U.S. patent application number 14/063450 was filed with the patent office on 2014-10-30 for rounded ridge cap with asphaltic foam materials.
This patent application is currently assigned to DEVPAT, LLC. The applicant listed for this patent is DEVPAT, LLC. Invention is credited to George F. Thagard, III, Casey G. Tzeng.
Application Number | 20140318034 14/063450 |
Document ID | / |
Family ID | 50543754 |
Filed Date | 2014-10-30 |
United States Patent
Application |
20140318034 |
Kind Code |
A1 |
Thagard, III; George F. ; et
al. |
October 30, 2014 |
ROUNDED RIDGE CAP WITH ASPHALTIC FOAM MATERIALS
Abstract
A method of making a rounded ridge cap includes providing an
intermediate product comprising a plurality of sections arranged
side by side and integrated as a single body of an asphaltic foam
material, each of the plurality of sections comprising a rounded
top surface, the plurality of sections comprising first and second
sections immediately neighboring each other. The first section
comprises a first side and the second section comprises a second
side integrated with the first side to form a bridge portion
between the first and second sections. The method further includes
bending the first section with respect to the second section about
the bridge portion, thereby forming a rounded ridge cap comprising
a rounded exterior surface. The rounded top surfaces of the first
and second sections form together the rounded exterior surface of
the rounded ridge cap.
Inventors: |
Thagard, III; George F.;
(Coto de Caza, CA) ; Tzeng; Casey G.; (Irvine,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
DEVPAT, LLC |
Fontana |
CA |
US |
|
|
Assignee: |
DEVPAT, LLC
FONTANA
CA
|
Family ID: |
50543754 |
Appl. No.: |
14/063450 |
Filed: |
October 25, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61718672 |
Oct 25, 2012 |
|
|
|
Current U.S.
Class: |
52/57 ; 156/212;
264/54 |
Current CPC
Class: |
E04D 2001/005 20130101;
E04D 1/30 20130101; Y10T 156/1028 20150115; E04D 2001/305
20130101 |
Class at
Publication: |
52/57 ; 156/212;
264/54 |
International
Class: |
E04D 1/30 20060101
E04D001/30 |
Claims
1. A method of making a rounded ridge cap, the method comprising:
providing an intermediate product comprising a plurality of
sections arranged side by side and integrated as a single body of
an asphaltic foam material, each of the plurality of sections
comprising a rounded top surface, the plurality of sections
comprising first and second sections immediately neighboring each
other, wherein the first section comprises a first side and the
second section comprises a second side integrated with the first
side of the first section to form a bridge portion between the
first and second sections; and bending the first section with
respect to the second section about the bridge portion, thereby
forming a rounded ridge cap comprising a rounded exterior surface,
wherein the rounded top surfaces of the first and second sections
form together the rounded exterior surface of the rounded ridge
cap.
2. The method of claim 1, wherein providing the intermediate
product comprises: providing a reaction mixture comprising an
asphalt in an mold; subjecting the reaction mixture to react to
form the asphalt foam material; and curing the asphaltic foam
material, thereby molding the single body of the intermediate
product in the mold.
3. The method of claim 2, further comprising detaching the molded
intermediate product from the mold, wherein the bending is
performed immediately after detaching.
4. The method of claim 2, wherein the bending is performed at a
temperature of the molded intermediate product which is about
140.degree. F.
5. The method of claim 2, further comprising, subsequently to
bending, additionally curing the asphaltic foam material.
6. The method of claim 2, wherein providing the intermediate
product further comprises: providing a conveyor belt; applying a
granule layer to said conveyor belt; and placing the reaction
mixture and the mold over the conveyer belt.
7. The method of claim 2, wherein providing a reaction mixture
comprises: providing the asphalt and one or more isocyanates,
thereby forming a first intermediate mixture; forming a second
intermediate mixture comprising one or more polyols, a blowing
agent, and a surfactant; and mixing said first intermediate mixture
with said second intermediate mixture, thereby forming the reaction
mixture.
8. The method of claim 1, wherein the rounded exterior surface
comprises granules embedded therein.
9. The method of claim 1, wherein the top surfaces of the plurality
sections of the intermediate product form an undulating top surface
of the intermediate product.
10. The method of claim 1, wherein the intermediate product
comprises a notch located between the first and second sections and
under the bridge portion.
11. The method of claim 10, wherein each of the first and second
sections of the intermediate product comprises a wall comprising
the rounded top surface, wherein the walls of the first and second
sections are integrated at the bridge portion, wherein the bridge
portion has a thickness smaller than that of the wall.
12. The method of claim 1, wherein the first and second sections
comprise a first and second stop surfaces, respectively, wherein
the first section is bent with respect to the second section until
the first and second stop surfaces contact to each other.
13. The method of claim 1, wherein the first and second sections
comprise male and female latches, respectively, wherein the first
section is bent with respect to the second section until the male
and female latches are engaged with each other.
14. The method of claim 1, wherein the rounded exterior surface of
the rounded ridge cap has a substantially semi-circular shape in a
cross-section perpendicular to a length direction of the rounded
ridge cap.
15. A rounded ridge cap comprising: a rounded exterior surface; and
a plurality of sections arranged side by side and integrated as a
single body of an asphaltic foam material, each of the plurality of
sections comprising a wall with a rounded surface portion, wherein
the rounded surface portions of the plurality of sections
configured to form together the rounded exterior surface, wherein
the plurality of sections comprising first and second sections
immediately neighboring each other, wherein the first section
comprises a first side and the second section comprises a second
side integrated with the first side to form a bridge portion
between the first and second sections, wherein the bridge portion
has a thickness smaller than that of the wall of each of the first
and second sections.
16. The rounded ridge cap of claim 15, wherein the wall of the
first section comprises a first surface and the wall of the second
section comprises a second stop surface contacting the first
surface and located under the bridge portion.
17. The rounded ridge cap of claim 15, wherein the first section
comprises a male latch and the second section comprises a female
latch engaged with the male latch.
18. The rounded ridge cap of claim 15, wherein the rounded exterior
surface comprises granules embedded therein.
19. The rounded ridge cap of claim 15, wherein the rounded exterior
surface of the rounded ridge cap has a substantially semi-circular
shape in a cross-section perpendicular to a length direction of the
rounded ridge cap.
20. The rounded ridge cap of claim 15, wherein the rounded exterior
surface has a continuously rounded shape throughout the rounded
exterior surface.
Description
RELATED APPLICATIONS
[0001] This application claims priority to and the benefit of U.S.
Provisional Patent Application No. 61/718,672, filed Oct. 25, 2012,
the disclosure of which is incorporated herein by reference in its
entirety.
BACKGROUND
[0002] 1. Field
[0003] The present disclosure relates to a rounded ridge cap with
asphaltic foams.
[0004] 2. Discussion of the Related Technology
[0005] Generally, ridge caps are installed over the ridge line or
the hip line of a roof to provide sealing between two slopes of the
roof. The ridge caps may also provide aesthetic looking to the
roof. The ridge caps can be made of various materials, for example,
metal, tile, or asphaltic foam material.
1. Asphaltic Foams
[0006] Many attempts have been made to incorporate asphalt into
polyurethane foams. Primarily, asphalt has been used as a filler
material for such foams, due to the fact that it is less expensive
than the precursor chemicals used to produce polyurethane foam. For
example, in Spanish Patent Application No. 375,769, a process is
described in which asphalt powder is added to a polyurethane
precursor mixture as a filler material. The asphalt powder and
polyurethane form a uniformly distributed plastic mass.
