U.S. patent application number 11/291577 was filed with the patent office on 2007-06-14 for roofing adhesive.
Invention is credited to David R. IV Jones.
Application Number | 20070130863 11/291577 |
Document ID | / |
Family ID | 38137879 |
Filed Date | 2007-06-14 |
United States Patent
Application |
20070130863 |
Kind Code |
A1 |
Jones; David R. IV |
June 14, 2007 |
Roofing adhesive
Abstract
An adhesive for a roofing material includes an asphalt material
and reinforcing fibers dispersed in the asphalt material. The
reinforcing fibers have an average length within a range of from
1.6 mm to 10 mm. The adhesive is capable of adhesively bonding a
first asphalt-based roofing material to a second asphalt-based
roofing material or to a roof. The adhesive is processable by
conventional adhesive manufacturing equipment. In one embodiment,
the adhesive further comprises a polymer mixed with the asphalt
material to produce a polymer modified asphalt.
Inventors: |
Jones; David R. IV; (Tampa,
FL) |
Correspondence
Address: |
OWENS CORNING
2790 COLUMBUS ROAD
GRANVILLE
OH
43023
US
|
Family ID: |
38137879 |
Appl. No.: |
11/291577 |
Filed: |
December 1, 2005 |
Current U.S.
Class: |
52/408 ; 156/71;
52/746.11 |
Current CPC
Class: |
E04D 2001/3435 20130101;
E04D 1/34 20130101; C08L 95/00 20130101; C09D 195/00 20130101; E04D
5/148 20130101; C08L 95/00 20130101; C08L 2666/72 20130101; C09D
195/00 20130101; C08L 2666/72 20130101 |
Class at
Publication: |
052/408 ;
052/746.11; 156/071 |
International
Class: |
E04B 5/00 20060101
E04B005/00; E04B 1/00 20060101 E04B001/00; E04G 23/00 20060101
E04G023/00 |
Claims
1. An adhesive for a roofing material comprising an asphalt
material and reinforcing fibers dispersed in the asphalt material,
the reinforcing fibers having an average length within a range of
from 1.6 mm to about 10 mm, the adhesive being capable of
adhesively bonding a first asphalt-based roofing material to a
second asphalt-based roofing material or to a roof, and the
adhesive being processable with conventional adhesive manufacturing
equipment.
2. The adhesive defined in claim 1 wherein the adhesive has a
viscosity within a range of from about 500 cps to about 2000 cps at
350.degree. F. (217.degree. C.).
3. The adhesive defined in claim 1 wherein the reinforcing fibers
are included in an amount within a range of from about 10 wt % to
about 50 wt %.
4. The adhesive defined in claim 1 wherein the reinforcing fibers
have an average diameter within a range of from about 10 microns to
about 20 microns.
5. The adhesive defined in claim 1 wherein the asphalt material
comprises an oxidized asphalt having a softening point of at least
about 150.degree. F. (66.degree. C.).
6. The adhesive defined in claim 1 wherein the adhesive contains
not more than about 5 wt % solvent.
7. The adhesive defined in claim 1 wherein the asphalt material
comprises an oxidized asphalt having a softening point of at least
about 150.degree. F. (66.degree. C.), the reinforcing fibers are
included in an amount within a range of from about 10 wt % to about
30 wt %, and the reinforcing fibers have an average length within a
range of from 1.6 mm to about 5 mm.
8. The adhesive defined in claim 1 which further comprises a
polymer mixed with the asphalt material to produce a polymer
modified asphalt.
9. The adhesive defined in claim 8 wherein the polymer modified
asphalt has a softening point within a range of from about
170.degree. F. (77.degree. C.) to about 220.degree. F. (104.degree.
C.).
10. The adhesive defined in claim 8 wherein the polymer comprises a
styrenic elastomer.
11. The adhesive defined in claim 8 wherein the reinforcing fibers
are included in an amount within a range of from 10 wt % to about
50 wt %.
12. The adhesive defined in claim 8 wherein the polymer comprises a
styrenic elastomer, the polymer modified asphalt has a softening
point within a range of from about 170.degree. F. (77.degree. C.)
to about 220.degree. F. (104.degree. C.), the reinforcing fibers
are included in an amount within a range of from about 10 wt % to
about 30 wt %, and the reinforcing fibers have an average length
within a range of from 1.6 mm to about 5 mm.
