CA2520244C - Roofing material - Google Patents
Roofing material Download PDFInfo
- Publication number
- CA2520244C CA2520244C CA002520244A CA2520244A CA2520244C CA 2520244 C CA2520244 C CA 2520244C CA 002520244 A CA002520244 A CA 002520244A CA 2520244 A CA2520244 A CA 2520244A CA 2520244 C CA2520244 C CA 2520244C
- Authority
- CA
- Canada
- Prior art keywords
- roofing shingle
- material according
- thin layer
- shingle material
- polypropylene
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Active
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- 239000000463 material Substances 0.000 title claims abstract description 76
- -1 polypropylene Polymers 0.000 claims abstract description 39
- 239000004743 Polypropylene Substances 0.000 claims abstract description 35
- 229920001155 polypropylene Polymers 0.000 claims abstract description 29
- 229920003023 plastic Polymers 0.000 claims abstract description 19
- 239000004033 plastic Substances 0.000 claims abstract description 19
- 239000004698 Polyethylene Substances 0.000 claims description 7
- 229920000573 polyethylene Polymers 0.000 claims description 7
- 239000000835 fiber Substances 0.000 claims description 6
- 239000008188 pellet Substances 0.000 claims description 6
- XECAHXYUAAWDEL-UHFFFAOYSA-N acrylonitrile butadiene styrene Chemical compound C=CC=C.C=CC#N.C=CC1=CC=CC=C1 XECAHXYUAAWDEL-UHFFFAOYSA-N 0.000 claims description 4
- 239000004676 acrylonitrile butadiene styrene Substances 0.000 claims description 4
- 229920000122 acrylonitrile butadiene styrene Polymers 0.000 claims description 4
- 229920000915 polyvinyl chloride Polymers 0.000 claims description 4
- 239000004800 polyvinyl chloride Substances 0.000 claims description 4
- 229920002725 thermoplastic elastomer Polymers 0.000 claims description 4
- 229920002943 EPDM rubber Polymers 0.000 claims description 3
- 229920001577 copolymer Polymers 0.000 claims description 3
- 229920000139 polyethylene terephthalate Polymers 0.000 claims description 3
- 239000005020 polyethylene terephthalate Substances 0.000 claims description 3
- 229920000098 polyolefin Polymers 0.000 claims description 3
- QTBSBXVTEAMEQO-UHFFFAOYSA-M Acetate Chemical compound CC([O-])=O QTBSBXVTEAMEQO-UHFFFAOYSA-M 0.000 claims description 2
- FERIUCNNQQJTOY-UHFFFAOYSA-M Butyrate Chemical compound CCCC([O-])=O FERIUCNNQQJTOY-UHFFFAOYSA-M 0.000 claims description 2
- FERIUCNNQQJTOY-UHFFFAOYSA-N Butyric acid Natural products CCCC(O)=O FERIUCNNQQJTOY-UHFFFAOYSA-N 0.000 claims description 2
- 239000004677 Nylon Substances 0.000 claims description 2
- 239000004793 Polystyrene Substances 0.000 claims description 2
- XBDQKXXYIPTUBI-UHFFFAOYSA-M Propionate Chemical compound CCC([O-])=O XBDQKXXYIPTUBI-UHFFFAOYSA-M 0.000 claims description 2
- DHKHKXVYLBGOIT-UHFFFAOYSA-N acetaldehyde Diethyl Acetal Natural products CCOC(C)OCC DHKHKXVYLBGOIT-UHFFFAOYSA-N 0.000 claims description 2
- 125000002777 acetyl group Chemical class [H]C([H])([H])C(*)=O 0.000 claims description 2
- 229920006397 acrylic thermoplastic Polymers 0.000 claims description 2
- DQXBYHZEEUGOBF-UHFFFAOYSA-N but-3-enoic acid;ethene Chemical compound C=C.OC(=O)CC=C DQXBYHZEEUGOBF-UHFFFAOYSA-N 0.000 claims description 2
- 239000000806 elastomer Substances 0.000 claims description 2
- 239000005038 ethylene vinyl acetate Substances 0.000 claims description 2
- 229920001778 nylon Polymers 0.000 claims description 2
- 239000000049 pigment Substances 0.000 claims description 2
- 229920001200 poly(ethylene-vinyl acetate) Polymers 0.000 claims description 2
- 229920003229 poly(methyl methacrylate) Polymers 0.000 claims description 2
- 229920002492 poly(sulfone) Polymers 0.000 claims description 2
- 239000004417 polycarbonate Substances 0.000 claims description 2
- 229920000515 polycarbonate Polymers 0.000 claims description 2
- 229920002223 polystyrene Polymers 0.000 claims description 2
- 229920002379 silicone rubber Polymers 0.000 claims description 2
- 239000004945 silicone rubber Substances 0.000 claims description 2
- ISXSCDLOGDJUNJ-UHFFFAOYSA-N tert-butyl prop-2-enoate Chemical compound CC(C)(C)OC(=O)C=C ISXSCDLOGDJUNJ-UHFFFAOYSA-N 0.000 claims description 2
- 239000012815 thermoplastic material Substances 0.000 claims 3
- 239000000155 melt Substances 0.000 claims 1
- 239000010426 asphalt Substances 0.000 description 9
- 238000004519 manufacturing process Methods 0.000 description 9
- 239000008187 granular material Substances 0.000 description 8
- 239000010454 slate Substances 0.000 description 8
- 238000000576 coating method Methods 0.000 description 7
- 239000011248 coating agent Substances 0.000 description 6
- 238000002844 melting Methods 0.000 description 5
- 230000008018 melting Effects 0.000 description 5
- 239000000203 mixture Substances 0.000 description 5
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 4
