U.S. patent application number 17/406302 was filed with the patent office on 2021-12-09 for shingles with increased hydrophobicity.
The applicant listed for this patent is Owens Corning Intellectual Capital, LLC. Invention is credited to Chris Armintrout, Donn R. Vermilion, William Brian Ward, Xiujuan Zhang.
Application Number | 20210381240 17/406302 |
Document ID | / |
Family ID | 1000005782584 |
Filed Date | 2021-12-09 |
United States Patent
Application |
20210381240 |
Kind Code |
A1 |
Vermilion; Donn R. ; et
al. |
December 9, 2021 |
SHINGLES WITH INCREASED HYDROPHOBICITY
Abstract
A shingle includes a substrate having an asphalt coating on a
top surface of the substrate and on a bottom surface of the
substrate. A surface layer of granules is embedded in the asphalt
on the top surface of the substrate. A backdust layer of particles
is embedded in the asphalt on the bottom surface of the substrate.
A sealant is disposed on the backdust. A hydrophobic material is
applied to the sealant.
Inventors: |
Vermilion; Donn R.; (Newark,
OH) ; Zhang; Xiujuan; (Granville, OH) ; Ward;
William Brian; (Brookville, OH) ; Armintrout;
Chris; (Warsaw, OH) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Owens Corning Intellectual Capital, LLC |
Toledo |
OH |
US |
|
|
Family ID: |
1000005782584 |
Appl. No.: |
17/406302 |
Filed: |
August 19, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16534204 |
Aug 7, 2019 |
11136761 |
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17406302 |
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14623688 |
Feb 17, 2015 |
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16534204 |
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61942673 |
Feb 21, 2014 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
Y10T 428/24413 20150115;
E04D 1/28 20130101; Y10T 428/24372 20150115; E04D 1/20 20130101;
Y10T 428/24364 20150115; E04D 1/00 20130101; E04D 1/26 20130101;
E04D 2001/005 20130101; Y10T 428/2438 20150115; Y10T 428/24388
20150115 |
International
Class: |
E04D 1/28 20060101
E04D001/28; E04D 1/00 20060101 E04D001/00; E04D 1/20 20060101
E04D001/20 |
Claims
1. A package, comprising: a plurality of stacked shingles, each of
the shingles comprising: a substrate; an asphalt coating; a
plurality of granules; a plurality of particles; and a hydrophobic
material; wherein the asphalt coating is disposed on a top surface
and a bottom surface of the substrate; wherein the plurality of
granules are embedded in the asphalt coating on the top surface of
the substrate; wherein the plurality of particles are embedded in
the asphalt coating on the bottom surface of the substrate; and
wherein the hydrophobic material is disposed on at least one
surface of the shingle such that the hydrophobic material prevents
moisture from infiltrating between adjacent shingles of the
plurality of stacked shingles.
2. The package according to claim 1, wherein the hydrophobic
material has a thickness that allows at least one of laminating
adhesives and sealants to bond to the shingle.
3. The package according to claim 1, wherein the hydrophobic
material is thinner than particles of the plurality of
particles.
4. The package according to claim 1, wherein the hydrophobic
material is about a few monolayers thick.
5. The package according to claim 1, wherein the hydrophobic
material extends inward from one or more edges of the shingle on a
first surface of the at least one surface of the shingle.
6. The package according to claim 5, wherein the hydrophobic
material covers less than half of the first surface of the
shingle.
7. The package according to claim 1, wherein the hydrophobic
material covers an entirety of a first surface of the at least one
surface of the shingle.
8. The package according to claim 1, wherein the hydrophobic
material is disposed on a top surface of the shingle.
9. The package according to claim 1, wherein the hydrophobic
material is disposed on a bottom surface of the shingle.
10. The package according to claim 1, wherein the hydrophobic
material is disposed on the plurality of particles.
11. The package according to claim 10, wherein the hydrophobic
material is disposed on the plurality of particles such that a
contact angle of the plurality of particles with the hydrophobic
material is greater than or equal to about 90 degrees.
