Highly reflective and emissive asphalt-based roofing membrane

Abstract

A prefabricated asphalt-based waterproof roofing membrane for use in a multi-ply asphalt-based commercial roofing system, e.g. a cap sheet that forms the exposed layer of a multi-ply built-up roofing system, is manufactured at a factory to have a highly reflective and emissive non-asphalt based elastomeric top coating layer. Preferably, a polymer primer layer is interposed between the highly reflective and emissive coating layer and an asphalt saturated and coated reinforcing substrate to keep oils and other colored components in the asphalt from exuding into the highly reflective and emissive coating layer.

1 . A prefabricated asphalt-based waterproof roofing membrane; the prefabricated asphalt-based waterproof roofing membrane having a length and a width; the prefabricated asphalt-based waterproof roofing membrane having an top major surface and a bottom major surface defined by the length and the width of prefabricated asphalt-based waterproof roofing membrane; the top major surface of the prefabricated asphalt-based waterproof roofing membrane having an exposed portion that is exposed to the weather when the prefabricated asphalt-based waterproof roofing membrane is installed on a roof and a lateral edge portion, extending for the length of the prefabricated asphalt-based waterproof roofing membrane, that is overlapped by an adjacent prefabricated asphalt-based waterproof roofing membrane when the prefabricated asphalt-based waterproof roofing membrane is installed on a roof, the prefabricated asphalt-based waterproof roofing membrane comprising: 
 an asphalt saturated reinforcing substrate having a length and a width; the asphalt saturated reinforcing substrate having a top major surface and a bottom major surface defined by the length and the width of the asphalt saturated reinforcing substrate; a top asphalt layer overlaying and coextensive with the top major surface of the asphalt saturated reinforcing substrate and a bottom asphalt layer overlaying and coextensive with the bottom major surface of the asphalt saturated reinforcing substrate; the top and bottom asphalt layers, with the asphalt saturated reinforcing substrate, forming an asphalt saturated and coated reinforcing substrate;    a highly reflective and emissive non-asphalt based elastomeric coating layer bonded to a top surface of the top asphalt layer; the highly reflective and emissive non-asphalt based elastomeric coating layer having a top surface forming a top surface of the exposed portion of the top major surface of the prefabricated asphalt-based waterproof roofing membrane; the top surface of the highly reflective and emissive non-asphalt based elastomeric coating layer having an initial solar reflectance of at least 0.70 and a thermal emittance of at least 0.75.    
   
   
       2 . The prefabricated asphalt-based waterproof roofing membrane according to  claim 1 , wherein: 
 the prefabricated asphalt-based waterproof roofing membrane includes a polymer primer layer intermediate the top asphalt layer and the highly reflective and emissive non-asphalt based elastomeric coating layer that is impermeable to oils and other colored components of the top asphalt layer to keep the oils and other colored components of the top asphalt layer from exuding into the highly reflective and emissive non-asphalt based elastomeric coating layer and reducing the reflectance of the highly reflective and emissive non-asphalt based elastomeric coating layer; and    the polymer primer layer is bonded the top surface of the top asphalt layer; and the highly reflective and emissive non-asphalt based elastomeric coating layer is bonded to the top surface of the top asphalt layer by being bonded to a top surface of the polymer primer layer.    
   
   
       3 . The prefabricated asphalt-based waterproof roofing membrane according to  claim 2 , wherein: 
 the highly reflective and emissive non-asphalt based elastomeric coating layer comprises a polymer binder material and a reflective and emissive pigment.    
   
   
       4 . The prefabricated asphalt-based waterproof roofing membrane according to  claim 3 , wherein: 
 the polymer binder material is selected from a group consisting essentially of: acrylic-based elastomers and isocyanate-based elastomers.    
   