- 239000000853 adhesive Substances 0.000 description 4
- 230000001070 adhesive effect Effects 0.000 description 4
- 238000009863 impact test Methods 0.000 description 3
- 229910052500 inorganic mineral Inorganic materials 0.000 description 3
- 238000000034 method Methods 0.000 description 3
- 239000011707 mineral Substances 0.000 description 3
- 230000000704 physical effect Effects 0.000 description 3
- 238000012360 testing method Methods 0.000 description 3
- 239000002131 composite material Substances 0.000 description 2
- 239000010445 mica Substances 0.000 description 2
- 229910052618 mica group Inorganic materials 0.000 description 2
- 239000004576 sand Substances 0.000 description 2
- 238000007789 sealing Methods 0.000 description 2
- 239000002893 slag Substances 0.000 description 2
- 239000000454 talc Substances 0.000 description 2
- 229910052623 talc Inorganic materials 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 description 1
- 235000019738 Limestone Nutrition 0.000 description 1
- 229920000426 Microplastic Polymers 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 239000003245 coal Substances 0.000 description 1
- 238000010924 continuous production Methods 0.000 description 1
- 229910052802 copper Inorganic materials 0.000 description 1
- 239000010949 copper Substances 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 230000003247 decreasing effect Effects 0.000 description 1
- 239000013013 elastic material Substances 0.000 description 1
- 239000011152 fibreglass Substances 0.000 description 1
- 239000000945 filler Substances 0.000 description 1
- 235000013312 flour Nutrition 0.000 description 1
- 238000009472 formulation Methods 0.000 description 1
- 239000003112 inhibitor Substances 0.000 description 1
- 238000009434 installation Methods 0.000 description 1
- 239000006028 limestone Substances 0.000 description 1
- 239000012764 mineral filler Substances 0.000 description 1
- 238000004806 packaging method and process Methods 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- 229920000642 polymer Polymers 0.000 description 1
- 239000000565 sealant Substances 0.000 description 1
- 238000003860 storage Methods 0.000 description 1
- 229920001169 thermoplastic Polymers 0.000 description 1
- 229920001187 thermosetting polymer Polymers 0.000 description 1
- 239000004416 thermosoftening plastic Substances 0.000 description 1
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D1/00—Roof covering by making use of tiles, slates, shingles, or other small roofing elements
- E04D1/28—Roofing elements comprising two or more layers, e.g. for insulation
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B11/00—Layered products comprising a layer of bituminous or tarry substances
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B11/00—Layered products comprising a layer of bituminous or tarry substances
- B32B11/04—Layered products comprising a layer of bituminous or tarry substances comprising such bituminous or tarry substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B11/046—Layered products comprising a layer of bituminous or tarry substances comprising such bituminous or tarry substance as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/18—Layered products comprising a layer of synthetic resin characterised by the use of special additives
- B32B27/20—Layered products comprising a layer of synthetic resin characterised by the use of special additives using fillers, pigments, thixotroping agents
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B27/00—Layered products comprising a layer of synthetic resin
- B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
- B32B3/02—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by features of form at particular places, e.g. in edge regions
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2250/00—Layers arrangement
- B32B2250/02—2 layers
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/40—Properties of the layers or laminate having particular optical properties
- B32B2307/402—Coloured
- B32B2307/4026—Coloured within the layer by addition of a colorant, e.g. pigments, dyes
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/712—Weather resistant
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/718—Weight, e.g. weight per square meter
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2419/00—Buildings or parts thereof
- B32B2419/06—Roofs, roof membranes
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D1/00—Roof covering by making use of tiles, slates, shingles, or other small roofing elements
- E04D2001/005—Roof covering by making use of tiles, slates, shingles, or other small roofing elements the roofing elements having a granulated surface
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/24—Structurally defined web or sheet [e.g., overall dimension, etc.]
