Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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INTEGRATED GRANULE PRODUCT
Field of the Invention
The invention relates to an integrated granule product, more particularly to
an
integrated granule product utilizing ceramic coated granules bonded to either
a film with a
cured adhesive or a self-supporting adhesive film. The present invention also
includes a
method of preparing integrated granule products.
Background
Roofing products are generally flat or sheet-like materials that can be
arranged on a
roof to prevent weather, e.g., wind, water, etc., from entering a roof
structure. A roofing
product can also serve to reflect heat energy from a roof. The roofing product
should be
durable enough to perform these functions for a number of years. Examples of
roofing
products include asphalt-based, wooden, or ceramic tile shingles.
Roofing products, particularly those which employ roofing granules, generally
have been prepared from a water-proof, durable substrate having roofing
granules
disposed on a surface of the substrate. Asphalt-based roofing shingles, for
example,
typically comprise an asphalt-based substrate with roofing granules embedded
into the
asphalt. The roofing granules are generally colored to provide a desired
aesthetic value
upon application of the roofing product onto a building. These types of
products are
prepared by conventional practices generally recognized in the roofing
products industry.
There is a continuing need in the roofing product art for new roofing product
constructions, and for new processes for preparing roofing products.
Conventional roofing
products, such as shingles, are often susceptible to weather related damage
that can either
tear the base substrate or adversely affect the bond of the granule in the
asphalt-based
substrate. The release of the granules from the base permits the passing of
light through to
the asphalt. The light can degrade the asphalt and may cause premature failure
of the
roofing product.
The asphalt-based substrate can adversely affect the aesthetics of the coated
granules applied onto the substrate. For example, lighter colored granules may
darken
upon application to the asphalt-based substrate. The darkening can be
attributed to
exposed black asphalt in gaps surrounding the granules. Additionally, the
lighter color
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pigments may darken over time after application onto a roof due to the
migration of the
lower molecular weight materials from the asphalt onto the surface of the
coated granules.
The aesthetics of a roofing product can also be effected by the undesirable
growth of algae
on the exposed surface of the roofing product. Algae, growing on the exposed
surface of
the granules, may have direct access to the asphalt, which provides nutrients
that can
sustain growth.
It would be an advantage to provide a roofing product that is capable of
withstanding severe weather conditions and capable of preventing the
degradation of the
underlying asphalt-based substrate. It would also be an advantage to provide a
roofing
product that prevents the discoloration of granules when applied onto an
asphalt-based
substrate.
Summary of the Invention
The present invention relates to an integrated granule product. The integrated
granule product is suitable for use in various applications that require a
layer of ceramic
coated granules applied onto a substrate. The integrated granule product of
the present
invention includes a film having a plurality of ceramic coated granules bonded
to the film
by a cured adhesive. The integrated granule product is generally considered an
intermediate product because it is suitable for application onto various
substrates.
In an alternative embodiment, a self-supporting adhesive film is utilized to
bond
the ceramic coated granules to either roofing or flooring substrates. A self-
supporting film
is generally defined as a film having uniform width, thickness, and length
that when
attached along its width to a supporting substrate the film will require no
support other
than itself or the substrate to which it is attached. The integrated granule
product
functions as an exposed surface layer on the specified substrates.
The integrated granule product is pliable and durable. The pliability of the
intermediate product is determined by the mandrel flexibility test ASTM D228-
00. The
cured adhesive is also flexible as evidenced by a tensile elongation result of
25% or
greater according to ASTM standard D882-97. Additionally, the adhesive of the
present
invention does not adversely affect the color of the ceramic coated granules.
End use applications of the integrated granule product of the present
invention
preferably include, for example, roofing products and flooring products.
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The present invention further contemplates a process for preparing the
integrated granule product wherein a plurality of ceramic coated granules are
bonded to a film
through the use of a curable adhesive. In a preferred embodiment, the adhesive
is first applied
onto the film with the ceramic coated granules then applied onto the adhesive.
The adhesive
is then subjected to a form of energy, such as ultraviolet radiation, thermal
radiation, actinic
radiation, ionizing radiation, moisture activation, photo-activation, or
combinations thereof, to
affect curing, chain extension, or both. Additionally, the integrated granule
product may be
further processed by bonding the integrated granule product to a substrate to
form such
articles as roofing shingles and flooring materials.