   
       5 . The prefabricated asphalt-based waterproof roofing membrane according to  claim 2 , wherein: 
 at least one of the top major surface and the bottom major surface of the prefabricated asphalt-based waterproof roofing membrane has a release layer thereon that is removed prior to installation of the prefabricated asphalt-based waterproof roofing membrane and that permits the prefabricated asphalt-based waterproof roofing membrane to be wound into a roll for packaging, storage, shipping, and handling and unwound from the roll for installation; and    the prefabricated asphalt-based waterproof roofing membrane is wound into a roll.    
   
   
       6 . The prefabricated asphalt-based waterproof roofing membrane according to  claim 2 , wherein: 
 the highly reflective and emissive non-asphalt based elastomeric coating layer overlies substantially the entire top major surface of the prefabricated asphalt-based waterproof roofing membrane.    
   
   
       7 . The prefabricated asphalt-based waterproof roofing membrane according to  claim 2 , wherein: 
 the highly reflective and emissive non-asphalt based elastomeric coating layer only overlies the exposed portion of the top major surface of the prefabricated asphalt-based waterproof roofing membrane.    
   
   
       8 . The prefabricated asphalt-based waterproof roofing membrane according to  claim 2 , wherein: 
 the highly reflective and emissive non-asphalt based elastomeric coating layer is bonded directly to the top surface of the top asphalt layer.    
   
   
       9 . The prefabricated asphalt-based waterproof roofing membrane according to  claim 8 , wherein: 
 the highly reflective and emissive non-asphalt based elastomeric coating layer comprises a polymer binder material and a reflective and emissive pigment.    
   
   
       10 . The prefabricated asphalt-based waterproof roofing membrane according to  claim 9 , wherein: 
 the polymer binder material is selected from a group consisting essentially of: acrylic-based elastomers and isocyanate-based elastomers.    
   
   
       11 . The prefabricated asphalt-based waterproof roofing membrane according to  claim 8 , wherein: 
 at least one of the top major surface and the bottom major surface of the prefabricated asphalt-based waterproof roofing membrane has a release layer thereon that is removed prior to installation of the prefabricated asphalt-based waterproof roofing membrane and that permits the prefabricated asphalt-based waterproof roofing membrane to be wound into a roll for packaging, storage, shipping, and handling and unwound from the roll for installation; and    the prefabricated asphalt-based waterproof roofing membrane is wound into a roll.    
   
   
       12 . The prefabricated asphalt-based waterproof roofing membrane according to  claim 8 , wherein: 
 the highly reflective and emissive non-asphalt based elastomeric coating layer overlies substantially the entire top major surface of the prefabricated asphalt-based waterproof roofing membrane.    
   
   
       13 . The prefabricated asphalt-based waterproof roofing membrane according to  claim 8 , wherein: 
 the highly reflective and emissive non-asphalt based elastomeric coating layer only overlies the exposed portion of the top major surface of the prefabricated asphalt-based waterproof roofing membrane.    
   
   
       14 . The prefabricated asphalt-based waterproof roofing membrane according to  claim 1 , wherein: 
 the top surface of the highly reflective and emissive non-asphalt based elastomeric coating layer is embossed to make the top surface more slip and skid resistant.    
   
   
       15 . The prefabricated asphalt-based waterproof roofing membrane according to  claim 1 , wherein: 
 the highly reflective and emissive non-asphalt based elastomeric coating layer includes a surfacing material to make the top surface more slip and skid resistant.    
   
   
       16 . The prefabricated asphalt-based waterproof roofing membrane according to  claim 15 , wherein: 
 the surfacing material of the highly reflective and emissive non-asphalt based elastomeric coating layer is a reflective and emissive surfacing material on the top surface of the highly reflective and emissive non-asphalt based elastomeric coating layer to make the top surface more slip and skid resistant.    
   
   
       17 . The prefabricated asphalt-based waterproof roofing membrane according to  claim 15 , wherein: 
 the surfacing material of the highly reflective and emissive non-asphalt based elastomeric coating layer is covered by and embedded in the highly reflective and emissive non-asphalt based elastomeric coating layer to make the top surface more slip and skid resistant.    
   