- Y10T428/24942—Structurally defined web or sheet [e.g., overall dimension, etc.] including components having same physical characteristic in differing degree
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31551—Of polyamidoester [polyurethane, polyisocyanate, polycarbamate, etc.]
- Y10T428/31616—Next to polyester [e.g., alkyd]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31786—Of polyester [e.g., alkyd, etc.]
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T428/00—Stock material or miscellaneous articles
- Y10T428/31504—Composite [nonstructural laminate]
- Y10T428/31786—Of polyester [e.g., alkyd, etc.]
- Y10T428/3179—Next to cellulosic
Abstract
An improved roofing material having an upper and lower surface in which a thin layer comprising re-melted polypropylene or other suitable plastic is adhered to at least a portion of its lower surface.
Description
ROOFING MATERIAL
Field of the Invention This invention relates to roofing material, and in particular to roofing shingles, having a novel backing which imparts improved characteristics such as resistance to damage from hail.
Background of the Invention Roofing material has a front upper surface, at least a portion of which is intended to be exposed to weather, and a back lower surface facing in the direction opposite to the upper surface.
Traditionally, the back, on-weather-exposed surface of roofing material such as shingles has been covered with finely ground mineral material ("fines") so that the asphalt backing does not adhere to contiguous roofing material when packaged for transport and storage. Such finely divided materials include mica flakes, copper slag, coal slag, sand, talc and silica dust.
In many regions the roofing materials on buildings, particularly the shingles on residential dwellings, are damaged by hail. The damage is caused by the impact of the hail stones on shingles resulting in visible cracking, tearing, snapping or imperceptible damage to the shingles' structure which can render the shingles less resistant to the elements of wind, rain, snow and ice. Frequently, such damage requires the costly replacement of roofing materials to prevent the elements from entering into the building.
U.S. Patent No. 6,341,462 B2, to Kiik et al., discloses a roofing material with improved resistance to damage by hail having an energy-absorbing backing layer adhered to its lower surface.
The backing layer of U.S. Patent No. 6,341,462 comprises fiber and binding components with a combined weight ranging between 0.5 and 5 lbs. Per square (100 square feet) of shingle material such that the exposed portion of a shingle made according to U.S. Patent No.
6,341,462 appears more substantial and is, indeed, visibly thicker prior to application than products made without the backing layer.
It is an object of the present invention to provide roofing materials, particularly shingles, which have a reduced susceptibility to damage during hail storms, and are nevertheless lightweight and simple to manufacture and package using conventional equipment.
SUMMARY OF THE INVENTION
In accordance with the invention, the wear of roofing materials such as shingles is improved by applying to at least a portion of their back surface, i. e., the non-weather-exposed surface facing the roof, a thin layer of plastic, such as a thermoplastic. In a preferred embodiment, the backing layer is at least approximately 0.5 mils (thousandths of an inch) thick and comprises essentially re-melted polypropylene rolled material, pellets, flakes, fibers and/or any other suitable polypropylene material.
According to an aspect of the present invention, there is provided in a roofing shingle material having a front surface, at least a portion of which is intended to be exposed to weather, and back surface facing in a direction opposite to the front surface, the improvement comprising a thin layer consisting essentially of a plastic material covering at least a portion of said back surface, said layer being between about 0.5 and 4 mils in thickness.
DETAILED DESCRIPTION OF THE INVENTION
Conventional asphalt roofing materials, including shingles, are manufactured using a continuous process in which a base fibrous web, such as a sheet of roofing felt or fiberglass mat, is impregnated with a bituminous material and then coated on one or both surfaces with a weather-resistant bituminous coating material. The bituminous coating usually contains a mineral filler such as slate flour or powdered limestone. More than one fibrous sheet may be laminated within multiple bituminous layers. Usually, a suitable granular material, such as slate granules or mineral surfacing, is applied to the bituminous coating on the surface that will be exposed to the weather. Finely divided materials such as mica flakes, talc, silica dust or the like are adhered to the non-weather exposed surface of the roofing shingle to prevent sticking of the adjacent layers of the roofing material in packages. Alternatively, as disclosed in U.S. Patent No. 6,341,462 patent, a backing layer comprising filler and binder materials may be adhered to the non-weather exposed surface of the roofing shingle in place of the fines to prevent sticking of adjacent roofing materials and provide additional strength and other advantageous physical properties.