According to another aspect of the present invention, there is provided an
integrated granule product for bonding to a substrate, said integrated granule
product
comprising a supporting film, a non-asphaltic adhesive coated on said film,
and a plurality of
ceramic coated granules bonded directly to said non-asphaltic adhesive, said
ceramic coated
granules including one or more of a biocide, antislip friction enhancement
particles,
UV absorption particles, UV blocking particles, high reflectivity particles,
low reflectivity
particles, retroreflective particles, pigments or combinations thereof.
According to still another aspect of the present invention, there is provided
an
integrated granule product for bonding to, and suitable as an exposed surface
layer for, a
roofing shingle construction, comprising a plurality of granules bonded
directly to a self
supporting cured non-asphaltic adhesive film having a uniform thickness, said
granules
including one or more of a biocide, antislip friction enhancement particles,
UV absorption
particles, UV blocking particles, high reflectivity particles, low
reflectivity particles,
retroreflective particles, pigments or combinations thereof
According to yet another aspect of the present invention, there is provided an
integrated granule product for bonding to, and suitable as, an exposed
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surface layer for a floor construction, comprising a plurality of granules
bonded directly to a
self supporting cured non-asphaltic adhesive film having a uniform thickness
and a polymeric
sealant coat applied over said plurality of granules, said granules including
one or more of a
biocide, antislip friction enhancement particles, UV absorption particles, UV
blocking
particles, high reflectivity particles, low reflectivity particles,
retroreflective particles,
pigments or combinations thereof.
According to a further aspect of the present invention, there is provided a
method of making an integrated granule product for bonding to a substrate,
comprising:
(a) providing a supporting film; (b) coating a curable non-asphaltic adhesive
onto said film;
(c) applying a plurality of ceramic coated granules onto the adhesive coating
on said film, said
ceramic coated granules including one or more of a biocide, antislip friction
enhancement
particles, UV absorption particles, UV blocking particles, high reflectivity
particles, low
reflectivity particles, retroreflective particles, pigments or combinations
thereof; and
(d) curing said curable adhesive to bond said plurality of ceramic coated
granules directly to
said film.
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For purposes of the present invention, the following terms used in this
application
are defined as follows:
"ceramic coated granule" means an inorganic base substrate of generally rock,
mineral, or recycled material (e.g. slag) in granular form having a coating
which includes
an amount of an alkali metal silicate binder sufficient to bind the coating to
the inorganic
granule;
"cure" means to supply sufficient energy to a composition to alter the
physical
state of the composition, to make it transform from a fluid to less fluid
state, to go from a
tacky to a non-tacky state, to go from a soluble to insoluble state, or to
decrease the
amount of polymerizable material by its consumption in a chemical reaction.
The term
"cure" may also include the removal of energy or alternatively, the
evaporation of a
carrier; and
"self-supporting" means a property of an article such that a segment of the
article
having uniform width, thickness, and length when attached along its width to a
supporting
substrate will require no support other than itself or the substrate to which
it is attached.
An article will be deemed to be self-supporting if the length of a segment so
supported
may exceed 5.cm without visible rupture of the segment. Preferably, the
minimum length
at which a segment of the article ceases to be self-supporting will be greater
than 5 m.
Other features and advantages will be apparent from the following description
of the
preferred embodiments thereof, and from the claims.
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Brief Description of the Drawings
The above, as well as other advantages of the present invention, will become
readily apparent to those skilled in the art from the following detailed
description of a
preferred embodiment when considered in the light of the accompanying drawings
in
which:
FIG. 1 is a segmented, cross-sectional view of an integrated granule product
of the
present invention, comprising a film, a cured adhesive, and granules applied
onto an
asphalt-based substrate;
FIG. 2 is a perspective view of a roofing shingle utilizing an embodiment of
the
present invention; and
FIG.3 is a cross-sectional view of another embodiment of the integrated
granule
product of the present invention.
Detailed Description
As depicted in FIG. 1, the integrated granule product 10 includes a film 12, a
cured
adhesive 14, and a plurality of granules 16 adhered to the film 12 by the
cured adhesive
14. The integrated granule product 10 is generally an intermediate product
suitable for
various end use applications. As used herein, the term "intermediate product,"
(also
referred to herein as "intermediate") means a composite material that has
sufficient
physical properties including flexibility and durability, that the
intermediate, either alone
or upon being attached to a substrate, can be processed and fabricated into a
useful
product. For example, the intermediate product could be utilized in the
formation of
roofing products or utilized as a floor covering. FIG. 1 depicts an asphalt-
based substrate
20 suitable for receiving the integrated granule product 10 of the present
invention. The
asphalt-based substrate 20 includes a substrate mat 22, saturated with
asphalt, and an outer
layer of asphalt 24 suitable for receiving the integrated granule product 10.