[0007] The addition of asphalt to a polyurethane foam can also,
however, impart certain desired characteristics to the foam. In
Japanese Patent Application No. 76/64,489, for example, a
polyurethane foam was waterproofed through the addition of asphalt
to the polyurethane precursors. Another asphalt-polyurethane
mixture having good sound absorption and anti-vibration properties
is disclosed in Japanese Patent Application No. 77/68,125.
[0008] Most prior art processes for incorporating asphalt into
polyurethane, such as Japanese Patent Application No. 76/64,489,
have made use of soft asphalts with low softening points. Such
asphalts can be liquefied and blended with polyols at relatively
low temperatures to form a uniform, liquid mixture of asphalt and
polyols. By completely blending the liquefied asphalt with the
polyols, a uniform asphalt-polyurethane foam product can then be
produced. In addition, because low softening point asphalt remains
liquid at relatively low temperatures, the asphalt-polyol mixture
can be reacted to form a foam at temperatures which are low enough
that a controlled reaction can take place. However, such foam
products generally have a relatively low asphalt content.
[0009] In Japanese Patent Application No. 76/64,489, for example, a
soft asphalt having a needle penetration degree of 80 to 100 is
used. This asphalt has a correspondingly low softening point of
under 150.degree.. In the process of this patent, the asphalt is
mixed with polyurethane precursors, and this mixture is then
reacted to form a compressible product, i.e. a soft foam.
[0010] The use of such soft asphalts in prior art processes is
acceptable when it is desirable for the resulting product to be a
soft foam. However, in certain applications, a rigid asphaltic
polyurethane foam would be advantageous. A process for making a
rigid asphaltic polyurethane foam is disclosed, for example, in
U.S. Pat. No. 4,225,678 to Roy. In this process, relatively high
molar ratios of isocyanate to polyols are recommended, in some
cases as high as 11:1. The Roy process therefore resulted in
products which were too friable and/or which lacked sufficient
compressive strength. When conventional roofing asphalt having a
softening point of over 200.degree. F. was used in the Roy process
to produce asphaltic foams, the foaming reaction also was too fast,
making manufacturing of asphaltic foams impracticable.
[0011] In U.S. Pat. Nos. 5,786,085; 5,813,176; 5,816,014; and
5,965,626 all to Tzeng et al., and U.S. Pat. No. 8,017,663 to
Thagard et al., all herein incorporated by reference, an asphaltic
foam useful in roofing applications is disclosed.
2. Asphalt in the Roofing Industry
[0012] Various asphalt-coated or asphalt-impregnated materials are
in common use in the roofing industry. For example, water absorbent
paper which has been saturated with low softening point asphalt,
known as saturated felt, is usually placed underneath other roofing
components. The asphalt of the saturated felt provides the felt
with secondary water repellency.
[0013] Higher softening point asphalt is put on either side of
saturated felt to form base sheets, which go under the tiles of a
roof to build up the roof system. Base sheets with mineral
surfacing on their upper surfaces, known as mineral surface rolls,
provide enhanced durability and fire retardancy to a roof and can
also enhance a roofs appearance. Mineral surface rolls have been
used as ridge caps, the largely ornamental structures which
straddle the peak of a roof.
[0014] However, asphalt-impregnated papers suffer from various
drawbacks. When used as ridge caps, for example, mineral surface
rolls must be bent to fit the ridge-line of a roof. Mineral surface
rolls are also sometimes bent to make them thicker and give a
ridge-line a layered appearance. Bending a mineral surface roll
causes the asphalt and substrate to crack, however, leaving the
cracked material exposed to the elements. The mineral surface roll
tends to deteriorate at the site of such cracks within 3 to 4 years
of being installed or even sooner, resulting in leaks and other
roof damage.
[0015] Alternative materials, such as rubberized asphalt with a
flexible polyester substrate, have also been used in the roofing
industry. For example, modified asphalt has been used in mineral
rolls to avoid cracking the asphalt and its substrate.
3. Polyurethane Foam in Shingles and Ridge Caps
[0016] One method for combining a polyurethane foam and an
asphaltic material in roofing applications is suggested in U.S.
Pat. Nos. 5,232,530 and 5,305,569 to Malmquist, et al. These
patents teach that a polyurethane foam can be attached to the
underside of an asphaltic material in order to produce a roofing
shingle. Of course, this involves the manufacturing step of
physically attaching the foam to the asphaltic material or
otherwise forming the foam on the asphaltic material. The
polyurethane foam and asphaltic material layers can, in addition,
become delaminated.
SUMMARY
[0017] One aspect provides a method of making a rounded ridge cap,
which can comprise: providing an intermediate product comprising a
plurality of sections arranged side by side and integrated as a
single body of an asphaltic foam material, each of the plurality of
sections comprising a rounded top surface, the plurality of
sections comprising first and second sections immediately
neighboring each other, wherein the first section comprises a first
side and the second section comprises a second side integrated with
the first side to form a bridge portion between the first and
second sections; and bending the first section with respect to the
second section about the bridge portion, thereby forming a rounded
ridge cap comprising a rounded exterior surface, wherein the
rounded top surfaces of the first and second sections form together
the rounded exterior surface of the rounded ridge cap.
[0018] In the foregoing method, providing the intermediate product
may comprise: providing a reaction mixture comprising an asphalt in
an mold; subjecting the reaction mixture to react to form the
asphalt foam material; and curing the asphaltic foam material,
thereby molding the single body of the intermediate product in the
mold. The method may further comprise detaching the molded
intermediate product from the mold, wherein the bending is
performed immediately after detaching. The bending may be performed
at a temperature of the molded intermediate product ranging from
about 120.degree. F. to about 170.degree. F. The method may further
comprise, subsequently to bending, additionally curing the
asphaltic foam material.
[0019] Still in the foregoing method, providing the intermediate
product may further comprise: providing a conveyor belt; applying a
granule layer to said conveyor belt; and placing the reaction
mixture and the mold over the conveyer belt. Providing a reaction
mixture may comprise: providing the asphalt and one or more
isocyanates, thereby forming a first intermediate mixture; forming
a second intermediate mixture comprising one or more polyols, a
blowing agent, and a surfactant; and mixing said first intermediate
mixture with said second intermediate mixture, thereby forming the
reaction mixture.
[0020] Yet in the foregoing method, the top surfaces of the
plurality sections of the intermediate product may form an
undulating top surface of the intermediate product. The
intermediate product may comprise a notch located between the first
and second sections and under the bridge portion. Each of the first
and second sections of the intermediate product may comprise a wall
comprising the rounded top surface, wherein the walls of the first
and second sections are integrated at the bridge portion, wherein
the bridge portion may have a thickness smaller than that of the
wall.
[0021] Further in the foregoing method, the first and second
sections may comprise a first and second stop surfaces,
respectively, wherein the first section may be bent with respect to
the second section until the first and second stop surfaces contact
to each other. The first and second sections may comprise male and
female latches, respectively, wherein the first section may be bent
with respect to the second section until the male and female
latches are engaged with each other. The rounded exterior surface
of the rounded ridge cap may have a substantially semi-circular
shape in a cross-section perpendicular to a length direction of the
rounded ridge cap.
[0022] Another aspect provides a rounded ridge cap, which may
comprise: a rounded exterior surface; and a plurality of sections
arranged side by side and integrated as a single body of an
asphaltic foam material, each of the plurality of sections
comprising a wall with a rounded surface portion, wherein the
rounded surface portions of the plurality of sections configured to
form together the rounded exterior surface, wherein the plurality
of sections comprising first and second sections immediately
neighboring each other, wherein the first section comprises a first
side and the second section comprises a second side integrated with
the first side to form a bridge portion between the first and
second sections, wherein the bridge portion has a thickness smaller
than that of the wall of each of the first and second sections.