Field of the Invention This invention relates to roofing material, and in particular to roofing shingles, having a novel backing which imparts improved characteristics such as resistance to damage from hail.
Background of the Invention Roofing material has a front upper surface, at least a portion of which is intended to be exposed to weather, and a back lower surface facing in the direction opposite to the upper surface.
Traditionally, the back, on-weather-exposed surface of roofing material such as shingles has been covered with finely ground mineral material ("fines") so that the asphalt backing does not adhere to contiguous roofing material when packaged for transport and storage. Such finely divided materials include mica flakes, copper slag, coal slag, sand, talc and silica dust.
In many regions the roofing materials on buildings, particularly the shingles on residential dwellings, are damaged by hail. The damage is caused by the impact of the hail stones on shingles resulting in visible cracking, tearing, snapping or imperceptible damage to the shingles' structure which can render the shingles less resistant to the elements of wind, rain, snow and ice. Frequently, such damage requires the costly replacement of roofing materials to prevent the elements from entering into the building.
U.S. Patent No. 6,341,462 B2, to Kiik et al., discloses a roofing material with improved resistance to damage by hail having an energy-absorbing backing layer adhered to its lower surface.
The backing layer of U.S. Patent No. 6,341,462 comprises fiber and binding components with a combined weight ranging between 0.5 and 5 lbs. Per square (100 square feet) of shingle material such that the exposed portion of a shingle made according to U.S. Patent No.
6,341,462 appears more substantial and is, indeed, visibly thicker prior to application than products made without the backing layer.
It is an object of the present invention to provide roofing materials, particularly shingles, which have a reduced susceptibility to damage during hail storms, and are nevertheless lightweight and simple to manufacture and package using conventional equipment.
SUMMARY OF THE INVENTION
In accordance with the invention, the wear of roofing materials such as shingles is improved by applying to at least a portion of their back surface, i. e., the non-weather-exposed surface facing the roof, a thin layer of plastic, such as a thermoplastic. In a preferred embodiment, the backing layer is at least approximately 0.5 mils (thousandths of an inch) thick and comprises essentially re-melted polypropylene rolled material, pellets, flakes, fibers and/or any other suitable polypropylene material.
According to an aspect of the present invention, there is provided in a roofing shingle material having a front surface, at least a portion of which is intended to be exposed to weather, and back surface facing in a direction opposite to the front surface, the improvement comprising a thin layer consisting essentially of a plastic material covering at least a portion of said back surface, said layer being between about 0.5 and 4 mils in thickness.
DETAILED DESCRIPTION OF THE INVENTION
Conventional asphalt roofing materials, including shingles, are manufactured using a continuous process in which a base fibrous web, such as a sheet of roofing felt or fiberglass mat, is impregnated with a bituminous material and then coated on one or both surfaces with a weather-resistant bituminous coating material. The bituminous coating usually contains a mineral filler such as slate flour or powdered limestone. More than one fibrous sheet may be laminated within multiple bituminous layers. Usually, a suitable granular material, such as slate granules or mineral surfacing, is applied to the bituminous coating on the surface that will be exposed to the weather. Finely divided materials such as mica flakes, talc, silica dust or the like are adhered to the non-weather exposed surface of the roofing shingle to prevent sticking of the adjacent layers of the roofing material in packages. Alternatively, as disclosed in U.S. Patent No. 6,341,462 patent, a backing layer comprising filler and binder materials may be adhered to the non-weather exposed surface of the roofing shingle in place of the fines to prevent sticking of adjacent roofing materials and provide additional strength and other advantageous physical properties.
-2-In the present invention, at least a portion of the fine or composite backing layer is replaced with a thin layer of plastic or re-melted plastic which prevents sticking of adjacent packaged roofing materials, is simple to manufacture, lightweight, barely increases the overall thickness of the roofing material, and yet improves the physical properties of the roofing material by, among other things, decreasing its susceptibility to damage from hail. In one embodiment, at least approximately 0.5 mils of re-melted polypropylene rolled material, pellets, flakes, fibres and/or other suitable polypropylene material are applied to the back surface of the roofing material. More preferably, a layer of approximately 3-4 mils is applied. The weight addition of such a polypropylene backing is therefore only up to approximately 2 pounds per square, which is less than the weight of conventional roofing materials with a backing of fines. An inventive backing formed using a greater thickness of polypropylene or sufficient thickness of another plastic will have a weight comparable to, or possibly greater than, conventional roofing materials. Depending on its composition and thickness, the inventive backing may weigh between 0.1 and 10 lbs/square.