FIG. 2
illustrates one potential use of the integrated granule product 34 as an
exposed surface of a
roofing shingle 30.
Materials
According to the present invention, the film can be any film material capable
of
carrying granules adhered to the film with an adhesive. Additionally, the film
must be
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capable of bonding to various substrates for end use applications.
Conventional films
capable of performing the noted functions are suitable for use with the
present invention.
Examples of film materials include paper, natural or synthetic fabrics,
polymeric materials
such as polyethylene terephthalate (PET), polypropylene, polyamide, polyimide
or lofty
fibrous mats. Preferred materials would include polymeric materials, most
preferably
polyethylene terephthalate (PET) and polypropylene.
In general the films must be provided at a thickness having sufficient
compositional strength to act as a support for the coating intermediate.
Preferably, the
film thickness is about 10 micrometers to about 300 micrometers.
The film may optionally be primed or otherwise treated, e.g., corona treated
or
surface treated, to improve bonding of an adhesive to the film. Preferred
primers include
ethylene acrylic acid or aziridine-based compositions.
The adhesive utilized in the present invention can be any non-asphaltic
material
capable of adhering granules to the film. Additionally, the adhesive
properties must allow
the adhesive to be processed into an integrated granule film suitable for
application onto
various substrates. The adhesive is generally a curable material that
possesses chemical
and mechanical properties to sufficiently bond the granules to the film.
The curable adhesive should have adhesive properties and sufficiently low
viscosity at coating temperatures that permit the adhesive to be applied
uniformly onto the
film or release liner using conventional coating methods. These conventional
coating
methods include, but are not limited to, roll coating, curtain coating, die
coating, knife
coating and spray coating. The adhesive can be coated at 100% solids, as an
emulsion, as
an aqueous dispersion or solvent borne. The coating viscosity of the adhesive
can be
varied by changing coating temperature, % solids or solvent type. For example,
an
TM
adhesive, such as Ebecryl 270 from UCB Chemicals of Smyrna, GA, would
generally be
knife coated at 100% solids, with a viscosity of about 3,000 centipoise at 60
C. .
Additionally, the adhesive should be applied at a thickness that enables the
application and
subsequent bonding of the granules to the film upon curing of the curable
adhesive.
Preferably the thickness of the adhesive is about 75 micrometers to about 500
micrometers, at 100% solids.
In general, the non-asphaltic adhesive can be of any chemistry that will
provide a
suitable coating on the film and permit the subsequent bonding of the ceramic
coated
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granules onto the film. Those skilled in the art are capable of selecting a
specific adhesive
to match film characteristics. Examples of suitable materials include
acrylated urethanes,
multifunctional acrylate monomers, acrylated epoxies, acrylated polyesters,
acrylated
polyethers, urethanes, epoxies, acrylics, phenolics, cyanate esters,
bismaleimides, hot
melts likes polyester, polyamides, polyolefins, derivatized polyolefins or
combinations
thereof. A particularly preferred adhesive includes acrylated aliphatic
urethanes, such as
Ebecryl 270 from UCB Chemicals Corporation of Smyrna, GA.
In an alternative embodiment, the ceramic coated granules may be bonded to a
self-supporting film. In this particular embodiment, the adhesive is strong
enough to
support its own weight and the weight of the ceramic coated granules. In
general, the
ceramic coated granules are partially embedded into a portion of an exposed
surface of the
adhesive film. Additionally, the adhesive film is thick enough to provide a
bonding
surface, opposite the exposed surface utilized for receiving the ceramic
coated granules.
The self-supporting adhesive film is generally produced utilizing the curable
adhesives
described for the first embodiment. FIG. 3 depicts the alternative embodiment
of an
integrated granule product 40 including a self-supporting adhesive film 42 and
a plurality
of ceramic coated granules 44 partially embedded in the self-supporting
adhesive film 42.
The self-supporting film may optionally include a release liner (not shown) in
the surface
opposite the ceramic coated granules.
