Self-healing impact resistant roofing materials and methods of making thereof

Patent metadata

Field	Value
Publication number	US-12305401-B2
Application number	US-202318371644-A
Country	US
Kind code	B2
Filing date	Sep 22, 2023
Priority date	Sep 26, 2022
Publication date	May 20, 2025
Grant date	May 20, 2025

Abstract

This invention, in embodiments, relates to a roofing material comprising (a) a substrate having a top surface and a back surface, (b) a plurality of self-healing particles embedded into the substrate, and (c) a coating applied onto the substrate having the plurality of self-healing particles embedded therein, to provide a coated substrate. The plurality of self-healing particles can be embedded into the top surface and/or the back surface of the substrate. The roofing material can further include a plurality of roofing granules applied to a top surface of the coating of the coated substrate. This invention, in embodiments, further relates to a method of preparing such a roofing material.

First claim

I claim:

1. A roofing material comprising:
(a) a substrate having a top surface and a back surface, the substrate being uncoated and comprising one of a fiberglass mat, a polyester mat, a scrim, or a combination thereof;
(b) a plurality of self-healing particles embedded into the top surface of the uncoated substrate, such that the plurality of self-healing particles directly contact the top surface of the uncoated substrate, wherein each self-healing particle of the plurality of self-healing particles comprises an external shell and a film-forming material within the external shell, such that one or more self-healing particles of the plurality of self-healing particles is configured to rupture upon impact to the substrate, to thereby dispense the film-forming material to help repair any damage to the roofing material; and
(c) a single coating applied onto the top surface of the substrate having the plurality of self-healing particles embedded therein, to provide a coated substrate, wherein the coating comprises one of an asphaltic coating, a non-asphaltic coating, a polymer-modified asphaltic coating, or a combination thereof,
wherein the top surface of the substrate has an average surface coverage amount of the plurality of self-healing particles of between 70% and 100%.

2. The roofing material according to claim 1 , wherein the roofing material further includes a plurality of roofing granules applied to a top surface of the coating of the coated substrate.

3. The roofing material according to claim 1 , wherein the self-healing particles further comprise one or more additives.

4. The roofing material according to claim 1 , wherein the roofing material having the plurality of self-healing particles achieves one of a Class 3 rating or a Class 4 rating for impact resistance, according to UL 2218.

5. The roofing material according to claim 1 , wherein the roofing material is one of a roofing shingle, a roofing membrane, and a roofing tile.

6. The roofing material according to claim 1 , wherein the roofing material is one of (i) an asphaltic shingle, (ii) a non-asphaltic shingle, and (ii) a polymer-modified asphalt shingle.

7. The roofing material according to claim 1 , wherein the roofing material exhibits an improved impact resistance as compared to a roofing material prepared without self-healing particles.

8. The roofing material according to claim 1 , wherein the top surface of the substrate has an average surface coverage amount of the plurality of self-healing particles of greater than 75%.

Assignees

• Bmic Llc

Inventors

• Michael Matthew

Classifications

• D06N3/0002

  characterised by the substrate · CPC title

• D06N2201/02

  Synthetic macromolecular fibres · CPC title

• D06N2201/082

  Glass fibres · CPC title

• E04D2001/005

  the roofing elements having a granulated surface · CPC title

• D06N2205/10

  Particulate form, e.g. powder, granule · CPC title