Roofing material with a non-asphalt backing

Patent metadata

Field	Value
Publication number	US-10370852-B2
Application number	US-201815898864-A
Country	US
Kind code	B2
Filing date	Feb 19, 2018
Priority date	Aug 24, 2015
Publication date	Aug 6, 2019
Grant date	Aug 6, 2019

Abstract

A roofing material including a substrate having a top face and a bottom face. The roofing material further includes a non-asphalt coating applied to the substrate and an asphalt layer covering at least a portion of the top face. The bottom face is asphalt-free, or substantially asphalt-free.

First claim

The invention claimed is:

1. A roofing material, comprising:
a substrate having a top face and a bottom face;
a non-asphalt coating on the substrate;
an asphalt coating on at least a portion of the top face of the substrate, wherein substantially no asphalt is on the bottom face of the substrate;
a first portion of the substrate is unimpregnated with the non-asphalt coating such that the asphalt coating on the top face of the substrate impregnates the first portion; and
a layer of granules adhered to the asphalt coating.

2. The roofing material of claim 1 wherein the substrate is at least partially impregnated with the non-asphalt coating.

3. The roofing material of claim 2 wherein the substrate is at least partially impregnated with asphalt from the asphalt coating.

4. The roofing material of claim 3 wherein the first portion is greater than 50% of the substrate.

5. The roofing material of claim 1 wherein the non-asphalt coating forms a discrete layer on the bottom face of the substrate.

6. The roofing material of claim 1 wherein the non-asphalt coating improves at least one shingle property of the group of tear resistance, tensile strength, nail pull resistance, wind resistance, fire resistance, shingle stiffness, cold curling resistance, masking ability, and shingle water shedding ability.

7. The roofing material of claim 1 wherein the non-asphalt coating includes at least one of the group of calcium carbonate, viscosity modifiers, dispersants, biocides, acrylic resins, clays, wollastonite, and powdered resins.

8. The roofing material of claim 1 wherein the roofing material is an asphalt roofing shingle.

9. A method of manufacturing a roofing material, comprising:
applying a non-asphalt coating to a substrate having a top face and a bottom face;
coating the top face of the substrate with asphalt, wherein substantially no asphalt is coated on a bottom face;
selectively leaving a first portion of the substrate unimpregnated with non-asphalt coating such that the step of coating the top face of the substrate with asphalt results in impregnating the first portion with asphalt; and
applying a layer of granules on the asphalt.

10. The method of claim 9 wherein the step of applying a non-asphalt coating includes at least partially impregnating the substrate with the non-asphalt coating.

11. The method of claim 9 wherein the step of applying a non-asphalt coating includes forming a discrete layer of non-asphalt coating on the bottom face.

Assignees

• Owens Corning Intellectual Capital Llc

Inventors

• Verhoff Jonathan M
• Vanhouten Desmond John
• Schweiger Scott William

Classifications

• E04D1/26

  Strip-shaped roofing elements {simulating a repetitive pattern, e.g.} appearing as a row of shingles · CPC title

• B05D1/02

  performed by spraying · CPC title

• B05D1/30

  performed by gravity only, i.e. flow coating · CPC title

• B05D3/0272

  with ovens · CPC title

• B05D5/02

  to obtain a matt or rough surface · CPC title