Sealant System and Methods of Use and Manufacture

Abstract

A roof sealing system method of manufacture and method of application comprising three parts: a caulk gap filler, a mastic, and a top coating. All three components combine to create a singular sealed membrane when applied to a roof surface. The roof sealing system utilizes inert polyethylene fibers in a liquid silicone polymer.

1 . A sealant composition configured to seal a substrate comprising:
 a polymer resin base;   fibers suspended in the polymer resin base;   a pigment;   at least one crosslinking agent;   an adhesion promoter;   at least one filler material; and   a curing catalyst.   
     
     
         2 . The sealant composition of  claim 1 , wherein the sealant composition comprises a first state and a second state, the sealant composition being in the first state prior to being applied and is in a gel or liquid form, and in the second state, the sealant composition is cured and in a solid form. 
     
     
         3 . The sealant composition of  claim 1 , wherein the sealant composition is a caulk. 
     
     
         4 . The sealant composition of  claim 3 , wherein the polymer resin base present in the range of about 40.35 to 70.0% by weight; the pigment present in the range of about 5.0 to 13.0% by weight; the at least one filler material present in the range of about 17.0 to 48.0% by weight; the at least one crosslinking agent present in the range of about 3.0 to 18.0% by weight; the adhesion promoter present in the range of about 0.2 to 1.0% by weight; the fibers present in the range of about 0.1 to 2.0% by weight; and the curing catalyst present in the range of about 0 to 1.0% by weight. 
     
     
         5 . The sealant composition of  claim 1 , wherein the sealant composition is a mastic, further comprising a solvent. 
     
     
         6 . The sealant composition of  claim 5 , wherein the polymer resin base present in the range of about 40.0 to 70.0% by weight; the pigment present in the range of about 4.0 to 12.0% by weight; the at least one filler material present in the range of about 17.0 to 48.0% by weight; the at least one crosslinking agent present in the range of about 3.0 to 18.0% by weight; the adhesion promoter present in the range of about 0.2 to 1.0% by weight; the solvent present in the range of about 5.0 to 23.0% by weight; at least two different fibers, the fibers present in the range of about 0.2 to 4.0% by weight; and the curing catalyst present in the range of about 0 to 1.0% by weight. 
     
     
         7 . The sealant composition of  claim 5 , wherein the solvent is a siloxane selected from octamethylcyclotetrasiloxane, dodecamethylcyclohexasiloxane, decamethylcyclopentasiloxane, or any combination thereof. 
     
     
         8 . The sealant composition of  claim 1 , wherein the sealant composition is a coating, further comprising a solvent. 
     
     
         9 . The sealant composition of  claim 8 , wherein the polymer resin base present in the range of about 40.0 to 70.0% by weight; the pigment present in the range of about 4.0 to 12.0% by weight; the at least one filler material present in the range of about 17.0 to 48.0% by weight; the at least one crosslinking agent present in the range of about 3.0 to 18.0% by weight; the adhesion promoter present in the range of about 0.2 to 1.0% by weight; the solvent present in the range of about 5.0 to 23.0% by weight; at least one fiber, the fiber present in the range of about 0.1 to 2.0% by weight; and the curing catalyst present in the range of about 0 to 1.0% by weight. 
     
     
         10 . The sealant composition of  claim 8 , wherein the solvent is a siloxane selected from octamethylcyclotetrasiloxane, dodecamethylcyclohexasiloxane, decamethylcyclopentasiloxane, or any combination thereof. 
     
     
         11 . The sealant composition of  claim 1 , wherein the polymer resin base is an organosilane. 
     
     
         12 . The sealant composition of  claim 1 , wherein the fibers are selected from the group consisting of plant fiber, mineral fiber, synthetic fiber, regenerated fiber, and semi-synthetic fiber, and combinations thereof. 
     
     
         13 . The sealant composition of  claim 12 , wherein the fibers are a synthetic fiber selected from the group consisting of polyethylene, polyethylene terephthalate, polyurethane, polypropylene, polyester, polyamide, nylon, polyacrylonitrile, poly-paraphenyulene terepthalamide, and aramids, and combinations thereof. 
     
     
         14 . The sealant composition of  claim 1 , wherein the pigment is selected from zinc oxide, antimony oxide, zirconium oxide, chromium oxide, iron oxide, lead oxide, zinc sulfide, titanium dioxide, lithopone, or any combination thereof. 
     
     
         15 . The sealant composition of  claim 1 , wherein the at least one crosslinking agent is a silane. 
     