12. The package according to claim 1, wherein the hydrophobic
material comprises a silane solution.
13. The package according to claim 12, wherein the silane solution
is a methyl silane solution.
14. The package according to claim 12, wherein the silane solution
has a silane concentration of between about 0.25% and about 2%.
15. The package according to claim 12, wherein between about 0.5 g
and about 2 g of silane solution is disposed on the at least one
surface of the shingle per square.
16. The package according to claim 1, wherein the hydrophobic
material comprises silicone.
17. The package according to claim 1, wherein the hydrophobic
material comprises Titanium dioxide.
18. The package according to claim 1, wherein the two or more
shingles are stacked such that the hydrophobic material of the
shingles prevents moisture from infiltrating between the shingles
when the shingles are exposed to 2.2 inches of rain per hour for 24
hours.
19. The package according to claim 1, wherein the asphalt coating
comprises a first asphalt coating that is disposed on a top surface
of the substrate and a second asphalt coating that is disposed on a
bottom surface of the substrate.
20. The package according to claim 19, wherein the first asphalt
coating and the second asphalt coating are made of the same
material.
Description
RELATED APPLICATIONS
[0001] The present application is a continuation of U.S. patent
application Ser. No. 16/534,204, filed on Aug. 7, 2019, which is a
continuation of U.S. patent application Ser. No. 14/623,688, filed
on Feb. 17, 2015, now abandoned, which claims the benefit of U.S.
Provisional Patent Application Ser. No. 61/942,673, filed on Feb.
21, 2014, all of which are incorporated herein by reference.
FIELD OF THE INVENTION
[0002] The present application relates to roofing materials, such
as shingles. In particular, the present application relates to
roofing materials, such as shingles, with increased hydrophobicity
as compared to otherwise identical, roofing materials or
shingles.
BACKGROUND
[0003] Asphalt-based roofing materials, such as roofing shingles,
roll roofing and commercial roofing, are installed on the roofs of
buildings to provide protection from the elements, and to give the
roof an aesthetically pleasing look. Typically, the roofing
material is constructed of a substrate such as a glass fiber mat or
an organic felt, an asphalt coating on the substrate, and a surface
layer of granules embedded in the asphalt coating. Furthermore,
physical and chemical factors such as surface roughness and
heterogeneity as well as particle shape and size have been found to
influence the contact angle and wetting behavior of solid
particles. See, e.g., T. T. Chau, et al., "A review of factors that
affect contact angle and implications for flotation practice,"
Advances in Colloid and Interface Science 150, pp. 106-115 (2009).
The entire disclosure of the Chau reference is hereby incorporated
by reference.
SUMMARY
[0004] One exemplary embodiment of a shingle includes a substrate
having an asphalt coating on a top surface of the substrate and on
a bottom surface of the substrate. A surface layer of granules is
embedded in the asphalt on the top surface of the substrate. A
backdust layer of particles is embedded in the asphalt on the
bottom surface of the substrate. A sealant is disposed on the
backdust. A hydrophobic material is applied to the sealant.