13. The adhesive defined in claim 12 wherein the reinforcing fibers
comprise glass fibers.
14. The adhesive defined in claim 1, wherein the roofing material
comprises a reinforcement member, the reinforcement member defining
a nail zone of the roofing material.
15. The adhesive defined in claim 1 which is used for bonding a
reinforcement member to a roofing shingle, where the reinforcement
member defines a nail zone of the shingle.
16. The adhesive as defined in claim 1, wherein the adhesive
comprises a laminate adhesive.
17. The adhesive as defined in claim 1, wherein the adhesive
comprises a sealant.
18. An adhesive for a roofing material comprising an asphalt
material, reinforcing fibers dispersed in the asphalt material, and
roofing filler dispersed in the asphalt material, the adhesive
being capable of adhesively bonding a first asphalt-based roofing
material to a second asphalt-based roofing material or to a roof,
and the adhesive being processable with conventional adhesive
manufacturing equipment.
19. The adhesive defined in claim 18 wherein the roofing filler is
included in an amount within a range of from 20 wt % to about 70 wt
%.
20. The adhesive defined in claim 18 wherein the reinforcing fibers
have an average length within a range of from 1.6 mm to about 10
mm.
21. The adhesive defined in claim 18 wherein the adhesive has a
viscosity within a range of from about 500 cps to about 2000 cps at
350.degree. F. (217.degree. C.).
22. The adhesive defined in claim 18 wherein the reinforcing fibers
are included in an amount within a range of from 10 wt % to about
50 wt %.
23. The adhesive defined in claim 18 which further comprises a
polymer mixed with the asphalt material to produce a polymer
modified asphalt.
24. The adhesive defined in claim 18 which is used for bonding a
reinforcement member to a roofing shingle, where the reinforcement
member defines a nail zone of the shingle.
25. A roofing assembly comprising a first asphalt-based roofing
material and an adhesive which is capable of adhesively bonding the
first roofing material to a second asphalt-based roofing material
or to a roof, the adhesive comprising an asphalt material and
reinforcing fibers dispersed in the asphalt material, the
reinforcing fibers having an average length within a range of from
1.6 mm to about 10 mm, the adhesive being processable with
conventional adhesive manufacturing equipment.
26. The roof assembly defined in claim 25 wherein the adhesive
further comprises a polymer mixed with the asphalt material to
produce a polymer modified asphalt.
27. A method of manufacturing an adhesive for a roofing material
comprising mixing a reinforced asphalt material with a filled
asphalt material to produce the adhesive, the reinforced asphalt
material comprising a first asphalt material and reinforcing fibers
dispersed in the first asphalt material, the filled asphalt
material comprising a second asphalt material and roofing filler
dispersed in the second asphalt material, the adhesive being
capable of adhesively bonding a first asphalt-based roofing
material to a second asphalt-based roofing material or to a roof,
and the adhesive being processable with conventional adhesive
manufacturing equipment.
28. The method defined in claim 27 wherein the reinforced asphalt
material further comprises a polymer.
Description
BACKGROUND OF THE INVENTION
[0001] This invention relates in general to adhesives, and in
particular to a roofing adhesive for use in bonding asphalt-based
roofing materials together.
[0002] Roofing adhesives are used in various applications. For
example, they are used during the manufacture of laminated roofing
shingles to bond together the different pieces of the shingles.
They are also used during the application of roofing materials on
roofs. For example, when roofing shingles are laid on a roof,
typically an adhesive is used to bond the tab portions of an upper
course of shingles to the headlap portions of the adjacent lower
course of shingles. Roofing adhesives are also used for bonding
sheets of roll roofing together on a roof.
[0003] Conventional roofing adhesives are usually made from
oxidized asphalt and/or polymer modified asphalt. These adhesives
rely on the stiffness of the asphalt for their bond strength.
