Asphalt emulsions, products made from asphalt emulsions, and processes for making fibrous mats from asphalt emulsions
View Patent ↗The invention relates to asphalt emulsions comprising an asphalt component selected from the group consisting of a solvent extracted asphalt, an oxidized asphalt, and combinations thereof. The invention also relates to products made therefrom, including fibrous mats comprising a fiber component, such as glass fibers, and a binder component comprising an asphalt emulsion. The invention further relates to wet-laid processes for manufacturing fibrous mats and that employ the use of an amphoteric surfactant, which is applied to a wet fiber web prepared from a dispersion of fiber components, such as glass fibers.
1. An asphalt emulsion consisting essentially of an asphalt component, a dispersant, a thixotropic agent, a surfactant, a catalyst, an aromatic oil and a polymer, wherein the aromatic oil comprises diesel fuel having about 65% by weight kerosene and about 35% by weight heavy lube oil.
2. The asphalt emulsion according to claim 1 , wherein the asphalt emulsion consists essentially of from about 5% to about 50% by weight asphalt component, from about 0.01% to about 1.0% by weight dispersant, from about 0.01% to about 1.0% by weight thixotropic agent, from about 0.01% to about 1.0% by weight surfactant, from about 0.01% to about 2.0% by weight catalyst, from about 0.01% to about 1.0% by weight aromatic oil, and from about 0.1% to about 5% by weight polymer.
3. An asphalt emulsion consisting essentially of an asphalt component, a surfactant, a catalyst, a resin, a cross-linking agent, a plasticizer, and a wax.
4. The asphalt emulsion according to claim 3 , wherein the asphalt emulsion consisting essentially of from about 5% to about 50% by weight asphalt component, from about 0.1% to about 2.0% by weight surfactant, from about 0.01% to about 2.0% by weight catalyst, from about 0.1% to about 15% by weight resin, from about 0.01% to about 1.0% by weight cross-linking agent, from about 0.01% to about 2.0% by weight plasticizer, and from about 0.01% to about 1.0% by weight wax.
5. An asphalt emulsion comprising asphalt consisting essentially of, a surfactant, a catalyst, a resin, a cross-linking agent, a plasticizer, a wax, and polymer.
6. The asphalt emulsion according to claim 5 , wherein the asphalt emulsion consisting essentially of from about 5% to about 50% by weight asphalt component, from about 0.1% to about 2.0% by weight surfactant, from about 0.01% to about 2.0% by weight catalyst, from about 0.1% to about 15% by weight resin, from about 0.01% to about 1.0% by weight cross-linking agent, from about 0.01% to about 2.0% by weight plasticizer, from about 0.01% to about 1.0% by weight wax, and from about 0.1% to about 5% by weight polymer.
7. The asphalt emulsion according to claim 2 , 1 , 3 , 4 , 5 or 6 , wherein the asphalt emulsion comprises an asphalt component selected from the group consisting of solvent extracted asphalt, oxidized asphalt, and combinations thereof.
8. A fibrous mat comprising a fiber component and a binder component, wherein the binder component consists essentially of the asphalt emulsion according to claim 2 , 1 , 3 , 4 , 5 or 6 .
9. A roofing material comprising the fibrous mat according to claim 8 .