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, and an aromatic oil, wherein the asphalt component is selected from the group consisting of solvent extracted asphalt, oxidized asphalt, and combinations thereof; wherein the dispersant is an epoxy resin dispersant; wherein the thixotropic agent is carboxy methylcellulose (CMC); wherein the surfactant is selected from the group consisting of a cationic surfactant and an anionic surfactant, and combinations thereof; wherein the catalyst is hydrochloric acid (HCl); and wherein the aromatic oil is diesel fuel.
2. 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 asphalt component is selected from the group consisting of solvent extracted asphalt, oxidized asphalt, and combinations thereof; wherein the dispersant is an epoxy resin dispersant; wherein the thixotropic agent is CMC; wherein the surfactant is selected from the group consisting of a cationic surfactant and an anionic surfactant, and combinations thereof; wherein the catalyst is HCl; wherein the aromatic oil is diesel fuel; and wherein the polymer is styrene butadiene (SBR).
3. The asphalt emulsion according to claim 1 or 2 , wherein the diesel fuel comprises kerosene and heavy lube oil.
4. An asphalt emulsion consisting essentially of an asphalt component, a dispersant, a thixotropic agent, and a resin, wherein the asphalt component is selected from the group consisting of solvent extracted asphalt, oxidized asphalt, and combinations thereof; wherein the dispersant is an epoxy resin dispersant; wherein the thixotropic agent is CMC; and wherein the resin is urea formaldehyde.
5. An asphalt emulsion consisting essentially of an asphalt component, a dispersant, a thixotropic agent, a resin, and a polymer, wherein the asphalt component is selected from the group consisting of solvent extracted asphalt, oxidized asphalt, and combinations thereof; wherein the dispersant is an epoxy resin dispersant; wherein the thixotropic agent is CMC; wherein the resin is urea formaldehyde, and wherein the polymer is SBR.
6. An asphalt emulsion consisting essentially of an asphalt component, a dispersant, a thixotropic agent, a surfactant, a catalyst, and a resin, wherein the asphalt component is selected from the group consisting of solvent extracted asphalt, oxidized asphalt, and combinations thereof; wherein the dispersant is an epoxy resin dispersant; wherein the thixotropic agent is CMC; wherein the surfactant is selected from the group consisting of a cationic surfactant and an anionic surfactant, and combinations thereof; wherein the catalyst is HCl; and wherein the resin comprises urea formaldehyde.
7. An asphalt emulsion consisting essentially of an asphalt component, a dispersant, a thixotropic agent, a surfactant, a catalyst, a resin and a polymer, wherein the asphalt component is selected from the group consisting of solvent extracted asphalt, oxidized asphalt, and combinations thereof; wherein the dispersant is an epoxy resin dispersant; wherein the thixotropic agent is CMC; wherein the surfactant is selected from the group consisting of a cationic surfactant and an anionic surfactant, and combinations thereof; wherein the catalyst is HCl; wherein the resin comprises urea formaldehyde; and wherein the polymer is SBR.