[0023] In the foregoing ridge cap, the wall of the first section
may comprise a first stop surface and the wall of the second
section may comprise a second stop surface contacting to the first
stop surface and located under the bridge portion. The first
section may comprise a male latch and the second section may
comprise a female latch engaged with the male latch. The rounded
exterior surface comprises granules embedded therein. The rounded
exterior surface may have a substantially arcuate shape having a
central angle ranging from about 90.degree. to 270.degree. in a
cross-section perpendicular to a length direction of the rounded
ridge cap. The rounded exterior surface has a continuously rounded
shape throughout the rounded exterior surface.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIGS. 1-6 are various views of an intermediate product of a
rounded ridge cap in accordance with an embodiment.
[0025] FIGS. 7-10 are various views of a final product of a rounded
ridge cap by bending the intermediate product shown in FIGS. 1-6
and cooling the bent product.
[0026] FIGS. 11-13 are various views showing engagement of the
rounded ridge caps shown in FIGS. 7-10.
[0027] FIG. 14 show steps of engaging a latch structure during
bending of the intermediate product shown in FIGS. 1-6.
[0028] FIGS. 15 and 16 are views of the intermediate product shown
in FIGS. 1-6 and a mold, showing a state that the intermediate
product is in the mold.
[0029] FIGS. 17-24 are various views of an intermediate product of
a rounded ridge cap in accordance with another embodiment.
[0030] FIGS. 25-29 are various views of a final product of a
rounded ridge cap by bending the intermediate product shown in
FIGS. 17-24 and cooling the bent product.
[0031] FIGS. 30-34 are various views showing engagement of the
rounded ridge caps shown in FIGS. 25-29.
[0032] FIGS. 35-36 show male and female latches of the intermediate
product of the rounded ridge cap shown in FIGS. 17-24.
[0033] FIGS. 37-40 are views of the intermediate product shown in
FIGS. 1-6 within a mold.
[0034] FIGS. 41-44 show a process of making a rounded ridge cap in
accordance with an embodiment.
[0035] FIGS. 45A and 45B are enlarged views of a bridge portion
between two sections before and after bending, respectively.
DETAILED DESCRIPTION
[0036] Embodiments of the invention will be described in
detail.
Rounded Ridge Cap
[0037] Referring to FIG. 11, in embodiments, ridge caps 10 are
placed on the roof ridge of a house. The ridge cap 10 has a rounded
shape which can provide improved aesthetic views as well as its
function of covering the roof ridge. In some embodiments, the
rounded shape can comprise the curvature of a circle or an ellipse;
however, other generally smoothly curved surfaces are also
encompassed by other embodiments.
Process of Making Rounded Ridge Cap
[0038] In embodiments, a rounded ridge cap is made with an
asphaltic foam material. Referring to FIG. 41, an asphaltic foam
material is molded in a mold to form an intermediate product with
two or more sections connected to each other. After partially
curing the intermediate product, the intermediate product is
detached from the mold. The sections of the intermediate product
are bendable in a warm temperature, for example around 140.degree.
F., as soon as the intermediate product is detached from the mold.
In some embodiments, the sections of the intermediate product are
bendable in a warm temperature between about 120.degree. F. to
about 170.degree. F. In other embodiments, the sections of the
intermediate product are bendable in a warm temperature between
about 125.degree. F. to about 150.degree. F.
[0039] Subsequently, the sections of the intermediate product are
bent to interlock the sections and form a complete round shape of
the ridge cap. After bending, the product is cooled to room
temperature and cured into a final product of the rounded ridge cap
having a sufficient rigidity. In embodiments, the cooling can be
completed by placing the bent product at room temperature.
Intermediate Product
[0040] Referring to FIGS. 1-6, in embodiments, an intermediate
product 50 of a rounded ridge cap 10 includes a middle section 52
and two side sections 54 and 56 connected to the middle section.
The middle section 52 is interposed between the side sections 54
and 56. As can be seen in the plan views in FIGS. 1(a) and 2(a),
each of the sections has a trapezoidal shape.
Middle Section
[0041] Referring to FIGS. 1-6, 45A and 45B, in embodiments, the
middle section 52 includes a rounded top wall 58. Granules are
embedded in a top surface 60 of the top wall 58. In one embodiment,
the thickness T of top wall 58 can be from about 3/8 inch to about
1/2 inch. The middle section 52 also includes elevated portions 62
raised from the bottom surface of the wall 58. One or more of the
elevated portions 62 have notches extending along a center line of
the rounded ridge cap 10. The notch 63 can receive the ridge of the
roof as shown in FIG. 11 when the final product of the rounded
ridge cap 10 is placed on the roof.
Side Sections
[0042] Referring to FIGS. 1-6, 45A and 45B, in embodiments, each of
the side sections 54 and 56 includes a rounded top wall 64.
Granules are embedded in a top surface 66 of each of the side
sections 54 and 56. In embodiments, the side sections can have a
color different from that of the middle section as shown in FIGS. 9
and 10.
[0043] Each of the side sections also includes elevated portions 68
and ribs 70 raised from the bottom of the wall 64. As show in FIG.
11, the ribs 70 contact the inclined surface of the roof and
support the structure of the ridge cap 10 when the final product of
the rounded ridge cap 10 is placed on the roof. In some
embodiments, the structures of the side section 54 and the
structures of the side section 56 can be symmetrically formed.
[0044] In one embodiment, the ribs can provide secure contact with
the roof having an angle of about 140.degree. between two inclined
roof surfaces. In some embodiments, the ribs can provide secure
contact with the roof having an angle of about 100.degree. to about
170.degree. between two inclined roof surfaces.
Number of Sections
[0045] In the foregoing embodiments, the number of the sections is
three (3). In other embodiments, the number of the sections of the
ridge caps 10 can be modified. For example, in an alternative
embodiment, a ridge cap can have only two sections which can be
bent to form a single rounded shape of the ridge cap.
Alternatively, a ridge cap can include four or more sections.
Connection Between Middle Section and Side Sections
[0046] Referring to FIGS. 1-6, 45A and 45B, in embodiments, the
middle section 52 is connected to each of the side sections 54 and
56 via a connecting bridge 76. To adjust the thickness Ta of the
connecting bridge 76, a notch 78 is formed between the middle
section 52 and each of the side sections 54 and 56. As shown in
FIG. 45B, the thickness Ta of the connecting bridge 76 may be
smaller than the thickness T of the top walls of the sections 52
and 54. In embodiments, the thickness Ta of the connecting bridge
76 can be about 1/32 inch to about 3/16 inch. In one embodiment,
the thickness Ta of the connecting bridge 76 can be about 1/32 or
1/16. In another embodiment, the thickness Ta of the connecting
bridge 76 can be about 1/8 inch. In some embodiments, the thickness
can be modified depending on the characteristics of the foaming
compositions.
[0047] In embodiments, the notch 78 may be formed by a first stop
surface 78a of the side section 54 and a second stop surface 78b.
When bending the sections 52 and 54, the stop surfaces 78a and 78b
become contact to each other. Such configuration can limit the
excessive bending. The contacting stop surfaces 78a and 78b in the
finished rounded ridge cap may have a length Tb in a thickness
direction of the top walls of the sections 52 and 54 smaller than
the thickness T of the top walls of the sections 52 and 54.
[0048] The connecting bridges 76 can be deformed to allow each of
the side sections to be bent with respect to the middle section at
a warm temperature (for example, about 140.degree. F.) higher than
a room temperature without generation of substantial cracks around
the connecting bridges 76. However, once the cooling process is
completed, the connecting bridges 76 become rigid sufficiently to
maintain the whole shape of the final product of the ridge cap 10
as shown in FIGS. 7-10. In some embodiments, the connecting bridges
76 can be deformed to allow each of the side sections to be bent
with respect to the middle section at a temperature between about
120.degree. F. to about 170.degree. F. In some embodiments, the
connecting bridges 76 can be deformed to allow each of the side
sections to be bent with respect to the middle section at a
temperature between about 125.degree. F. to about 150.degree.