As noted above, one embodiment of the inventive backing may be formed using polypropylene in any one or more of several different forms. In addition to those mentioned above, spun bond polypropylene may also be used. Further embodiments may employ different suitable polyolefins or copolymers comprising at least one polyolefin: for example, polyethylene, polyvinylchloride, ethylene vinyl acetate, acrylonitrile butadiene styrene ("ABS"), acetal, acetate, butyrate, nylon, polyalomer, polycarbonate, polystyrene, styrene-butadine-copolymers, polysulfone, propionate or polyvinyl chloride. In other embodiments, thermoset or elastic materials, such as sheets of ethylene propylene diene monomer rubber ("EPDM"), high density silicone rubber, thermoplastic rubber, elastomers or sprayable and curable acrylics may be used. Yet other embodiments may employ laminates or multi-layers optimized to provide the desired adhesive, mechanical and other properties of the backing layer. For example, the backing may comprise a first layer of spun bond polypropylene coated with one or more layers of polyethylene or a layer of spun bond polypropylene with one or more polyethylene layers laminated thereto.
Alternatively, the backing may comprise a non-woven polyethylene terephthalate ("PET") mat that is coated with polyethylene.
As noted above, one embodiment of the inventive backing may be formed using polypropylene in any one or more of several different forms. In addition to those mentioned above, spun bond polypropylene may also be used. Further embodiments may employ different suitable polyolefins or copolymers comprising at least one polyolefin: for example, polyethylene, polyvinylchloride, ethylene vinyl acetate, acrylonitrile butadiene styrene ("ABS"), acetal, acetate, butyrate, nylon, polyalomer, polycarbonate, polystyrene, styrene-butadine-copolymers, polysulfone, propionate or polyvinyl chloride. In other embodiments, thermoset or elastic materials, such as sheets of ethylene propylene diene monomer rubber ("EPDM"), high density silicone rubber, thermoplastic rubber, elastomers or sprayable and curable acrylics may be used. Yet other embodiments may employ laminates or multi-layers optimized to provide the desired adhesive, mechanical and other properties of the backing layer. For example, the backing may comprise a first layer of spun bond polypropylene coated with one or more layers of polyethylene or a layer of spun bond polypropylene with one or more polyethylene layers laminated thereto.
Alternatively, the backing may comprise a non-woven polyethylene terephthalate ("PET") mat that is coated with polyethylene.
-3-The inventive backing material is applied to the face of the back of the shingle in place of the fines, granules or other standard backing material that is conventionally applied at the slating drum stage during shingle manufacturing. As such, the inventive shingles may be manufactured using a standard line where asphalt is coated on the moving web and mineral granules are dropped on the upper surface of the hot asphalt coated web. A preferred application technique for the inventive backing is similar to the current industry practice of applying fines, granules or other standard backing material, except that plastic pellets, flakes and/or fibers may be substituted for the fines, granules or other standard backing material. However, any other suitable method of application may be used, including applying one or more layers of extruded or pre-melted plastic to the shingle.
In a preferred embodiment, the inventive backing is formed from at least approximately 0.5 mils of polypropylene that is preferably greater than 2 mils, and more preferably 3-4 mils. Since polypropylene has a melting point of approximately 350 F, while the asphalt coating on the moving web is typically maintained at about 400 F during shingle manufacturing, certain polypropylene rolled material, pellets, flakes and/or fibers melt upon contact with the asphalt coating, thereby forming a molten layer of substantially uniform thickness that covers part or all of the asphalt surface. As polypropylene-coated roofing material is moved through the production process, the molten polypropylene cools to form a continuous resolidified layer of substantially uniform composition and thickness that is adhered to the back of the shingle. Pigments and other additives may be combined with the polypropylene, as needed, preferably in pellet form, to change the color of the polypropylene layer and to provide enhanced resistance to UV damage, though the black color typically used to minimize edge visibility is inherently a good UV inhibitor.