BRIEF DESCRIPTION OF THE DRAWINGS
[0005] FIG. 1A is a side elevational view of an exemplary
embodiment of a shingle;
[0006] FIG. 1B is a side elevational is a side elevational view of
a shingle;
[0007] FIG. 1C is a top perspective view of a laminated
shingle;
[0008] FIG. 1D is a bottom perspective view of the laminated
shingle illustrated by FIG. 1C;
[0009] FIG. 1E is a bottom plan view of a top layer of the
laminated shingle illustrated by FIG. 1C;
[0010] FIG. 1F is a bottom plan view of a bottom layer of the
laminated shingle illustrated by FIG. 1C;
[0011] FIG. 2A illustrates an exemplary embodiment of shingles
stacked in a package;
[0012] FIG. 2B is a schematic illustration of shingles stacked in a
package and moisture wicking or infiltrating between the layers of
the stacked shingles;
[0013] FIG. 3A illustrates the contact angle of a moisture droplet
that is greater than ninety degrees;
[0014] FIG. 3B illustrates the contact angle of a moisture droplet
that is less than 90 degrees;
[0015] FIG. 4 is a schematic illustration of an exemplary
embodiment where a moisture droplet moving down along a side of a
stack of shingles;
[0016] FIG. 5 is a cross sectional view of an exemplary embodiment
of a shingle with a hydrophobic material applied to a back or lower
surface of the shingle;
[0017] FIG. 6 is a bottom view of an exemplary embodiment of a
shingle with a hydrophobic material applied only to edges of a
lower surface of the shingle;
[0018] FIG. 7A illustrates an exemplary embodiment of particles
embedded in an asphalt coating of a shingle;
[0019] FIG. 7B illustrates an exemplary embodiment of a hydrophobic
material applied to the particles and asphalt coating of the
shingle illustrated by FIG. 7A;
[0020] FIG. 8 illustrates an exemplary embodiment of a shingle
having hydrophobic particles embedded in the asphalt coating along
with other particles embedded in the asphalt coating;
DETAILED DESCRIPTION
[0021] In the embodiments herein, the invention of the present
application is discussed for use with roofing shingles. However, it
should be understood that the invention of the present application
may be used with any type of roofing material, such as, for
example, asphalt-based roll roofing and commercial roofing.
[0022] As illustrated in FIG. 1A, a shingle 100 generally comprises
a substrate 116 that is infiltrated with asphalt forming a first
asphalt coating 114 on the top surface of the substrate and a
second asphalt coating 118 on the bottom surface of the substrate.
The shingle also generally comprises a surface layer of granules
112 embedded in the first asphalt coating and a backdust layer of
particles 120 embedded in the second asphalt coating. The first
asphalt coating 114 is positioned above the substrate 116 when the
shingles are installed on a roof and the second asphalt coating 118
is positioned below the substrate when the shingles are installed
on the roof.
[0023] A shingle may also comprise one or more sheets laminated
together to form a laminated shingle. For example, as illustrated
in FIG. 1B, a shingle 150 comprises an upper or overlay sheet 160
attached to a lower or underlay sheet 180 with an adhesive 152 to
form the laminated shingle. The overlay sheet 160 extends the full
width of the shingle 150 and includes cutouts 161 defining tabs 163
on a front tab portion of the shingle. An optional release paper
covered adhesive strip (not shown) may be disposed on a lower or
rear surface of the overlay sheet 160 along a rear headlap portion
of the shingle 150. Similar to the shingle 100, each sheet
generally comprises a substrate 116, a first asphalt coating 114 on
the top surface of the substrate, a surface layer of granules 112
embedded in the first asphalt coating, a second asphalt coating 118
on the bottom surface of the substrate, and a backdust layer of
particles 120 embedded in the second asphalt coating.
[0024] The substrate of the shingle can be any type known for use
in reinforcing asphalt-based roofing materials, such as a web,
scrim or felt of fibrous materials such as mineral fibers,
cellulose fibers, rag fibers, mixtures of mineral and synthetic
fibers, or the like. Combinations of materials can also be used in
the substrate. In certain embodiments, the substrate is a nonwoven
web of glass fibers. The substrate may be any conventional
substrate used in asphalt shingles, roll roofing, low-slope
membranes, and the like.
[0025] The asphalt coatings are generally formed from a layer of
hot, melted asphalt applied to the substrate. The asphalt coating
can be applied to the substrate in any suitable manner. For
example, the substrate can be submerged in the asphalt or the
asphalt can be rolled on, sprayed on, or applied to the substrate
by other means. The asphalt coating may also be any type of
bituminous material suitable for use on a roofing material, such as
asphalts, tars, pitches, or mixtures thereof. The asphalt can be
either a manufactured asphalt produced by refining petroleum or a
naturally occurring asphalt. The asphalt coating can include
various additives and/or modifiers, such as inorganic fillers or
mineral stabilizers, organic materials such as polymers, recycled
streams, or ground tire rubber. In certain embodiments, the asphalt
coatings comprise asphalt and inorganic fillers or mineral
stabilizers. The asphalt coatings may be any conventional asphalt
used in shingles, and can be applied in any conventional manner and
in any conventional amount or thickness.