In accordance with the present invention, initiators and catalysts can
optionally be
utilized in the curable adhesive composition. In the case of the free radical
curable
acrylated urethanes, multifunctional acrylates, acrylated polyesters,
acrylated polyethers,
these adhesives can be cured by free radical photoinitiators or thermal
initiators.
Examples of useful photoinitiators, which generate a free radical source when
exposed to
ultraviolet light, include, but are not limited to, organic peroxides, azo
compounds,
quinones, benzophenones, nitroso compounds, acyl halides, hydrazones, mercapto
compounds, pyrylium compounds, triacylimidazoles, acylphosphine oxides,
bisimidazoles,
chloroalkyltriazines, benzoin ethers, benzil ketals, thioxanthones, and
acetophenone
derivatives, and mixtures thereof. A preferred photoinitiator is
"IrgacureA651", which is
commercially available from Ciba Specialty Chemicals of Tarrytown, NY. Thermal
free
radical initiators include, but are not limited to, azo, peroxide, persulfate,
and redox
initiators. In the case of epoxy and urethanes resins these adhesives can be
cured by
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catalysts which include, but are not limited to, tertiary amines, imidazoles,
aliphatic
amines, cyclic anhydrides, diols, Lewis acids, organotin compounds and
photogenerated
catalysts like metallocene, and salts of onium cations.
The curable adhesives are cured through the use of conventional curing
techniques.
For example, the curable adhesive may be cured through the use of ultraviolet
radiation,
thermal radiation, actinic radiation, ionizing radiation, moisture activation,
photo-
activation, or combinations thereof. Those skilled in the art are capable of
selectively
matching adhesives with appropriate curing practices to effectively bond the
granules to
the film.
Upon curing, the cured adhesive is both flexible and durable. The properties
of
cured adhesive should be sufficiently flexible to allow the integrated granule
product to be
further processed into a derivative thereof, e.g., applied to a substrate for
end use
applications. The flexibility of the adhesive is generally measured through
tensile
elongation. The cured adhesive, in an unfilled state, is flexible as indicated
by a tensile
elongation result of 25% or greater according to ASTM standard D882-97.
The adhesive must be durable in order to maintain the bond between the granule
and the film for extended period of time. The durability is measured by the
industry
standard Granule Adhesion to Shingles test, generally recognized in the
shingle
manufacturing industry. The present invention meets standard requirements
under the
Granule Adhesion to Shingles test of 0.3 gram loss or less. Because of the
desired end use
applications, the adhesive must also be capable of withstanding various
weather
conditions. The failure of the bond between the adhesive and the ceramic
coated granules
may undesirably exposed the film, and any underlying asphalt-based substrate,
to direct
light, which can result in premature failure of the roofing product.
Optionally, the adhesive or the film may include other conventional materials
to
enhance either physical, mechanical or aesthetic properties of the adhesive or
the film and
the bond between the granules, the adhesive, and the film. Suitable additives
may include
toughening agents at about 0-10% by weight, pigments at about 0-10% by weight,
dyes at
about 0-10% by weight, adhesion promoters at about 0-5% by weight, filling
agents at
about 0-70% by weight or combinations thereof. Additionally, antimicrobials or
algaecides may be included in the film or the adhesive in an effective amount
to prevent
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the growth of algea. Those skilled in the art are capable of selecting
conventional
additives to achieve desired properties in a specific adhesive composition.
