U.S. patent application number 11/531709 was filed with the patent office on 2007-02-01 for integrated granule product.
This patent application is currently assigned to 3M Innovative Properties Company. Invention is credited to Thomas E. Boettcher, Gregg D. Dahlke, Duane M. Pinault, Ernest L. Thurber.
Application Number | 20070026195 11/531709 |
Document ID | / |
Family ID | 24776204 |
Filed Date | 2007-02-01 |
United States Patent
Application |
20070026195 |
Kind Code |
A1 |
Pinault; Duane M. ; et
al. |
February 1, 2007 |
INTEGRATED GRANULE PRODUCT
Abstract
An integrated granule product that includes a film having a
plurality of ceramic coated granules bonded to the film by a cured
adhesive. The integrated granule product is generally considered an
intermediate product because it is suitable for application onto
various substrates for end use applications such as roofing
products and flooring products.
Inventors: |
Pinault; Duane M.; (Cottage
Grove, MN) ; Thurber; Ernest L.; (Woodbury, MN)
; Dahlke; Gregg D.; (St. Paul, MN) ; Boettcher;
Thomas E.; (Hastings, MN) |
Correspondence
Address: |
3M INNOVATIVE PROPERTIES COMPANY
PO BOX 33427
ST. PAUL
MN
55133-3427
US
|
Assignee: |
3M Innovative Properties
Company
|
Family ID: |
24776204 |
Appl. No.: |
11/531709 |
Filed: |
September 14, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
09691352 |
Oct 18, 2000 |
7125601 |
|
|
11531709 |
Sep 14, 2006 |
|
|
|
Current U.S.
Class: |
428/141 ;
428/143; 428/147; 428/148 |
Current CPC
Class: |
B05D 5/02 20130101; B32B
5/00 20130101; E04D 1/26 20130101; E04D 5/12 20130101; E04D 13/002
20130101; Y10T 428/24355 20150115; Y10T 428/24413 20150115; Y10T
428/24372 20150115; Y10T 428/24405 20150115; E04D 2001/005
20130101 |
Class at
Publication: |
428/141 ;
428/143; 428/148; 428/147 |
International
Class: |
G11B 5/64 20060101
G11B005/64; B44C 5/04 20060101 B44C005/04; D06N 7/00 20060101
D06N007/00 |
Claims
1. An integrated granule product suitable as an exposed surface
layer for a roofing shingle construction, comprising a plurality of
ceramic coated granules bonded to a self-supporting cured adhesive
film.
2. The product of claim 1, wherein said cured adhesive is selected
from acrylated urethanes, multifunctional acrylate monomers,
acrylated epoxies, acrylated polyesters, acrylated polyethers,
urethanes, epoxies, acrylics, phenolics, cyanate esters,
bismaleimides, hot melts likes polyester, polyamides, polyolefins,
derivatized polyolefins or combinations thereof.
3. The product of claim 1, wherein said product is pliable as
determined by mandrel flexibility test procedures according to ASTM
D-228-00.
4. The product of claim 1, wherein said cured adhesive is flexible
as indicated by a tensile elongation result of 25% or greater
according to ASTM D-882.97.
5. The product of claim 1, wherein said cured adhesive film
includes toughening agents, pigments, adhesion promoters, dyes,
filling agents, initiators, catalysts, ultraviolet stabilizers,
ultraviolet absorbers, antioxidants or combinations thereof.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. Ser. No.
09/691,352, filed Oct. 18, 2000, now allowed, the disclosure of
which is incorporated by reference in its entirety herein.
FIELD OF THE INVENTION
[0002] The invention relates to an integrated granule product, more
particularly to an integrated granule product utilizing ceramic
coated granules bonded to either a film with a cured adhesive or a
self-supporting adhesive film. The present invention also includes
a method of preparing integrated granule products.
BACKGROUND
[0003] Roofing products are generally flat or sheet-like materials
that can be arranged on a roof to prevent weather, e.g., wind,
water, etc., from entering a roof structure. A roofing product can
also serve to reflect heat energy from a roof. The roofing product
should be durable enough to perform these functions for a number of
years. Examples of roofing products include asphalt-based, wooden,
or ceramic tile shingles.
[0004] Roofing products, particularly those which employ roofing
granules, generally have been prepared from a water-proof, durable
substrate having roofing granules disposed on a surface of the
substrate. Asphalt-based roofing shingles, for example, typically
comprise an asphalt-based substrate with roofing granules embedded
into the asphalt. The roofing granules are generally colored to
provide a desired aesthetic value upon application of the roofing
product onto a building. These types of products are prepared by
conventional practices generally recognized in the roofing products
industry.