[0026] The granules are generally deposited onto the asphalt
coating after the coating is applied to the substrate. The shingles
may be passed through rollers to further embed the granules into
the asphalt coating. The granules may comprise a variety of
different materials. The granules may be ceramic roofing grade
granules that are made in any known or conventional manner. Any
type of roofing granule may be used. The granules may comprise a
variety of different particle sizes and colors. Further, a variety
of different granules may be blended together, e.g., to provide
different color blends or to provide the appearance of varying
thickness to the shingle.
[0027] The backdust particles are generally deposited onto the
asphalt coating after the coating is applied to the substrate. The
shingles may be passed through rollers to further embed the
backdust particles into the asphalt coating. The backdust may
comprise a variety of different materials, including but not
limited to, Quartz (SiO.sub.2), K-Feldspar (KAlSi.sub.3O.sub.8),
Na-Feldspar (NaAlSi.sub.3O.sub.8), Dolomite (CaMg(CO.sub.3).sub.2),
pulverized sand, talc, mica, calcium carbonate, ground recycled
glass, or other common inorganic material. The backdust may
comprise a variety of different particle sizes. For example, the
backdust particles may have an average particle size between about
20 and 1000 .mu.m, 60 and 600 .mu.m, 100 and 400 .mu.m, or 100 and
300 .mu.m. In certain embodiments, the backdust particles have an
average particle size of about 200 .mu.m. The backdust may be any
material that prevents the shingles from sticking together after
being stacked, packaged, and/or stored for a prolonged period of
time.
[0028] One or more portions of the shingle may comprise an
additional layer, such as a reinforcement layer. In certain
embodiments, the additional layer may be attached to the asphalt
coating, e.g., by the adhesive mixture of the asphalt coating or
other adhesives. In certain embodiments, the additional layer may
be a polymeric layer formed from, for example, a polyester,
polyolefin (e.g., polypropylene or polyethylene), or the like.
However, the additional layer may be formed from other materials,
such as, for example, paper, film, scrim material, and woven or
non-woven glass.
[0029] For example, in certain embodiments, the shingle may include
a strip of woven polyester material applied to the surface of the
shingle after application of the asphalt coating, such that the
asphalt material penetrates the strip between the woven fibers of
the polyester fabric, to embed the strip of material in the base
asphaltic layer and secure the strip to the shingle. The polyester
strip may be applied prior to granule coating of the shingle, and
the granules may not adhere to the strip-covered portion of the
shingle. The strip of polyester material may, for example, define a
shingle nail zone and provide reinforcement for the nailed portion
of the shingle.
[0030] In certain embodiments, a portion of the lower surface of
the shingle may be covered by a sheet of spun-bound nonwoven
polyester web or mat material that is pressed into the hot asphalt
material of the asphalt coating prior to backdust coating of the
shingle. The hot asphalt material penetrates between the nonwoven
polyester fibers to embed the mat in the base asphaltic layer. The
nonwoven mat may provide additional impact resistance for the
shingle, to resist damage caused by hail or other such impacts.
[0031] Shingles are generally stacked and packaged for storage and
transport, e.g. in a wrapper, bag, box, or the like. The package
may take a wide variety of forms, such as a plastic wrapper, a
plastic bag, shrink wrap, a cardboard box, a polyethylene wrapper
(e.g., 1.5-2.5 mil thick), or the like. FIG. 2A illustrates
shingles 200 stacked in a package 210. Often, over time, the
package 210 will develop small holes or openings that permit
moisture penetration during extended storage periods. Further, the
package 210 may become damaged during handling permitting moisture
to enter the shingle package. As illustrated in FIG. 2B, the
moisture 250 will often wick or infiltrate between the layers of
stacked shingles 200 resulting in the shingles being in a wet
condition.
