to provide solar reflectance in asphalt shingles, then solar reflectance is improved, but adhesion to the substrate is poor and granules are removed over time
Solution Approach 1:
The patent uses an asphalt-based adhesive layer as an intermediary between the substrate and reflective granules. This adhesive layer is applied to the substrate surface and provides improved bonding for the granules, preventing their removal over time while maintaining solar reflectance properties.
Solution Approach 2:
The patent modifies the substrate surface by applying an adhesive layer that changes the surface properties. This adhesive layer creates a more suitable interface for granule attachment, transforming the poor adhesion characteristic of bare asphalt into reliable granule retention.
2Illumination intensity
If white pigments such as titanium dioxide are added to asphalt substrate to lighten color, then solar reflectance is improved, but manufacturing cost increases and viscosity increases during processing
Solution Approach 1:
The patent extracts the lightening function from the asphalt substrate itself and relocates it to a separate reflective granule layer. This allows the substrate to remain black and processable, while the reflective granules provide the solar reflectance function that would otherwise require lightening the asphalt.
Solution Approach 2:
The patent creates a composite structure combining black asphalt substrate with light-reflective granules. This composite approach separates the functions of substrate integrity (maintained by black asphalt) and solar reflectance (provided by reflective granules), avoiding the need to lighten the asphalt itself.
3Illumination intensity
If conventional multilayer roof coverings are made with separate reflective and weatherable layers, then solar reflectance is improved, but device complexity increases and mechanical properties are limited
Solution Approach 1:
The patent merges the reflective layer and weatherable layer into a single integrated layer. This layer contains both reflective granules for solar reflectance and asphalt binder for weatherability, eliminating the need for separate layers while maintaining both functions.
Solution Approach 2:
The patent creates a single layer that performs multiple functions: it provides solar reflectance through reflective granules, weatherability through asphalt binder, and structural integrity through the combination. This multi-functional layer replaces what would otherwise require separate specialized layers.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution achieves solar reflectance ratings of 30% or higher and thermal emissivity of 70% or more, significantly improving energy reflection and durability, while allowing for the reuse of waste materials and reducing manufacturing costs.
Implementation Method 1
thermoplastic polymer encapsulated vulcanizates
Implementation Method 2
solar reflectance ratings of 30% or higher
Implementation Method 3
thermal emissivity of 70% or more
Data Source
AI summary
The present invention provides shaped articles comprising one or more composite layer of (i) a vulcanizate encapsulated in a colored or uncolored thermoplastic polymer matrix containing one or more passivating agent, and (ii) a reflective material chosen from colored fluidizable particles of a thermoplastic reflective colorant encapsulated vulcanizate, roofing granules, thermoplastic encapsulated roofing granules, the colored thermoplastic polymer matrix, and combinations thereof. The articles can be laminates of colored or reflective layers on uncolored or other layers, or one or more colored layer having colored fluidizable particles are dispersed within the surface of the uppermost composite layer or having either the colored fluidizable particles or the granules are dispersed on the surface of the composite layer or are adhered thereto with a thermoplastic resin. Roofing shingles are provided.