In the above-described process for producing polypropylene-backed roofing material, suitable plastics with a melting point below about 400 F may be substituted for or mixed with the polypropylene rolled material, pellets, flakes and/or fibers. Furthermore, plastic materials with melting points above 400 F, such as EDPM, or certain polypropylene materials with higher melting points, may be used so long as molten asphalt adheres to such materials at the typical manufacturing temperature of around above 400 F.
It is known in the art to manufacture roofing shingles with an adhesive or sealant disposed on the upper edge region of the upper surface of the shingle, such that in an assembled roof
In a preferred embodiment, the inventive backing is formed from at least approximately 0.5 mils of polypropylene that is preferably greater than 2 mils, and more preferably 3-4 mils. Since polypropylene has a melting point of approximately 350 F, while the asphalt coating on the moving web is typically maintained at about 400 F during shingle manufacturing, certain polypropylene rolled material, pellets, flakes and/or fibers melt upon contact with the asphalt coating, thereby forming a molten layer of substantially uniform thickness that covers part or all of the asphalt surface. As polypropylene-coated roofing material is moved through the production process, the molten polypropylene cools to form a continuous resolidified layer of substantially uniform composition and thickness that is adhered to the back of the shingle. Pigments and other additives may be combined with the polypropylene, as needed, preferably in pellet form, to change the color of the polypropylene layer and to provide enhanced resistance to UV damage, though the black color typically used to minimize edge visibility is inherently a good UV inhibitor.
In the above-described process for producing polypropylene-backed roofing material, suitable plastics with a melting point below about 400 F may be substituted for or mixed with the polypropylene rolled material, pellets, flakes and/or fibers. Furthermore, plastic materials with melting points above 400 F, such as EDPM, or certain polypropylene materials with higher melting points, may be used so long as molten asphalt adheres to such materials at the typical manufacturing temperature of around above 400 F.
It is known in the art to manufacture roofing shingles with an adhesive or sealant disposed on the upper edge region of the upper surface of the shingle, such that in an assembled roof
-4-comprising multiple courses of shingles, the lower edges of next course of shingles will overlap and cover the adhesive, thereby resulting in adhesion between the two courses.
Alternatively, it is known to manufacture shingles with the adhesive on the lower portion of the back surface of the shingle to obtain the same result. In the present invention, to maintain good adhesion the shingles may have an adhesion or sealing region at the lower portion of the back surface of the shingle that does not include the inventive backing material. Instead, the adhesion or sealing region is covered with conventional fines.
Shingles made with the polypropylene backing described herein have better tear strength than the 1800-2100 grams that is typical of standard shingles backed with fines.
The tear strength of the polypropylene-backed shingles is typically in excess of 3000 grams at the point of manufacture which is comparable to or better than that of shingles made with a comparable thickness of the composite backing of U.S. Patent No. 6,341,462. The inventive shingles are also less susceptible to machine breaks and fractures and tears during field application, i. e., they better tolerate the rigors of shingle installation, than conventional shingles. Further, the inventive shingles provide enhanced impact resistance despite their light product weight, provide increased nail holding ability and maintain structural integrity at elevated temperatures. Also, the polypropylene sheet applied to the back of the shingle is water impervious. Thus an enhanced impact resistant seal against water penetration is provided.
The inventive backing described herein may be applied to any design or formulation of roofing material such as built up roofing materials, roll roofing and modified roll products, but it is particularly effective as a shingle backing. Shingles manufactured with such a backing that partially or fully covers their lower surface, demonstrate enhanced physical properties even though the internal composition of the shingle remains unchanged. In contrast to the shingles manufactured using the backing layer of U.S. Patent No. 6,341,462, the plastic-backed shingles described herein are no more substantial than products manufactured with a fine sand backing, thereby maintaining familiar handle ability and minimizing the need for packaging adjustments.
Alternatively, it is known to manufacture shingles with the adhesive on the lower portion of the back surface of the shingle to obtain the same result. In the present invention, to maintain good adhesion the shingles may have an adhesion or sealing region at the lower portion of the back surface of the shingle that does not include the inventive backing material. Instead, the adhesion or sealing region is covered with conventional fines.
Shingles made with the polypropylene backing described herein have better tear strength than the 1800-2100 grams that is typical of standard shingles backed with fines.
The tear strength of the polypropylene-backed shingles is typically in excess of 3000 grams at the point of manufacture which is comparable to or better than that of shingles made with a comparable thickness of the composite backing of U.S. Patent No. 6,341,462. The inventive shingles are also less susceptible to machine breaks and fractures and tears during field application, i. e., they better tolerate the rigors of shingle installation, than conventional shingles. Further, the inventive shingles provide enhanced impact resistance despite their light product weight, provide increased nail holding ability and maintain structural integrity at elevated temperatures. Also, the polypropylene sheet applied to the back of the shingle is water impervious. Thus an enhanced impact resistant seal against water penetration is provided.