[0004] Some different types of roofing adhesives are described in
the following patents. U.S. Pat. No. 4,755,545 by Lalwani (GAF
Corp.), issued Jul. 5, 1988, discloses a self-sealing roofing
adhesive comprising a bituminous component, a thermoplastic block
polymer, and 4-40 wt % inert filler. Suitable fillers include
limestone, stone dust, or ground glass fibers to add strength. The
bituminous component is a road paving asphalt or a blend of road
paving asphalt and hard resin asphalt. The road paving asphalt has
a softening point of 110-130.degree. F., a viscosity of 1,000-5,000
poise, and a penetration of 40-80 dmm at 77.degree. F. The hard
resin asphalt has a softening point of 165-195.degree. F., and a
penetration of 30-60 dmm at 130.degree. F. The adhesive has a peel
strength between 1.5 lbs. and about 6 lbs. at 75.degree. F.
[0005] U.S. Pat. No. 4,923,913 by Chich et al. (GAF Corp.), issued
May 8, 1990, discloses a self-sealing roofing adhesive comprising a
hard asphaltic bitumen fraction, an elastomeric composition
composed of a thermoplastic elastomer and a plasticizer, and 5-50
wt % filler such as ground glass fibers, limestone or stone dust.
The hard asphaltic fraction has a softening point of 150.degree.
F.-220.degree. F. and a penetration of 0-30 dmm at 77.degree. F.
The adhesive has a softening point of 140.degree. F.-230.degree.
F., and a penetration of 30-100 dmm at 130.degree. F.
[0006] U.S. Pat. No. 6,753,362 by Khan et al. (Building Materials
Inv. Corp.), issued Jun. 22, 2004, discloses a roofing adhesive
comprising a non-blown asphalt optionally containing a minor amount
of blown asphalt, a block copolymer, 13-30 wt % hydrocarbon
solvent, and optionally 0-10 wt % reinforcing fibers. The
reinforcing fibers are preferably cellulose fibers having a length
of 0.02-1.5 mm and a diameter of not more than 0.06 mm. The
adhesive preferably has a viscosity of 60-140 cps and a penetration
of 50-120 dmm at 25.degree. C. An example of the adhesive has a
peel strength of 13.5 foot lbs./inch at ambient temperature.
[0007] U.S. Pat. No. 5,362,316 by Paradise (Imperbel America
Corp.), issued Nov. 8, 1994, discloses a roofing adhesive
comprising asphalt or polymer modified asphalt, terpene solvent,
and optionally a filler such as an organic or inorganic fiber,
limestone or stone dust. The examples include 1-6 wt % cellulose
fibers and 20-40 wt % limestone. The asphalt can be an oxidized
asphalt or an asphalt flux such as those used in roof coatings and
waterproofing applications. The roofing adhesive has a viscosity of
30,000-50,000 cps at 77.degree. F.
[0008] U.S. Pat. No. 5,929,144 by Fields (unassigned), issued Jul.
27, 1999, discloses a roofing asphalt comprising oxidized asphalt,
SEBS polymer, solvent, and optionally fibers and/or fillers. The
oxidized asphalt has a softening point greater than 225.degree. F.
The mixture of asphalt and polymer has a viscosity of 50-350 cps at
400.degree. F., and a softening point between 90.degree. F. and
225.degree. F. depending on the polymer content.
SUMMARY OF THE INVENTION
[0009] This invention relates to an adhesive for a roofing
material. The adhesive comprises an asphalt material and
reinforcing fibers dispersed in the asphalt material. The
reinforcing fibers have an average length within a range of from
1.6 mm to about 10 mm. The adhesive is capable of adhesively
bonding a first asphalt-based roofing material to a second
asphalt-based roofing material or to a roof. The adhesive is
processable with conventional adhesive manufacturing equipment. In
one embodiment, the. adhesive further comprises a polymer mixed
with the asphalt material to produce a polymer modified asphalt in
which the fibers are dispersed.
[0010] In another embodiment, the invention relates to an adhesive
for a roofing material which comprises an asphalt material,
reinforcing fibers dispersed in the asphalt material, and roofing
filler dispersed in the asphalt material.
[0011] In another embodiment, the invention relates to a roofing
assembly. The roofing assembly comprises a first asphalt-based
roofing material, and an adhesive which is capable of adhesively
bonding the first roofing material to a second asphalt-based
roofing material or to a roof. The adhesive comprises an asphalt
material and reinforcing fibers dispersed in the asphalt material.
