Note: Descriptions are shown in the official language in which they were submitted.
CA 02831303 2013-10-24
ROUNDED RIDGE CAP WITH ASPHALTIC FOAM MATERIALS
RELATED APPLICATIONS
[00011 This application claims priority to and the benefit of U.S.
Provisional
Patent Application No. 61/718,672, filed October 25, 2012, the disclosure of
which is
incorporated herein by reference in its entirety.
BACKGROUND
Field
[00021 The present disclosure relates to a rounded ridge cap with
asphaltic foams.
Discussion of the Related Technology
[00031 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
100041 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.
[00051 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.
100061 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
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'
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.
[0007] 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 . 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.
[0008] 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 F was used in the Roy process to produce asphaltic
foams, the
foaming reaction also was too fast, making manufacturing of asphaltic foams
impracticable.
[0009] In U.S. Patent Nos. 5,786,085; 5,813,176; 5,816,014; and
5,965,626 all to
Tzeng et al., and U.S. Patent 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
[0010] 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.
[0011] 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
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surface rolls have been used as ridge caps, the largely ornamental structures
which straddle
the peak of a roof.
[0012] 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.
[0013] 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
[0014] 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
[0015] 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.
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[0016] 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 F to
about I70 F. The method may further comprise, subsequently to bending,
additionally curing
the asphaltic foam material.
[0017] 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.
[0018] 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.
[0019] 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.
[0020] 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
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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.
100211 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 to 270 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
[0022] Figures 1-6 are various views of an intermediate product of a
rounded
ridge cap in accordance with an embodiment.
[0023] Figures 7-10 are various views of a final product of a rounded
ridge cap by
bending the intermediate product shown in Figures 1-6 and cooling the bent
product.
[0024] Figures 11-13 are various views showing engagement of the
rounded ridge
caps shown in Figures 7-10.
[0025] Figure 14 show steps of engaging a latch structure during
bending of the
intermediate product shown in Figures 1-6.
[0026] Figures 15 and 16 are views of the intermediate product shown
in Figures
1-6 and a mold.
[0027] Figures 17-24 are various views of an intermediate product of a
rounded
ridge cap in accordance with another embodiment.
[0028] Figures 25-29 are various views of a final product of a rounded
ridge cap
by bending the intermediate product shown in Figures 17-24 and cooling the
bent product.
[0029] Figures 30-34 are various views showing engagement of the
rounded ridge
caps shown in Figures 25-29.
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,
. .
[0030] Figures 35-36 show male and female latches of the
intermediate product of
the rounded ridge cap shown in Figures 17-24.
[0031] Figures 37-40 are views of the intermediate product
shown in Figures 1-6
within a mold.
[0032] Figures 41-44 show a process of making a rounded ridge
cap in
accordance with an embodiment.
[0033] Figures 45A and 45B are enlarged views of a bridge
portion between two
sections before and after bending, respectively.
DETAILED DESCRIPTION
[0034] Embodiments of the invention will be described in
detail.
Rounded Ridge Cap
[0035] Referring to Figure 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
[0036] In embodiments, a rounded ridge cap is made with an
asphaltic foam
material. Referring to Figure 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 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 F to about 170 F. In other embodiments, the sections of the intermediate
product are
bendable in a warm temperature between about 125 F to about 150 F.
[0037] 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.
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,
, . .
,
,
Intermediate Product
[0038] Referring to Figures 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 Figures 1(a) and 2(a), each of the
sections has a
trapezoidal shape.
Middle Section
[0039] Referring to Figures 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 Figure 11 when the final product of the rounded ridge
cap 10 is
placed on the roof.
Side Sections
[0040] Referring to Figures 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 Figures 9 and 10.
[0041] Each of the side sections also includes elevated
portions 68 and ribs 70
raised from the bottom of the wall 64. As show in Figure 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.
[0042] In one embodiment, the ribs can provide secure contact
with the roof
having an angle of about 140 between two inclined roof surfaces. In some
embodiments, the
ribs can provide secure contact with the roof having an angle of about 1000 to
about 170
between two inclined roof surfaces.
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Number of Sections
[0043] 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
[0044] Referring to Figures 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 Figure 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.
[0045] 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.
[0046] 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 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 Figures 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 F to about 170 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 F to about 150 F.
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Engagement between Middle Section and Side Sections
100471 Referring to Figures 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.
100481 Each of the locking mechanisms includes a male latch 72 and a
female
latch 74. As shown in Figure 14, the male latch and the female latch can have
undercuts. In
a high temperature of the molded intermediate product, for example, about 140
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
as shown in Figures 8, 9, 10 and 14. Thus, in embodiments, no adhesive
material is used
between two immediate neighboring sections, but not limited thereto.
Final Product
100491 Referring to Figures 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
[0050] Referring to Figures 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.
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The receptacles 90 are sized to receive the thickness-reduced portions 82,
respectively. Thus,
as shown in Figures 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
[0051] Figures 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
Figures 1-16.
Compositions and Process for Molding Ridge Cap
I. Definitions of Terms
[0052] As used herein, the terms listed below shall be defined as
follows, unless a
contrary meaning is clearly meant in context:
[0053] "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.
[0054] "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 VistamerTM, a surface modified particulate
rubber.
[0055] "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 F (25 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
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softer material more rapidly than a harder material, higher penetration values
correspond to
softer materials.
[0056] "Reaction mixture" shall refer to any combination of reactants
used in the
process of the embodiments prior to being reacted in a foaming reaction.
[0057] "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).
[0058] The previously discussed definitions pertain as well to other
grammatical
forms derived from these terms, including plurals.
