Roofing materials with increased wind uplift resistance and methods of making thereof

Patent metadata

Field	Value
Publication number	US-11788290-B2
Application number	US-202016799023-A
Country	US
Kind code	B2
Filing date	Feb 24, 2020
Priority date	Feb 24, 2020
Publication date	Oct 17, 2023
Grant date	Oct 17, 2023

Abstract

This invention, in embodiments, relates to a roofing material having (a) a front surface, (b) a back surface, and (c) a sealant attachment zone disposed on at least the front surface of the roofing material, the sealant attachment zone including surfacing media that comprise at least one of mineral particles, polymeric particles, and combinations thereof. The sealant attachment zone has an average surface coverage of the surfacing media of 30% to 70%. The roofing material exhibits an increased wind uplift resistance, as measured according to ASTM D6381, as compared to a roofing material without a sealant attachment zone having an average surface coverage of surfacing media of 30% to 70%.

First claim

We claim:

1. A roofing material comprising:
a front surface;
a back surface;
a sealant attachment zone disposed on at least the front surface of the roofing material,
wherein the sealant attachment zone is visually defined by a first line and a second line,
wherein the sealant attachment zone comprises surfacing media disposed between the first line and the second line,
wherein the surfacing media comprise mineral particles, polymeric particles, or any combination thereof,
wherein the surfacing media are disposed on at least the front surface of the roofing material,
wherein the sealant attachment zone has an average surface coverage of the surfacing media of 40% to 60%, and
wherein the surfacing media are exposed on the front surface of the roofing material.

2. The roofing material according to claim 1 , wherein the sealant attachment zone has an average surface coverage of the surfacing media of 40% to 55%.

3. The roofing material according to claim 1 , wherein the sealant attachment zone has an average surface coverage of the surfacing media of 45% to 60%.

4. The roofing material according to claim 1 , wherein the surfacing media comprise mineral particles that include at least one of slag fines, granule fines, sands, limestone fines, calcium carbonate, slate fines, and combinations thereof.

5. The roofing material according to claim 1 , wherein the surfacing media comprise polymeric particles that include at least one of rubber particles, linear low-density polyethylene (LLDPE) particles, styrene-butadiene-styrene (SBS) powders, and combinations thereof.

6. The roofing material according to claim 1 , wherein the surfacing media have a particle size distribution of 16 to 270 US mesh.

7. The roofing material according to claim 6 , wherein the surfacing media have a particle size distribution of 16 to 100 US mesh.

8. The roofing material according to claim 1 , wherein the surfacing media have a mean particle size of 100 to 250 microns.

9. The roofing material according to claim 1 , wherein the sealant attachment zone comprises (i) a first region having a percentage of surface coverage of the surfacing media that is less than the average surface coverage, and (ii) a second region having a percentage of surface coverage of the surfacing media that is greater than the average surface coverage.

10. The roofing material according to claim 1 , wherein the polymeric particles comprise particles having a polar functional group that is selected from the group consisting of an alcohol, a carboxyl, a phenolic, an amine, a thiol, and combinations thereof.

11. The roofing material according to claim 1 , wherein the surfacing media further comprise a tackifier, an encapsulated adhesion promoter, magnetic powder, and combinations thereof.

12. The roofing material according to claim 1 , wherein the surfacing media further comprise ferrous metal powder.

13. The roofing material according to claim 1 , wherein the roofing material is a roofing shingle.

14. The roofing material according to claim 1 , wherein the surfacing media directly contact a sealant of an overlying roofing material when the roofing material is installed on a surface.

15. A method of preparing a roofing material, the method comprising:
obtaining a substrate;
obtaining surfacing media that comprise mineral particles, polymeric particles, or any combination thereof; and
applying the surfacing media to a surface of the substrate to form a roofing material having a sealant attachment zone with an average surface coverage of the surfacing media of 40% to 60%,
wherein the sealant attachment zone is visually defined by a first line and a second line,
wherein the surfacing media are disposed on the roofing material in the sealant attachment zone between the first line and the second line,
and

wherein the surfacing media are exposed on the surface of the roofing material.

16. The method according to claim 15 , wherein the sealant attachment zone has an average surface coverage of the surfacing media of 40% to 55%.

17. The method according to claim 15 , wherein the sealant attachment zone has an average surface coverage of the surfacing media of 45% to 60%.

18. The method according to claim 15 , further comprising heating the surfacing media prior to applying the surfacing media to the surface of the substrate.

19. The method according to claim 15 , wherein the applying the surfacing media to the surface of the substrate is conducted by controlling an amount of the surfacing media applied to the surface of the substrate.

20. The method according to claim 19 , wherein the controlling the amount of the surfacing media applied to the surface of the substrate is conducted by forming (i) a first region of the sealant attachment zone that has a percentage of surface coverage of the surfacing media that is less than the average surface coverage, and (ii) a second region of the sealant attachment zone that has a percentage of surface coverage of the surfacing media that is greater than the average surface coverage.

21. The method according to claim 15 , wherein the surfacing media comprise mineral particles that include at least one of slag fines, granule fines, sands, limestone fines, calcium carbonate, slate fines, and combinations thereof.

22. The method according to claim 15 , wherein the surfacing media comprise polymeric particles that include at least one of rubber particles, linear low-density polyethylene (LLDPE) particles, styrene-butadiene-styrene (SBS) powders, and combinations thereof.

23. The method according to claim 15 , wherein the surfacing media have a particle size distribution of 16 to 270 US mesh.

24. The method according to claim 23 , wherein the surfacing media have a particle size distribution of 16 to 100 US mesh.

25. The method according to claim 15 , wherein the surfacing media have a mean particle size of 100 to 250 microns.

26. The method according to claim 15 , wherein the polymeric particles comprise particles having a polar functional group that is selected from the group consisting of an alcohol, a carboxyl, a phenolic, an amine, a thiol, and combinations thereof.

27. The method according to claim 15 , wherein the surfacing media further comprise a tackifier, an encapsulated adhesion promoter, magnetic powder, ferrous metal powder, and combinations thereof.

28. A roofing material comprising:
a front surface;
a back surface; and
a sealant attachment zone disposed on at least the front surface of the roofing material,
wherein the sealant attachment zone is visually defined by a first line and a second line,
wherein the sealant attachment zone comprises surfacing media disposed between the first line and the second line,
wherein the surfacing media comprise mineral particles,
wherein the surfacing media having a particle size distribution of 16 to 270 US mesh,

wherein the sealant attachment zone has an average surface coverage of the surfacing media of 40% to 60%, and

wherein the surfacing media are exposed on the front surface of the roofing material.

Assignees

• Bmic Llc

Inventors

• Shiao Ming-Liang
• Ferraro Joey
• Duque Luis
• Lee Brian
• Lock Tim
• Boss Daniel E

Classifications

• E04D1/26 Primary

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

• E04D2001/005

  the roofing elements having a granulated surface · CPC title

• E04D1/20

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

• Y02W30/91

  Use of waste materials as fillers for mortars or concrete · CPC title