Roofing materials with synthetic roofing granules and methods of making thereof

Abstract

This invention, in embodiments, relates to a roofing material comprising (a) a coated substrate having a top surface and a back surface, and (b) a plurality of roofing granules applied to the top surface of the coated substrate. The plurality of roofing granules comprises from 50% to 100% of unitary, uncoated, non-mineral based particles. This invention, in embodiments, further relates to a method of preparing such roofing material.

1 - 20 . (canceled) 
     
     
         21 . A roofing material comprising:
 a coated substrate having (i) a top surface, (ii) a back surface, (iii) an upper portion comprising a headlap portion, and (iv) a lower portion comprising a buttlap portion, wherein the buttlap portion includes a plurality of tabs;   a backer strip attached to the back surface of the coated substrate, wherein the backer strip has (i) a top surface and (ii) a back surface; and   a plurality of roofing granules applied to at least one of (i) the plurality of tabs of the buttlap portion of the coated substrate, or (ii) at least a portion of the top surface of the backer strip,   wherein the plurality of roofing granules comprises unitary, uncoated, non-mineral based particles having a particle size of #8 US mesh to #60 US mesh,   wherein the plurality of roofing granules is exposed across the at least one of (i) the plurality of tabs of the buttlap portion of the coated substrate, or (ii) the at least a portion of the top surface of the backer strip,   wherein the roofing material is configured to be installed on a roof to form a roofing system, and   wherein, when the roofing material is installed on the roof to form the roofing system, the plurality of roofing granules forms an exposed surface of the roofing system.   
     
     
         22 . The roofing material according to  claim 21 , wherein the substrate comprises one of a fiberglass mat, a polyester mat, a scrim, a coated scrim, or a combination thereof. 
     
     
         23 . The roofing material according to  claim 21 , wherein the roofing material is one of a roofing shingle and a roofing tile. 
     
     
         24 . The roofing material according to  claim 21 , wherein the plurality of roofing granules are applied at an average surface coverage amount of the roofing granules of greater than 55%. 
     
     
         25 . The roofing material according to  claim 21 , wherein each roofing granule of the plurality of roofing granules has a density of 1.2 g/cm 3  to 2.5 g/cm 3 . 
     
     
         26 . The roofing material according to  claim 21 , wherein the non-mineral based particles comprise at least one of a thermoplastic polymer, filled polymers, filled rubbers, filled plastics, a polymer-sand composite, a rubber particle, a wood filled polymer, a bio-based particle, a thermoset material, a fiber-reinforced polymer, and combinations thereof. 
     
     
         27 . The roofing material according to  claim 26 , wherein the at least one of a thermoplastic polymer, filled polymers, filled rubbers, filled plastics, a polymer-sand composite, a rubber particle, a wood filled polymer, a bio-based particle, a thermoset material, a fiber-reinforced polymer, and combinations thereof comprises a recycled material. 
     
     
         28 . The roofing material according to  claim 21 , wherein the non-mineral based particles comprise a synthetic particle. 
     
     
         29 . The roofing material according to  claim 21 , wherein the non-mineral based particles have a particle size of from #20 US mesh to #60 US mesh. 
     
     
         30 . The roofing material according to  claim 21 , wherein the non-mineral based particles have a particle size of from #30 US mesh to #60 US mesh. 
     
     
         31 . The roofing material according to  claim 21 , wherein the non-mineral based particles have an aspect ratio of from 1.5 to 50. 
     
     
         32 . A method of applying roofing granules to a roofing material, the method comprising:
 obtaining a roofing material comprising:
 (a) a coated substrate having (i) a top surface, (ii) a back surface, (iii) an upper portion comprising a headlap portion, and (iv) a lower portion comprising a buttlap portion, wherein the buttlap portion includes a plurality of tabs; and 
 (b) a backer strip attached to the back surface of the coated substrate, wherein the backer strip has (i) a top surface and (ii) a back surface; 
   obtaining a plurality of roofing granules, wherein the plurality of roofing granules comprises unitary, uncoated, non-mineral based particles having a particle size of #8 US mesh to #60 US mesh; and   applying the plurality of roofing granules to at least one of (i) the plurality of tabs of the buttlap portion of the coated substrate, or (ii) at least a portion of the top surface of the backer strip,   wherein the plurality of roofing granules are exposed across the at least one of (i) the plurality of tabs of the buttlap portion of the coated substrate, or (ii) the at least a portion of the top surface of the backer strip,   wherein the roofing material is configured to be installed on a roof to form a roofing system, and   wherein, when the roofing material is installed on the roof to form the roofing system, the plurality of roofing granules forms an exposed surface of the roofing system.   
     
     
         33 . The method according to  claim 32 , wherein the non-mineral based particles comprise at least one of a thermoplastic polymer, filled polymers, filled rubbers, filled plastics, a polymer-sand composite, a rubber particle, a wood filled polymer, a bio-based particle, a thermoset material, a fiber-reinforced polymer, and combinations thereof. 
     
     
         34 . The method according to  claim 33 , wherein the at least one of a thermoplastic polymer, filled polymers, filled rubbers, filled plastics, a polymer-sand composite, a rubber particle, a wood filled polymer, a bio-based particle, a thermoset material, a fiber-reinforced polymer, and combinations thereof comprises a recycled material. 
     
     
         35 . The method according to  claim 32 , wherein the non-mineral based particles comprise a synthetic particle. 
     
     
         36 . The method according to  claim 32 , wherein the non-mineral based particles have a particle size of from #30 US mesh to #60 US mesh. 
     
     
         37 . A roofing material comprising:
 a coated substrate having (i) a top surface, (ii) a back surface, (iii) an upper portion comprising a headlap portion, and (iv) a lower portion comprising a buttlap portion, wherein the buttlap portion includes a plurality of tabs; and   a plurality of roofing granules applied to the plurality of tabs of the buttlap portion of the coated substrate,   wherein the plurality of roofing granules comprises unitary, uncoated, non-mineral based particles having a particle size of #8 US mesh to #60 US mesh,   wherein the plurality of roofing granules is exposed across the plurality of tabs of the buttlap portion of the coated substrate,   wherein the roofing material is configured to be installed on a roof to form a roofing system, and   wherein, when the roofing material is installed on the roof to form the roofing system, the plurality of roofing granules forms an exposed surface of the roofing system.   
     
     
         38 . The roofing material according to  claim 37 , wherein the non-mineral based particles comprise at least one of a thermoplastic polymer, filled polymers, filled rubbers, filled plastics, a polymer-sand composite, a rubber particle, a wood filled polymer, a bio-based particle, a thermoset material, a fiber-reinforced polymer, and combinations thereof. 
     
     
         39 . The roofing material according to  claim 38 , wherein the at least one of a thermoplastic polymer, filled polymers, filled rubbers, filled plastics, a polymer-sand composite, reinforced polymer, and combinations thereof comprises a recycled material. 
     
     
         40 . The roofing material according to  claim 37 , wherein the non-mineral based particles have a particle size of from #30 US mesh to #60 US mesh.