[0032] The Applicants have discovered that applying a hydrophobic
material to surfaces of the shingles increases the contact angle of
the moisture on the surfaces and decreases the wetting of the
shingle bundle by prohibiting the moisture from wicking or
infiltrating between the stacked shingles. Thus, the greater the
contact angle the less moisture infiltrates between the layers of
shingles. The contact angle of a moisture droplet is the angle
formed by the moisture droplet at the three phase boundary where
the liquid, gas, and solid intersect. FIGS. 3A and 3B illustrate
the contact angle of a moisture droplet of greater than 90 degrees
and less than 90 degrees, respectively.
[0033] For example, FIG. 2B illustrates the moisture droplet 250
having a contact angle less than about 70 degrees with the shingle
back, e.g., between about 40 and 70 degrees, infiltrating between
stacked shingles 200 in the bundle. FIG. 4 illustrates a moisture
droplet 450 having a contact angle greater than about 70 degrees
with the shingle back, e.g., between about 70 and 120 degrees, that
is inhibited from infiltrating between the shingles 400. The
applicants have discovered that a contact angle greater than about
70 degrees, greater than about 80 degrees, and greater than about
90 degrees sufficiently inhibits the moisture from infiltrating
between the shingles such that the shingles were almost completely
dry (i.e., less than 25%, less than 15%, less than 10%, or less
than 5% of the bottom surface area of the second shingle from the
top of the stack was wet) when the bundle is exposed to 2.2 inches
of rain per hour for 24 hours.
[0034] The hydrophobic material applied to the shingles may take a
variety of different forms. For example, the hydrophobic material
may be a coating on one or more surfaces of the shingle. Further,
the backdust and/or granules may be coated with a hydrophobic
material before being applied to the shingle (e.g., at the
supplier) and/or after being applied to the shingle. Further, the
material of the backdust and/or granules themselves may have
hydrophobic properties. The hydrophobic material may also be
applied to any surface of the shingle, such as, for example, around
only the edges of the shingle, only on the back of the shingle, or
on the back and front of the shingle. Further, the hydrophobic
material may also be applied only to the edges of the shingle
bundle to prohibit moisture infiltration between the shingles.
[0035] For example, FIG. 5 illustrates a cross sectional view of a
shingle 500 with a hydrophobic material 510 applied to the back or
lower surface of the shingle. The hydrophobic material 510 may be
sprayed on, rolled on, or otherwise applied to the surface of the
shingle 500. Further, the backdust of the shingle may be coated
with the hydrophobic material 510 before being applied to the
shingle (e.g., at the supplier) and/or after being applied to the
shingle or some of the backdust may be a hydrophobic material, such
as Titanium dioxide. FIG. 6 illustrates a bottom view of a shingle
600 with a hydrophobic material 610 applied only to the edges of
the lower surface of the shingle. As shown, the hydrophobic
material 610 extends a distance between about 0.5 and 3 inches in
from each edge of the lower surface, such as between 1 and 2 inches
from each edge of the lower surface. However, the hydrophobic
material may be applied closer or further from the edge of the
lower surface, such as, for example, depending on the size and
makeup of the shingle and/or the surrounding environmental
conditions. It should be understood that the hydrophobic material
may be applied to other portions of the shingle as well, including
the top surface and sides of the shingle.
[0036] Referring to FIGS. 1D, 1E, and 1F, in one exemplary
embodiment, the hydrophobic material 510 (illustrated by dashed
lines) is applied to a rear surface 550 of the underlay sheet 180
and to a rear surface 552 of the overlay sheet 160. In the
illustrated embodiment, the hydrophobic material 510 is applied to
the entire rear surface 550 or substantially the entire rear
surface 550 of the underlay sheet 180. In the illustrated
embodiment, the hydrophobic material 510 is applied to the portion
554 of the rear surface 552 of the overlay sheet 180 that is not
covered by the underlay sheet 160 or that is substantially not
covered by the underlay sheet. In one exemplary embodiment, the
hydrophobic material 510 is applied to a rear surface 552 of a
headlap portion 556 of the overlay sheet 180 and the hydrophobic
material 510 is not applied to a rear surface 552 of tab portions
558 of the overlay sheet 180.
