Roofing product including recycled roofing material

Patent metadata

Field	Value
Publication number	US-9259860-B2
Application number	US-93802610-A
Country	US
Kind code	B2
Filing date	Nov 2, 2010
Priority date	Nov 3, 2009
Publication date	Feb 16, 2016
Grant date	Feb 16, 2016

Abstract

A roofing product can include a base material and a first coating including a bituminous material. In one embodiment, the first coating can include recycled roofing material adjacent to the base material. The recycled roofing material has a first recycled roofing content of less than 40 weight %. In another embodiment, the roofing product can include a base material and a first coating including a bituminous material. The first coating is adjacent to the base material. The roofing product can also include particles along a first exposed surface of the roofing product, wherein the particles include recycled roofing material particles. Methods of forming such roofing products are also disclosed.

First claim

What is claimed is:

1. A roofing product comprising:
a base material;
a bituminous material having no greater than 1 weight % of abrasive particles, wherein the base material includes a ceramic base material having an open structure, and the bituminous material substantially fills the open structure;
a first coating adjacent to the base material, the first coating including a recycled roofing material, wherein the recycled roofing material has a first recycled roofing content of at least 5 weight % and less than 30 weight %; and
a second coating disposed between the first coating and the base material, wherein the second coating has a second recycled roofing content at least 5 weight % and different from the first recycled roofing content; and
an adhesive compound adjacent to the base material, the adhesive compound comprising a polyvinylbutyral, a silicone, an acrylate, a styrene-isoprene-styrene rubber, or any combination thereof.

2. The roofing product of claim 1 , further comprising particles along an exposed surface of the roofing product, wherein the particles include recycled roofing particles.

3. The roofing product of claim 1 , further comprising a release sheet, wherein the adhesive compound is disposed between the base material and the release sheet, and the base material is disposed between the first coating and the adhesive compound.

4. The roofing product of claim 1 , wherein before the roofing product is installed on a structure, the first coating has a less oxidized region and a more oxidized region, wherein the less oxidized region is disposed between the more oxidized region and the base material, and the more oxidized region occupies at least approximately 10% of a thickness of the first coating.

5. The roofing product of claim 4 , wherein the more oxidized region occupies at most approximately 80% of a thickness of the first coating.

6. The roofing product of claim 1 , further comprising a parting agent disposed on a principal surface of the base material, wherein the base material is disposed between the first coating and the parting agent.

7. The roofing product of claim 6 , wherein the parting agent includes another recycled roofing material having a second recycled roofing content different from the first recycled roofing content.

8. The roofing product of claim 1 , wherein the roofing product is a membrane-type roofing product.

9. The roofing product of claim 1 , wherein the roofing product is a shingle-type roofing product.

10. The roofing product of claim 1 , wherein the recycled roofing material has a first recycled roofing content of less than 30 weight %.

11. A roofing product comprising:
a first base material;
a bituminous material having no greater than 1 weight % of abrasive particles, wherein the first base material includes a ceramic base material having an open structure, and the bituminous material substantially fills the open structure;
a first coating adjacent to the first base material, the first coating including a recycled roofing material, wherein the recycled roofing material has a first recycled roofing content of at least 5 weight % and less than 30 weight %;
a second base material adjacent to and in direct contact with the first coating;
a second coating adjacent to the second base material, the second coating including a recycled roofing material, wherein the recycled roofing material has a second recycled roofing content of at least 5 weight % and less than 40 weight %; and
an adhesive compound adjacent to the first base material, the adhesive compound comprising a polyvinylbutyral, a silicone, an acrylate, a styrene-isoprene-styrene rubber, or any combination thereof.

12. The roofing product of claim 11 , further comprising a third coating disposed between the second coating and the second base material, wherein the second coating has a second recycled roofing content different from the first recycled roofing content.

13. The roofing product of claim 11 , further comprising particles along an exposed surface of the roofing product, wherein the particles include recycled roofing particles.

14. The roofing product of claim 11 , further comprising a release sheet, wherein the adhesive compound is disposed between the first base material and the release sheet, and the first base material is disposed between the first coating and the adhesive compound.

15. The roofing product of claim 11 , wherein before the roofing product is installed on a structure, the second coating has a less oxidized region and a more oxidized region, wherein the less oxidized region is disposed between the more oxidized region and the second base material, and the more oxidized region occupies at least approximately 10% of a thickness of the second coating.

16. The roofing product of claim 11 , further comprising a parting agent disposed on a principal surface of the first base material, wherein the first base material is disposed between the first coating and the parting agent.

17. The roofing product of claim 16 , wherein the parting agent includes another recycled roofing material having a second recycled roofing content different from the first recycled roofing content.

Assignees

• Kalkanoglu Husnu M
• Jacobs Gregory F
• Benensky Paul A
• Certain Teed Corp

Inventors

• Kalkanoglu Husnu M
• Jacobs Gregory F
• Benensky Paul A

Classifications

• Y02W30/62

  Plastics recycling; Rubber recycling · CPC title

• B32B2309/68

  Vacuum · CPC title

• B32B2315/085

  Glass fiber cloth or fabric · CPC title

• B32B2307/744

  Non-slip, anti-slip · CPC title

• E04D5/10

  by making use of compounded or laminated materials, e.g. metal foils or plastic films coated with bitumen · CPC title