Polymer modified asphalt roofing material

Patent metadata

Field	Value
Publication number	US-12264476-B2
Application number	US-202318504275-A
Country	US
Kind code	B2
Filing date	Nov 8, 2023
Priority date	Dec 15, 2017
Publication date	Apr 1, 2025
Grant date	Apr 1, 2025

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; and
an asphalt coating on the first surface of the substrate, wherein the asphalt coating is formed from an asphalt coating composition comprising:
20 wt. % to 80 wt. % of a filler;
20 wt. % to 50 wt. % of an asphalt base composition;
0.5 wt. % to 20 wt. % of at least one polymer additive, the at least one polymer additive comprising reclaimed rubber, based on the total weight of a non-filler portion of the asphalt coating composition; and
0.5 wt. % to 7 wt. % of a secondary additive comprising one or more of a wax, a salt of a fatty acid ester, or an amide of a fatty acid, based on the total weight of a non-filler portion of the asphalt coating composition, and;

wherein:
the non-filler portion of the asphalt coating composition has a softening point in the range of 190° F. to 240° F. and a penetration at 77° F. in the range of 15 dmm to 40 dmm;
the roofing shingle meets or surpasses the UL2218 Class 3 impact resistance standard; and
the roofing shingle is free from an integrated polymeric backing that imparts impact resistance to the roofing shingle.

2. The roofing shingle of claim 1 , wherein the asphalt base composition comprises paving-grade asphalt.

3. The roofing shingle of claim 1 , wherein the asphalt base composition has a softening point in the range of 60° F. to 130° F. and a penetration at 77° F. of at least 25 dmm.

4. The roofing shingle of claim 1 , wherein the secondary additive comprises a wax having a melting point of at least 100° C.

5. The roofing shingle of claim 1 , wherein the secondary additive comprises a Fischer-Tropsch wax.

6. The roofing shingle of claim 1 , wherein the asphalt coating composition further comprises at least one elastomeric radial or linear copolymer.

7. The roofing shingle of claim 6 , wherein the at least one elastomeric radial or linear copolymer comprises a styrene-butadiene block copolymer (SBS).

8. The roofing shingle of claim 6 , wherein the at least one elastomeric radial or linear copolymer is included in the asphalt coating composition in an amount of from about 2.0 wt. % to about 7.0 wt. %, based on the total weight of a non-filler portion of the asphalt coating composition.

9. The roofing shingle of claim 1 , wherein the filler is selected from the group consisting of ground limestone, dolomite, silica, talc, sand, cellulosic material, fiberglass, calcium carbonate, and combinations thereof.

10. The roofing shingle of claim 1 , further comprising a plurality of granules deposited onto the asphalt coating.

11. The roofing shingle of claim 1 , wherein the asphalt coating composition has a stain index of zero when measured according to ASTM D2746-07.

12. The roofing shingle of claim 1 , wherein the polymer additive is present in the asphalt coating composition in an amount of 1 wt. % to 15 wt. %.

13. A roofing shingle comprising:
a substrate having a first surface and an opposing second surface; and
an asphalt coating on the first surface of the substrate, wherein the asphalt coating is formed from an asphalt coating composition comprising:
20 wt. % to 80 wt. % of a filler;
20 wt. % to 50 wt. % of an asphalt base composition;
1 wt. % to 15 wt. % of at least one polymer additive, the at least one polymer additive comprising reclaimed rubber, based on the total weight of a non-filler portion of the asphalt coating composition; and
0.5 wt. % to 7 wt. % of a secondary additive comprising one or more of a wax, a salt of a fatty acid ester, or an amide of a fatty acid, based on the total weight of a non-filler portion of the asphalt coating composition, and;

wherein:
the non-filler portion of the asphalt coating composition has a softening point in the range of 190° F. to 320° F. and a penetration at 77° F. in the range of 15 dmm to 40 dmm;
the roofing shingle meets or surpasses the UL2218 Class 3 impact resistance standard; and
the roofing shingle is free from an integrated polymeric backing that imparts impact resistance to the roofing shingle.

14. The roofing shingle of claim 13 , wherein the asphalt base composition comprises paving-grade asphalt.

15. The roofing shingle of claim 13 , wherein the asphalt base composition has a softening point in the range of 60° F. to 130° F. and a penetration at 77° F. of at least 25 dmm.

16. The roofing shingle of claim 13 , wherein the secondary additive comprises a mixture of different waxes, and wherein the waxes comprise polypropylene wax.

17. The roofing shingle of claim 13 , wherein the filler is selected from the group consisting of ground limestone, dolomite, silica, talc, sand, cellulosic material, fiberglass, calcium carbonate, and combinations thereof.

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
• Latta Ganesh

Classifications

• C08K3/013

  Fillers, pigments or reinforcing additives · CPC title

• E04D2001/3482

  the fastening means taking hold directly on elements of succeeding rows and fastening them simultaneously to the structure · CPC title

• E04D2001/3491

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

• E04D2001/347

  characterised by the fastening pattern · CPC title

• E04D1/34 Primary

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