[0005] There is a continuing need in the roofing product art for
new roofing product constructions, and for new processes for
preparing roofing products. Conventional roofing products, such as
shingles, are often susceptible to weather related damage that can
either tear the base substrate or adversely affect the bond of the
granule in the asphalt-based substrate. The release of the granules
from the base permits the passing of light through to the asphalt.
The light can degrade the asphalt and may cause premature failure
of the roofing product.
[0006] The asphalt-based substrate can adversely affect the
aesthetics of the coated granules applied onto the substrate. For
example, lighter colored granules may darken upon application to
the asphalt-based substrate. The darkening can be attributed to
exposed black asphalt in gaps surrounding the granules.
Additionally, the lighter color pigments may darken over time after
application onto a roof due to the migration of the lower molecular
weight materials from the asphalt onto the surface of the coated
granules. The aesthetics of a roofing product can also be effected
by the undesirable growth of algae on the exposed surface of the
roofing product. Algae, growing on the exposed surface of the
granules, may have direct access to the asphalt, which provides
nutrients that can sustain growth.
[0007] It would be an advantage to provide a roofing product that
is capable of withstanding severe weather conditions and capable of
preventing the degradation of the underlying asphalt-based
substrate. It would also be an advantage to provide a roofing
product that prevents the discoloration of granules when applied
onto an asphalt-based substrate.
SUMMARY OF THE INVENTION
[0008] The present invention relates to an integrated granule
product. The integrated granule product is suitable for use in
various applications that require a layer of ceramic coated
granules applied onto a substrate. The integrated granule product
of the present invention includes a film having a plurality of
ceramic coated granules bonded to the film by a cured adhesive. The
integrated granule product is generally considered an intermediate
product because it is suitable for application onto various
substrates.
[0009] In an alternative embodiment, a self-supporting adhesive
film is utilized to bond the ceramic coated granules to either
roofing or flooring substrates. A self-supporting film is generally
defined as a film having uniform width, thickness, and length that
when attached along its width to a supporting substrate the film
will require no support other than itself or the substrate to which
it is attached. The integrated granule product functions as an
exposed surface layer on the specified substrates.
[0010] The integrated granule product is pliable and durable. The
pliability of the intermediate product is determined by the mandrel
flexibility test ASTM D228-00. The cured adhesive is also flexible
as evidenced by a tensile elongation result of 25% or greater
according to ASTM standard D882-97. Additionally, the adhesive of
the present invention does not adversely affect the color of the
ceramic coated granules.
[0011] End use applications of the integrated granule product of
the present invention preferably include, for example, roofing
products and flooring products.
[0012] The present invention further contemplates a process for
preparing the integrated granule product wherein a plurality of
ceramic coated granules are bonded to a film through the use of a
curable adhesive. In a preferred embodiment, the adhesive is first
applied onto the film with the ceramic coated granules then applied
onto the adhesive. The adhesive is then subjected to a form of
energy, such as ultraviolet radiation, thermal radiation, actinic
radiation, ionizing radiation, moisture activation,
photo-activation, or combinations thereof, to affect curing, chain
extension, or both. Additionally, the integrated granule product
may be further processed by bonding the integrated granule product
to a substrate to form such articles as roofing shingles and
flooring materials.
[0013] For purposes of the present invention, the following terms
used in this application are defined as follows:
[0014] "ceramic coated granule" means an inorganic base substrate
of generally rock, mineral, or recycled material (e.g. slag) in
granular form having a coating which includes an amount of an
alkali metal silicate binder sufficient to bind the coating to the
inorganic granule;
[0015] "cure" means to supply sufficient energy to a composition to
alter the physical state of the composition, to make it transform
from a fluid to less fluid state, to go from a tacky to a non-tacky
state, to go from a soluble to insoluble state, or to decrease the
amount of polymerizable material by its consumption in a chemical
reaction. The term "cure" may also include the removal of energy or
alternatively, the evaporation of a carrier; and
[0016] "self-supporting" means a property of an article such that a
segment of the article having uniform width, thickness, and length
when attached along its width to a supporting substrate will
require no support other than itself or the substrate to which it
is attached. An article will be deemed to be self-supporting if the
length of a segment so supported may exceed 5 cm without visible
rupture of the segment. Preferably, the minimum length at which a
segment of the article ceases to be self-supporting will be greater
than 5 m.