In another optional embodiment, either the film, the adhesive or both may
include
ultraviolet stabilizers, ultraviolet absorbers, antioxidants, or combinations
thereof. The
noted compounds are generally included in polymeric compositions to prevent
transmission of ultraviolet radiation by either absorbing or reflecting the
ultraviolet
radiation. With the incorporation of the present invention onto an asphalt
based substrate,
it may be desirable to utilize ultraviolet stabilizers, ultraviolet absorbers,
antioxidants, or
combinations thereof to prevent the undesirable degradation of the asphalt by
ultraviolet
radiation. Conventional ultraviolet stabilizers, ultraviolet absorbers, and
antioxidants
recognized by those skilled in the art are suitable for use in the present
invention. An
example of an ultraviolet stabilizer includes that available under the trade
designation
"TINUVINTM 292" (bis(1,2,2,6,6-pentamethy1-4-piperidinyl)sebacate) and an
example of
an ultraviolet absorber includes that available under the trade designation
"TINUVINTM
113 0" (hydroxyphenyl benzotriazole), both of which are available from Ciba-
Geigy. The
adhesive or film can include an amount of either an ultraviolet stabilizer or
an ultraviolet
absorber to impart the desired result. Preferably, the ultraviolet stabilizer
or absorber is
present in an amount up to about 10% by weight. Examples of Antioxidants
include, but
are not limited to, low melting hindered phenols and triesters. Specific
examples include
2,6-di-tert- butyl-4- methylphenol commercially available under the trade
designation
"ULTRANOXTm 226" antioxidant from Borg Warner Chemicals, Inc., Parkersburg,
NY;
octadecyl 3,5-di-tert- butyl-4-hydroxycinnamate commercially available under
the trade
designations "ISONOXTMI32" antioxidant (Schenectady Chemicals, Inc.,
Schenectady,
NY) or "VANOXTMI320" antioxidant (Vanderbilt Co., Inc., Norwalk, CT). The
adhesive
of film compositions can include sufficient amounts of antioxidant to impart
the desired
result. Preferably, the antioxidant is present in an amount up to about 3 % by
weight.
The ceramic coated granules utilized in the present invention can be
conventional
granule materials utilized in such application as roofing products. Such
granule materials
typically comprise a durable slate or rock base granule, either in natural
form or,
preferably, coated by an organic or an inorganic coating, e.g., a colored
ceramic coating.
The ceramic coating may include a variety of ingredients to provide desired
aesthetic or
anti-microbial properties.
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In general, the base granule can be prepared from any mineral material which
is
dense and properly graded by screening for the desired coverage. Such mineral
materials
are crushed and graded and optionally and preferably, coated with a colorant,
and
optionally with other materials such as an antimicrobial material. Preferably,
minerals are
crushed and screened to a size desirable for use in a chosen product such as
roofing,
flooring, pools, which typically implies that it pass a #12 mesh (U.S.
Standard) screen and
be retained in a #40 mesh (U.S. Standard) screen. Methods to add a ceramic
color coating
to base granules are generally disclosed by Beyard et al. in U.S. Patent No.
3,752,696.
Suitable base granules can be prepared from a wide class of relatively porous
or
non-porous and weather-resistant rock or mineral materials, including trap
rocks, slates,
argillite, greystone, greenstone, quartz, quartzite, certain granites, metal
oxides such as
aluminum oxide, or certain synthetic granules made from clay or other
ceramics.
Commercially available granules useful in products and methods according to
the
present invention include, for example, the entire line of roofing granules,
ColorquartzTM
granules, and other aggregate including larger and smaller grade byproduct
materialmanufactured by 3M Company of St. Paul, MN. Additional granules useful
in
products and methods according to the present invention, include any
variations on this
line of products such that the granules provide additional functionality to
the present
invention. Examples include but are not limited to, biocide granules such as
algae
resistant, fungicide and antimicrobial granules, antislip friction enhancing
granules such
used in Safety WaJkTM manufactured by 3M Company, high or low reflectivity
particles,
particles with retroreflective properties, and UV absorbent or blocking
particles. In a
preferred embodiment, the granules may contain photocatalytic compositions
such as
those described in U.S. Patent No. 6,569,520.
Preparation of Integrated Granule Product
The integrated granule product of the present invention is generally produced
by
bonding a plurality of ceramic coated granules onto the film through the use
of the curable
adhesive. The resulting product is a suitable intermediate for various end use
applications.
In the process of the present invention, a film capable of carrying ceramic
coated
granules is first provided. The film may have been optionally treated with a
primer, or
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other physical method, in order to enhance the bond between the adhesive and
the film.
The adhesive is then coated onto the film. The optional additives may have
been mixed by
conventional methods into the adhesive prior to application onto the film. The
adhesive is
applied by conventional practices such as knife coating techniques. The
adhesive is
applied at a temperature of about 60 C to about 100 C and a viscosity of in
the range of
2500 centipoise to about 20,000 centipoise. The temperature is selected at a
point low
enough to prevent distortion of the film yet provide a suitable viscosity for
sufficient
application of the adhesive onto the film.
The adhesive is applied at a thickness that permits sufficient holding
properties of
the granules but does not completely cover the granules. In general, the
adhesive is
applied at a thickness in the range of about 75 micrometers to about 500
micrometers.