11. Improved Asphaltic Foam
A. Reactants
1. Asphalt
[0059] 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.
[0060] 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.
[0061] 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.
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. '
[0062] 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 F-170 F) where the
reaction rate is
controlled, asphalt with a penetration range of about 90-110 and softening
point of about
110 F can be used.
[0063] 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%.
[0064] 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 F
to about 200 F can be used. In one embodiment, an asphalt having a softening
point of about
100 F to about 150 F is used, and in another embodiment, an asphalt having a
softening point
of about 120 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.
[0065] 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.
[0066] 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 F and less than
about 120 F, and a
penetration range of greater than about 85 and less than about 120. This
asphalt is composed
(in weight percentages) of about 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
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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.
[0067] 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.
[0068] 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.
[0069] 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.
[0070] 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
[0071] 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.
[0072] 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.
- 13 -
CA 02831303 2013-10-24
100731 In order to blend the polypropylene into asphalt, the asphalt
is first heated
to about 400 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 F and so
will melt on exposure to the hot asphalt.
[0074] 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.
100751 One modifier which has been found to be particularly useful is
VistamerTM
(sold as VistamerTM R or VistamerTM 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). VistamerTm 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), VistamerTM 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 VistamerTM 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 VistamerTM, the
asphalt is heated to
about 400 F before adding the VistamerTM to the asphalt.
3. Polyols
[0076] 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
- 14 -
CA 02831303 2013-10-24
,
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.
[0077] 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.
[0078] 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:
(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;
(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.
(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.
[0079] 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
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CA 02831303 2013-10-24
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.
[0080] 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.
[0081] 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-propy1)-ethylenediamine, which is
commercially
available under the trade name of "Quadrol" from BASF Wyandotte Corporation.
4. Blowing Agent
[0082] 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.
- 16-
CA 02831303 2013-10-24
[0083] 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.
[0084]
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.
[0085]
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
[0086] 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.
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CA 02831303 2013-10-24
,
,
[0087]
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.
100881
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
[0089]
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.
[0090]
Plasticizers, such as dioctylphthalate, diisooctylphthalate, dibutylphthalate,
diisobutylphthalate, di caprylphthal ate,
dii sodecylphthal ate, 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.
[0091]
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
- 18 -
CA 02831303 2013-10-24
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.
100921 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 DABCOO 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.
100931 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 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 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. Another
flame retardant
that can be used in the embodiments is VERSASHIELD which is available from Elk
Technologies, Inc., Dallas, TX. VERSASHIELD is a roofing underlayment, a
coated
substrate product with fire-resistant qualities, upon which the asphaltic foam
of the
embodiments can be layered.
B. Process Steps
[0094] 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 F
to assure
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CA 02831303 2013-10-24
that the viscosity of the asphalt will be sufficiently lowered to enable
proper mixing of the
asphalt and polyisocyanate.
[0095] 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 F to about 170 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.
[0096] 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.
[0097] 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.
[0098] 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.
[0099] 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
- 20 -
CA 02831303 2013-10-24
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.
[0100] 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 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.
[0101] In the second stage of the foaming reaction, called the -rise
time," the
foam begins to expand. During this stage, sufficient CO) 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.
[0102] 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.
[0103] Although the reaction can be run at temperatures higher than
about 180 F,
the speed of the reaction increases ten times for every 10 F increase in
temperature over
180 F. Thus, although the present reaction can be performed at temperatures of
up to about
200 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
- 21 -
CA 02831303 2013-10-24
reducing their viscosity, but, as stated previously, this aid in manufacturing
can be balanced
against the difficulty of controlling faster reactions.
[0104] Using temperatures above about 200 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.
[0105] 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.
[0106] 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
[0107] 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 F is first selected. This asphalt is
available from
Paramount Petroleum. About 1039.5 lb of this asphalt is heated to 250 F in a
container. A
Mondur MR polyisocyanate is next added to the asphalt to form Mixture A.
[0108] 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.
[0109] 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.
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CA 02831303 2013-10-24
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
[0110] In one embodiment, the asphaltic foam of the previously
discussed
embodiments is formed into an intermediate product 50 of a ridge cap 10
(Figure 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.
[0111] 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.
- 23 -
CA 02831303 2013-10-24
101121 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.
[0113] 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 Figures 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.
[0114] The asphaltic foam is produced as described in the foregoing in
a mold. In
embodiments, the mold is heated to about 200 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' 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.
[0115] 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 (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
[0116] An intermediate product 50 of a ridge cap 10 shown in Figures 1-
6 is made
with the improved asphaltic foam of the embodiments as follows according to
the flow chart
in Figure 42. A mold 810 shown in Figures 15, 16 and 37-40 is made to contain
the reacting
foam and thereby form a molded asphaltic polyurethane product.
[0117] On a flat, moving conveyor 800 is placed a layer of roofing
granules 900.
See Figure 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).
[0118] 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 F are then placed on top of the reaction
mixture, which starts
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CA 02831303 2013-10-24
expanding and fills the mold cavities. In about 60 seconds the asphaltic foam
is totally
formed within the mold.
[0119] 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.
[0120] In the foregoing, the configuration and the making process of a
ridge cap
is discussed, but the invention is not limited thereto. U.S. Patent Nos.
5,786,085,
5,813,176, 5,816,014 and 5,965,626 and 8,017,663 and U.S. Patent Application
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.
Patent Nos. 5,786,085, 5,813,176, 5,816,014 and 5,965,626 and 8,017,663 and
U.S. Patent
Application No. 13/207,319 is incorporated by reference herein.
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