Non-asphaltic coatings, non-asphaltic roofing materials, and methods of making thereof

Abstract

This invention, in embodiments, relates to non-asphaltic coatings for roofing materials, to roofing materials made therefrom and to methods of preparing such coatings and roofing materials. By blending thermoplastic polymers with appropriate fillers and/or recycled materials, a composition is produced that can be pressed into a desired shape, or that can be additionally mixed with oils, resins and/or waxes to provide a liquid that can be poured onto an appropriate substrate.

We claim: 
     
         1 . A roofing material comprising:
 (a) a substrate having a top surface and a bottom surface;   (b) a first coating applied onto the top surface of the substrate, the first coating comprising:
 (i) 5% to 70% by weight of a thermoplastic polymer; and 
 (ii) 10% to 70% by weight of a filler, wherein the filler comprises at least one of an organic filler, an inorganic mineral filler, and combinations thereof, 
   wherein the first coating is free of asphalt; and   (c) a second coating applied onto the bottom surface of the substrate, the second coating comprising asphalt.   
     
     
         2 . The roofing material according to  claim 1 , wherein the first coating comprises at least one layer that is applied to the top surface of the substrate. 
     
     
         3 . The roofing material according to  claim 2 , wherein the second coating comprises at least one layer that is applied to the bottom surface of the substrate. 
     
     
         4 . The roofing material according to  claim 1 , wherein the roofing material is configured to be prepared on a substantially standard manufacturing line for asphaltic shingles at a standard speed of 110 FPM to 1000 FPM. 
     
     
         5 . The roofing material according to  claim 1 , wherein the substrate comprises one of a fiberglass mat, a polyester mat, a scrim, a coated scrim, or a combination thereof. 
     
     
         6 . The roofing material according to  claim 1 , wherein the roofing material is a roofing shingle. 
     
     
         7 . The roofing material according to  claim 1 , further comprising granules. 
     
     
         8 . The roofing material according to  claim 1 , wherein the roofing material exhibits a reflectivity of from 30% to 80%, as measured according to ASTM E 903. 
     
     
         9 . The roofing material according to  claim 1 , wherein the roofing material has an overall thickness of from 50 to 100 mils. 
     
     
         10 . The roofing material according to  claim 1 , wherein the thermoplastic polymer includes at least one of a polyolefin, a vinyl polymer, and combinations thereof. 
     
     
         11 . The roofing material according to  claim 10 , wherein the polyolefin comprises one of (i) a polypropylene, (ii) a polyethylene, or (iii) a copolymer of propylene and ethylene. 
     
     
         12 . The roofing material according to  claim 1 , wherein the filler is at least one of calcium carbonate, barium sulfate, calcium sulfate, talc, limestone, perlite, silica, fumed silica, precipitated silica, quartz, aluminum trihydrate, magnesium hydroxide, colemanite, titanium dioxide, snow white, fly ash, graphene nanoparticles, carbon black, recycled rubber tires, recycled shingles, recycled thermoplastic resins, basalt, roofing granules, clay, and combinations thereof. 
     
     
         13 . The roofing material according to  claim 1 , wherein the coating further comprises 30% to 80% by weight of an oil, a resin, a wax, or a combination thereof. 
     
     
         14 . The roofing material according to  claim 1 , wherein the coating further comprises a dye, a pigment, a fire retardant, a UV stabilizer, or a combination thereof. 
     
     
         15 . A method of preparing a roofing material, the method comprising:
 (a) obtaining a substrate having a top surface and a bottom surface;   (b) obtaining a first coating comprising:
 (i) 5% to 70% by weight of a thermoplastic polymer; and 
 (ii) 10% to 70% by weight of a filler, wherein the filler comprises at least one of an organic filler, an inorganic mineral filler, and combinations thereof, 
   wherein the first coating is free of asphalt;   (c) obtaining a second coating comprising asphalt;   (d) applying the first coating to the top surface of the substrate; and   (e) applying the second coating to the bottom surface of the substrate, to form the roofing material.   
     
     
         16 . The method according to  claim 15 , wherein the applying the first coating to the top surface of the substrate is conducted by applying the first coating as at least one layer to the top surface of the substrate. 
     
     
         17 . The method according to  claim 16 , wherein the applying the second coating to the bottom surface of the substrate is conducted by applying the second coating as at least one layer to the bottom surface of the substrate.