A plurality of ceramic coated granules are then applied onto an exposed
surface of
the adhesive. The granules can be applied using conventional application
methods such
as, for example, drop coating techniques. The granules can be applied at
varying
thicknesses and coverage patterns. For example, the granules can be drop
coated onto the
adhesive at a rate to provide an even distribution of granules. Generally, the
granules are
coated to excess to provide the desirable coverage. Additionally, more than
one layer of
granules or different types of ceramic coated granules may be applied onto the
film. One
skilled in the art is capable of selecting a coating rate to achieve desired
coating coverage
over the film.
The coated film is then subjected to a curing step in order to form a cured
adhesive
and a bond between the film and the granules. The curing may include such
conventional
practices such as the use of ultraviolet radiation, thermal radiation, actinic
radiation,
moisture activation, photo-activation, or combinations thereof. The duration
and amount
of energy applied during the curing step is affected by variables such as, for
example, the
amount and thickness of adhesive, line speeds, the form of activation energy,
and the
presence of initiators. Those skilled in the art are capable of matching the
appropriate
processing conditions to achieve the desired bond between the granules and the
film.
The film may be in the form of single sheets of desired dimensions or may
include
webs or rolls of film wherein the adhesive and ceramic coated granules are
applied in a
continuous process. With a web based process, the coated film is collected in
a web form
at the end of the process for end use applications.
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The integrated granule product is flexible and durable. The integrated granule
product is pliable as determined by mandrel flexibility test procedures as
described in the
"Examples" section. The process of the present invention results in a
composite structure
that isolates the ceramic coated granules from the underlying asphalt based
substrate. The
advantage in separating the ceramic coated granules from the asphalt may
prevent the
adverse discoloration of the aesthetic color of the ceramic coated granules.
The
prevention of discoloration is indicated by a one unit or more change in any
Hunter color
scale coordinates of L*, a*, or b*. Preferably, the finished integrated
granule product,
when utilizing standard white pigmented granules, exhibits an L* value of 64
or greater
according to HunterLab spectrocolorimeter test procedures.
Optionally, the film or the adhesive of the present invention include various
fillers
or pigments in the film to achieve desirable color effects. The use of fillers
in the
adhesive, or the underlying film, can mask the dark color of the asphalt. For
example,
white pigments in a film with white granules can produce a significantly
lighter, whiter
shingle than the gray which can be obtained if the black asphalt shows through
the gaps
between granules. Similarly, interesting color effects may be obtained by
choosing a color
or colors, other than the color of the granules, as fillers in the adhesive or
film. For
example, a patterned film with a clear adhesive may be used to impart
desirable shading
effects, e.g., wood grain, to the shingle. In a patterned flooring, visual
elements such as
repeating geometric patterns or logos, etc., may be supplied.
Application of the Integrated Granule Product
The integrated granule product may be applied onto various substrates to form
different products. The substrates generally serve as a base for receiving the
integrated
granule product of the present invention. The base substrate may be function
as a
mechanism for attaching the product to another object. For example, the
integrated
granule product can be applied onto an asphalt-based substrates to form a
roofing shingle.
The roofing shingle is then attached to the roof of a building structure.
Alternatively, the
integrated granule product may be attached directly to a fixed substrate, such
as a floor or
other stationary building structure.
FIG. 2 depicts a preferred embodiment of the present invention. A three tab
shingle 30 is produced using a conventional asphalt-based substrate 32 and the
integrated
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granule film 34 of the present invention. The integrated granule film 34 would
serve as
the exposed surface of the tab area 36. The headlap area 38 would be covered
by a
subsequent layer of shingles.
Suitable substrates for the present invention include asphalt-based substrate,
metal
substrate, polymeric substrate, concrete substrate, tile substrate, fiber
substrate, wood
substrate or combinations thereof. Preferably, the substrate is an asphalt-
based substrate.
An asphalt-based substrate ("asphalt substrate" or "substrate") can be any
asphalt-based
material suitable for use in a roofing product, many of which are well known.
In general,
substrates may include a non-asphalt-based material in the form of a mat or
web
("substrate mat" or "mat") wherein the mat is saturated or coated with
asphalt. Various
materials may be used as the substrate mat. Preferred materials comprise a non-
woven
matting of either fiberglass or cellulose fibers. Generally, fiberglass
matting is
manufactured from a silicate glass fiber blown in a non-woven pattern in
streams of about
30-200 micrometers in diameter, with the resultant mat being approximately 1-5
millimeters in thickness. Fiberglass matting is commercially available from
Owens-Corning Fiberglass Corporation, Toledo, Ohio, and Manville Roofing
Systems,
Denver, Colorado. In general, most any fiberglass mat with similar physical
properties
could be incorporated into the product and process of the invention with
satisfactory
results.