The reinforcing fibers have an average length within a range of
from 1.6 mm to about 10 mm.
[0012] In a further embodiment, the invention relates to a method
of manufacturing an adhesive for a roofing material. The method
comprises mixing a reinforced asphalt material with a filled
asphalt material to produce the adhesive. The reinforced asphalt
material comprises a first asphalt material and reinforcing fibers
dispersed in the first asphalt material. The filled asphalt
material comprises a second asphalt material and roofing filler
dispersed in the second asphalt material. The adhesive is capable
of adhesively bonding a first asphalt-based roofing material to a
second asphalt-based roofing material or to a roof. In one
embodiment, the reinforced asphalt material further comprises a
polymer.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0013] The present invention relates to a roofing adhesive having
increased bond strength compared to conventional roofing adhesives
made from oxidized asphalt and/or polymer modified asphalt. The
roofing adhesive contains reinforcing fibers that provide optimum
bond strength gains per unit of fiber. At the same time, the
reinforcing fibers are selected to reduce any difficulties in
processing the adhesive with conventional manufacturing equipment.
For example, the type, size and amount of the fibers can be
selected so that the resulting adhesive provides a strong bond but
does not have a viscosity which is too high for processing with
conventional equipment.
[0014] The adhesive is capable of adhesively bonding a first
asphalt-based roofing material to a second asphalt-based roofing
material or to a roof. The asphalt-based roofing materials can be
pieces of roof covering products that are bonded together during
manufacture of the roof covering product, for example, the
different pieces of a laminated roofing shingle (such an adhesive
being commonly referred to as a "laminate adhesive"). The
asphalt-based roofing materials can also be first and second roof
covering products that are bonded together on a roof, such as
roofing shingles, sheets of roll roofing, or any other type of
asphalt-based materials suitable for use as roof coverings (such an
adhesive being commonly referred to as a "sealant"). The roof can
be any part of the roof of a building or any material which is
attached to the roof beneath the roof covering, for example, it can
be a roof deck or a waterproof membrane attached to the deck.
[0015] In one embodiment, the adhesive is used in conjunction with,
or as an adhesive for bonding, a reinforcement member used on a
roofing shingle, and preferably where the reinforcement member
defines a nail zone of the shingle, as described in U.S. patent
application Ser. No. 11/198,522 (the '522 application), entitled
"Shingle with Reinforced Nail Zone and Method of Manufacturing",
filed Aug. 5, 2005(incorporated by reference herein in its
entirety). The reinforcement member may be attached as taught in
the '522 application, or with the adhesive at different locations
on the roofing shingle, and it may be used with different types of
roofing shingles such as three-tab shingles (commonly as sealant)
and laminated shingles (commonly as laminate adhesive and/or
sealant).
[0016] The adhesive includes an asphalt material and the
reinforcing fibers dispersed in the asphalt material. By "asphalt
material", as used herein, is meant any type of bituminous material
suitable for use on a roof covering, such as asphalts, tars,
pitches, asphaltites, or mixtures thereof. The asphalt can be
either a naturally occurring asphalt or a manufactured asphalt,
such as an asphalt produced by refining petroleum or by other known
means. The asphalt can be an oxidized asphalt (produced by an
air-blowing process) or an asphalt flux. Mixtures of different
asphalts can also be used. In one embodiment, the asphalt is an
oxidized asphalt having a softening point of at least about
150.degree. F. (66.degree. C.), preferably within a range of from
about 200.degree. F. to about 240.degree. F., and more preferably
from about 210.degree. F. to about 230.degree. F. Preferably, the
asphalt has a penetration within a range of from about 15 to about
22 at 77.degree. F. (25.degree. C.).
[0017] In one embodiment, the adhesive also includes one or more
polymers mixed with the asphalt material to produce a polymer
modified asphalt. Any type of polymer suitable for producing an
adhesive having the properties described herein can be used.