[0017] Other features and advantages will be apparent from the
following description of the preferred embodiments thereof, and
from the claims.
BRIEF DESCRIPTION OF THE DRAWINGS
[0018] The above, as well as other advantages of the present
invention, will become readily apparent to those skilled in the art
from the following detailed description of a preferred embodiment
when considered in the light of the accompanying drawings in
which:
[0019] FIG. 1 is a segmented, cross-sectional view of an integrated
granule product of the present invention, comprising a film, a
cured adhesive, and granules applied onto an asphalt-based
substrate;
[0020] FIG. 2 is a perspective view of a roofing shingle utilizing
an embodiment of the present invention; and
[0021] FIG.3 is a cross-sectional view of another embodiment of the
integrated granule product of the present invention.
DETAILED DESCRIPTION
[0022] As depicted in FIG. 1, the integrated granule product 10
includes a film 12, a cured adhesive 14, and a plurality of
granules 16 adhered to the film 12 by the cured adhesive 14. The
integrated granule product 10 is generally an intermediate product
suitable for various end use applications. As used herein, the term
"intermediate product," (also referred to herein as "intermediate")
means a composite material that has sufficient physical properties
including flexibility and durability, that the intermediate, either
alone or upon being attached to a substrate, can be processed and
fabricated into a useful product. For example, the intermediate
product could be utilized in the formation of roofing products or
utilized as a floor covering. FIG. 1 depicts an asphalt-based
substrate 20 suitable for receiving the integrated granule product
10 of the present invention. The asphalt-based substrate 20
includes a substrate mat 22, saturated with asphalt, and an outer
layer of asphalt 24 suitable for receiving the integrated granule
product 10. FIG. 2 illustrates one potential use of the integrated
granule product 34 as an exposed surface of a roofing shingle
30.
Materials
[0023] According to the present invention, the film can be any film
material capable of carrying granules adhered to the film with an
adhesive. Additionally, the film must be capable of bonding to
various substrates for end use applications. Conventional films
capable of performing the noted functions are suitable for use with
the present invention. Examples of film materials include paper,
natural or synthetic fabrics, polymeric materials such as
polyethylene terephthalate (PET), polypropylene, polyamide,
polyimide or lofty fibrous mats Preferred materials would include
polymeric materials, most preferably polyethylene terephthalate
(PET) and polypropylene.
[0024] In general the films must be provided at a thickness having
sufficient compositional strength to act as a support for the
coating intermediate. Preferably, the film thickness is about 10
micrometers to about 300 micrometers.
[0025] The film may optionally be primed or otherwise treated,
e.g., corona treated or surface treated, to improve bonding of an
adhesive to the film. Preferred primers include ethylene acrylic
acid or aziridine-based compositions.
[0026] The adhesive utilized in the present invention can be any
non-asphaltic material capable of adhering granules to the film.
Additionally, the adhesive properties must allow the adhesive to be
processed into an integrated granule film suitable for application
onto various substrates. The adhesive is generally a curable
material that possesses chemical and mechanical properties to
sufficiently bond the granules to the film.
[0027] The curable adhesive should have adhesive properties and
sufficiently low viscosity at coating temperatures that permit the
adhesive to be applied uniformly onto the film or release liner
using conventional coating methods. These conventional coating
methods include, but are not limited to, roll coating, curtain
coating, die coating, knife coating and spray coating. The adhesive
can be coated at 100% solids, as an emulsion, as an aqueous
dispersion or solvent borne. The coating viscosity of the adhesive
can be varied by changing coating temperature, % solids or solvent
type. For example, an adhesive, such as Ebecryl 270 from UCB
Chemicals of Smyrna, Ga., would generally be knife coated at 100%
solids, with a viscosity of about 3,000 centipoise at 60.degree. C.
Additionally, the adhesive should be applied at a thickness that
enables the application and subsequent bonding of the granules to
the film upon curing of the curable adhesive. Preferably the
thickness of the adhesive is about 75 micrometers to about 500
micrometers, at 100% solids.
[0028] In general, the non-asphaltic adhesive can be of any
chemistry that will provide a suitable coating on the film and
permit the subsequent bonding of the ceramic coated granules onto
the film. Those skilled in the art are capable of selecting a
specific adhesive to match film characteristics. Examples of
suitable materials include acrylated urethanes, multifunctional
acrylate monomers, acrylated epoxies, acrylated polyesters,
acrylated polyethers, urethanes, epoxies, acrylics, phenolics,
cyanate esters, bismaleimides, hot melts likes polyester,
polyamides, polyolefins, derivatized polyolefins or combinations
thereof. A particularly preferred adhesive includes acrylated
aliphatic urethanes, such as Ebecryl 270 from UCB Chemicals
Corporation of Smyrna, Ga.