Cellulose felt (dry felt) is typically made from various combinations of rag,
wood,
and other cellulose fibers or cellulose-containing fibers, blended in
appropriate proportions
to provide desirable strength, absorption capacity, and flexibility.
Roofing asphalt, sometimes termed "asphalt flux", is a petroleum-based fluid
comprising a mixture of bituminous materials.
A cellulose mat is generally soaked or otherwise impregnated or saturated to
the
greatest possible extent with a "saturant" asphalt. Saturant asphalt is high
in oily
constituents, and other preservatives, which provide waterproof and
weatherproof
properties.
The saturated mat is sealed on both sides by application of a hard or more
viscous
"coating asphalt", which is further protected by a covering of mineral
granules. In the
case of fiberglass mat-based asphalt roofing products, it is well understood
that the coating
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asphalt can be applied directly to the unsaturated fiberglass mat, without the
need for a
first application of saturant asphalt.
Saturant asphalt and the coating asphalt can be prepared by processing asphalt
flux
in such a way as to modify the temperature at which the asphalt will soften.
The softening
point of saturant asphalt varies from about 37 C to about 72 C, whereas the
softening
point of desirable coating asphalt runs as high as about 127 C. The softening
temperature
may be modified for application to roofing products in varying climates.
A variety of stabilizers and fillers may be included in the either the
saturant asphalt
of the coating asphalt. For example, silica, slate dust, talc, micaceous
materials, dolomite,
and trap rock, and calcium carbonate or limestone, may be used as stabilizers
or fillers in
the coating asphalt. Such materials render the asphalt substrate improved with
respect to
shatter resistance and shock resistance. In addition, they provide fire
protection. Also,
they provide raw material cost savings and improved weathering
characteristics.
The integrated granule product may be applied to an asphalt-based substrate by
heating the substrate to soften the asphalt surface. The film side of the
integrated granule
product is then applied onto the softened asphalt surface. Generally, the
substrate is
heated to a temperature in the range of about 150 C to about 250 C. Upon
cooling the
film bonds to the asphalt and forms an article suitable for use in roofing
applications. The
asphalt-based substrate may be provided in either shingle or rolled web form.
Thus the end
product may also be provided in either form.
The use of the integrated granule product on asphalt-based substrates
generally
results in a product with improved properties over conventional asphalt
singles or roofing
products. The present invention, when utilized in a roofing shingle, exhibits
a tensile
strength according to American Roofing Manufacturers Association Test Index
No. 2,126,
of greater than 50% over a shingle without the integrated granule product.
Additionally,
the use of the product of the present invention prevents the asphalt from
adversely
affecting the aesthetic color of the ceramic coated granules.
The application of the present invention onto flooring substrates preferably
includes the use of a polymeric sealant or top coat over the exposed ceramic
coated
granules. The top coat protects the granules from excessive wear and reduces
the abrasive
nature of exposed granules. Polymeric sealants include conventional top coat
polymers
such as, for example, epoxies urethanes, and methacrylates.
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Examples
Example 1
A primed (ethylene-acrylic acid copolymer) 100 micrometer polyethylene
teraphthalate film was knife-coated with a commercially available acrylated
urethane
oligomer (EBECRYL 270 available from UCB Chemicals) and catalyzed with
approximately 1% photoinitiator (Irgacure 651 from Ciba Additives) to a
thickness of 375
micrometers. White ceramic-coated roofing granules were drop-coated and hand-
pressed
into the still-liquid resin coating. This construction was then processed
through a UV
curing station at 6.1 m/min and irradiated with a Fusion Systems "D" bulb (600
W/in).
This process yielded a solid, tough granule-containing film material that
adheres well
when heat-laminated onto asphalt-saturated roofing mats.
