Compositions: coating or plastic – Coating or plastic compositions – Bituminous material or tarry residue
Reexamination Certificate
2000-02-25
2001-10-30
Brunsman, David (Department: 1755)
Compositions: coating or plastic
Coating or plastic compositions
Bituminous material or tarry residue
C524S060000
Reexamination Certificate
active
06309456
ABSTRACT:
FIELD OF THE INVENTION
This invention relates to coatings. More specifically, this invention relates to a wear resistant multi-color asphalt emulsion coating.
DESCRIPTION OF PRIOR ART
Asphalt roof shingles are the most common covering used on residential properties in North America. Asphalt shingles have been produced as early as the 1880's and used widely since early in the twentieth century for their low cost, ease of installation, fire-resistance, and a variety of colors and textures. Asphalt shingles are generally made from organic and predominantly fiberglass felts saturated with asphalt and covered with an granulated mineral surface, intended to last 20 to 30 years, with some lasting up to 40 years.
The expected life of a roof covering, such as asphalt shingles, depends on many variables, including type and quality of roofing materials selected, installation and workmanship details such as nailing errors, improper patterns of installation, and improper location. Wear and damage caused by weather, including rain, wind, hail, snow, ice and sunlight, gradually causes granules to erode and slough off, and edges to curl, indicating that the roof covering is reaching the end of its service life.
Apart from the elements listed above that can cause wear, the year-round climate in which the roofing material is installed has an effect on the expected life of the material. Higher thermal load, that is hotter climates, generally result in a shorter product life, whereas cooler climates allow the material to have a longer product life. In any climate, however, thermal splitting, or cracking, is one of the principle causes or roofing material damage. Thermal splitting, which is actually tearing of an asphalt shingle, has been found to occur in the lightest weight shingle and the most durable shingle product.
Asphalt roofing shingles are susceptible to other types of wear and damage such as granule loss, shingle cupping, shingle curling, organic growth such as algal and fungal growth, and the inevitable loss of shingles caused by wind blow-off when nails work loose.
Asphalt shingles are also susceptible to aesthetic or cosmetic roofing problems. Variations in manufacturing process can effect how a shingled roof looks from the ground. Of course, during the life of the product any of the above mentioned structural problems results in an asphalt shingle roof which becomes an eye sore.
Often, new layers of asphalt shingles are applied over old shingles in an attempt to save on the cost of removing the old shingles. This is generally a short term solution and may be done no more than twice until the built up roof must be entirely stripped of asphalt shingles and new asphalt shingles installed.
SUMMARY OF THE INVENTION
The present invention provides a multi-color asphalt emulsion coating and process for the preparation thereof for use as a coating over old existing asphalt shingle roofs and especially fiberglass based systems as well as any other surfaces, more specifically an emulsified asphalt base is mixed with a globular color component in a water-based carrier. The globular color component is prevented from mixing with the emulsified asphalt base by the relative viscosity and colloidal strength of the color component.
The emulsified asphalt base includes water as the dispersion medium, a slow setting asphalt as the disperse phase and a colloidal stabilizer to maintain the asphalt in suspension. The emulsified asphalt base also includes one or more wear resistant compositions.
The globular color component also uses water as a dispersion medium and a colloidal stabilizer to maintain a desired pigment in suspension. The globular color component may include wear resistant compositions and preservatives to lengthen the life of the product and prevent the multi-color asphalt emulsion coating from spoiling prior to and after application to a desired substrate.
The water-based carrier in which the emulsified asphalt base and globular color components are mixed includes an electrolyte to reduce the viscosity of a hectorite clay to allow for ease of application.
The inventive process for preparing the multi-color asphalt emulsion coating includes preparing separately the emulsified asphalt base, the globular color component and the water based carrier. As many globular color components are prepared as desired in order to achieve an acceptable multi-colored product. After each of the emulsified asphalt base, globular color component and water-based carrier are prepared, the emulsified asphalt base is first mixed with the water-based carrier in a ratio of about 1 part to about 2.25 parts, respectively. The globular color component is then blended with the emulsified asphalt base and water-based carrier at a desired ratio at relatively slow speeds to achieve a desired color globule size in the range of about 2 to about 5 millimeters.
In use, the multi-color asphalt emulsion coating may be applied to a desired substrate with either a high volume and low pressure texture sprayer or with a fringed rubber squeegee. Use of a texture sprayer or fringed rubber squeegee is preferred in order to prevent the color globules from streaking from use of excess force breaking the color globules during application. The multi-color asphalt emulsion coating is suitable for use on numerous surface, including but not limited to, asphalt shingles, asphalt rolled roofing, modified bitumen membrane, clay tile roofs, concrete and metal roofing.
The benefits derived from application of the multi-color asphalt emulsion coating upon any of the above-mentioned surfaces are far reaching. The wear composition included in the preparation of the emulsified asphalt base and the globular color component provides a product which, when cured upon a desired substrate, is impact resistant and resists damage caused by, for instance, hail and falling tree limbs. The cured product also has greater water resistance because it is a continuous coating, unlike granulated asphalt shingles of the prior art. The wear composition also provides resistance to degradation from ice and snow, whereby the cured product will not become brittle and break under freezing and other thermal splitting conditions since the wear composition provides a large degree of flexibility to the product, whereas prior art asphalt shingles will degrade, become brittle and crack under similar thermal splitting conditions.
Finally, the cost of use of the multi-color asphalt emulsion coating is substantially less than prior art asphalt shingles and other roofing products. Application of the present inventive multi-color asphalt emulsion coating would be about half the cost of re-roofing the same roof with asphalt shingles and have the cost-benefit expectation of a similar product life.
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Brunsman David
The Brewer Company
Wood Herron & Evans LLP
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