Polymer modified asphalt roofing material

Patent metadata

Field	Value
Publication number	US-10907353-B2
Application number	US-201816222223-A
Country	US
Kind code	B2
Filing date	Dec 17, 2018
Priority date	Dec 15, 2017
Publication date	Feb 2, 2021
Grant date	Feb 2, 2021

Abstract

A shingle coating asphalt composition is provided that is produced from a paving grade asphalt. The asphalt composition comprises a paving-grade asphalt that has been modified with one or more polymer additives; and a secondary additive comprising one or more of a viscosity reducing agent, a wax, a salt of a fatty acid ester, and an amide of a fatty acid. The shingle coating asphalt coating composition is used to make a shingle. The shingle includes a substrate, the asphalt, and roofing granules.

First claim

The invention claimed is:

1. A roofing shingle comprising:
a substrate having a first surface and an opposing second surface;
a polymer and wax modified asphalt coating on the first surface of the substrate;
wherein the polymer and wax modified asphalt coating comprises:
40-80 wt. % of a filler based on the total weight of the polymer-modified asphalt composition;
a paving-grade asphalt;
a polymer additive; and
wax;
wherein the polymer and wax modified asphalt coating comprises 85-99 wt. % asphalt, 1-13 wt. % polymer additive, and 1-6 wt. % wax based on the total weight of the components of the polymer and wax modified asphalt coating, excluding the filler;
a strip of nail zone reinforcement material on a first portion of the polymer and wax modified asphalt coating, the strip of nail zone reinforcement material having a length and a width, where the width is from about 0.5 inches to about 2.0 inches and the length is greater than the width; and
roofing granules on a second portion of the polymer and wax modified asphalt coating;
wherein a nail pull-through resistance through a test fixture with a 2.0 inch diameter hole at the strip of nail zone reinforcement material of the shingle with the polymer and wax modified asphalt coating is greater than a nail pull-through resistance through a test fixture with a 2.0 inch diameter hole of an otherwise identical shingle at the strip of nail zone reinforcement material, the otherwise identical shingle having the same nail zone reinforcement material and a conventional oxidized asphalt without wax and without polymer additive.

2. The roofing shingle of claim 1 wherein the strip of nail zone reinforcement material is a woven polyester fabric.

3. The roofing shingle of claim 1 wherein the polymer additive is styrene-butadiene rubber.

4. The roofing shingle of claim 1 wherein the wax is a Fischer-Tropsch wax.

5. The roofing shingle of claim 1 wherein the nail pull-through resistance through a test fixture with a 2.0 inch diameter hole is more than 10% greater than the nail pull-through resistance through a test fixture with a 2.0 inch diameter hole of the otherwise identical shingle.

6. The roofing shingle of claim 1 wherein the polymer and wax modified asphalt coating includes the polymer additive in an amount of 2-7 wt. % and the wax in an amount of 1.6-3 wt. % based on the total weight of the components of the polymer and secondary additive modified asphalt coating excluding the filler.

7. A roofing shingle comprising:
a substrate having a first surface and an opposing second surface;
a polymer and wax modified asphalt coating on the first surface of the substrate;
wherein the polymer and wax modified asphalt coating comprises:
40-80 wt. % of a filler based on the total weight of the polymer-modified asphalt composition;
a paving-grade asphalt;
a polymer additive; and
wax;
wherein the polymer and wax modified asphalt coating comprises 85-99 wt. % asphalt, 1-13 wt. % polymer additive, and 1-6 wt. % wax based on the total weight of the components of the polymer and wax modified asphalt coating, excluding the filler;

a strip of nail zone reinforcement material on a first portion of the polymer and wax modified asphalt coating, the strip of nail zone reinforcement material having a length and a width, where the width is from about 0.5 inches to about 2.0 inches and the length is greater than the width; and
roofing granules on a second portion of the polymer and wax modified asphalt coating;
wherein a nail pull-through resistance at the strip of nail zone reinforcement material determined with a test fixture with a 2.0 inch diameter hole is greater than 63 lbf.