Example 2
A primed (ethylene-acrylic acid copolymer) 100 micrometer polyethylene
teraphthalate film was knife-coated at 93 C with a resin mixture of 258 g of
Ebecryl 270,
42 g of tripropylene glycol diacrylate, (tripropylene glycol diacrylate is
commercially
available from UCB Radcure, Syrma, GA under the tradename TRPGDA), 306 g of
TM
Minspar 3 (Minspar 3 is a feldspar filler available from the K-T Feldspar
Corporation,
Spruce Pine, NC), and 6 g of photoinitiator Irgacure 651 (Irgacure 651 is
commercially
available from Ciba Specialty Chemicals Tarrytown, NY. The resulting coating
had a
thickness of 375 micrometer. White ceramic-coated roofing granules were drop-
coated
and hand-pressed into the still-liquid resin coating. This construction was
then processed
through a UV curing station at 6.1 m/min and irradiated with a Fusion Systems
"D" bulb
(600 W/in). This process yielded a solid, tough granule-containing film
material that
adheres well when heat-laminated onto asphalt-saturated roofing mats.
Example 3
A primed (ethylene-acrylic acid copolymer) 100 micrometer polyethylene
teraphthalate film was knife-coated at 93 C with a resin mixture of 80 g of
Ebecryl 270,
TM
50 g of Minspar 3, 2 g of White Cloud-60 Lithopone (a white pigment
commercially
available from Sino-American Pigment Systems, Inc., Berkley, CA.) and 1 g of
Irgacure
651. The resulting. coating had a thickness of 375 micrometer. White ceramic-
coated
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roofing granules were drop-coated and hand-pressed into the still-liquid resin
coating.
This construction was then processed through a UV curing station at 6.1 m/min
and
irradiated with a Fusion Systems "D" bulb (600 W/in). This process yielded a
solid, tough
granule-containing film material that adheres well when heat-laminated onto
asphalt-saturated roofing mats.
Example 4
The process of Example 1 was utilized in producing a ceramic-coated sand
(3M ColorQuartz) containing construction by lowering the resin coating
thickness from
TM
375 micrometer to 100 micrometer and substituting ColorQuartz obtained from 3M
Company of St. Paul, MN for the roofing granules. After UV curing, an adhesive
coating
was then applied to the backside of the PET film to create a tape-type
construction. The
construction was then applied onto a metal roofing panel.
Examples 5-6
Examples 5 and 6 demonstrate the improved tensile strength of the present
invention.
For Example 6, a film was made according to Example 1 was laminated onto an
asphalt roofing base material consisting of an asphalt-saturated base web,
coated on the
weather-exposed side with standard roofing asphalt to form a completed roofing
shingle.
For Example 5, an identical shingle was used without the film. The ceramic
coated
granules were drop coated directly onto the asphalt. Samples were prepared
according to
Asphalt Roofing Industry Bureau Test Procedure 2.224. Specimens measured 15.24
cm by
2.54 cm and represented both film-containing and non-film-containing examples
of the
shingle web for direct comparison.
The instrument used was an Instron Model 1122 Tensile Tester equipped with a
453.5 Kg load cell, recently calibrated. The sample jaws were set so that 3.81
cm of
sample was inserted in the top and bottom clamp and 7.62 cm of sample appeared
between
the clamps. The instrument was setup to deliver a uniform travel of 30.48 cm
per minute
for this test. Values were recorded at the instant of sample failure. The test
was run on six
different times for each Example.
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CA 02423226 2003-03-24
Example 5 exhibited a tensile strength of 10.75 kg/cm. Example 6 demonstrated
a
tensile strength of 24.57 kg/cm.
Example 7
The integrated granule product of Example 1 was tested for
flexibility/pliability
under the Mandrel Flexibility Test as defined by ASTM-D228-00 Test Methods For
Asphalt Roll Roofing Cap Sheets and Shingles. A 2.54 cm by 20.32 cm specimen
was cut
from Example 1 and bent through 90 degrees over a 1.27 cm aluminum rounded
block as
specified in the above method. The specimen passed and did not produce
cracking of the
cured adhesive portion of the integrated granule product.
Example 8
An integrated granule product was laminated to a web of standard asphalt-
impregnated fiberglass shingle mat by coating a 0.158 cm layer of Trumbull
asphalt #4110
at 87.7 C along the entire web width. A 15.24 cm roll of integrated granule
product made
according to the procedure of Example 1 was laminated, by press-roll, on one
side of the
web and headlap granules were drop-coated into the liquid asphalt on the
remainder of the
web to form the completed roofing shingle. The product was then fed into a
standard
shingle die cutter to obtain individual shingle samples
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