[0029] In an alternative embodiment, the ceramic coated granules
may be bonded to a self-supporting film. In this particular
embodiment, the adhesive is strong enough to support its own weight
and the weight of the ceramic coated granules. In general, the
ceramic coated granules are partially embedded into a portion of an
exposed surface of the adhesive film. Additionally, the adhesive
film is thick enough to provide a bonding surface, opposite the
exposed surface utilized for receiving the ceramic coated granules.
The self-supporting adhesive film is generally produced utilizing
the curable adhesives described for the first embodiment. FIG. 3
depicts the alternative embodiment of an integrated granule product
40 including a self-supporting adhesive film 42 and a plurality of
ceramic coated granules 44 partially embedded in the
self-supporting adhesive film 42. The self-supporting film may
optionally include a release liner (not shown) in the surface
opposite the ceramic coated granules.
[0030] In accordance with the present invention, initiators and
catalysts can optionally be utilized in the curable adhesive
composition. In the case of the free radical curable acrylated
urethanes, multifunctional acrylates, acrylated polyesters,
acrylated polyethers, these adhesives can be cured by free radical
photoinitiators or thermal initiators. Examples of useful
photoinitiators, which generate a free radical source when exposed
to ultraviolet light, include, but are not limited to, organic
peroxides, azo compounds, quinones, benzophenones, nitroso
compounds, acyl halides, hydrazones, mercapto compounds, pyrylium
compounds, triacylimidazoles, acylphosphine oxides, bisimidazoles,
chloroalkyltriazines, benzoin ethers, benzil ketals, thioxanthones,
and acetophenone derivatives, and mixtures thereof. A preferred
photoinitiator is "Irgacure 651", which is commercially available
from Ciba Specialty Chemicals of Tarrytown, N.Y. Thermal free
radical initiators include, but are not limited to, azo, peroxide,
persulfate, and redox initiators. In the case of epoxy and
urethanes resins these adhesives can be cured by catalysts which
include, but are not limited to, tertiary amines, imidazoles,
aliphatic amines, cyclic anhydrides, diols, Lewis acids, organotin
compounds and photogenerated catalysts like metallocene, and salts
of onium cations.
[0031] The curable adhesives are cured through the use of
conventional curing techniques. For example, the curable adhesive
may be cured through the use of ultraviolet radiation, thermal
radiation, actinic radiation, ionizing radiation, moisture
activation, photo-activation, or combinations thereof. Those
skilled in the art are capable of selectively matching adhesives
with appropriate curing practices to effectively bond the granules
to the film.
[0032] Upon curing, the cured adhesive is both flexible and
durable. The properties of cured adhesive should be sufficiently
flexible to allow the integrated granule product to be further
processed into a derivative thereof, e.g., applied to a substrate
for end use applications. The flexibility of the adhesive is
generally measured through tensile elongation. The cured adhesive,
in an unfilled state, is flexible as indicated by a tensile
elongation result of 25% or greater according to ASTM standard
D882-97.
[0033] The adhesive must be durable in order to maintain the bond
between the granule and the film for extended period of time. The
durability is measured by the industry standard Granule Adhesion to
Shingles test, generally recognized in the shingle manufacturing
industry. The present invention meets standard requirements under
the Granule Adhesion to Shingles test of 0.3 gram loss or less.
Because of the desired end use applications, the adhesive must also
be capable of withstanding various weather conditions. The failure
of the bond between the adhesive and the ceramic coated granules
may undesirably exposed the film, and any underlying asphalt-based
substrate, to direct light, which can result in premature failure
of the roofing product.
[0034] Optionally, the adhesive or the film may include other
conventional materials to enhance either physical, mechanical or
aesthetic properties of the adhesive or the film and the bond
between the granules, the adhesive, and the film. Suitable
additives may include toughening agents at about 0-10% by weight,
pigments at about 0-10% by weight, dyes at about 0-10% by weight,
adhesion promoters at about 0-5% by weight, filling agents at about
0-70% by weight or combinations thereof. Additionally,
antimicrobials or algaecides may be included in the film or the
adhesive in an effective amount to prevent the growth of algea.
Those skilled in the art are capable of selecting conventional
additives to achieve desired properties in a specific adhesive
composition.