F.
Engagement Between Middle Section and Side Sections
[0049] Referring to FIGS. 1-6, in embodiments, the middle section
52 and the side section 54 include locking mechanisms on the
elevated portions 62 and 68. The middle section 52 and the side
section 56 also include locking mechanisms on the elevated portions
62 and 68.
[0050] Each of the locking mechanisms includes a male latch 72 and
a female latch 74. As shown in FIG. 14, the male latch and the
female latch can have undercuts. In a high temperature of the
molded intermediate product, for example, about 140.degree. F., the
male and female latches can be slightly deformed to engage each
other. When bending the side section 54 with respect to the middle
section 52, the male and female latches 72 and 74 are engaged. Once
the ridge cap 10 is cooled to room temperature, however, the
latches 72 and 74 are firmly cured and engaged to each other, and
thus, the locking mechanisms can provide another means that
sufficiently maintain the whole shape of the final product of the
ridge cap 10 as shown in FIGS. 8, 9, 10 and 14. Thus, in
embodiments, no adhesive material is used between two immediate
neighboring sections, but not limited thereto.
Final Product
[0051] Referring to FIGS. 7-10 and 45B, in embodiments, the final
product of the ridge cap 10 includes an exterior wall 80 having a
smooth rounded shape. In one embodiment, the rounded walls 58 and
64 of the sections 52, 54 and 56 have substantially the same
curvature to form a smooth rounded shape of the exterior wall 80.
Under the wall; the final product of the ridge cap 10 includes the
elevated portions 62 and 68, the latches 72 and 74 firmly engaged
with each other, and the ribs 70. When placing the ridge cap 10 on
the roof ridge, the ends of the ribs 70 contact the inclined roof.
In embodiments, the size of the ribs 70 can be adjusted such that
the rounded wall 80 does not touch the roof and the ridge cap 10 is
supported by the ribs 70.
Connection Between Two Neighboring Ridge Caps
[0052] Referring to FIGS. 7-10, in embodiments, the ridge cap 10
includes thickness-reduced portions 82 at a trailing end portion
84. The ridge cap 10 further includes protrusions 86 that are
formed at the elevated portions 62 and 68 located near a leading
end portion 88. The protrusions 86 project from the elevated
portions 62 and 68 toward the leading end portion 88 to form
receptacles 90 between the protrusions 86 and the wall 80. The
receptacles 90 are sized to receive the thickness-reduced portions
82, respectively. Thus, as shown in FIGS. 11-13, when placing the
ridge caps 10 on the roof, two neighboring ridge caps 10 can be
assembled by fitting of the protrusion 86 and the receptacles 90.
As shown in the drawings the trailing end of a ridge cap 10 is
located under the leading end portion of the wall 80 of another
ridge cap.
Another Example of Ridge Cap Structure
[0053] FIGS. 17-36 illustrate another example of a ridge cap 10a.
The ridge cap 10a has raised portions 92 which contact the roof and
support the ridge cap 10a. Other structures of the ridge cap 10a
are generally similar to those of the ridge cap 10 illustrated in
FIGS. 1-16.
Compositions and Process for Molding Ridge Cap
I. Definitions of Terms
[0054] As used herein, the terms listed below shall be defined as
follows, unless a contrary meaning is clearly meant in context:
[0055] "Foaming reaction" shall mean a sum of chemical reactions
that concur when a polyisocyanate is put in contact with a polyol
and water to form a polyurethane and carbon dioxide as a blowing
agent.
[0056] "Modified asphalt" shall refer to asphalt which has been
blended with polypropylene, particularly atactic polypropylene, or
with other asphalt modifiers such as styrene-butydiene-styrene
(SBS) or Vistamer.TM., a surface modified particulate rubber.
[0057] "Penetration" shall mean the hardness of a material, as
measured by the resistance of the material to penetration by a
needle mounted on a penetrometer. A penetrometer is a device which
holds a needle with a 100 gram (+-0.05 grams) load and moves
vertically without measurable friction. To determine the
penetration value of a material, the tip of the needle of a
penetrometer is positioned on the surface of a material whose
hardness is to be tested, and the needle is allowed to penetrate
into the material for 5 (+-0.1) seconds at 77.degree. F.
(25.degree. C.). The amount of penetration is rated in terms of the
length of the needle, measured in tenths of millimeters, which
penetrated the material in those 5 seconds. A numeric value
corresponding to amount of penetration, in tenths of millimeters,
is then assigned as the penetration value of the material. This
procedure follows the standard test method for the penetration of
bituminous materials promulgated by the American Society' for
Testing and Materials (ASTM Designation D 5-83). Since a needle
will pass through a softer material more rapidly than a harder
material, higher penetration values correspond to softer
materials.
[0058] "Reaction mixture" shall refer to any combination of
reactants used in the process of the embodiments prior to being
reacted in a foaming reaction.
[0059] "Softening point" means the temperature at which asphalt
attains a particular degree of softness. Asphalt does not have a
definite melting point, but instead changes slowly from a harder to
a softer material with increasing temperature. The softening point
is determined by placing a steel ball (9.53 mm in diameter) on a
mass of asphalt contained in a brass ring. The ring has a brass
plate at the bottom in contact with the asphalt sample. The asphalt
and ball are then heated in a water or glycerol bath until the ball
drops to the plate, which is 25 mm under the ring. The temperature
at which the ball drops to the plate is the softening point. This
procedure follows the standard test method for the softening point
of bitumen promulgated by the American Society for Testing and
Materials (ASTM Designation D 36-76).
[0060] The previously discussed definitions pertain as well to
other grammatical forms derived from these terms, including
plurals.
II. Improved Asphaltic Foam
A. Reactants
1. Asphalt
[0061] Asphalt is a solid or semisolid mixture of hydrocarbons and
small amounts of non-hydrocarbon materials, occurring naturally or
obtained through the distillation of coal or petroleum. Most of the
hydrocarbons in asphalt are bituminous, meaning that they are
soluble in carbon disulfide. As is known to those of skill in the
art, asphalt is a complex, colloidal mixture containing a broad
spectrum of different hydrocarbon components. These components can
generally be broken down into three main categories: two solid
components, the asphaltenes and asphaltic resins, and one liquid
component, the oily constituents.
[0062] Asphaltenes generally comprise the highest molecular weight
and most aromatic components of asphalt. Asphaltenes are defined as
the components of asphalt which are soluble in carbon disulfide but
insoluble in paraffin oil (paraffin naphtha) or in ether.
[0063] Broadly categorized, the asphaltic resins and oily
constituents can be further separated into saturated components,
aromatic components, and resins or polar components. The polar
components are responsible to some degree for the viscosity of an
asphalt.
[0064] In order to produce an asphaltic foam of the embodiments,
asphalt meeting certain specifications can be used in the process
for manufacturing this foam. We have found that the hardness of the
asphalt component of the foam contributes to the rigidity of the
final foam product. Therefore, in order to give the final product
sufficient rigidity, an asphalt having a penetration range of about
5 to about 25 can be chosen. In one embodiment, an asphalt having a
penetration range of between about 8 and about 18 is used, and in
another embodiment, an asphalt having a penetration of about 12 is
used. However, in order to keep the reactants at a lower
temperature range (about 120.degree. F.-170.degree. F.) where the
reaction rate is controlled, asphalt with a penetration range of
about 90-110 and softening point of about 110.degree. F. can be
used.