The inventive backing described herein may be applied to any design or formulation of roofing material such as built up roofing materials, roll roofing and modified roll products, but it is particularly effective as a shingle backing. Shingles manufactured with such a backing that partially or fully covers their lower surface, demonstrate enhanced physical properties even though the internal composition of the shingle remains unchanged. In contrast to the shingles manufactured using the backing layer of U.S. Patent No. 6,341,462, the plastic-backed shingles described herein are no more substantial than products manufactured with a fine sand backing, thereby maintaining familiar handle ability and minimizing the need for packaging adjustments.
-5-EXAMPLES
Conventional Capstone and Raised Profile shingles manufactured by Elk Premium Building Products, Inc. were prepared using either of mat nos. 1.7 or 2.3, having mat basis weights of 1.7 and 2.3 pounds/100 square feet, respectively, and comprising 15, 20 or 100% formula FLXTM
and a polypropylene backing of 2-4 mils, where FLXTM is a proprietary asphalt coating developed by Elk that provides improved handling and strength. Lesser amounts of FLXTM
were used in the samples having the inventive backing. Raised Profile and Domain Winslow shingles manufactured by Elk, were also tested without the inventive backing for comparison purposes.
Rolled polypropylene manufactured by DEKU Kunststoff GmbH was used to make the inventive coatings. Fire and impact tests were run on these polypropylene-backed samples, as shown in Tables 1 and 2, respectively. The fire tests shown in Table 1 were performed per ASTM E108/UL
790 Class A burning brand specifications. The time indicated in the final column being the time in minutes when the burning stopped entirely (a pass) or the underside of the deck ignited (a fail). The impact test shown in Table 2 were performed per UL 2290, Class 4. As noted above, standard shingles manufactured by Elk were also tested for comparison purposes. Tables 1 and 2, below show the results of the fire and impact testing, respectively, and demonstrate the comparable or improved performance of the inventive shingles as compared to standard shingles.
Test Time # Product Mat FLX % Granules Backing (minutes)/Result 1 Capstone 1.7 20 Slate 4 mil PP 44/Pass 2 Capstone 2.3 20 Slate 4 mil PP 40/Pass 3 Raised Profile 2.3 100 Standard Standard 39/Fail 4 Capstone 2.3 15 Standard 4 mil PP 37/Pass 5 Capstone 1.7 15 Standard 4 mil PP 40/Pass
Conventional Capstone and Raised Profile shingles manufactured by Elk Premium Building Products, Inc. were prepared using either of mat nos. 1.7 or 2.3, having mat basis weights of 1.7 and 2.3 pounds/100 square feet, respectively, and comprising 15, 20 or 100% formula FLXTM
and a polypropylene backing of 2-4 mils, where FLXTM is a proprietary asphalt coating developed by Elk that provides improved handling and strength. Lesser amounts of FLXTM
were used in the samples having the inventive backing. Raised Profile and Domain Winslow shingles manufactured by Elk, were also tested without the inventive backing for comparison purposes.
Rolled polypropylene manufactured by DEKU Kunststoff GmbH was used to make the inventive coatings. Fire and impact tests were run on these polypropylene-backed samples, as shown in Tables 1 and 2, respectively. The fire tests shown in Table 1 were performed per ASTM E108/UL
790 Class A burning brand specifications. The time indicated in the final column being the time in minutes when the burning stopped entirely (a pass) or the underside of the deck ignited (a fail). The impact test shown in Table 2 were performed per UL 2290, Class 4. As noted above, standard shingles manufactured by Elk were also tested for comparison purposes. Tables 1 and 2, below show the results of the fire and impact testing, respectively, and demonstrate the comparable or improved performance of the inventive shingles as compared to standard shingles.