[0035] In another optional embodiment, either the film, the
adhesive or both may include ultraviolet stabilizers, ultraviolet
absorbers, antioxidants, or combinations thereof. The noted
compounds are generally included in polymeric compositions to
prevent transmission of ultraviolet radiation by either absorbing
or reflecting the ultraviolet radiation. With the incorporation of
the present invention onto an asphalt based substrate, it may be
desirable to utilize ultraviolet stabilizers, ultraviolet
absorbers, antioxidants, or combinations thereof to prevent the
undesirable degradation of the asphalt by ultraviolet radiation.
Conventional ultraviolet stabilizers, ultraviolet absorbers, and
antioxidants recognized by those skilled in the art are suitable
for use in the present invention. An example of an ultraviolet
stabilizer includes that available under the trade designation
"TINUVIN.TM. 292"
(bis(1,2,2,6,6-pentamethyl-4-piperidinyl)sebacate) and an example
of an ultraviolet absorber includes that available under the trade
designation "TINUVIN.TM. 113 0" (hydroxyphenyl benzotriazole), both
of which are available from Ciba-Geigy. The adhesive or film can
include an amount of either an ultraviolet stabilizer or an
ultraviolet absorber to impart the desired result. Preferably, the
ultraviolet stabilizer or absorber is present in an amount up to
about 10% by weight. Examples of Antioxidants include, but are not
limited to, low melting hindered phenols and triesters. Specific
examples include 2,6-di-tert-butyl-4-methylphenol commercially
available under the trade designation "ULTRANOX.TM. 226"
antioxidant from Borg Warner Chemicals, Inc., Parkersburg, N.Y.;
octadecyl 3,5-di-tert-butyl-4-hydroxycinnamate commercially
available under the trade designations "ISONOX.cndot. I32"
antioxidant (Schenectady Chemicals, Inc., Schenectady, N.Y.) or
"VANOX.TM. I320" antioxidant (Vanderbilt Co., Inc., Norwalk,
Conn.). The adhesive of film compositions can include sufficient
amounts of antioxidant to impart the desired result. Preferably,
the antioxidant is present in an amount up to about 3% by
weight.
[0036] The ceramic coated granules utilized in the present
invention can be conventional granule materials utilized in such
application as roofing products. Such granule materials typically
comprise a durable slate or rock base granule, either in natural
form or, preferably, coated by an organic or an inorganic coating,
e.g., a colored ceramic coating. The ceramic coating may include a
variety of ingredients to provide desired aesthetic or
anti-microbial properties.
[0037] In general, the base granule can be prepared from any
mineral material which is dense and properly graded by screening
for maximum coverage. Such mineral materials are crushed and graded
and optionally and preferably, coated with a colorant, and
optionally with other materials such as an antimicrobial material.
Preferably, minerals are crushed and screened to a size desirable
for use in a chosen roofing product, e.g., to pass a #12 mesh (U.S.
Standard) screen and to be retained in a #40 mesh (U.S. Standard)
screen. Methods to add a ceramic color coating to base granules are
generally disclosed by Beyard et al. in U.S. Pat. No. 3,752,696,
incorporated herein by reference.
[0038] Suitable base granules can be prepared from a wide class of
relatively porous or non-porous and weather-resistant rock or
mineral materials, including trap rocks, slates, argillite,
greystone, greenstone, quartz, quartzite, certain granites, or
certain synthetic granules made from clay or other ceramics.
[0039] Commercially available roofing granules useful in products
and methods according to the present invention include, for
example, the entire line of roofing granules manufactured by
Minnesota Mining and Manufacturing Company of St. Paul, Minn.
Preparation of Integrated Granule Product
[0040] The integrated granule product of the present invention is
generally produced by bonding a plurality of ceramic coated
granules onto the film through the use of the curable adhesive. The
resulting product is a suitable intermediate for various end use
applications.
[0041] In the process of the present invention, a film capable of
carrying ceramic coated granules is first provided. The film may
have been optionally treated with a primer, or other physical
method, in order to enhance the bond between the adhesive and the
film. The adhesive is then coated onto the film. The optional
additives may have been mixed by conventional methods into the
adhesive prior to application onto the film. The adhesive is
applied by conventional practices such as knife coating techniques.
The adhesive is applied at a temperature of about 60.degree. C. to
about 100.degree. C. and a viscosity of in the range of 2500
centipoise to about 20,000 centipoise. The temperature is selected
at a point low enough to prevent distortion of the film yet provide
a suitable viscosity for sufficient application of the adhesive
onto the film.
