U.S. patent application number 10/883050 was filed with the patent office on 2006-01-05 for coating for granulated products to improve granule adhesion, staining, and tracking.
This patent application is currently assigned to BUILDING MATERIALS INVESTMENT CORPORATION. Invention is credited to Michael D. De Souto, Louis L. Grube, Anthony Ruffine.
Application Number | 20060003651 10/883050 |
Document ID | / |
Family ID | 35514609 |
Filed Date | 2006-01-05 |
United States Patent
Application |
20060003651 |
Kind Code |
A1 |
Grube; Louis L. ; et
al. |
January 5, 2006 |
Coating for granulated products to improve granule adhesion,
staining, and tracking
Abstract
A building material product and a method of making building
material products, having increased resistance to granule rub off
and staining. The building material product comprises a substrate
having embedded granules and an acrylic latex coating positioned on
the granules, where the polymer of the acrylic latex coating has
the repeating structural unit [CH.sub.2--C(R.sup.1)(R.sup.2)],
where R.sup.1 is hydrogen or C.sub.1-C.sub.8 alkyl; R.sup.2 is
hydrogen, cyano or --COOR; and R is a linear or branched
hydrocarbon containing 1-22 carbon atoms, with the proviso that
R.sup.1 and R.sup.2 are both not hydrogen. The method includes
applying this acrylic latex water based composition to a granule
embedded substrate.
Inventors: |
Grube; Louis L.; (Bound
Brook, NJ) ; De Souto; Michael D.; (Somerset, MA)
; Ruffine; Anthony; (Morristown, NJ) |
Correspondence
Address: |
Attn: William J. Davis, Esq.;GAF MATERIALS CORPORATION
Legal Department, Building No. 8
1361 Alps Road
Wayne
NJ
07470
US
|
Assignee: |
BUILDING MATERIALS INVESTMENT
CORPORATION
|
Family ID: |
35514609 |
Appl. No.: |
10/883050 |
Filed: |
July 1, 2004 |
Current U.S.
Class: |
442/74 ; 442/164;
442/180 |
Current CPC
Class: |
C08L 95/00 20130101;
Y10T 442/2992 20150401; Y10T 442/2131 20150401; D06N 2203/04
20130101; D06N 2203/041 20130101; B05D 7/04 20130101; B32B 11/02
20130101; C08K 9/02 20130101; C09D 133/14 20130101; Y10T 428/24372
20150115; D06N 2211/066 20130101; Y10T 442/2861 20150401; D06N
2211/063 20130101; B05D 1/28 20130101; C08K 9/10 20130101; D06N
5/003 20130101; Y10T 442/2115 20150401; B05D 1/38 20130101; B05D
2520/05 20130101; D06N 5/00 20130101; B05D 1/18 20130101; B32B 5/02
20130101; B05D 1/36 20130101; B05D 2502/00 20130101; B05D 2520/00
20130101; E04D 5/12 20130101; B05D 7/02 20130101; D06N 2211/06
20130101; B05D 2502/005 20130101; Y10T 442/2123 20150401; B05D 1/02
20130101; B05D 2252/02 20130101; B05D 7/52 20130101; Y10T 442/2107
20150401; B32B 17/04 20130101; B05D 7/00 20130101; Y10T 442/2041
20150401; B05D 2201/02 20130101; Y10T 442/2098 20150401; D06N
2203/08 20130101; C08L 95/00 20130101; C08L 2666/72 20130101; C08L
95/00 20130101; C08L 2666/04 20130101 |
Class at
Publication: |
442/074 ;
442/180; 442/164 |
International
Class: |
B32B 27/20 20060101
B32B027/20; B32B 5/24 20060101 B32B005/24; B32B 5/18 20060101
B32B005/18; B32B 27/02 20060101 B32B027/02; B32B 5/16 20060101
B32B005/16; B32B 17/04 20060101 B32B017/04; B32B 17/02 20060101
B32B017/02 |
Claims
1. A building product comprising: a substrate; granules embedded in
said substrate; and an acrylic latex coating said granules, a
polymer of said acrylic latex coating includes the repeating
structural unit [CH.sub.2--C(R.sup.1)(R.sup.2)], where R.sup.1 is
hydrogen or C.sub.1-C.sub.8 alkyl; R.sup.2 is hydrogen, cyano or
--COOR, where R is a linear branched hydrocarbon containing 1-22
carbon atoms, with the proviso that R.sup.1 and R.sup.2 are not
both hydrogen.