8. The roofing shingle of claim 7 wherein the strip of nail zone reinforcement material is a woven polyester fabric.

9. The roofing shingle of claim 7 wherein the polymer additive is styrene-butadiene rubber.

10. The roofing shingle of claim 7 wherein the wax is a Fischer-Tropsch wax.

11. The roofing shingle of claim 7 wherein the nail pull-through resistance through a test fixture with a 2.0 inch diameter hole at the strip of nail zone reinforcement material of the shingle with the polymer and wax modified asphalt coating is more than 10% greater than the nail pull-through resistance through a test fixture with a 2.0 inch diameter hole of an otherwise identical shingle having the same nail zone reinforcement material and a conventional oxidized asphalt without wax and without polymer additive.

12. The roofing shingle of claim 7 wherein the polymer and wax modified asphalt coating includes the polymer additive in an amount of 2-7 wt. % and the wax in an amount of 1.6-3 wt. % based on the total weight of the components of the polymer and secondary additive modified asphalt coating excluding the filler.

13. A roofing shingle comprising:
a substrate having a first surface and an opposing second surface;
a polymer and wax modified asphalt coating on the first surface of the substrate;
wherein the polymer and wax modified asphalt coating comprises:
40-80 wt. % of a filler based on the total weight of the polymer-modified asphalt composition;
a paving-grade asphalt;
a polymer additive; and
wax;

wherein the polymer and wax modified asphalt coating comprises 85-99 wt. % asphalt, 1-13 wt. % polymer additive, and 1-6 wt. % wax based on the total weight of the components of the polymer and wax modified asphalt coating, excluding the filler;
a strip of nail zone reinforcement material on a first portion of the polymer and wax modified asphalt coating, the strip of nail zone reinforcement material having a length and a width, where the width is from about 0.5 inches to about 2.0 inches and the length is greater than the width; and
roofing granules on a second portion of the polymer and wax modified asphalt coating;
wherein a transverse adhesion of the strip of nail zone reinforcing material to the polymer and wax modified asphalt coating is greater than a transverse adhesion of an otherwise identical shingle having the same nail zone reinforcement material and a conventional oxidized asphalt without wax and without polymer additive;
wherein a longitudinal adhesion of the strip of nail zone reinforcing material to the polymer and wax modified asphalt coating is greater than a longitudinal adhesion of the otherwise identical shingle;
wherein a nail pull-through resistance through a test fixture with a 2.0 inch diameter hole of the shingle with the polymer and wax modified asphalt coating is greater than a nail pull-through resistance through a test fixture with a 2.0 inch diameter hole of the otherwise identical shingle; and
wherein a cutting force required to cut the shingle through the nail zone reinforcement is less than a cutting force required to cut through a nail zone reinforcement area of the otherwise identical shingle.

14. The roofing shingle of claim 13 wherein the polymer and wax modified asphalt coating includes the polymer additive in an amount of 2-7 wt. % and the wax in an amount of 1.6-3 wt. % based on the total weight of the components of the polymer and secondary additive modified asphalt coating excluding the filler.

15. A roofing shingle comprising:
a substrate having a first surface and an opposing second surface;
a polymer and wax modified asphalt coating on the first surface of the substrate;
wherein the polymer and wax modified asphalt coating comprises:
40-80 wt. % of a filler based on the total weight of the polymer-modified asphalt composition;
a paving-grade asphalt;
a polymer additive; and
wax;

wherein the polymer and wax modified asphalt

Assignees

• Owens Corning Intellectual Capital Llc
• Owens Coming Intellectual Capital Llc

Inventors

• Latorre Carmen Anthony
• Honsvick Jacob Paul
• Kasprzak Christopher Patrick
• Buckwalter Daniel James
• Harrington Edward R
• Davis Jonathan Ross
• Lewandowski Laurand Henry
• Ploense David Michael
• Smith William Edwin
• Schweiger Scott W

Classifications

• E04D12/002

  Sheets of flexible material, e.g. roofing tile underlay · CPC title

• E04D2001/3467

  through apertures, holes or slots · CPC title

• E04D1/30

  Special roof-covering elements, e.g. ridge tiles, gutter tiles, gable tiles, ventilation tiles (E04D3/40 takes precedence) · CPC title

• E04D1/34 Primary

  Fastenings for attaching roof-covering elements to the supporting elements · CPC title

• E04D7/005 Primary

  characterised by loose or embedded gravel or granules as an outer protection of the roof covering · CPC title