[0042] The adhesive is applied at a thickness that permits
sufficient holding properties of the granules but does not
completely cover the granules. In general, the adhesive is applied
at a thickness in the range of about 75 micrometers to about 500
micrometers.
[0043] A plurality of ceramic coated granules are then applied onto
an exposed surface of the adhesive. The granules can be applied
using conventional application methods such as, for example, drop
coating techniques. The granules can be applied at varying
thicknesses and coverage patterns. For example, the granules can be
drop coated onto the adhesive at a rate to provide an even
distribution of granules. Generally, the granules are coated to
excess to provide the desirable coverage. Additionally, more than
one layer of granules or different types of ceramic coated granules
may be applied onto the film. One skilled in the art is capable of
selecting a coating rate to achieve desired coating coverage over
the film.
[0044] The coated film is then subjected to a curing step in order
to form a cured adhesive and a bond between the film and the
granules. The curing may include such conventional practices such
as the use of ultraviolet radiation, thermal radiation, actinic
radiation, moisture activation, photo-activation, or combinations
thereof The duration and amount of energy applied during the curing
step is affected by variables such as, for example, the amount and
thickness of adhesive, line speeds, the form of activation energy,
and the presence of initiators. Those skilled in the art are
capable of matching the appropriate processing conditions to
achieve the desired bond between the granules and the film.
[0045] The film may be in the form of single sheets of desired
dimensions or may include webs or rolls of film wherein the
adhesive and ceramic coated granules are applied in a continuous
process. With a web based process, the coated film is collected in
a web form at the end of the process for end use applications.
[0046] The integrated granule product is flexible and durable. The
integrated granule product is pliable as determined by mandrel
flexibility test procedures as described in the "Examples" section.
The process of the present invention results in a composite
structure that isolates the ceramic coated granules from the
underlying asphalt based substrate. The advantage in separating the
ceramic coated granules from the asphalt may prevent the adverse
discoloration of the aesthetic color of the ceramic coated
granules. The prevention of discoloration is indicated by a one
unit or more change in any Hunter color scale coordinates of L*,
a*, or b*. Preferably, the finished integrated granule product,
when utilizing standard white pigmented granules, exhibits an L*
value of 64 or greater according to HunterLab spectrocolorimeter
test procedures.
[0047] Optionally, the film or the adhesive of the present
invention include various fillers or pigments in the film to
achieve desirable color effects. The use of fillers in the
adhesive, or the underlying film, can mask the dark color of the
asphalt. For example, white pigments in a film with white granules
can produce a significantly lighter, whiter shingle than the gray
which can be obtained if the black asphalt shows through the gaps
between granules. Similarly, interesting color effects may be
obtained by choosing a color or colors, other than the color of the
granules, as fillers in the adhesive or film. For example, a
patterned film with a clear adhesive may be used to impart
desirable shading effects, e.g., wood grain, to the shingle. In a
patterned flooring, visual elements such as repeating geometric
patterns or logos, etc., may be supplied.
Application of the Integrated Granule Product
[0048] The integrated granule product may be applied onto various
substrates to form different products. The substrates generally
serve as a base for receiving the integrated granule product of the
present invention. The base substrate may be function as a
mechanism for attaching the product to another object. For example,
the integrated granule product can be applied onto an asphalt-based
substrates to form a roofing shingle. The roofing shingle is then
attached to the roof of a building structure. Alternatively, the
integrated granule product may be attached directly to a fixed
substrate, such as a floor or other stationary building
structure.
[0049] FIG. 2 depicts a preferred embodiment of the present
invention. A three tab shingle 30 is produced using a conventional
asphalt-based substrate 32 and the integrated granule film 34 of
the present invention. The integrated granule film 34 would serve
as the exposed surface of the tab area 36. The headlap area 38
would be covered by a subsequent layer of shingles.
[0050] Suitable substrates for the present invention include
asphalt-based substrate, metal substrate, polymeric substrate,
concrete substrate, tile substrate, fiber substrate, wood substrate
or combinations thereof. Preferably, the substrate is an
asphalt-based substrate. An asphalt-based substrate ("asphalt
substrate" or "substrate") can be any asphalt-based material
suitable for use in a roofing product, many of which are well
known. In general, substrates may include a non-asphalt-based
material in the form of a mat or web ("substrate mat" or "mat")
wherein the mat is saturated or coated with asphalt. Various
materials may be used as the substrate mat. Preferred materials
comprise a non-woven matting of either fiberglass or cellulose
fibers. Generally, fiberglass matting is manufactured from a
silicate glass fiber blown in a non-woven pattern in streams of
about 30-200 micrometers in diameter, with the resultant mat being
approximately 1-5 millimeters in thickness. Fiberglass matting is
commercially available from Owens-Corning Fiberglass Corporation,
Toledo, Ohio, and Manville Roofing Systems, Denver, Colo. In
general, most any fiberglass mat with similar physical properties
could be incorporated into the product and process of the invention
with satisfactory results.