2. The building product of claim 1 wherein said acrylic latex
coating comprises a homopolymer or copolymer of methacrylic acid, a
methacrylate ester, an acrylate ester or acrylonitrile.
3. The building product of claim 1 wherein said acrylic latex
coating is applied such that its concentration is in the range of
between about 0.5 grams/square foot and about 20 grams/square
foot.
4. The building product of claim 3 wherein said acrylic latex
coating concentration is in the range of between about 1
grams/square foot and about 10 grams per square foot.
5. The building product of claim 1 wherein said granules are
greenstone, nephelene syeniate, common gravel, slate, ganister,
quartz, sand, quartzite, greystone, argillite, coal slag, copper
slag, or nickel slag.
6. The building product of claim 5 wherein said granules are coated
with a ceramic coating comprising a reaction product of an alkali
metal silicate and an aluminosilicate.
7. The building product of claim 5 wherein said granules are
encapsulated in a coating comprising said polymer.
8. The building product of claim 1 wherein said substrate is coated
with an asphalt coating.
9. The building product of claim 8 wherein said building product is
rolled roofing and said asphalt coating is a modified bitumen
having a polymer additive.
10. The building product of claim 8 wherein said building material
product is a shingle and said asphalt coating is a non-modified
bitumen.
11. The building product of claim 1 wherein said substrate
comprises a glass fiber web or polymeric web bound by a resin
binder.
12. The building product of claim 11 wherein said resin binder
comprises a urea-formaldehyde resin, a phenol-formaldehyde resin, a
phenolic resin, polyvinyl alcohol, polyvinyl acetate, an acrylic
resin, polyvinyl acetate, or bone glue.
13. The building product of claim 1 wherein said substrate
comprises a plastic material.
14. The building product of claim 13 wherein said plastic material
comprises polyolefin, polycarbonate, polyvinyl chloride, polyvinyl
flouride, acrylic resins, acrylonitrile, butadiene, styrene,
copolymers of acrylonitrile, butadiene or styrene.
15. The building of product of claim 14 wherein said substrate
further comprises a filler.
16. The building product of claim 15 wherein said filler comprises
calcium carbonate, talc, asbestos, silicates, or wood flour.
17. The building product of claim 1 wherein said substrate
comprises glass fibers, polyester fibers, cellulosic fibers,
asbestos, steel fibers, alumina fibers, ceramic fibers, nylon
fibers, graphite fibers, wool fibers, boron fibers, carbon fibers,
jute fibers, polyolefin fibers, polystyrene fibers, acrylic fibers,
phenolformaldehyde resin fibers, aromatic polyamide fibers,
aliphatic polyamide fibers, polyacrylamide fibers, polyacrylimide
fibers or mixtures thereof.
18. The building product of claim 1 wherein said building product
is flexible flooring, floor tiles, siding, roofing panels, rolled
roofing, or roofing shingles.
19. A method for coating a building product comprising applying an
acrylic latex water based composition, a polymer of said acrylic
latex coating including the repeating structural unit
[CH.sub.2--C(R.sup.1)(R.sup.2)], where R.sup.1 is hydrogen or R is
a linear or branched hydrocarbon containing 1-22 carbon atoms, with
the proviso that R.sup.1 and R.sup.2 are both not hydrogen, to a
substrate on which granules are embedded.
20. The method of claim 19 wherein said acrylic latex water based
composition comprises between about 10% and about 90% polymer and
about 90% to about 10% water, said percentages being by weight
based on the total weight of the composition.
