Surfacing media with flame retarding effects and high solar reflectance, and method of making same

Abstract

A roofing material includes a fire-retardant particulate material on its upper surface. A solar-reflective surface coating encapsules the fire-retardant particulate.

1 . A solar-reflective, fire-retardant roofing material comprising:
 (a) a base material having an upper surface;   (b) a fire-retardant particulate material applied to the upper surface of the base material; and   (c) a solar-reflective surface coating, the solar reflective surface coating at least partially encapsulating the fire-retardant particulate material.   
   
   
       2 . A roofing material according to  claim 1  wherein the fire-retardant particulate material is partially embedded in and partially protruding from the solar reflective surface coating. 
   
   
       3 . A roofing material according to  claim 1  wherein the fire-retardant particulate material is fully encapsulated in the solar reflective surface coating. 
   
   
       4 . A roofing material according to  claim 1  wherein the fire-retardant material is selected from the group consisting of hydrated metal silicates, alumina hydrates, antimony-containing compounds, phosphorous-containing compounds, and halogenated compounds. 
   
   
       5 . A roofing material according to  claim 1  wherein the solar reflective coating is formed from a solar-reflective coating composition including at least one solar-reflective pigment. 
   
   
       6 . (canceled) 
   
   
       7 . A roofing material according to  claim 5  wherein the solar reflective coating composition comprises at least one binder material selected from the group consisting of metal silicate compositions, silicas, phosphates, and polymeric binder compositions. 
   
   
       8 . (canceled) 
   
   
       9 . A method of making solar-reflective, fire-retardant roofing materials, the method comprising:
 (a) providing a base material having an upper surface;   (b) applying a solar-reflective surface coating composition to the upper surface of the base material;   (c) depositing a fire-retardant particulate material on the upper surface of the base material in the solar-reflective surface coating composition; and   (d) curing the solar-reflective surface coating composition to at least partially encapsulate the fire-retardant particulate material.   
   
   
       10 . A method according to  claim 9  wherein the fire-retardant material is selected from the group consisting of hydrated metal silicates, alumina hydrates, antimony-containing compounds, phosphorous-containing compounds, and halogenated compounds. 
   
   
       11 . A method according to  claim 9  wherein the solar-reflective coating composition includes at least one solar-reflective pigment. 
   
   
       12 . (canceled) 
   
   
       13 . A method according to  claim 9  wherein the solar reflective coating composition comprises at least one binder material selected from the group consisting of metal silicate compositions, silicas phosphates, and polymeric binder compositions. 
   
   
       14 . (canceled) 
   
   
       15 . A method of making solar-reflective, fire-retardant roofing materials, the method comprising:
 (a) providing a fire-retardant particulate material;   (b) applying a solar-reflective surface coating composition to fire-retardant particulate material;   (c) curing the solar-reflective surface coating composition to at least partially encapsulate the fire-retardant particulate material with a solar-reflective surface coating; and   (d) depositing the encapsulated fire-retardant particulate material on the upper surface of the base material.   
   
   
       16 . A method according to  claim 15  wherein the fire-retardant material is selected from the group consisting of hydrated metal silicates, alumina hydrates, antimony-containing compounds, phosphorous-containing compounds, and halogenated compounds. 
   
   
       17 . A method according to  claim 16  wherein the solar reflective coating is formed from a solar-reflective coating composition including at least one solar-reflective pigment. 
   
   
       18 . (canceled) 
   
   
       19 . A method according to  claim 15  wherein the solar reflective coating composition comprises at least one binder material selected from the group consisting of metal silicate compositions, silicas phosphates, and polymeric binder compositions. 
   
   
       20 . (canceled) 
   
   
       21 . A method of coating a substrate surface, the method comprising:
 (a) providing a substrate surface;   (b) applying a liquid surface coating composition to the substrate surface;   (c) depositing a fire-retardant particulate material on an upper surface of the liquid surface coating;   (d) at least partially encapsulating the fire-retardant particulate material; and   (e) causing the liquid surface coating to cure to a solid state;   whereby a tack-free time of a thusly coated substrate surface is shorter than the tack-free time of a coated substrate surface cured without the fire-retardant particulate material deposited thereon.   
   
   
       22 . A method according to  claim 21  wherein the substrate surface comprises a roofing material. 
   
   
       23 . A method according to  claim 21  wherein the liquid surface coating composition is a solar-reflective coating composition in a cured state. 
   
   
       24 . A method according to  claim 23  wherein the solar reflective coating composition includes at least one solar-reflective pigment. 
   
   
       25 . A method according to  claim 21  wherein the fire-retardant particulate material is selected from the group consisting of intumescent and non-intumescent fire-retardant materials. 
   
   
       26 . A granular particulate material for surfacing roofing materials, the particulate comprising fire-retardant material at least partially encapsulated in a solar-reflective coating. 
   
   
       27 . A granular particulate material according to  claim 26  wherein the fire-retardant material is selected from the group consisting of hydrated metal silicates, alumina hydrates, antimony-containing compounds, phosphorous-containing compounds, and halogenated compounds. 
   
   
       28 . A granular particulate material according to  claim 26  wherein the fire-retardant material is selected from the group consisting of intumescent and non-intumescent fire retardant materials. 
   
   
       29 . A granular particulate material according to  claim 26  wherein the solar reflective coating is formed from a solar-reflective coating composition including at least one solar-reflective pigment. 
   
   
       30 . (canceled) 
   
   
       31 . A granular particulate material according to  claim 29  wherein the at least one solar reflective pigment has an integrated reflectance of at least about 50% over the wavelength range from 700 to 2500 nm. 
   
   
       32 . A granular particulate material according to  claim 29  wherein the solar reflective coating composition comprises at least one binder material selected from the group consisting of metal silicate compositions, silicas, phosphates, and polymeric binder compositions. 
   
   
       33 . (canceled)