Polymer modified asphalt roofing material

Patent metadata

Field	Value
Publication number	US-10934715-B2
Application number	US-201816222234-A
Country	US
Kind code	B2
Filing date	Dec 17, 2018
Priority date	Dec 15, 2017
Publication date	Mar 2, 2021
Grant date	Mar 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 wt. % to 80 wt. % of a filler based on the total weight of the polymer and wax modified asphalt coating;
asphalt;
2.0 to 7.0 wt. % of a polymer additive based on the total weight of the non-filler portion of the polymer and wax modified asphalt coating;
1.6 to 3.0 wt. % of a wax based on the total weight of the non-filler portion of the polymer and wax modified asphalt coating;

a strip of nail zone reinforcement material comprising a woven or nonwoven fabric on the polymer and wax modified asphalt coating, where the polymer and wax modified asphalt coating bleeds into the woven or nonwoven fabric, 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 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 an 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 cutting force required to cut the shingle through the nail zone reinforcement is reduced by at least 5% when compared to the otherwise identical shingle.

3. The roofing shingle of claim 1 wherein the cutting force required to cut the shingle through the nail zone reinforcement when the shingle is at a temperature of 73 degrees F. is reduced by at least 5 Newtons when compared to the otherwise identical shingle at a temperature of 73 degrees F.

4. The roofing shingle of claim 1 wherein the cutting force required to cut the shingle through the nail zone reinforcement when the shingle is at a temperature of 70 degrees C. is reduced by at least 5 Newtons when compared to the otherwise identical shingle at a temperature of 70 degrees C.

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

6. The roofing shingle of claim 1 wherein the polymer and wax modified asphalt coating further comprises a filler and wherein the polymer and wax modified asphalt coating comprises 89-99 wt. % asphalt, prior to addition of the filler.

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

8. The roofing shingle of claim 6 wherein the polymer additive is styrene-butadiene rubber.

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

10. The roofing shingle of claim 6 wherein the wax is a Fischer-Tropsch wax.

11. The roofing shingle of claim 6 wherein the cutting force required to cut the shingle through the nail zone reinforcement is reduced by at least 5% when compared to an otherwise identical shingle having the same nail zone reinforcement material and a conventional oxidized asphalt without wax and without polymer additive.

12. 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 wt. % to 80 wt. % of a filler based on the total weight of the polymer and wax modified asphalt coating;
asphalt;
2.0 to 7.0 wt. % of a polymer additive based on the total weight of the non-filler portion of the polymer and wax modified asphalt coating;
1.6 to 3.0 wt. % of a wax based on the total weight of the non-filler portion of the polymer and wax modified asphalt coating;

a strip of nail zone reinforcement material comprising a woven or nonwoven fabric on the polymer and wax modified asphalt coating, where the polymer and wax modified asphalt coating bleeds into the woven or nonwoven fabric, 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 cutting force required to cut the shingle at a temperature of 70 degrees C. through the nail zone reinforcement is less than 65 Newtons.

13. The roofing shingle of claim 12 wherein the strip of nail zone reinforcement material is a woven polyester fabric.

14. The roofing shingle of claim 12 wherein the polymer and wax modified asphalt coating further comprises a filler and wherein the polymer and wax modified asphalt coating comprises 89-99 wt. % asphalt prior to addition of the filler.

15. The roofing shingle of claim 12 wherein the polymer additive is styrene-butadiene rubber.

16. The roofing shingle of claim 14 wherein the polymer additive is styrene-butadiene rubber.

17. The roofing shingle of claim 12 wherein the wax is a Fischer-Tropsch wax.

18. The roofing shingle of claim 14 wherein the wax is a Fischer-Tropsch wax.

19. 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 wt. % to 80 wt. % of a filler based on the total weight of the polymer and wax modified asphalt coating;
asphalt;
2.0 to 7.0 wt. % of a polymer additive based on the total weight of the non-filler portion of the polymer and wax modified asphalt coating;
1.6 to 3.0 wt. % of a wax based on the total weight of the non-filler portion of the polymer and wax modified asphalt coating;

a strip of nail zone reinforcement material comprising a woven or nonwoven fabric on the polymer and wax modified asphalt coating, where the polymer and wax modified asphalt coating bleeds into the woven or nonwoven fabric, 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 cutting force required to cut the shingle at a temperature of 73 degrees F. through the nail zone reinforcement is less than 70 Newtons.

20. The roofing shingle of claim 19 wherein the strip of nail zone reinforcement material is a woven polyester fabric.

21. The roofing shingle of claim 19 wherein the polymer and wax modified asphalt coating further comprises a filler and wherein the polymer and wax modified asphalt coating comprises 89-99 wt. % asphalt, prior to addition of the filler.

22. The roofing shingle of claim 21 wherein the polymer additive is styrene-butadiene rubber.

23. The roofing shingle of claim 19 wherein the polymer additive is styrene-butadiene rubber.

24. The roofing shingle of claim 21 wherein the wax is a Fischer-Tropsch wax.

25. The roofing shingle of claim 19 wherein the wax is a Fischer-Tropsch wax.

Assignees

• Owens Corning 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

• E04D1/20

  of plastics; {of asphalt;} of fibrous materials · CPC title

• E04D2001/347

  characterised by the fastening pattern · CPC title