[0037] Referring to FIGS. 1D, 1E, and 1F, in one exemplary
embodiment, the hydrophobic material 510 is applied to a rear
surface 550 of the underlay sheet 180 and to a rear surface 552 of
the overlay sheet 160 before the underlay sheet 180 and the overlay
sheet 160 are laminated together. In another exemplary embodiment,
the hydrophobic material 510 is applied to a rear surface 550 of
the underlay sheet 180 and to a rear surface 552 of the overlay
sheet 160 after the underlay sheet 180 and the overlay sheet 160
are laminated together.
[0038] In another exemplary embodiment, the hydrophobic material
510 applied only to the edges of the lower surface of the laminated
shingle 150. For example, the hydrophobic material 510 extends a
distance between about 0.5 and 3 inches in from each edge of the
lower surface, such as between 1 and 2 inches from each edge of the
lower surface.
[0039] The Applicants have found that applying the hydrophobic
material to at least one of the upper surface (i.e., top) and lower
surface (i.e., back or bottom) of the shingle (e.g., around the
edges of the lower surface) prohibits moisture from infiltrating
between the stacked shingles. As illustrated in FIGS. 2B and 4,
when moisture travels down the side of the stacked shingles, the
moisture will attempt to infiltrate between the shingles. When the
moisture contacts a hydrophobic material applied to either the
upper or lower surface of the shingle, or both, the moisture will
"bead" up and prohibit moisture from infiltrating between the
shingles. In this regard, the contact angle of the moisture
contacting the hydrophobic material is such that the moisture is
prohibited from penetrating between the shingles. For example, in
certain embodiments the contact angle may be greater than about 70
degrees, greater than about 80 degrees, or greater than about 90
degrees. As such, the hydrophobic material repels the moisture. As
discussed below, the Applicants have found that applying the
hydrophobic material to the lower surface sufficiently prohibits
the moisture from infiltrating between the shingles.
[0040] However, applying the hydrophobic material to both the upper
and lower surfaces of the shingle further improves the
hydrophobicity of the stacked shingles and further inhibits wicking
of water between stacked shingles.
[0041] A variety of different hydrophobic materials may be used.
For example, in certain embodiments, a non-polar silane such as
methyl, propyl, or similar material is used. The silane material
may be applied to the shingle as a dilute water solution and then
dried. However, a variety of other hydrophobic materials may be
used, such as, for example, wax emulsions, oils, silicones,
siloxanes, SBR or esters of acrylic resins. As discussed above,
these hydrophobic materials increase the hydrophobicity of the
surface as measured by the contact angle of moisture droplets that
contact the surface.
[0042] In certain embodiments, a silane solution having a silane
concentration in the range of about 0.25% to 2% was applied to the
back of a shingle sheet during production at a rate of about 0.3 to
6 g silane/sq (One sq is 300 sf of shingles). The silane solution
increased the dynamic contact angle of the sheet at 10 minutes from
the 40-60 degrees range to the 80-120 degree range. In one
exemplary embodiment, a silane solution having a silane
concentration of about 0.5% was applied to the back of a shingle
sheet during production at a rate of about 1.1 g silane/sq. The
silane solution increased the dynamic contact angle of the sheet at
10 minutes from the 40-60 degrees range to the 80-120 degree range.
As such, after the silane solution was applied to the back of the
sheet and the sheet was cut into shingles and bundled, the bundles
of shingles did not wick water in between the layers of
shingles.
[0043] In certain embodiments, the back of shingle sheets were
sprayed with a silane solution having a silane concentration of
about 0.5% during production at the rate of about 0.7 g silane/sq.
The sheets were cut and laminated into shingles and wrapped into
bundles with 2.2 mil polyethylene wrappers. Bundles of shingles
(both treated and untreated) were then placed on pallets in a
shower that delivered 44 inches of water over a 48 hour period. The
wrappers were opened and the shingles were observed for water. The
bundles having been treated shingles were almost completely dry
(i.e., less than 25% of the bottom surface area of the second
shingle from the top of the stack was wet) while the bundles of
untreated shingles contained substantial amounts of water between
shingles (i.e., greater than 25% of the bottom surface area of the
second shingle from the top of the stack was wet).