21. The method of claim 19 wherein said polymer comprises a
homopolymer or a copolymer of methacrylic acid, a methacrylate
ester, an acrylate ester or acrylonitrile.
22. The method of claim 19 wherein said acrylic latex water based
composition comprises less than 200 ppm styrene and 200 ppm butyl
acrylate.
23. The method of claim 19 wherein said acrylic latex water based
composition is applied by dipping, roller application brushing, or
spraying.
24. The method of claim 19 wherein said acrylic latex water based
composition is applied such that said polymer is present on said
substrate in an amount ranging from about 0.5 g/ft.sup.2 to about
20 g/ft.sup.2.
25. The method of claim 19 wherein said polymer is present in an
amount ranging from about 1 g/ft.sup.2 to about 10 g/ft.sup.2.
26. The method of claim 19 wherein said substrate further comprises
asphalt.
27. The method of claim 26 wherein said asphalt comprises modified
bitumen having a polymer additive.
28. The method of claim 26 wherein said asphalt comprises a
non-modified asphalt.
29. The method of claim 19 wherein said substrate comprises
polyolefin, polycarbonate, polyvinyl chloride, polyvinyl flouride,
acrylic resins, acrylonitrile, butadiene, styrene, copolymers of
acrylonitrile, butadiene or styrene.
30. The method of claim 29 wherein said substrate further comprises
a filler.
31. The method of claim 30 wherein said filler comprises calcium
carbonate, talc, asbestos, silicates, or wood flour.
32. The method of claim 19 wherein said substrate comprises glass
fibers, polyester fibers, cellulosic fibers, asbestos, steel
fibers, alumina fibers, ceramic fibers, nylon fibers, graphite
fibers, wool fibers, boron fibers, carbon fibers, jute fibers,
polyolefin fibers, polystyrene fibers, acrylic fibers,
phenolformaldehyde resin fibers, aromatic and aliphatic polyamide
fibers, polyacrylamide fibers, polyacrylimide fibers or mixtures
thereof.
33. The method of claim 19 wherein said granules comprise
greenstone, nephelene syeniate, common gravel, slate, ganister,
quartz, sand, quartzite, greystone, argillite, coal slag, copper
slag, or nickel slag.
34. The method of claim 33 wherein said granules are coated with
said polymer prior to being embedded into said substrate.
Description
FIELD OF INVENTION
[0001] This invention relates to granule surface building products,
and more particularly, to granule surface building material
products having exceptional granule rub loss qualities, improved
staining and improved tracking at high temperatures.
BACKGROUND OF INVENTION
[0002] Building products have utilized granule coated or embedded
surfaces in a variety of anti-slip, weather-resistant,
fire-resistant, and decorative surface applications. These building
products include asphalt and non-asphaltic materials.
[0003] Asphalt building products may comprise felt or fabric stock
impregnated with asphalt and covered with weather resistant mineral
granules. Some examples of asphalt building products include
asphalt shingles, asphalt siding, and rolled roofing. Typically,
rolled roofing comprises modified bitumen asphalt including a
polymer filling and asphalt roofing shingles comprise non-modified
bitumen asphalt, which may include limestone as an additive.
Alternatively, rolled roofing may comprise non-modified bitumen
asphalt. Modified bitumen asphalt shingles have also been
contemplated. Typical asphalt products have a glass or polyester
substrate and a multitude of granules placed thereon and have
served as relatively inexpensive alternatives to tile, slate and
wood building products.
[0004] The granules serve to protect and provide coloring to the
asphalt building product. For instance, granules serve to provide
coloring to shingles and rolled roofing products and thus to the
roof. Additionally, the granular material generally protects the
underlying asphalt coating from damage due to exposure to light, in
particular ultraviolet (UV) light. That is, the granules reflect
light and protect the asphalt from deterioration by
photo-degradation. In addition, such granular material improves
fire resistance and weathering characteristics. In general,
granules are embedded in the coating asphalt by the application of
pressure and are retained therein by adherence to the asphalt.