[0065] The hardness of asphalt is, in turn, generally correlated to
its asphaltene content, although the asphaltic resin components of
asphalt will also contribute to an asphalt's hardness. The asphalt
used to produce the foam of the embodiments has an asphaltene
content in the range of about 10% to about 30% by weight, in
another embodiment, in the range of about 12% to about 18%. In a
particular embodiment, the asphalt used in the embodiments has an
asphaltene content of about 12%.
[0066] The asphalt used to produce the present asphaltic foam can
be chosen so as to have a relatively low softening point. An
asphalt having a softening point of about 100.degree. F. to about
200.degree. F. can be used. In one embodiment, an asphalt having a
softening point of about 100.degree. F. to about 150.degree. F. is
used, and in another embodiment, an asphalt having a softening
point of about 120.degree. F. is used. As is known to those of
skill in the art, the softening point of asphalt is influenced by
the resin or oil content of the asphalt.
[0067] In one embodiment, the asphalt used to produce the present
asphaltic foam, in addition, is chosen so as to have a lower
viscosity. The lower viscosity can be achieved with or without the
use of viscosity reducers.
[0068] An asphalt for use in the embodiments is a non-blown (i.e.,
not air-oxidized) asphalt obtained from Paramount Petroleum
(California) having the following specifications: a softening point
of greater than about 90.degree. F. and less than about 120.degree.
F., and a penetration range of greater than about 85 and less than
about 120. This asphalt is composed (in weight percentages) of
about 0.12-13% asphaltene, about 9-12% saturated hydrocarbons,
about 38-44% polar aromatics, and about 35-38% naphthalene
aromatics. For example, Saturant 701 asphalt meeting these
specifications can be used. The use of one of the previously
discussed asphalt is advantageous such that with mixing of the
asphalt and isocyanate, flaking or boiling off of the components
would not occur. Additionally, a use of one of the previously
discussed asphalt will result in an asphaltic foam that is more
flexible.
[0069] In total, the asphalt component of the reactants used in the
process of the embodiments can comprise up to about 24% by weight
of the final finished product. Asphalt can, however, make up
between about 5% and about 33% of the finished product used in the
present process.
[0070] The use of lower amounts of asphalt in the process of the
embodiments will not significantly affect the reaction of that
process. However, using greater amounts of asphalt than this can
lead to the reaction mixture becoming more viscous (in the absence
of viscosity reducers), necessitating the use of higher reaction
temperatures in order to blend the reaction mixture components.
This in turn increases the reaction rate to a point which becomes
hard to control during manufacturing.
[0071] Generally, the more asphalt used, the more economical the
final product will be, since asphalt is generally less expensive
than the other components of the present asphaltic foam. Asphalt
does, however, require energy to heat it. Higher asphalt levels
will also lead to higher viscosity in the reaction mixture, which
may cause manufacturing difficulties.
[0072] In addition, the amount of asphalt used will affect the
physical properties of the finished asphaltic foam product of the
embodiments. With a higher asphalt content, the foam tends to be
softer and to have a higher density. More free asphalt can also be
extracted from the foam at higher asphalt levels.
2. Asphalt Modifiers
[0073] When producing the asphaltic foam of the embodiments, it is
possible, though not essential, to blend an asphalt modifier into
the asphalt component of the reaction mixture. For example, the
addition of polypropylene to the asphalt enhances the strength of
the final foam product of the present process. In one embodiment,
atactic polypropylene (APP) is used because it blends well with the
asphalt.
[0074] When polypropylene is used in the present process, it is
blended into the asphalt component of the reaction mixture in an
amount of up to about 10% by weight of the asphalt. In one
embodiment, polypropylene is added in an amount of between about 3%
and about 8%, and in another embodiment, is used in an amount of
about 5% by weight of the asphalt.
[0075] In order to blend the polypropylene into asphalt, the
asphalt is first heated to about 400.degree. F. The polypropylene
is then dropped into the hot asphalt and blended in with a
mechanical mixer. Atactic polypropylene typically has a melting
point of over 350.degree. F. and so will melt on exposure to the
hot asphalt.
[0076] Other modifiers can also be used in the same way as APP to
modify the characteristics of the asphalt and/or the
characteristics of the final asphaltic foam product of the
embodiments. Such modifiers include isotactic polypropylene (IPP),
styrene-butydiene-styrene (SBS), styrene-isoprene-styrene (SIS),
ethylene-propylene (EPM), ethylene-propylene-diene (EPDM),
ethylene-vinyl acetate (EVAc), ethylene-acrylic ester (EAC),
ethylene copolymer bitumen (ECB), polyethylene (PE), polyethylene
chlorosulfonate (CMS), polyvinylchloride (PVC), butyl rubber (IIR),
polyisobutylene (PIB), and polychloroprene (CR). If the modifier
used has a lower melting point than APP, the asphalt in that case
only needs to be heated to a sufficient temperature to cause the
modifier to melt and blend into the asphalt and to cause the
asphalt to be sufficiently liquid so that other components can be
mixed into the asphalt.
[0077] One modifier which has been found to be particularly useful
is Vistamer.TM. (sold as Vistamer.TM. R or Vistamer.TM. RD,
depending on the water content of the particles), which is a
surface modified particulate rubber product made by Composite
Particles, Inc. (2330 26th St. SW., Allentown, Pa. 18103).
Vistamer.TM. is a free-flowing black powder made from post-consumer
tire materials. When added to the asphalt used in the present
process in an amount of about 10% (by weight of the asphalt),
Vistamer.TM. not only improves the viscosity of the asphalt and
makes it easier to blend the asphalt with the polyol component of
the process, it also increases the compressive strength of the
final foam product by about 10-15%. Smaller amounts of Vistamer.TM.
can also be added, of course, and this modifier can also be used
together with other modifiers, in amounts of up to about 10% total
modifier (by weight of the asphalt). Due to the high melting point
of Vistamer.TM., the asphalt is heated to about 400.degree. F.
before adding the Vistamer.TM. to the asphalt.
3. Polyols
[0078] Polyols are one of the precursors necessary to form a
polyurethane or isocyanurate foam. A polyol is a hydrogen donor
having a plurality of hydroxyl groups (--OH). Polyols also
sometimes comprise other hydrogen donor moieties, such as --NH,
--SH, and/or --COOH. NH groups are generally more reactive than OH
groups, followed by SH and COOH groups in reactivity. Polyols
comprised mainly of --OH hydrogen donors react quickly enough to be
commercially feasible but not so quickly as to produce a foaming
reaction which cannot be controlled. Polyols comprised mainly of
--OH hydrogen donors and polyols with amino groups have been found
to be in the present process.
[0079] In the foaming reaction of the present process, the
polyisocyanate mixed with asphalt prior to reaction, is reacted
with a mixture of polyols to form an asphaltic polyurethane or
isocyanurate foam (depending on the proportion of polyisocyanate in
the mixture). The polyisocyanate/water reaction is employed to form
the carbon dioxide gas as blowing agent. Several characteristics of
the polyols influence their reactivity in foaming reactions as well
as the nature of the foams produced by such reactions. One
characteristic of the polyols is its functionality, that is, the
number of reactive sites per molecule, such as hydroxyl groups or
amino groups, available to react in a foaming reaction.
[0080] In embodiments, a polyol having 2 or 3 functionalities can
be used to produce the asphaltic foam of embodiments.
Alternatively, a mixture of polyols which, in aggregate, have an
average of about 2 to about 3 functionalities can be used in the
present process. In the present process, the best results have, in
fact, been obtained when polyols used in the process comprise a
mixture of the following three polyols: [0081] (1) Carpol TEAP 265
(made by Carpenter Co., Chemicals Division, Richmond, Va. 23230),
which has an average of 3 functionalities per molecule, a hydroxyl
number (mg KOH/g) of 635, and a molecular weight of about 265;
[0082] (2) Carpol GP-6015 (made by Carpenter Co., Chemicals
Division, Richmond, Va. 23230), which has an average of 3
functionalities per molecule, a hydroxyl number (mg KOH/g) of
26-30, and a molecular weight of about 6000. [0083] (3) Carpol
PGP-1000 (made by Carpenter Co., Chemicals Division, Richmond, Va.