   
       18 . A method of making a prefabricated asphalt-based waterproof roofing membrane; the prefabricated asphalt-based waterproof roofing membrane having a length and a width; the prefabricated asphalt-based waterproof roofing membrane having an top major surface and a bottom major surface defined by the length and the width of prefabricated asphalt-based waterproof roofing membrane; the top major surface of the prefabricated asphalt-based waterproof roofing membrane having an exposed portion that is exposed to the weather when the prefabricated asphalt-based waterproof roofing membrane is installed on a roof and a lateral edge portion, extending for the length of the prefabricated asphalt-based waterproof roofing membrane, that is overlapped by an adjacent prefabricated asphalt-based waterproof roofing membrane when the prefabricated asphalt-based waterproof roofing membrane is installed on a roof, the method comprising: 
 providing a reinforcing substrate having a length and a width; the reinforcing substrate having a top major surface and a bottom major surface defined by the length and the width of the reinforcing substrate;    saturating the reinforcing substrate with asphalt;    forming a top asphalt layer overlaying and coextensive with the top major surface of the reinforcing substrate and a bottom asphalt layer overlaying and coextensive with the bottom major surface of the reinforcing substrate so that the top and bottom asphalt layers, with the asphalt saturated reinforcing substrate, form an asphalt saturated and coated reinforcing substrate;    applying and bonding a highly reflective and emissive non-asphalt based elastomeric coating layer to a first portion of a top surface of the top asphalt layer of the saturated and coated reinforcing substrate; the highly reflective and emissive non-asphalt based elastomeric coating layer forming the portion of the top major surface of the prefabricated asphalt-based waterproof roofing membrane that is exposed to the weather when the prefabricated asphalt-based waterproof roofing membrane is installed on a roof; the highly reflective and emissive non-asphalt based elastomeric coating layer having a top surface that has an initial solar reflectance of at least 0.70 and a thermal emittance of at least 0.75;    applying a release means to at least one of the major surfaces of the prefabricated asphalt-based waterproof roofing membrane so that the prefabricated asphalt-based waterproof roofing membrane can to be wound into a roll for packaging, storage, shipping, and handling and unwound from the roll for installation; and    winding the prefabricated asphalt-based waterproof roofing membrane into a roll.    
   
   
       19 . The method of making a prefabricated asphalt-based waterproof roofing membrane according to  claim 18 , including: 
 applying a polymer primer layer, which is impermeable to oils and other colored components of the top asphalt layer, to the top asphalt layer so that: the polymer primer layer is interposed between the top asphalt layer and the highly reflective and emissive non-asphalt based elastomeric coating layer to keep the oils and other colored components of the top asphalt layer from exuding into the highly reflective and emissive non-asphalt based elastomeric coating layer and reducing the reflectance of the highly reflective and emissive non-asphalt based elastomeric coating layer; the polymer primer layer being bonded the top surface of the top asphalt layer; and the highly reflective and emissive non-asphalt based elastomeric coating layer being bonded to the top surface of the top asphalt layer by being bonded to a top surface of the polymer primer layer.    
   
   
       20 . The method of making a prefabricated asphalt-based waterproof roofing membrane according to  claim 19 , wherein: 
 the highly reflective and emissive non-asphalt based elastomeric coating layer comprises a polymer binder material and a reflective and emissive pigment.    
   
   
       21 . The method of making a prefabricated asphalt-based waterproof roofing membrane according to  claim 20 , wherein: 
 the polymer binder material is selected from a group consisting essentially of: acrylic-based elastomers and isocyanate-based elastomers.    
   
   
       22 . The method of making a prefabricated asphalt-based waterproof roofing membrane according to  claim 18 , wherein: 
 the highly reflective and emissive non-asphalt based elastomeric coating layer is applied to substantially the entire top surface of the top asphalt layer of the saturated and coated reinforcing substrate so that the highly reflective and emissive non-asphalt based elastomeric coating layer forms substantially the entire top major surface of the prefabricated asphalt-based waterproof roofing membrane.    
   