[0044] The silane bonds to the lower surface of the shingle,
including the surfaces of the backdust particles, and will
generally only be a few monolayers thick at the concentrations used
(e.g., between about 0.25% to 2% silane). As such, the silane
produces a hydrophobic surface but does not prevent laminating
adhesives and sealants from bonding to the back of the shingle. For
example, FIG. 7A illustrates backdust particles 702 embedded in the
asphalt coating 704 of a shingle 700. FIG. 7B illustrates silane
706 applied to the lower surface of the shingle 700 while the
asphalt coating is still hot. As shown, the silane 706 coats the
backdust particles, the lower surface between the backdust
particles 702, and also seeps in between the backdust particles and
the asphalt coating.
[0045] As shown in FIG. 1B, shingles are often formed from shingle
sheets laminated together with an adhesive. Further, a shingle
sealant is generally applied to the surface of a shingle and is
used to bond adjacent shingles together when installed on a roof.
Sealants may be applied to the surface of a shingle before and/or
after the hydrophobic coating is applied to the surface of the
shingle. The Applicants have discovered that adding the silane
solution to the surface of the shingle does not affect the bond
strength between two shingles via the sealant, but actually may
enhance the bonding of the shingles together with the sealant. For
example, the Applicants tested sheets having 0.25% and 0.5% silane
solutions sprayed on the back of the shingle sheet while the
asphalt was still hot at a rate of 0.16 lb. of solution/100 sq. ft.
No reduction in bond strength between the shingles per ASTM D3462
due to the addition of the silane was observed in any of the tests.
In some of the tests, the bond strength between the shingles
increased with the silane solution. Thus, adding the silane
solution to one or more surfaces of a shingle does not affect the
bond strength between two shingles via the sealant but instead can
enhance the bonding between the shingles.
[0046] Silicones and wax emulsions are also effective in producing
a hydrophobic surface and may block water absorption. However,
these types of materials will often act as a release agent and form
a barrier film on the surface of the shingle, thus affecting the
ability of laminating adhesives and sealants to bond to the back of
the shingle.
[0047] The hydrophobic material of the present application may also
comprise certain particles or materials included in the backdust or
granules of the shingle that increase the hydrophobicity of the
shingle. The Applicants have discovered that the addition of
certain particles or materials in the backdust or granules of the
shingles, even in small amounts, affects the
hydrophobic/hydrophilic nature of the shingle.
[0048] For example, FIG. 8 illustrates a shingle 800 having
hydrophobic particles 804 embedded in the asphalt coating 806 on
the lower surface of the shingle along with backdust particles 802.
In certain embodiments, the hydrophobic particles 804 are embedded
in the asphalt coating on the upper surface of the shingle along
with the granules. Similar to the hydrophobic coatings described
above, the hydrophobic particles 804 increase the contact angle of
the moisture contacting the back surface of the shingle, thus
prohibiting moisture from infiltrating between the stacked
shingles. The hydrophobic particles may be a variety of particles,
including but not limited to Titanium dioxide (TiO.sub.2), talc,
and alumina.
[0049] The Applicants have discovered that certain Titanium
minerals make the shingles more hydrophobic as measured both by
contact angles and water pickup through the back of the shingle and
also as measured with the bundle rain test. For example, in certain
embodiments, small amounts of TiO.sub.2 are added to the silica
sand backdust on the lower surface of shingle sheets. In one
embodiment, 0.25% TiO.sub.2 was added to the silica sand before the
backdust was applied to the back of the shingle. The addition of
this TiO.sub.2 increased the contact angle of the lower surface
greater than 20 degrees, or about 22 degrees. Further, the 0.25%
TiO.sub.2 shingle was soaked by placing it on a wet sponge for
about two weeks to measure the water absorption of the shingle. The
weight of the shingle increased less than 1.5% during this time,
whereas the weight of a shingle without the 0.25% TiO.sub.2
increased almost 2.0%, over a 30% increase. As such, the TiO.sub.2
reduced the shingle's ability to absorb moisture.
