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. A process for manufacturing a fibrous mat comprising the steps of:
a. preparing a fiber dispersion comprising chopped fibers, with at least water, one dispersant and a viscosity modifier;
b. forming a wet fiber web with the fiber dispersion;
c. applying an amphoteric surfaactant to the wet fiber web; and
d. applying a binder component to the surfactant-covered web to form the fibrous mat; wherein the binder component consists of an asphalt emulsion.
2. The process according to claim 1 , wherein the dispersant and the viscosity modifier are anionic.
3. The process according to claim 1 , wherein the dispersant is anionic.
4. The process according to claim 1 , wherein the viscosity modifier is anionic.
5. A process for manufacturing a fibrous mat comprising the step of:
a. preparing a fiber dispersion;
b. forming a wet fiber web with the fiber dispersion;
c. applying an amphoteric surfactant to the wet fiber web;
d. applying a binder component to the surfactant-covered web to form the fibrous mat; wherein the binder component consists essentially of an asphalt emulsion; and
e. applying a vacuum at approximately the same time as the binder component is being applied.
6. A process for manufacturing a fibrous mat comprising the steps of:
a. preparing a fiber dispersion;
b. forming a wet fiber web with the fiber dispersion;
c. applying an amphoteric surfactant to the wet fiber web;
d. applying a binder component to the surfactant-covered web to form the fibrous mat; wherein the binder component consists essentially of an asphalt emulsion; and
e. drying the fibrous mat at approximately 350° F. to approximately 400° F.
7. The process according to claim 6 , wherein the process further comprises the step of exposing the fibrous mat to infrared rays at approximately 2200° F.
8. A process for manufacturing a fibrous mat comprising the step of:
a. preparing a fiber dispersion;
b. forming a wet fiber web with the fiber dispersion;
c. applying an amphoteric surfactant to the wet fiber web; and
d. applying a binder component to the surfactant-covered web to form the fibrous mat; wherein the binder component consists essentially of an emulaion; wherein the asphalt emulsionconsists essentially of an asphalt component, a dispersant, a thixotropic agent, a surfactant, a catalyst, and an aromatic oil; and wherein the aromatic oil comprises diesel fuel having about 65% by weight kerosene and about 35% by weight heavy lube oil.
9. A process for manufacturing a fibrous mat comprising the steps of:
a. preparing a fiber dispersion;
b. forming a wet fiber web with the fiber dispersion;
c. applying an amphoteric surfactant to the wet fiber web; and
d. applying a binder component to the surfactant-covered web to form the fibrous mat; wherein the binder component consists essentially of an emulaion; wherein the asphalt emulsion consists essentially of an asphalt component, a dispersant, a thixotropic agent, a surfactant, a catalyst, an aromatic oil and a polymer, and wherein the aromatic oil comprises diesel fuel having about 65% by weight kerosene and about 35% by weight heavy lube oil.
10. The process according to claim 1 , 5 , 6 , 8 , or 9 , wherein the surfactant concentration is from about 0.25% to about 2.5% by weight.
11. The process according to claim 10 , wherein the surfactant is selected from the group consisting of an aliphatic acid, a cationic amine-quat complex, and a non-ionic surfactant.
12. The process according to claim 1 , 5 , 6 , 8 , or 9 , wherein the fiber is glass fiber.
13. The process according to claim 12 , wherein the glass fiber is from about 1.0″ to about 1⅜″ in length.
14. A fibrous mat manufactured by the process according to claim 1 , 5 , 6 , 8 , or 9 .
15. A roofing material comprising the fibrous mat according to claim 14 .
16. The process according to claim 1 , 5 , 6 , 8 , or 9 , wherein the asphalt emulsion consists essentially of an asphalt component, a dispersant, a thixotropic agent, and a resin; and wherein the dispersant is an epoxy resin dispersant.
17. The process according to claim 1 , 5 , 6 , 8 , or 9 , wherein the asphalt emulsion consists essentially of an asphalt component, a dispersant, a thixotropic agent, a resin, and a polymer; and wherein the dispersant is an epoxy resin dispersant.
18. The process according to claim 1 , 5 , 6 , 8 , or 9 , wherein the asphalt emulsion consists essentially of an asphalt component, a dispersant, a thixotropic agent, a surfactant, a catalyst, and a resin; and wherein the dispersant is an epoxy resin dispersant.
19. The process according to claim 1 , 5 , 6 , 8 , or 9 , wherein the asphalt emulsion consists essentially of an asphalt component, a dispersant, a thixotropic agent, a surfactant, a catalyst, a resin and a polymer; and wherein the dispersant is an epoxy resin dispersant.
20. The process according to claim 1 , 5 , 6 , 8 , or 9 , wherein the asphalt emulsion consists essentially of an asphalt component, a surfactant, a catalyst, a resin, a cross-linking agent, a plasticizer, and a wax.
21. The process according to claim 1 , 5 , 6 , 8 , or 9 , wherein the asphalt emulsion consists essentially of an asphalt component, a surfactant, a catalyst, a resin, a cross-linking agent, a plasticizer, a wax, and a polymer.