[0005] Non-asphaltic building materials, such as plastic siding
panels for surfacing walls and roofs of buildings, may comprise
extruded or pressed thermo-plastic materials such as
polyvinylchloride (PVC). Plastic flooring is another example of
non-asphaltic building materials. Similar to asphalt building
products, non-asphaltic building products comprising coated or
embedded granules can have improved fire resistance, weathering
characteristics and aesthetic appearance.
[0006] Good adherence of the granules to the building product is
beneficial. In the case of some asphaltic roofing products, loss of
granules reduces the life of the roof, since it is associated with
acceleration of photo-degradation of the asphalt. In addition, the
aesthetics of the roofing system may be compromised if granules are
lost.
[0007] Granule loss can occur due to physical abrasion of the
granular surface. This may occur during installation of the
building material product; during maintenance; or may result from
environmental conditions. Buiding products are especially
susceptible to granule rub loss and tracking at elevated
temperatures, in which granule loss and tracking may occur when an
individual walks on the roof, leaving footprints or skuffs
permanently imprinted into the roofing or walk on the building
product while it is stored or shipped.
[0008] In asphalt building products, as granules are secured to the
asphalt surface, there is a tendency for oils in the asphalt
surface to creep onto or be adsorbed on the granules' surfaces.
This creeping or adsorption of the asphalt oils on the granules'
surface causes discoloration or staining of the granules and hence
reduces the building material products aesthetic effect.
[0009] It is an object of the present invention to provide granular
surface building products, and a method of producing same, having
increased protection against granule rub off, improved resistance
to tracking, and improved resistance to discoloration than
previously known in granular surface building materials.
SUMMARY OF THE INVENTION
[0010] The present disclosure relates to granular surface building
products for roofs, sidewalls and other surfaces such as, but not
limited to, asphaltic and non-asphaltic roofing materials, wherein
the granular surface building materials have increased resistance
to granule rub off, increased resistance to staining and decreased
tracking. In accordance with the present invention, an acrylic
latex coated granule surface building product having increased
rub-off protection is provided. The acrylic latex coated granule
surface building product comprises a substrate having granules
embedded and/or adhered therein and coated with an acrylic latex
polymer, applied from a latex composition, wherein the acrylic
polymer has the repeating structural formula
[CH.sub.2--C(R.sup.1)(R.sup.2)] where R.sup.1 is hydrogen or
C.sub.1-C.sub.8 alkyl; R.sup.2 is hydrogen, cyano or a linear or
branched hydrocarbon containing 1 to 22 carbon atoms, with the
proviso that R.sup.1 and R.sup.2 cannot both be hydrogen.
[0011] Another aspect of the present invention is a process of
making an acrylic latex coated granuled asphalt building product.
In this process, an asphalt coating is applied to a glass fiber mat
to form an asphalt product. Granules are thereupon deposited atop
the asphalt substrate followed by dry embedding of the granules
into the asphalt laden glass fiber mat by pressure. The granule
embedded asphalt mat is then coated with an acrylic latex
water-based composition. The latex may be applied using
conventional processes such as, but not limited to, spraying or
dipping. Additionally, the acrylic latex may be applied in-line
during the manufacturing process, wherein the latex is applied
following pressure embedding of the granules prior to cutting and
packaging of the asphalt-roofing product.
[0012] Following the application of the acrylic latex coating, the
structure is then dried to form an acrylic latex coated granule
surface asphalt building product having increased rub off
resistance, improved tracking resistance, and resistance to
staining. Optionally, as an alternative to applying the acrylic
latex coating during the manufacturing process, the acrylic latex
coating may be applied following the production of the granule
surface asphalt building product.
[0013] Another aspect of the present invention is a process of
making an acrylic latex coated granule surface non-asphaltic
building product. A non-asphaltic substrate is first provided which
may include such conventional substrates as vinyl, polyvinyl
chloride (PVC), plastisol or organosol layers as commonly used in
vinyl flooring, siding and roofing. The granules may be embedded
into the non-asphaltic substrate by heating the non-asphaltic
substrate close to its softening temperature, dispersing granules
across the surface of the non-asphaltic substrate, and then
embedding the granules into the surface of the non-asphaltic
substrate with a press.