Preferably, the polymer is an elastomer. For example, the elastomer
may be a diene rubber or butadiene based polymer or co-polymer,
preferably a styrenic elastomer, such as a styrene-butadiene random
copolymer (SBR), a di-block copolymer (SB), a tri-block copolymer
(SBS), or a combination thereof. The polymer modified asphalt
preferably has a softening point within a range of from about
170.degree. F. (77.degree. C.) to about 220.degree. F. (104.degree.
C.).
[0018] In one embodiment, the adhesive further includes one or more
roofing fillers dispersed in the asphalt material. Any type of
filler suitable for use in an asphalt roofing material can be used,
e.g., mineral filler/stabilizers such as small particles of
limestone, silica, dolomite or other rocks. The filler can be
included in any suitable amount. In some embodiments, the filler is
included in an amount within a range of from about 20 wt % to about
70 wt %, and preferably from about 30 wt % to about 50 wt %.
[0019] The reinforcing fibers dispersed in the asphalt material can
be any that are suitable for providing the above-described bond
strength and processing advantages. The fibers can be any suitable
type, or a mixture of different types, and they can be naturally
occurring fibers or fibers manufactured from a fiberizable
material. Some examples of inorganic reinforcing fibers include
fibers made from a fiberizable mineral material, such as glass,
rock, slag, basalt or diabase; and metal fibers such as fibers made
from or coated with aluminum, copper, silver, iron or chromium.
Inorganic fibers such as glass fibers are preferred because they
are substantially non-absorbent relative to the asphalt material,
resulting in a lower processing viscosity that facilitates
manufacturing the adhesive with conventional processing
equipment.
[0020] Some examples of organic reinforcing fibers include carbon
fibers, and fibers made from polymers, including polypropylene,
polyester such as polyethylene terephthalate, poly-paraphenylene
terephthalamide (KEVLAR.RTM.), polyisobutylene, polyamide (e.g.,
NYLON.RTM.), regenerated cellulose (e.g., RAYONS.RTM.),
polyphenylene such as polyphenylene sulfide, polyolefin,
polyurethane, polycarbonate, polystyrene, acrylic, and vinyl
polymer. The polymer fibers may be reclaimed or scrap fibers.
Naturally occurring organic fibers include cellulosic fibers such
as wood pulp, flax or jute.
[0021] The reinforcing fibers can have any suitable size. In some
embodiments, relatively short fiber lengths are used to reduce any
difficulties in processing the adhesive. Preferably, the
reinforcing fibers having an average length within a range of from
1.6 mm to about 10 mm, and more preferably from 1.6 mm to about 5
mm. The reinforcing fibers preferably have an average diameter
within a range of from about 5 microns to about 30 microns, more
preferably from about 10 microns to about 20 microns, and most
preferably from about 13 microns to about 16 microns.
[0022] The reinforcing fibers can be included in the adhesive in
any suitable amount. The amount of fiber used in the adhesive may
be regulated so as to reduce any processing issues caused by too
high a viscosity. In practice a level of less than about 50% by
weight of fiber is preferred, preferably an amount within a range
of from about 10 wt % to about 50 wt %, and more preferably from
about 10 wt % to about 30 wt %. The amount of fiber and the other
aspects of the invention impart the desired bond strength
improvement without unduly affecting the processing properties of
the adhesive.
[0023] In contrast to many adhesives known in the art, the adhesive
of the invention can usually be made without a substantial amount
of solvent. Preferably, the adhesive contains not more than about 5
wt % solvent, and more preferably it contains substantially no
solvent.
[0024] In another embodiment, the adhesive of the invention can be
made by mixing a reinforced asphalt material with a filled asphalt
material to produce the adhesive. The reinforced asphalt material
comprises a first asphalt material and reinforcing fibers dispersed
in the first asphalt material. The filled asphalt material
comprises a second asphalt material and roofing filler dispersed in
the second asphalt material. The first and second asphalt materials
may be any of those described above, and they may be the same or
different from each other. The reinforcing fibers and the roofing
filler may also be any of those described above. The reinforce
asphalt material may further include a polymer such as any of those
described above.
[0025] In accordance with the provisions of the patent statutes,
the principle and mode of operation of this invention have been
described in its preferred embodiments. However, it must be
understood that this invention may be practiced otherwise than as
specifically described without departing from its spirit or
scope.
* * * * *