[0050] The 0.25% TiO.sub.2 shingle was also tested to determine
whether the TiO.sub.2 could withstand rain and whether the
TiO.sub.2 affected the adhesion of the backdust or granules. The
Applicants found that no noticeable amount of the TiO.sub.2 washed
off the lower surface of the shingle and that there was no
observable difference in shingle bond strength when compared to the
shingle without the TiO.sub.2.
[0051] As discussed herein, the addition of a hydrophobic material
(e.g., the hydrophobic coatings and hydrophobic particles discussed
herein) prohibits moisture from infiltrating between the stacked
shingles. As such, the hydrophobic material reduces granule loss
during handling and installation of the shingles and reduces the
ability of the shingles to freeze together in cold weather.
Furthermore, the hydrophobic material may increase shingle life by
keeping the underside of the shingle dry on the roof and preventing
water infiltration under the shingle. The hydrophobic material may
also help reduce leaks by preventing water from wicking under
shingles. Also, the hydrophobic material may reduce the wet time of
shingles on the roof, which has been shown to directly correlate to
reduced algae growth, thus reducing the need for algae resistant
granules.
[0052] As described herein, when one or more components are
described as being connected, joined, affixed, coupled, attached,
or otherwise interconnected, such interconnection may be direct as
between the components or may be in direct such as through the use
of one or more intermediary components. Also as described herein,
reference to a "member," "connector", "component," or "portion"
shall not be limited to a single structural member, component, or
element but can include an assembly of components, members or
elements.
[0053] While the present invention has been illustrated by the
description of embodiments thereof, and while the embodiments have
been described in considerable detail, it is not the intention of
the applicants to restrict or in any way limit the scope of the
invention to such details. Additional advantages and modifications
will readily appear to those skilled in the art. For example, where
components are releasably or removably connected or attached
together, any type of releasable connection may be suitable
including for example, locking connections, fastened connections,
tongue and groove connections, etc. Still further, component
geometries, shapes, and dimensions can be modified without changing
the overall role or function of the components. Therefore, the
inventive concept, in its broader aspects, is not limited to the
specific details, the representative apparatus, and illustrative
examples shown and described. Accordingly, departures may be made
from such details without departing from the spirit or scope of the
applicant's general inventive concept.
[0054] While various inventive aspects, concepts and features of
the inventions may be described and illustrated herein as embodied
in combination in the exemplary embodiments, these various aspects,
concepts and features may be used in many alternative embodiments,
either individually or in various combinations and sub-combinations
thereof. Unless expressly excluded herein all such combinations and
sub-combinations are intended to be within the scope of the present
inventions. Still further, while various alternative embodiments as
to the various aspects, concepts and features of the
inventions-such as alternative materials, structures,
configurations, methods, devices and components, alternatives as to
form, fit and function, and so on-may be described herein, such
descriptions are not intended to be a complete or exhaustive list
of available alternative embodiments, whether presently known or
later developed. Those skilled in the art may readily adopt one or
more of the inventive aspects, concepts or features into additional
embodiments and uses within the scope of the present inventions
even if such embodiments are not expressly disclosed herein.
Additionally, even though some features, concepts or aspects of the
inventions may be described herein as being a preferred arrangement
or method, such description is not intended to suggest that such
feature is required or necessary unless expressly so stated. Still
further, exemplary or representative values and ranges may be
included to assist in understanding the present disclosure,
however, such values and ranges are not to be construed in a
limiting sense and are intended to be critical values or ranges
only if so expressly stated. Moreover, while various aspects,
features and concepts may be expressly identified herein as being
inventive or forming part of an invention, such identification is
not intended to be exclusive, but rather there may be inventive
aspects, concepts and features that are fully described herein
without being expressly identified as such or as part of a specific
invention, the inventions instead being set forth in the appended
claims. Descriptions of exemplary methods or processes are not
limited to inclusion of all steps as being required in all cases,
nor is the order that the steps are presented to be construed as
required or necessary unless expressly so stated.
* * * * *