23230), which has an average of 2 functionalities per molecule, a
hydroxyl number (mg KOH/g) of 112, and a molecular weight of about
1000.
[0084] In general, the use of polyol having low functionality, for
example, functionality of 2 or 3 rather than high functionality
would reduce the cross linking, and thus, would reduce the rigidity
during the post-processing of the molded product. A mixture of
polyols for use in embodiments comprises Carpol TEAP 265, Carpol
GP-6015 and Carpol PGP-1000. In one embodiment, the ratio of Carpol
TEAP 265, Carpol GP-6015 and Carpol PGP-1000 (Carpol TEAP
265:Carpol GP-6015:Carpol PGP-1000) by weight can be 1:a:b (a is
about 0.6 to about 0.8, and b is about 0.5 to about 0.7). In
another embodiment, the ratio of Carpol TEAP 265, Carpol GP-6015
and Carpol PGP-1000 (Carpol TEAP 265:Carpol GP-6015:Carpol
PGP-1000) by weight can be 1:a:b (a is about 0.69, and b is about
0.6). The foregoing ratio can provide an intermediate product which
is soft sufficient to be deformed or bent before the cooling
process, and can also provide a final product having a sufficient
rigidity after the cooling process.
[0085] There are several other factors to consider when choosing
polyols for use in the embodiments. The viscosity of a polyol, for
example, is important. In embodiments, less viscous polyols are
generally used, since the asphalt component of the reaction mixture
is itself highly viscous, and less viscous polyols can help to
lessen the viscosity of the reaction mixture. Polyols with a lower
equivalent weight can be used for conferring more strength to the
foam but a certain amount of high equivalent weight polyols is
desirable for bringing in some foam flexibility.
[0086] Of course, other polyols besides those enumerated above are
available commercially and can be used in the present process.
Representative polyols which can be used according to the
parameters outlined above include both polyester polyols and
polyether polyols. Representative polyether polyols include
poly(oxypropyrene) glycols, poly(oxypropylene-b-oxyethylene)
glycols (block copolymers), poly(oxypropylene) adducts of glycerol,
poly(oxypropylene) adducts of trimethylolpropane,
poly(oxypropylene-b-oxyethylene) adducts of trimethylolpropane,
poly(oxypropylene) adducts of 1,2,6-hexanetriol, poly(oxypropylene)
adducts of pentaerythritol, poly(oxypropylene-b-oxyethylene)
adducts of ethylenediamine (block copolymers), and
poly(oxypropylene) adducts of sucrose methylglucoside, sorbitol.
Representative polyester polyols include those prepared from the
following monomers: adipic acid, phthalic anhydride, ethylene
glycol, propylene glycol 1,3-butylene glycol, 1,4-butylene glycol,
diethylene glycol, 1,2,6-hexanetriol, trimethylopropane and
1,1,1-trimethylolethane. Other polyols which can be used include
N,N,N',N'-tetrakis (2-hydroxy-propyl)-ethylenediamine, which is
commercially available under the trade name of "Quadrol" from BASF
Wyandotte Corporation.
4. Blowing Agent
[0087] In order to produce an asphaltic foam product with a greater
degree of foaming, compositions referred to as "blowing agents" can
be added to the reaction mixture. When added to a reaction mixture,
blowing agents are initially liquids. However, blowing agents
become gaseous during the foaming reaction and expand in volume.
Such expansion causes the now gaseous blowing agents to exert force
against the polymerizing reactants, thereby forming bubbles or
cells in the final foam product.
[0088] One blowing agent which can be used is water. When water is
added to the reaction mixture, it reacts with the polyisocyanate in
the mixture to give an amine or polyamine and also carbon dioxide.
Since water is dispersed homogeneously in the mixture, the carbon
dioxide gas is evolved throughout the cell structure. It is
advantageous for such carbon dioxide to be formed during the
foaming reaction, in order for the bubbles formed by the carbon
dioxide to produce the cells characteristic of polyurethane and
isocyanurate foams. Therefore, polyisocyanate and water is not
mixed together until the foaming reaction is begun.
[0089] When water is used as the sole blowing agent in the present
process, it is added to the reaction mixture in an amount of
between about 0.5% and about 5% by weight; in another embodiment,
in an amount of between about 0.7% and about 2.5% by weight; and in
another embodiment, in an amount of about 1.3% by weight, based on
the weight of the reaction mixture containing polyols. If other
blowing agents were added to the reaction mixture in addition to
water, a correspondingly lesser amount of water would be added.
Excess water is not added, because the water is a reactant and will
react with the isocyanate, thereby preventing the isocyanate-polyol
reaction. The addition of too much water would prevent a foam cell
structure from forming and would cause too much carbon dioxide to
evolve.
[0090] Other blowing agents used to foam polyurethane or
isocyanurate polymers generally operate by vaporizing at
temperatures which are lower than that at which the foaming
reaction takes place, rather than by reacting with any of the
components of the reaction mixture. Such other blowing agents
include halocarbons, such as trichlorofluoromethane,
dichlorodifluoromethane, and methylene chloride; ethanol mixed with
dibutylphthalate; and other volatile liquids or liquid mixtures.
Because these blowing agents act by vaporizing, they are generally
added, like water, just before the foaming reaction begins.
However, we have found that under most circumstances it is not
feasible to use such conventional physical blowing agents due to
the temperature requirement of the asphalt-polyol mixture, which is
highly viscous at lower temperatures.
5. Polyisocyanate
[0091] A number of polyisocyanates can be used to create the
asphaltic foam of the embodiments. These polyisocyanates can have
at least two and in another embodiment, three functionalities per
polyisocyanate molecule.
[0092] In the process of the embodiments, polyisocyanates are added
to the reaction mixture in a particular stoichiometric molar ratio
compared to the amount of polyol added. In order to form a
polyurethane asphaltic foam, this ratio can be in the range of
about 1.3:1 to 1:1 (polyisocyanate:polyol), and about 1.1:1 in one
embodiment. In order to form an isocyanurate foam, though, the
ratio can be in the range of about 2.0:1 to 2.5:1, and in another
embodiment, can be about 2.5:1. In another embodiment, in order to
form a polyurethane asphaltic foam, the polyisocyanate is added to
the asphalt in a weight ratio of about 0.8:1 to 3.2:1
polyisocyanate:asphalt, and in a further embodiment, in a ratio of
about 1:1 to 1.5:1 polyisocyanate:asphalt.
[0093] In an embodiment, a polyisocyanate molecule having about 3
NCO functionalities is used in the process of embodiments. This
molecule is a polymeric methylene diphenyl diisocyanate (MDI)-type
molecule. Polymeric MDI is due to its low toxicity and low vapor
pressure at room temperature. Mondur MR (Miles, Inc.) is a
polymeric MDI which has been found to produce a satisfactory
asphaltic foam product. Other polyisocyanates which can be used
include PAPI 580 (Dow), PAPI 901 (Dow), PAPI 27 (Dow), Mondur E-489
(Miles), Mondur 437 (Miles), Rubinate HF-185 (ICI), and LUPRANATE
M70 (BASF).
6. Other Ingredients
[0094] A variety of other ingredients can be added to the reaction
mixture in minor amounts according to the process of the
embodiments in order to impart certain desired characteristics to
the final asphaltic foam product. For example, in order to assure
an even cell structure in the foam material, a silicone surfactant
such as Air Products DABCO DC 5357 can be added during the blending
of the polyol-asphalt mixture. If up to about 4% of a surfactant
(based on the weight of the polyol and asphalt together) is added
to the reaction mixture, a foam having smaller, homogenous cells is
obtained.
