Polymer modified asphalt roofing material

Patent metadata

Field	Value
Publication number	US-11035123-B2
Application number	US-201816222262-A
Country	US
Kind code	B2
Filing date	Dec 17, 2018
Priority date	Dec 15, 2017
Publication date	Jun 15, 2021
Grant date	Jun 15, 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;
a polymer and secondary additive modified asphalt coating on the substrate;
wherein the polymer and secondary additive modified asphalt coating comprises:
62 wt. % to 80 wt. % of a filler based on the total weight of the polymer and secondary additive modified asphalt coating;
an asphalt having a softening point of 60° F. to 130° F.;
2.0 to 7.0 wt. % of a polymer additive based on the total weight of the non-filler portion of the polymer-modified asphalt coating;
1.6 to 3.0 wt. % of a secondary additive based on the total weight of the non-filler portion of the polymer-modified asphalt coating;
wherein the polymer and secondary additive modified asphalt coating has a softening point in the range of 200° F. to 230° F.; and a penetration at 77° F. in the range of 17 dmm to 40 dmm;

a strip of nail zone reinforcement material adhered to the polymer and secondary additive modified asphalt coating; and
roofing granules on the polymer and secondary additive 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 secondary additive and without polymer additive.

2. The roofing shingle of claim 1 wherein the secondary additive comprises one or more of a wax, a salt of a fatty acid ester, and an amide of a fatty acid.

3. The roofing shingle of claim 1 wherein the secondary additive is an asphalt viscosity reducing agent.

4. 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.

5. 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.

6. 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.

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

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

9. The roofing shingle of claim 1 wherein the secondary additive includes a Fischer-Tropsch wax.

10. The roofing shingle of claim 8 wherein the secondary additive includes a Fischer-Tropsch wax.

11. The roofing shingle of claim 8 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 secondary additive and without polymer additive.

12. The roofing shingle of claim 1 wherein the polymer additive includes a radial styrene-butadiene block copolymer.

13. The roofing shingle of claim 1 wherein the secondary additive includes an ethylene bis-stearamide wax.

14. A roofing shingle comprising:
a substrate;
a polymer and secondary additive modified asphalt coating on the substrate;
wherein the polymer and secondary additive modified asphalt coating comprises:
62 wt. % to 80 wt. % of a filler based on the total weight of the polymer-modified asphalt coating;
an asphalt having a softening point of 60° F. to 130° F.;
2.0 to 7.0 wt. % of a polymer additive based on the total weight of the non-filler portion of the polymer-modified asphalt coating;
1.6 to 3.0 wt. % of a secondary additive based on the total weight of the non-filler portion of the polymer-modified asphalt coating;
wherein the polymer and secondary additive modified asphalt coating has a softening point in the range of 200° F. to 230° F.; and a penetration at 77° F. in the range of 17 dmm to 40 dmm;

a strip of nail zone reinforcement material adhered to the polymer and secondary additive modified asphalt coating; and
roofing granules on the polymer and secondary additive 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.

15. The roofing shingle of claim 14 wherein the secondary additive comprises one or more of a wax, a salt of a fatty acid ester, and an amide of a fatty acid.

16. The roofing shingle of claim 14 wherein the secondary additive is an asphalt viscosity reducing agent.

17. The roofing shingle of claim 14 wherein the strip of nail zone reinforcement material is a woven polyester fabric.

18. The roofing shingle of claim 14 wherein the polymer additive includes styrene-butadiene rubber.

19. The roofing shingle of claim 14 wherein the secondary additive includes a Fischer-Tropsch wax.

20. The roofing shingle of claim 14 wherein the polymer additive includes a radial styrene-butadiene block copolymer.

21. The roofing shingle of claim 14 wherein the secondary additive includes an ethylene bis-stearamide wax.

22. A roofing shingle comprising:
a substrate;
a polymer and secondary additive modified asphalt coating on the substrate;
wherein the polymer and secondary additive modified asphalt coating comprises:
62 wt. % to 80 wt. % of a filler based on the total weight of the polymer-modified asphalt coating;
an asphalt having a softening point of 60° F. to 130° F.;
2.0 to 7.0 wt. % of a polymer additive based on the total weight of the non-filler portion of the polymer-modified asphalt coating;
1.6 to 3.0 wt. % of a secondary additive based on the total weight of the non-filler portion of the polymer-modified asphalt coating;
wherein the polymer and secondary additive modified asphalt coating has a softening point in the range of 200° F. to 230° F.; and a penetration at 77° F. in the range of 17 dmm to 40 dmm;

a strip of nail zone reinforcement material adhered to the polymer and secondary additive modified asphalt coating; and
roofing granules on the polymer and secondary additive 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.

23. The roofing shingle of claim 22 wherein the secondary additive comprises one or more of a wax, a salt of a fatty acid ester, and an amide of a fatty acid.

24. The roofing shingle of claim 22 wherein the secondary additive is an asphalt viscosity reducing agent.

25. The roofing shingle of claim 22 wherein the strip of nail zone reinforcement material is a woven polyester fabric.

26. The roofing shingle of claim 22 wherein the polymer additive includes styrene-butadiene rubber.

27. The roofing shingle of claim 22 wherein the polymer additive includes a radial styrene-butadiene block copolymer.

28. The roofing shingle of claim 22 wherein the secondary additive includes an ethylene bis-stearamide 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

• E04D2001/005

  the roofing elements having a granulated surface · CPC title

• C09D195/00

  Coating compositions based on bituminous materials, e.g. asphalt, tar, pitch · CPC title

• B32B2262/10

  Inorganic fibres · CPC title

• E04D2001/3491

  made of flexible material, e.g. shingles · CPC title