[0051] Cellulose felt (dry felt) is typically made from various
combinations of rag, wood, and other cellulose fibers or
cellulose-containing fibers, blended in appropriate proportions to
provide desirable strength, absorption capacity, and
flexibility.
[0052] Roofing asphalt, sometimes termed "asphalt flux," is a
petroleum-based fluid comprising a mixture of bituminous
materials.
[0053] A cellulose mat is generally soaked or otherwise impregnated
or saturated to the greatest possible extent with a "saturant"
asphalt. Saturant asphalt is high in oily constituents, and other
preservatives, which provide waterproof and weatherproof
properties.
[0054] The saturated mat is sealed on both sides by application of
a hard or more viscous "coating asphalt," which is further
protected by a covering of mineral granules. In the case of
fiberglass mat-based asphalt roofing products, it is well
understood that the coating asphalt can be applied directly to the
unsaturated fiberglass mat, without the need for a first
application of saturant asphalt.
[0055] Saturant asphalt and the coating asphalt can be prepared by
processing asphalt flux in such a way as to modify the temperature
at which the asphalt will soften. The softening point of saturant
asphalt varies from about 37.degree. C. to about 72.degree. C.,
whereas the softening point of desirable coating asphalt runs as
high as about 127.degree. C. The softening temperature may be
modified for application to roofing products in varying
climates.
[0056] A variety of stabilizers and fillers may be included in the
either the saturant asphalt of the coating asphalt. For example,
silica, slate dust, talc, micaceous materials, dolomite, and trap
rock, and calcium carbonate or limestone, may be used as
stabilizers or fillers in the coating asphalt. Such materials
render the asphalt substrate improved with respect to shatter
resistance and shock resistance. In addition, they provide fire
protection. Also, they provide raw material cost savings and
improved weathering characteristics.
[0057] The integrated granule product may be applied to an
asphalt-based substrate by heating the substrate to soften the
asphalt surface. The film side of the integrated granule product is
then applied onto the softened asphalt surface. Generally, the
substrate is heated to a temperature in the range of about
150.degree. C. to about 250.degree. C. Upon cooling the film bonds
to the asphalt and forms an article suitable for use in roofing
applications. The asphalt-based substrate may be provided in either
shingle or rolled web form. Thus the end product may also be
provided in either form.
[0058] The use of the integrated granule product on asphalt-based
substrates generally results in a product with improved properties
over conventional asphalt singles or roofing products. The present
invention, when utilized in a roofing shingle, exhibits a tensile
strength according to American Roofing Manufacturers Association
Test Index No. 2,126, of greater than 50% over a shingle without
the integrated granule product. Additionally, the use of the
product of the present invention prevents the asphalt from
adversely affecting the aesthetic color of the ceramic coated
granules.
[0059] The application of the present invention onto flooring
substrates preferably includes the use of a polymeric sealant or
top coat over the exposed ceramic coated granules. The top coat
protects the granules from excessive wear and reduces the abrasive
nature of exposed granules. Polymeric sealants include conventional
top coat polymers such as, for example, epoxies urethanes, and
methacrylates.
EXAMPLES
Example 1
[0060] A primed (ethylene-acrylic acid copolymer) 100 micrometer
polyethylene teraphthalate film was knife-coated with a
commercially available acrylated urethane oligomer (EBECRYL 270
available from UCB Chemicals) and catalyzed with approximately 1%
photoinitiator (Irgacure 651 from Ciba Additives) to a thickness of
375 micrometers. White ceramic-coated roofing granules were
drop-coated and hand-pressed into the still-liquid resin coating.
This construction was then processed through a UV curing station at
6.1 m/min and irradiated with a Fusion Systems "D" bulb (600 W/in).
This process yielded a solid, tough granule-containing film
material that adheres well when heat-laminated onto
asphalt-saturated roofing mats.