[0014] The granule embedded non-asphaltic substrate is then coated
with an acrylic latex water-based composition. The acrylic latex
may be applied by any suitable coating technique such as spraying,
dipping, knife coating or roll coating, with roll coating being
preferred. Additionally, the acrylic latex may be applied in-line
during the manufacturing process, wherein the latex is applied
following pressure embedding of the granules prior to cutting and
packaging of the non-asphaltic building products. Optionally, as an
alternative to applying the acrylic latex coating during the
manufacturing process, the acrylic latex coating may be applied
following the production of the non-asphaltic building product.
[0015] Following the application of the acrylic latex coating the
structure is then dried to form a granule surfaced building product
having increased rub off resistance and resistance to staining.
DETAILED DESCRIPTION OF THE INVENTION
[0016] The building product of the present invention includes an
asphaltic or non-asphaltic substrate embedded with granules, which
is coated with an acrylic latex coating. The acrylic polymer
employed in the latex composition coating the substrate embedded
with roofing granules, has the repeating structural unit
[CH.sub.2--C(R.sup.1)(R.sup.2)] where R.sup.1 is hydrogen or
C.sub.1-C.sub.8 alkyl; R.sup.2 is hydrogen, cyano or --COOR; and R
is a linear or branched hydrocarbon containing 1-22 hydrocarbons,
with the proviso the R.sup.1 and R.sup.2 cannot both be hydrogen.
In a preferred embodiment, the polymer employed in the latex
composition is a homopolymer or copolymer of methacrylic acid, a
methacrylic ester, an acrylate ester or acrylonitrite.
[0017] The granules can be, for example, of a weather-resistant
mineral rock such as greenstone, nephelene syenite, common gravel,
slate, gannister, quartz, quartzite, greystone, argillite, coal
slag, copper slag, nickel slag, etc. The granules may be coated
with a ceramic coating comprising a reaction product of an alkali
metal silicate and an aluminosilicate. Typical granules have sizes
ranging from about 420-1680 micrometers (40 to 12 mesh US). The use
of somewhat larger or smaller granules, however, is within the
scope of this invention, provided the granules have a size that
permits their functioning as granules in building products.
Preferably, the granules are embedded in the substrate at a depth
of about 1/4 to 3/4 of the diameter of the granules.
[0018] The substrate may be an asphaltic or non-asphaltic material.
Asphalt substrates typically include a base mat covered with
asphalt and filled with a mineral filler or stabilizer. Asphalt is
a cementitious material having bitumens as a main constituent.
Optionally, the asphalt may be admixed with fine mineral filler,
such as limestone, talc, mica or sand.
[0019] Non-asphaltic substrates include a variety of building
materials such as vinyl flooring, vinyl floor tiles, vinyl siding,
etc. The present invention is particularly applicable to rigid
and/or flexible plastic substrates manufactured from conventional
thermoplastic materials such as polyolefin (e.g. polyethylene),
polycarbonate, polyvinyl chloride (PVC), polyvinyl flouride,
acrylic resins, acrylonitrile, butadiene, styrene, copolymers of
acrylonitrile, butadiene and styrene (ABS), etc. PVC is a preferred
plastic for the non-asphaltic substrate of the invention.
[0020] In addition to the above-described plastics, the
non-asphaltic substrate may comprise glass fibers, polyester
fibers, cellulosic fibers, asbestos, steel fibers, alumina fibers,
ceramic fibers, nylon fibers, graphite fibers, wool fibers, boron
fibers, carbon fibers, jute fibers, polyolefin fibers, polystyrene
fibers, acrylic fibers, phenolformaldehyde resin fibers, aromatic
and aliphatic polyamide fibers, polyacrylamide fibers,
polyacrylimide fibers or mixtures thereof which may include
bicomponent fibers.