[0095] Plasticizers, such as dioctylphthalate, diisooctylphthalate,
dibutylphthalate, diisobutylphthalate, dicaprylphthalate,
diisodecylphthalate, tricresylphosphate, trioctylphosphate,
diisooctyladipate, and diisodecyladipate, can also be used in the
present process to make the reactants used in the process less
viscous. Plasticizers in this application act as emulsifiers and as
viscosity reducers.
[0096] In one embodiment, catalysts to speed the foaming reaction
are not added when producing a polyurethane foam. It has been
found, for example, that catalysts such as triethylamine and
triethanolamine cause a foaming reaction which is too rapid to be
used in manufacturing polyurethane foam products. However,
catalysts which speed the curing of the final foam product are
advantageously used. Curing catalysts such as Air Products DABCO 33
LV or POLYCAT 5 can be added in amounts of up to 2% based on the
total weight of the polyol mixture.
[0097] When producing isocyanurate foams, though, a catalyst can be
added to the reaction mixture in order to make the foaming reaction
sufficiently rapid to be commercially useful. Between about 8% and
10% (by weight of the polyol mixture) of a catalyst such as
DABCO.RTM. TMR-4 (available from Air Products and Chemicals, Inc.,
Box 538, Allentown, Pa. 18105) can be added to the polyol mixture
prior to the commencement of the foaming reaction in order to
produce a rapidly foaming isocyanurate foam product.
[0098] In addition, other additives such as flame retardants,
fillers, and U.V. protectors can also be added to the reactant
mixture in order to impart other desired characteristics to the
asphaltic foam of the embodiments without deleteriously effecting
the rigidity and other physical properties which are achieved in
the final foam product. For example, the flame retardant
Antiblaze.RTM. 80 and Fyrol 6 (diethyl-N,
N-bis(2-hydroxyethyl)aminomethyl phosphonate) have been
successfully incorporated into the asphaltic polyurethane foams of
the embodiments to increase the flame retardancy of the foam
material. Antiblaze.RTM. 80 is a neutral, chlorinated phosphate
ester which is available from Albright & Wilson, P.O. Box
26229, Richmond; VA 23260. Flame retardants, if used, are added to
the reaction mixture prior to foaming in amounts of about 8% to 10%
(by weight of the polyol-asphalt mixture). The flame retardant TCPP
(Tris-(chloroisopropyl)phosphate) has also been successfully
incorporated into the asphaltic polyurethane foams of the
embodiments to increase the flame retardancy of the foam material.
Smaller amounts of fire retardant can also be incorporated into the
foams of the embodiments, although the amount of fire retardancy
imparted to such foams will of course be decreased.
B. Process Steps
[0099] To form the asphaltic foam of the embodiments, the asphalt
described above is first heated to a temperature over its softening
point, so that polyisocyanate can be mixed homogeneously with the
asphalt. The asphalt is heated to about 250-280.degree. F. to
assure that the viscosity of the asphalt will be sufficiently
lowered to enable proper mixing of the asphalt and
polyisocyanate.
[0100] Polyisocyanate is added to asphalt to form a first
intermediate mixture (Mixture A). When the polyisocyanate is added
to the asphalt, the temperature of the reactants will generally be
about 120.degree. F. to about 170.degree. F. In order to form a
polyurethane asphaltic foam, the polyisocyanate is added to the
asphalt in a weight ratio of about 0.8:1 to 3.2:1
polyisocyanate:asphalt, and in another embodiment, in a ratio of
about 1:1 to 1.5:1 polyisocyanate:asphalt.
[0101] A second intermediate mixture (Mixture B) comprises a
mixture of polyols and a blowing agent. In Mixture B, polyols are
in amounts of between about 5% and about 100% by weight of the
asphaltic foam, though, in another embodiment, they are in amounts
of about 32% by weight of the asphaltic foam. Between about 0.5%
and about 5%, and in another embodiment, about 1.3% water is added
to the Mixture B.
[0102] Mixture B can also contain, each as an optional component, a
surfactant, catalyst, and fire retardant. A surfactant is DABCO DC
5357 in an amount of about 2.4% by weight of Mixture B. Catalysts
are DABCO 33LV in an amount of about 0.1% by weight of Mixture B
and POLYCAT 5 in an amount of about 0.7% by weight of Mixture B. A
fire retardant is TCPP in an amount of about 8-25% by weight of
Mixture B, that is, about 5-10% by weight of total foam
mixture.
[0103] The chemical process comprises pumping Mixture A and Mixture
B at about 1.35:1 ratio and a total flow rate of about 7.4 lbs/min.
in 2 impingement dispensing heads. In embodiments, the ratio of
Mixture A and Mixture B can be about 1.2:1 to about 1.45:1. The
mixed materials can be dispensed on a conveyor that runs
continuously and molds can be placed over the mixture.
Alternatively, the mixed material can be dispensed directly into a
mold. An advantage to the present process is the ability to turn
off the machinery at any time. Also, cleaning of the impingement
dispensing heads is minimal and with ease. Alternatively, for some
applications the foam can also be allowed to rise freely without a
mold.
[0104] The foaming reaction begins as soon as the polyisocyanate is
mixed with the remaining ingredients of the reaction mixture. With
segregating polyisocyanate from polyol within Mixture A and Mixture
B respectively, the foaming reaction can be controlled by mixing
Mixture A (containing polyisocyanate) and Mixture B (containing
polyols). With a more controlled foaming reaction, there is less
loss of the blowing agent which is able to evaporate otherwise. If
the Carpol TEAP 265, Carpol GP-6015 and a diol Carpol PGP-1000 are
used as the polyol for this reaction, a moderate, controlled
foaming reaction will take place. If other polyols are used,
however, some adjustments to the process may need to be made in
order to assure a controlled reaction, as outlined above.
[0105] The initial stage of the reaction, from the time the Mixture
A and the Mixture B come into contact until the time the foam
begins to rise, is called the "cream time." During this stage, the
foaming reaction mixture thickens. At about 120.degree. F., cream
stage lasts for about 15-20 seconds. Thus, the polyisocyanate and
other reactants can be mixed together for no longer than about 2-6
seconds before being placed into a mold. Otherwise, the foam may
expand to a point beyond that desired in the final molded product,
or may cure before taking on the desired form of the mold.
[0106] In the second stage of the foaming reaction, called the
"rise time," the foam begins to expand. During this stage,
sufficient CO.sub.2 is produced to cause expansion of the foam. In
addition, if blowing agents have been added, such blowing agents
volatilize at this time, due to the heat created by the foaming
reaction. The length of the cream time and rise time of the foaming
reaction will depend on the chemical reaction rate, which in turn
depends on the temperature of the mixture, the mold temperature,
and the temperature of the environment. The foam is cured when the
foam surface is no longer tacky, which usually occurs within about
1.5 to 2 minutes.
[0107] One of the great advantages of the present process is that
it can be performed under the previously discussed conditions,
which are sufficiently controlled to be useful in a manufacturing
process. Asphaltic polyurethane foams produced by prior art methods
were, generally, made using lower percentages of asphalt or softer
asphalts, as well as lower reaction temperatures. For this reason,
such reactions required catalysts to be commercially useful.
However, due to the use of the higher reaction temperatures of the
present process, catalysts other than the NH groups which can be
present in the polyol cannot be used when producing an asphaltic
polyurethane foam according to the embodiments.
[0108] Although the reaction can be run at temperatures higher than
about 180.degree. F., the speed of the reaction increases ten times
for every 10.degree. F. increase in temperature over 180.degree. F.