Example 2
[0061] A primed (ethylene-acrylic acid copolymer) 100 micrometer
polyethylene teraphthalate film was knife-coated at 93.degree. C.
with a resin mixture of 258 g of Ebecryl 270, 42 g of tripropylene
glycol diacrylate, (tripropylene glycol diacrylate is commercially
available from UCB Radcure, Syrma, Ga. under the tradename TRPGDA),
306 g of Minspar 3 (Minspar 3 is a feldspar filler available from
the K-T Feldspar Corporation, Spruce Pine, N.C.), and 6 g of
photoinitiator Irgacure 651 (Irgacure 651 is commercially available
from Ciba Specialty Chemicals Tarrytown, N.Y. The resulting coating
had a thickness of 375 micrometer. White ceramic-coated roofing
granules were drop-coated and hand-pressed into the still-liquid
resin coating. This construction was then processed through a UV
curing station at 6.1 m/min and irradiated with a Fusion Systems
"D" bulb (600 W/in). This process yielded a solid, tough
granule-containing film material that adheres well when
heat-laminated onto asphalt-saturated roofing mats.
Example 3
[0062] A primed (ethylene-acrylic acid copolymer) 100 micrometer
polyethylene teraphthalate film was knife-coated at 93.degree. C.
with a resin mixture of 80 g of Ebecryl 270, 50 g of Minspar 3, 2 g
of White Cloud-60 Lithopone (a white pigment commercially available
from Sino-American Pigment Systems, Inc., Berkley, Calif.) and 1 g
of Irgacure 651. The resulting coating had a thickness of 375
micrometer. White ceramic-coated roofing granules were drop-coated
and hand-pressed into the still-liquid resin coating. This
construction was then processed through a UV curing station at 6.1
m/min and irradiated with a Fusion Systems "D" bulb (600 W/in).
This process yielded a solid, tough granule-containing film
material that adheres well when heat-laminated onto
asphalt-saturated roofing mats.
Example 4
[0063] The process of Example 1 was utilized in producing a
ceramic-coated sand (3M ColorQuartz) containing construction by
lowering the resin coating thickness from 375 micrometer to 100
micrometer and substituting ColorQuartz obtained from Minnesota
Mining and Manufacturing of St. Paul, Minn. for the roofing
granules. After UV curing, an adhesive coating was then applied to
the backside of the PET film to create a tape-type construction.
The construction was then applied onto a metal roofing panel.
Examples 5-6
[0064] Examples 5 and 6 demonstrate the improved tensile strength
of the present invention.
[0065] For Example 6, a film was made according to Example 1 was
laminated onto an asphalt roofing base material consisting of an
asphalt-saturated base web, coated on the weather-exposed side with
standard roofing asphalt to form a completed roofing shingle. For
Example 5, an identical shingle was used without the film. The
ceramic coated granules were drop coated directly onto the asphalt.
Samples were prepared according to Asphalt Roofing Industry Bureau
Test Procedure 2.224. Specimens measured 15.24 cm by 2.54 cm and
represented both film-containing and non-film-containing examples
of the shingle web for direct comparison.
[0066] The instrument used was an Instron Model 1122 Tensile Tester
equipped with a 453.5 Kg load cell, recently calibrated. The sample
jaws were set so that 3.81 cm of sample was inserted in the top and
bottom clamp and 7.62 cm of sample appeared between the clamps. The
instrument was setup to deliver a uniform travel of 30.48 cm per
minute for this test. Values were recorded at the instant of sample
failure. The test was run on six different times for each
Example.
[0067] Example 5 exhibited a tensile strength of 10.75 kg/cm.
Example 6 demonstrated a tensile strength of 24.57 kg/cm.
Example 7
[0068] The integrated granule product of Example 1 was tested for
flexibility/pliability under the Mandrel Flexibility Test as
defined by ASTM-D228-00 Test Methods For Asphalt Roll Roofing Cap
Sheets and Shingles. A 2.54 cm by 20.32 cm specimen was cut from
Example 1 and bent through 90 degrees over a 1.27 cm aluminum
rounded block as specified in the above method. The specimen passed
and did not produce cracking of the cured adhesive portion of the
integrated granule product.
Example 8
[0069] An integrated granule product was laminated to a web of
standard asphalt-impregnated fiberglass shingle mat by coating a
0.158 cm layer of Trumbull asphalt #4110 at 87.7.degree. C. along
the entire web width. A 15.24 cm roll of integrated granule product
made according to the procedure of Example 1 was laminated, by
press-roll, on one side of the web and headlap granules were
drop-coated into the liquid asphalt on the remainder of the web to
form the completed roofing shingle. The product was then fed into a
standard shingle die cutter to obtain individual shingle
samples
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