[0021] The material of the non-asphaltic material can contain a
filler such as calcium carbonate, talc, silicates, wood flour or
any other suitable filler as known within the skill of the art.
[0022] Flexible materials used as non-asphaltic substrates
in-building products of the present invention may be further
supported by asbestos sheet, woven or non-woven fibrous web, other
plastisol layers, plastisol on felt backing, etc. It should be
understood that where appropriate, a non-asphaltic substrate of the
invention may include a layer having printing or other decorative
effects superimposed thereon.
[0023] In another aspect of the present invention, a process of
making granular surface building products having improved rub off
resistance is provided. In a first process step, a building
material substrate is provided, which provides the base structure
for the subsequently formed granular surface building product.
Suitable building material substrates include interior and exterior
sheet flooring, tile flooring, rolled roofing, shingles, paneling,
siding, etc.
[0024] In one embodiment of the present invention the granular
surfaced building product may comprise an asphalt building material
substrate. In this embodiment of the inventive process, a base mat,
which may be a glass fiber mat or a polymeric web, bound by a resin
binder, is provided. The resin binder may be a thermosetting resin
such as urea-formaldehyde resin, a phenol-formaldehyde resin or
other phenolic resin. Alternatively, the resin binder may be a
thermoplastic resin such as polyvinyl alcohol, polyvinyl acetate,
an acrylic resin, polyvinyl acetate and bone glue. The binder may
also include conventional polymeric modifiers.
[0025] The base mat is then coated with asphalt, which may include
optional mineral fillers, to form an asphalt substrate. The term
"asphalt substrate" denotes that the substrate can comprise asphalt
or modified asphalt. When forming an asphalt building product the
asphalt substrate is preferably a non-modified bitumen that is
applied at a preferred temperature ranging from about 325.degree.
F. to about 450.degree. F. In one embodiment, wherein asphalt
shingles are prepared the asphalt coating includes limestone as an
additive. In another embodiment, wherein rolled roofing is formed,
the asphalt is preferably modified with one or more polymer
additives. The modified asphalt can be applied at a preferred
temperature ranging from about 300.degree. F. to about 425.degree.
F. More preferably, the modified asphalt is applied at a
temperature of approximately 365.degree. F.
[0026] In another embodiment of the invention, the building
material substrate is a non-asphaltic material. The non-asphaltic
material may be a plastic (polymeric) material, preferably being a
thermoplastic material, such as PVC. In the embodiment in which the
non-asphaltic substrate comprises a plastic material, the
non-asphaltic substrate may be constructed by any suitable
conventional technique such as, but not limited too: compression
and transfer molding, injection molding, extrusion, blow molding,
casting, or conventional vacuum forming operations.
[0027] Granules are then applied to the building material
substrate. Granules may be applied to asphalt substrates, for
example, by dropping them onto a hot asphalt surface. The roofing
granules are then pressed into the asphalt substrate surface, where
the granules are embedded to a depth of about 1/4 to 3/4 the
diameter of the granules into the asphalt building material
substrate.
[0028] In the embodiments of the present invention wherein the
substrate comprises a non-asphaltic material such as a
thermoplastic, the granules may be applied to the thermoplastic
substrate by softening the surface of the thermoplastic substrate
and then applying the granules, wherein the granules are pressed
into the softened surface of the thermoplastic substrate. The
thermoplastic substrate may be softened by heating the
thermoplastic substrate to its softening temperature using
conventional processes such as infrared heating, air knife heating,
heated blowers, heated rolls, heated oven and/or like
processes.
[0029] Following the application of the granules, an acrylic latex
coating is applied. The acrylic latex coating is applied from an
acrylic latex water based composition comprising from about 20% to
about 90% water. As stated above, the acrylic polymer of the latex
has the repeating structural formula recited above and is
preferably a homopolymer or copolymer of methacrylic acid,
methacrylic ester or acylonitrile. In a particularly preferred
embodiment, the polymer of the latex is a copolymer of an acrylic
ester and styrene. In this preferred embodiment, a latex of the
styrene/acrylate copolymer is dispersed in water such that
copolymer comprises about 49% to about 51% and water is present in
a concentration of said percentages being by weight, based on the
total weight of the latex composition.