     
         16 . The sealant composition of  claim 15 , wherein the silane is a ketoxime silane selected from the group consisting of phenyl tris(methylethylketoxime)silane, vinyl tris-(methylethylketoxime)silane, dimethyl bis(methylethylketoxime)silane, tetra(methylethylketoxime)silane, methyl tris(methylethylketoxime)silane, and combinations thereof. 
     
     
         17 . The sealant composition of  claim 1 , wherein the adhesion promoter is selected from aminoethylaminopropyl-trimethoxysilane, 3-(2-Aminoethylamino) propyldimethoxymethylsilane, N-3-(Trimethoxysilyl)propylethylenediamine, vinyltris(2-methoxyethoxy)silane, 3-methacryloxypropyltrimethoxysilane, 2-(3,4-epoxycyclohexyl)ethyl trimethoxysilane, 3-glycidoxypropyltrimethoxysilane, 3-glycidoxypropylmethyldiethoxysilane, N-(2-aminoethyl)3-aminopropyltrimethoxysilane, 3-aminopropyltriethoxysilane, 3-(N-aminomethylbenzylamino)propyltrimethoxysilane, 3-mercaptopropyltrimethoxysilane, 3-aminopropyltris(methylethylketoxime)silane, 3-glycidoxy propyltriisopropenoxysilane, and 3-glycidoxypropylmethyldiisopropenoxysilane, or any combination thereof. 
     
     
         18 . The sealant composition of  claim 1 , wherein the curing catalyst is selected from dibutyltin diacetate, stannous octoate, dibutyltin dioctoate, dibutyltin dilaurate, dibutyltin dimethoxide, dibutyltin bis(acetylacetonate), dibutyltin bis(benzylmalate), dimethyltin dimethoxide, dimethyltin diacetate, dioctyltin dioctate, dioctyltin dilaurate, tin dioctate, tin laulate, tetraisopropyl titanate, tetra-n-butyl titanate, tetra-tertiary butyl titanate, tetra-n-propyl titanate, tetra-2-ethylhexyl titanate, diisopropyl di-tertiary butyl titanate, dimethoxy titanium bisacetylacetonate, diisopropoxy titanium bisethyl acetoacetate, di-tertiary butoxy titanium bisethyl acetoacetate, and di-tertiary butoxy titanium bismethyl acetoacetate, or any combination thereof. 
     
     
         19 . A sealing system configured to be capable of being applied to a roof substrate, comprising:
 a sealing caulk having a viscosity configured to allow the sealing caulk to be dispensed from a pressurized tube in a bead adapted to fill pre-existing seams, joints, and cracks for pipes, vents, and structural edges;   a mastic having a viscosity configured to allow the mastic to be spread over the sealing caulk and uneven surfaces; and   a coating for layering over the sealing caulk, the mastic and the roof substrate,   wherein the sealing caulk, the mastic, and the coating all comprise a silicone polymer material and an inert fiber infused within the silicone polymer material; and   wherein the coating has at least two layers applied to the roof substrate.   
     
     
         20 . A method of applying a sealant system to a roofing substrate, comprising the steps of:
 clearing a targeted area of any debris or obstacles of the roofing substrate;   providing the sealant system, comprising of a caulk, a mastic gap filler, and a coating,   wherein the caulk, the mastic gap filler, and the coating comprise a polymer base material and inert fibers infused within the polymer base material;   applying the caulk to coat all pre-existing seams, cracks in structural features, gaps between structural features, or joints located within the targeted area;   overlaying the mastic gap filler over the caulk forming a seal over any of pre-existing seams, cracks in structural features, gaps between structural features, or joints located within the targeted area;   coating the roofing substrate with a first application;   applying a second application of the coating while the first application is tacky or fully cured to provide the roofing substrate with a watertight barrier; and   curing the coating on the roofing substrate.   
     
     
         21 . The method of applying the sealant system of  claim 20 , wherein curing is facilitated by ambient moisture via condensation curing. 
     
     
         22 . The method of applying the sealant system of  claim 20 , wherein fibers are a synthetic fiber selected from the group consisting of polyethylene, polyethylene terephthalate, polyurethane, polypropylene, polyester, polyamide, nylon, polyacrylonitrile, poly-paraphenyulene terepthalamide, and aramids, and combinations thereof. 
     
     
         23 . The method of applying the sealant system of  claim 20 , wherein overlaying the mastic gap filler over the caulk creates a substantially flat surface for which to apply the coating.