Thus, although the present reaction can be performed at
temperatures of up to about 200.degree. F., in another embodiment,
such high temperatures are not used due to the greatly increased
speed of the reaction and a concomitant increase in the difficulty
of manufacture at such increased speed. In the case of certain
highly viscous asphalts which can be used according to the
embodiments, higher temperatures will help such asphalts to flow
better by reducing their viscosity, but, as stated previously, this
aid in manufacturing can be balanced against the difficulty of
controlling faster reactions.
[0109] Using temperatures above about 200.degree. F. is, in most
cases, disfavored in the present process. At such higher
temperatures, the speed of the foaming reaction becomes
unacceptably violent. Nevertheless, in certain formulations higher
temperatures can be tolerated.
[0110] Generally, the foam takes about 1.5 to 2 minutes to cure
once it has expanded to fill a mold into which it has been placed.
However, the cure time will depend on the reaction temperature, the
type of polyol used, the process environment, and other
variables.
[0111] In one embodiment, the reaction mixture is placed in a mold
(or, alternatively, a mold is placed around the mixture) in order
to form a molded article. The asphaltic foams of the embodiments
can, in an alternative embodiment, comprise asphaltic polystyrene
or asphaltic PVA foams. In such embodiments, the asphalt used in
the present process would be mixed with the precursors of
polystyrene or PVA in the amounts described previously in
connection with the production of polyurethane and isocyanurate
foams.
Example 1
[0112] A small batch of an improved asphaltic polyurethane foam is
produced as follows and according to Table 1. A non-blown asphalt
having a penetration of about 90-110 and a softening point of about
110.degree. F. is first selected. This asphalt is available from
Paramount Petroleum. About 1039.5 lb of this asphalt is heated to
250.degree. F. in a container. A Mondur MR polyisocyanate is next
added to the asphalt to form Mixture A.
[0113] In Mixture B, the polyols are Carpol TEAP 265, Carpol
GP-6015 and Carpol PGP-1000. A mixture of about 611.52 lb Carpol
TEAP 265, about 419.2 lb Carpol GP-6015 and about 366.08 lb Carpol
PGP-1000 is formed. Following this, about 20.8 lb of water is mixed
into the reaction mixture. About 131.2 lb of TCPP fire retardant,
about 38.4 lb of DABCO DC5357, about 1.6 lb of DABCO 33LV, and
about 11.2 lb of POLYCAT 5 was mixed into the reaction mixture. The
TCPP fire retardant is an optional component.
[0114] Using high pressure rotary piston pumps with a metering
ratio of 1.35:1 (Mixture A:Mixture B), Mixture A and Mixture B are
pumped at a flow rate of about 5 lb/min/head in 2 impingement
heads. Within about 2-3 seconds, this mixture is then deposited in
a mold. The mixture begins rising and forming a foam, and after
about 60 seconds the foam is completely formed.
TABLE-US-00001 TABLE 1 MATERIALS FOR ASPHALTIC FOAM CHEMICAL NAME
Approximate % Approximate LBS BATCH B Carpol TEAP 265 38.22 611.52
Carpol GP-6015 26.2 419.20 Carpol PGP-1000 22.88 366.08 TCPP 8.2
131.2 Water 1.3 20.8 DABCO DC 5357 2.4 38.4 DABCO 33LV 0.1 1.6
POLYCAT 5 0.7 11.2 Total for Batch B 100 1600 BATCH A SATURANT 701
38.5 1039.5 MONDUR MR 61.5 1660.5 Total for Batch A 100 2700
III. Process of Molding Ridge Cap
Example 2
[0115] In one embodiment, the asphaltic foam of the previously
discussed embodiments is formed into an intermediate product 50 of
a ridge cap 10 (FIG. 1-6). On a conveyor belt is placed a layer of
roofing granules. These granules will serve as a protective weather
layer for the ridge cap 10. The granules themselves are about 40
mesh in size (Grade #11), although any size roofing granules can be
used, as long as such granules will stick to and cover the surface
of the foaming material. The protective layer can also be slate
flake or other material capable of providing protection from the
weather elements.
[0116] The granules are placed on the conveyor belt from a
discharge holding tank using a system of dispensing rolls driven by
a variable speed electrical motor. This dispensing system drops the
granules into a box that holds them directly on the belt. One side
of the box is a gate that can be slid up and down allowing a
controlled amount of granules to travel away with the belt.
[0117] In an embodiment, different solid color granules are gravity
fed from 2-3 ton bulk bags into holding tanks or hoppers. From this
hopper, the granules are dispensed in controlled ratios on a
conveyor belt and from there they are homogeneously colored blended
by dropping them several times from one conveyor to another toward
the machine holding tank.
[0118] A scraper having a wavy surface is held over the granule
layer at a predetermined height (corresponding to the desired
thickness and shape of the granule layer) in order to assure a
granule layer 900 conforming the rounded shape of the intermediate
product 50. (See FIGS. 43 and 44.) In some embodiments, the layer
of roofing granules is about 1/4'' deep, but can be between about
3/16'' and 1/2'' deep. In other embodiments, the layer of roofing
granules can be between about 1/16'' and 1'' deep.
[0119] The asphaltic foam is produced as described in the foregoing
in a mold. In embodiments, the mold is heated to about 200.degree.
F. Heating of the mold can be accomplished with blowing hot air
with a fan. After the asphaltic foam is produced in the mold, the
mold containing the asphaltic foam is flipped about 180.degree. so
that the top of the mold contacts the granules on the conveyor
belt. The asphaltic foam is then compressed and cured onto the
granules.
[0120] The inside surfaces of the molds used in the embodiments are
treated with a spray mold release, such as a silicone based mold
release. Alternatively, the inside of the molds can comprise a
layer of Teflon.RTM. (PTFE) to facilitate the removal of the
finished foam product from the molds. Alternatively, a spray mold
release comprises motor oil, such as CALISTA 122 motor oil 10W40.
Alternatively, a silicone rubber mold can be used without
application of a release agent.
Example 3
[0121] An intermediate product 50 of a ridge cap 10 shown in FIGS.
1-6 is made with the improved asphaltic foam of the embodiments as
follows according to the flow chart in FIG. 42. A mold 810 shown in
FIGS. 15, 16 and 37-40 is made to contain the reacting foam and
thereby form a molded asphaltic polyurethane product.
[0122] On a flat, moving conveyor 800 is placed a layer of roofing
granules 900. See FIG. 43. These granules will serve as both a
protective weather layer and color matching with the roof. The
granules themselves are about 40 mesh in size (Grade #11).
[0123] After placing the layer of roofing granules on the conveyor
surface, the mixed reactants are dispensed on the granules that
come with the conveyor belt. The molds, which are heated to about
200.degree. F. are then placed on top of the reaction mixture,
which starts expanding and fills the mold cavities. In about 60
seconds the asphaltic foam is totally formed within the mold.
[0124] The inside surfaces of the molds used in the embodiments are
treated with a spray mold release, such as a spray mold release
comprising motor oil, such as CALISTA 122 motor oil 10W40.
[0125] In the foregoing, the configuration and the making process
of a ridge cap 10 is discussed, but the invention is not limited
thereto. U.S. Pat. Nos. 5,786,085, 5,813,176, 5,816,014 and
5,965,626 and 8,017,663 and U.S. patent application Ser. No.
13/207,319 disclose the configuration of ridge caps and the process
of making ridge caps. The process and compositions disclosed in the
foregoing patents and the patent application can be used or
modified to form the ridge cap 10. Thus, the entire disclosure of
each of U.S. Pat. Nos. 5,786,085, 5,813,176, 5,816,014 and
5,965,626 and 8,017,663 and U.S. patent application Ser. No.
13/207,319 is incorporated by reference herein.
* * * * *