Non-asphaltic coatings, non-asphaltic roofing materials, and methods of making the same
Non-asphaltic coatings for roofing materials, roofing materials made therefrom and methods of preparing such coatings and roofing materials utilize a combination of a crude tall oil-based continuous phase material, a resinous hardening agent, and a polymer.
1. A roofing material comprising a substrate having a coating that comprises:
(a) 40-50 wt % of a plant-or bio-derived continuous phase material;
(b) 40-50 wt % of a resinous hardening agent; and
(c) 5-20 wt % of a polymer;
wherein a ratio of the plant-or bio-derived continuous phase material to the resinous hardening agent is about 1:1, based on wt %;
wherein a viscosity of the coating ranges from 200-12,500 cP measured at 400° F.; and
wherein the roofing material is selected from the group consisting of an underlayment, modified bitumen roofing, a rolled product, and a roofing membrane.
2. The roofing material according to claim 1 , wherein the plant-or bio-derived continuous phase material comprises corn oil, vegetable oil, triglycerides, or a combination thereof.
3. The roofing material according to claim 1 , wherein the resinous hardening agent comprises esters of maleated rosin with pentaerythritol; rosin, maleated, polymer with glycerol; alpha methyl styrene tall oil resin; or a combination thereof.
4. The roofing material according to claim 1 , wherein the polymer comprises poly (styrene-butadiene-styrene) (SBS), poly (styrene-ethylenebutylene-styrene) (SEBS), ethylene-vinyl acetate copolymer (EVA), polyvinyl butyral (PVB), or a combination thereof.
5. 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.
6. The roofing material according to claim 1 , wherein the substrate comprises a fiberglass mat, a polyester mat, a scrim, a coated scrim, or a combination thereof.
7. The roofing material according to claim 1 , wherein a thickness of the coating on the substrate ranges from 5-100 mils.
8. The roofing material according to claim 1 , wherein the roofing material comprises one or more layers of the coating.
9. The roofing material according to claim 1 , wherein the coating does not comprise asphalt.
10. The roofing material according to claim 1 , wherein the polymer comprises poly (styrene-butadiene-styrene) (SBS), polyvinyl butyral (PVB), or a combination thereof.
11. The roofing material according to claim 1 , wherein the coating comprises 40-45 wt % of the resinous hardening agent.