[0030] In this preferred embodiment, the latex dispersion of a
copolymer of styrene and butyl acrylate includes trace amounts of
unreacted styrene and butyl acrylate monomers. Specifically, the
latex, includes each of these monomers in a concentration of less
than about 200 parts per million (ppm). In this preferred
embodiment the polymeric particles of a size in the range of
between about 120 and 140 nanometers.
[0031] The acrylic latex may be applied at any temperature by any
conventional method including dipping, roller application,
brushing, or spraying. Independent of the method of application,
the acrylic latex water based coating is applied in the amount such
that the weight of acrylic polymer is present in a concentration of
from about 0.5 g/ft.sup.2 to about 20 g/ft.sup.2; more preferably,
from about 1.0 g/ft.sup.2 to about 10.0 g/ft.sup.2, and even more
preferably from about 2.5 g/ft.sup.2 to about 5.0 g/ft.sup.2. The
acrylic latex water based coating is preferably applied under
ambient temperature and pressure. Alternatively, the acrylic latex
coating may be applied to encapsulate the granules prior to the
granules being embedded in the substrate.
[0032] The acrylic latex coating is then dried, using any
conventional drying method. Among the conventional drying means
that may be utilized are infrared heating, air knife drying, heated
blowers drying, heated rolls, heated oven drying and the like. The
drying time typically ranges from less than 30 seconds to about
five minutes. Following drying, the acrylic latex coated granular
surface building material product is then cut and packaged. The
granular surfaced building products of the present invention, which
have been treated with the acrylic latex coating, are then used in
the conventional manner known to those skilled in the art.
[0033] The following examples are given to illustrate the scope of
the present invention. Because these examples are given for
illustrative purposes only, the invention should not be deemed
limited thereto.
EXAMPLE 1
Granule Adhesion Measurement of Latex Coated Asphalt Roofing
Products
[0034] Latex coated test samples and control samples were produced
and tested for granule adhesion in accordance with ASTM standard D
4977 utilizing a 3M RTM 400 four-head tester granule adhesion test
apparatus, a 3M abrasion test brush and balance.
[0035] Control samples were first produced from granule embedded
rolled polymer modified asphalt-roofing. The rolled asphalt-roofing
comprised a non-woven polyester mat substrate having a polymer
filled asphalt coating and embedded granules. Six control samples
were prepared from a rolled asphalt-roofing sheet by cutting six
specimens, wherein two of the samples were cut from a middle region
of the sheet adjacent to the machine direction; two samples were
cut two inches in from the non-selvege edge adjacent to the machine
direction and two samples were cut two inches in from the selvege
edge adjacent to the machine direction, the machine direction being
the direction in which the asphalt-roofing product is produced on a
line prior to being cut. A second set of samples in which a latex
of a copolymer of butyl acrylate and styrene was applied to the
asphalt rolled roofing in accordance with the present invention was
prepared in accordance with the procedure utilized in the
preparation of the control samples.
[0036] Each latex coated test sample and control sample, after
being weighed, was then secured into a 3M RTM 400 four-head tester
granule adhesion test apparatus, incorporating a 3M abrasion test
brush. The test brush then contacted the surface of the latex
coated test sample, where the test brush was then stroked
longitudinally across the test sample for 50 cycles, where one
cycle equals 2 strokes. The test samples where then weighed a
second time. The difference between the first weight and second
weight represented the granule rub loss. The test was repeated for
each latex coated test sample and each control sample. The results
of the granule loss measurements are provided in Table 1.
[0037] The granule rub loss sample is under pressure from the 3M
RTM 400 abrasion test. Friction between granules and the bristles
in the brush produce heat. Therefore, improved rub loss directly
correlates with improved tracking resistance, as measured by this
test. If the depth at which the bristles penetrate the test sample
decreases, an increase in tracking resistance is present.