   
       23 . The method of making a prefabricated asphalt-based waterproof roofing membrane according to  claim 18 , wherein: 
 the highly reflective and emissive non-asphalt based elastomeric coating layer is applied only to the first portion of the top surface of the top asphalt layer of the saturated and coated reinforcing substrate so that the highly reflective and emissive non-asphalt based elastomeric coating layer only forms the exposed portion of the top major surface of the prefabricated asphalt-based waterproof roofing membrane and an uncoated second portion of the top surface of the top asphalt layer forms the lateral edge portion of the prefabricated asphalt based waterproof roofing membrane that extends for the length of the prefabricated asphalt-based waterproof roofing membrane and is overlapped by an adjacent prefabricated asphalt-based waterproof roofing membrane when the prefabricated asphalt-based waterproof roofing membrane is installed on a roof.    
   
   
       24 . The method of making a prefabricated asphalt-based waterproof roofing membrane according to  claim 18 , wherein: 
 the highly reflective and emissive non-asphalt based elastomeric coating layer is bonded directly to the top surface of the top asphalt layer.    
   
   
       25 . The method of making a prefabricated asphalt-based waterproof roofing membrane according to  claim 24 , wherein: 
 the highly reflective and emissive non-asphalt based elastomeric coating layer comprises a polymer binder material and a reflective and emissive pigment.    
   
   
       26 . The method of making a prefabricated asphalt-based waterproof roofing membrane according to  claim 25 , wherein: 
 the polymer binder material is selected from a group consisting essentially of: acrylic-based elastomers and isocyanate-based elastomers.    
   
   
       27 . The method of making a prefabricated asphalt-based waterproof roofing membrane according to  claim 24 , wherein: 
 the highly reflective and emissive non-asphalt based elastomeric coating layer is applied to substantially the entire top surface of the top asphalt layer of the saturated and coated reinforcing substrate so that the highly reflective and emissive non-asphalt based elastomeric coating layer forms substantially the entire top major surface of the prefabricated asphalt-based waterproof roofing membrane.    
   
   
       28 . The method of making a prefabricated asphalt-based waterproof roofing membrane according to  claim 24 , wherein: 
 the highly reflective and emissive non-asphalt based elastomeric coating layer is applied only to the first portion of the top surface of the top asphalt layer of the saturated and coated reinforcing substrate so that the highly reflective and emissive non-asphalt based elastomeric coating layer only forms the exposed portion of the top major surface of the prefabricated asphalt-based waterproof roofing membrane and an uncoated second portion of the top surface of the top asphalt layer forms the lateral edge portion of the prefabricated asphalt based waterproof roofing membrane that extends for the length of the prefabricated asphalt-based waterproof roofing membrane and is overlapped by an adjacent prefabricated asphalt-based waterproof roofing membrane when the prefabricated asphalt-based waterproof roofing membrane is installed on a roof.    
   
   
       29 . The method of making a prefabricated asphalt-based waterproof roofing membrane according to  claim 18 , including: 
 embossing the top surface of the highly reflective and emissive non-asphalt based elastomeric coating layer to make the top surface more slip and skid resistant.    
   
   
       30 . The method of making a prefabricated asphalt-based waterproof roofing membrane according to  claim 18 , including: 
 applying a reflective and emissive surfacing material to the highly reflective and emissive non-asphalt based elastomeric coating layer to make the top surface more slip and skid resistant.    
   
   
       31 . The method of making a prefabricated asphalt-based waterproof roofing membrane according to  claim 18 , including: 
 applying surfacing material on the top surface of the top asphalt layer; and    applying the highly reflective and emissive non-asphalt based elastomeric coating layer over the surfacing material to make the top surface more slip and skid resistant.