Asphalt nanocomposite-based roofing products
View Patent ↗An asphalt-based nanocomposite useful as a coating for various applications including building materials products, such as shingles, is provided. The asphalt-based nanocomposites are particle-filled matrices that include an asphalt flux or derivate thereof and a layered clay mineral in an amount ranging from about 1 to about 15 weight %. Coated articles such as shingles including the asphalt-based nanocomposite are also disclosed as well as various methods of preparing the asphalt-based nanocomposite.
1. A method of preparing a shingle, the method comprising
mixing from about 1 to about 15 weight % of a layered clay mineral into an asphalt flux of partially or fully oxidized asphalt to form a nanocomposite;
wherein the mixing is performed in a blender than can operate at low shear conditions at 500-1200 rpm mixing speed;
applying a coating comprising the nanocomposite to at least one surface of a substrate wherein said substrate is a base layer or a material layer of a building materials product; and wherein said building materials product is a shingle.
2. A method of preparing a nanocomposite comprising
fractionating an asphalt flux or partially or fully oxidized asphalt into an asphaltene fraction, a polar aromatic fraction, a naphthene fraction and a saturate fraction;
mixing from about 1 to about 15 weight % of a layered clay mineral into one of said fractions;
and recombining said fraction containing said layered clay mineral with said other fractions.
3. The method of claim 2 wherein said fractionating is performed in a column or tower.
4. The method of claim 2 wherein said mixing of said layered clay mineral occurs in an asphaltene fraction.
5. A method of preparing a nanocomposite comprising
introducing from about 1 to about 15 weight % of a layered clay mineral into an asphalt flux or partially or fully oxidized asphalt to provide a premix; and
oxidizing (blowing) the premix.
6. The method of claim 5 wherein said oxidizing occurs in a blowing still.
7. The method of claim 5 herein said oxidizing is performed in an oxygen-containing atmosphere.
8. A coated article comprising
a substrate having at least one surface that is coated with a nanocomposite, said nanocomposite comprising an asphalt flux or partially or fully oxidized asphalt; and
a layered clay mineral in an amount from about 1 to about 15 weight %, based on the total weight of the nanocomposite;
wherein said substrate is a base layer or a material layer of a building materials product, and wherein said building materials product is a shingle.