TABLE-US-00001 TABLE 1 GRANULE RUB LOSS Sample No. AVER- STD 1 2 3
4 5 6 AGE DEV Granule 1.53 3.37 2.84 3.19 2.99 3.29 2.87 .68 loss
for samples having no coating (grams) Granule .09 .08 .12 .12 .15
.96 .25 .35 loss for samples having latex coating (grams)
EXAMPLE 2
Granule Stain Testing of Latex Coated Asphalt Roofing
[0038] Latex coated test samples and control samples were produced
and tested for granule staining in accordance with the below
disclosed testing procedure utilizing a force hot dry oven and a
Macbeth color surveillance system.
[0039] Control samples were first cut from granule embedded rolled
modified asphalt-roofing. The asphalt-roofing comprised a non-woven
polyester substrate coated with polymer filled asphalt upon which
granules were embedded. Three 10''.times.10'' control samples were
prepared from rolled asphalt-roofing where a first control sample
was cut two inches in from the selvege edge, another sample was cut
from a middle region of the sheet; and a third sample was cut four
inches in from the non-selvege edge. Three 10''.times.10'' latex
coated test samples were then cut in the above manner from a latex
coated asphalt-roofing product. The tests specimen were then heated
in a force hot dry oven for approximately four hours at a
temperature of about 210.degree. F. The test specimens were then
cooled to room temperature.
[0040] The Macbeth color surveillance system was then calibrated
using a white ceramic calibration tile. Following calibration, the
lightness of the test samples was then measured and recorded using
the Macbeth color surveillance system. Measurements of the test
samples were taken in both machine and transverse directions. The
Macbeth color surveillance system expresses lightness numerically,
where a value of 0 corresponds to black and increasing numerical
values indicate increasing lightness up to a value of 100
indicative of pure white. Variations in the lightness of the
asphalt coated rolled roofing samples indicates staining. The
results of the lightness measurements are provided in Table 2.
TABLE-US-00002 TABLE 2 STAINING UNCOATED LATEX COATED SAMPLE 1
SAMPLE 3 Transverse direction 69.31 Transverse direction 67.15
Machine direction 68.33 Machine direction 67.28 AVERAGE 68.82
AVERAGE 67.215 SAMPLE 2 SAMPLE 4 Transverse direction 53.89
Transverse direction 61.81 Machine direction 54.71 Machine
direction 60.71 AVERAGE 54.3 AVERAGE 61.26 Difference between 21.1%
Difference between 8.9% sample 1 average sample 3 average and and
sample 2 average sample 4 average. % IMPROVEMENT FOR LATEX COATED
SAMPLES OVER UNCOATED SAMPLES 59%
SUMMARY OF THE RESULTS
[0041] The results summarized in Table 1 indicate that latex coated
asphalt roofing products have an increased resistance to rub loss
and substantially better tracking resistance at elevated
temperature when compared to similarly prepared roofing products
without a latex coating. More specifically, the results summarized
in Table 1 indicate that granule loss is decreased by approximately
90% in latex coated roofing products.
[0042] The results summarized in Table 2 indicate that an increase
in resistance to staining is achieved by coating asphalt-roofing
products with a latex coating. Staining is indicated by a variation
in lightness values between different and heat aged roofing
products. Table 2 indicates that the lightness of uncoated asphalt
rolled roofing varies by approximately 21% and that the lightness
value of latex coated shingles varies by approximately 9%. Table 2
indicates an improvement in staining resistance by approximately
59% for latex coated shingles as compared to shingles without the
inventive latex coating.
[0043] The above embodiments and examples are given above to
illustrate the scope and spirit of the present invention. These
embodiments and examples will make apparent, to those of ordinary
skill in the art, other embodiments and examples. These other
embodiments and examples are within the contemplation of the
present invention. Therefore, the present invention should be
limited only by the appended claims.
* * * * *