Test Time # Product Mat FLX % Granules Backing (minutes)/Result 1 Capstone 1.7 20 Slate 4 mil PP 44/Pass 2 Capstone 2.3 20 Slate 4 mil PP 40/Pass 3 Raised Profile 2.3 100 Standard Standard 39/Fail 4 Capstone 2.3 15 Standard 4 mil PP 37/Pass 5 Capstone 1.7 15 Standard 4 mil PP 40/Pass
6 Raised Profile 1.7 20 Standard 3 mil PP 42/Pass
7 Raised Profile 1.7 20 Standard 3 mil PP 40/Pass Test # Product Mat FLX % Granules Backing Result 1 Capstone 1.7 15 Standard 3 mil PP Pass 2 Capstone 2.3 15 Standard 3 mil PP Pass 3 Capstone 1.7 15 Standard 4 mil PP Pass 4 Capstone 2.3 15 Standard 4 mil PP Pass 5 Capstone 2.3 20 Slate 3 mil PP Pass 6 Capstone 1.7 20 Slate 4 mil PP Pass 7 Capstone 2.3 20 Slate 4 mil PP Pass
8 Capstone 1.7 20 Slate 3 mil PP Pass
9 D. Winslow 2.3 100 Standard Standard Pass
10 Raised Profile 2.3 100 Standard Standard Fail
11 Raised Profile 2.3 20 Standard 4 mil PP Pass
12 Raised Profile 1.7 20 Standard 4 mil PP Pass
13 Raised Profile 2.3 20 Standard 3 mil PP Pass
14 Raised Profile 1.7 20 Standard 3 mil PP Pass
15 Capstone 1.7 15 Standard 2 mil PP Pass
16 Raised Profile 1.7 20 Standard 2 mil PP Fail It should be understood that the foregoing description and examples are illustrative, and that compositions other than those described above can be used as the backing while still utilizing the principles underlying the present invention. For example, plastics other than polypropylene that have a suitable melting temperature and mechanical properties may be used to formulate the backing layer. Furthermore, the backing layer may be composed of a combination ofpolypropylene and other suitable plastic or plastics. Moreover, the backing layer may be applied to various types of roofing products.
Claims (18)
1. In a roofing shingle material having a front surface, at least a portion of which is intended to be exposed to weather, and back surface facing in a direction opposite to the front surface, the improvement comprising a thin layer consisting essentially of a plastic material covering at least a portion of said back surface, said layer being between about 0.5 and 4 mils in thickness.
2. A roofing shingle material according to claim 1, wherein said plastic material consists essentially of a thermoplastic material.
3. A roofing shingle material according to claim 2, wherein said thermoplastic material consists essentially of polypropylene.
4. A roofing shingle material according to claim 3, wherein said thin layer comprises re-melted polypropylene rolled material, pellets, flakes or fibers.
5. A roofing shingle material according to any one of claims 1 to 4, wherein said thin layer is between about 3 and 4 mils in thickness.
6. A roofing shingle material according to claim 3, wherein said thin layer further comprises a pigment.
7. A roofing shingle material according to any one of claims 1, 2, 3 and 5, wherein the roofing shingle material comprises a bituminous material.
8. A roofing shingle material according to claim 2 or 3, wherein the thin layer covers the entire back surface.
9. A roofing shingle material according to claim 2 or 3 wherein at least a portion of the lower edge of the back surface remains uncovered by the thin layer.
10. A roofing shingle material according to any one of claims 1 to 9, wherein the thin layer comprises more than one layer, each layer comprising a different plastic.
11. A roofing shingle material according to claim 10, wherein the thin layer comprises a polypropylene layer and a polyethylene layer.
12. A roofing shingle material according to claim 3, wherein the thin layer comprises spun bond polypropylene.
13. A roofing shingle material according to claim 10, wherein the thin layer comprises a polyethylene terephthalate mat coated with polyethylene.
14. A roofing shingle material according to claim 2, wherein the thermoplastic material consists essentially of a polyolefin.
15. A roofing shingle material according to claim 1 wherein the plastic material is selected from the group consisting of polyethylene, polyvinylchloride, ethylene vinyl acetate, acrylonitrile butadiene styrene ("ABS"), acetal, acetate, butyrate, nylon, polyalomer, polycarbonate, polystyrene, styrene-butadine-copolymers, polysulfone, propionate, polyvinyl chloride, ethylene propylene diene monomer rubber, high density silicone rubber, thermoplastic rubber, elastomers and curable and sprayable acrylics.
16. A roofing shingle material according to any one of claims 1 to 15, wherein said plastic material melts at less than about 400 °F.
17. A roofing shingle material according to any one of claims 1 to 16, wherein said plastic material adheres to a bituminous material at about 400 °F.
18. A roofing shingle material according to any one of claims 1 to 17 wherein said plastic material layer is between about 3 and 4 mils in thickness.
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US11/053,718 US7851051B2 (en) | 2005-02-08 | 2005-02-08 | Roofing material |
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