Modified asphaltic foam materials
An asphaltic isocyanurate foam useful in roofing applications. Asphalt is liquified and mixed with a mixture of polyisocyanate. In a separate mixture, other chemicals, such as polyols, surfactant, catalyst, and blowing agent are combined. The mixtures are combined and reacted to form an asphaltic polyurethane foam.
1. A method for producing asphaltic foam comprising the steps of:
providing an asphalt;
liquefying said asphalt;
adding to said asphalt one or more isocyanates, thereby forming a first intermediate mixture;
bringing the temperature of said first intermediate mixture to between about 120° F. and 170° F.;
forming a second intermediate mixture comprising one or more polyols, a blowing agent, and a surfactant, wherein the second intermediate mixture is segregated from the first intermediate mixture;
forcing said first intermediate mixture through a first impingement dispensing head;
forcing said second intermediate mixture through a second impingement dispensing head; and
mixing said first intermediate mixture forced through said first impingement dispensing head with said second intermediate mixture forced through said second impingement dispensing head, thereby forming a final reaction mixture, wherein said first intermediate mixture and said second intermediate mixture react and expand in a controllable manner such that the final reaction mixture does not expand beyond a form desired in a final molded asphaltic foam or cure before taking on said form to produce said asphaltic foam.
2. The method of claim 1 , wherein the asphalt comprises the following components:
about 12-13% by weight asphaltene;
about 9-12% by weight saturated hydrocarbons;
about 38-44% by weight polar components; and
about 35-38% by weight naphthalene aromatic constituents.
3. The method of claim 1 , wherein the second intermediate mixture comprises at least one additional ingredient selected from the group consisting of catalyst and fire retardant.
4. The method of claim 1 , wherein the surfactant is a silicone surfactant.
5. The method of claim 3 , wherein the catalyst is a curing catalyst.
6. The method of claim 3 , wherein the fire retardant is TCPP.
7. The method of claim 1 , wherein the isocyanate is polymeric methylene diphenyl diisocyanate (MDI).
8. The method of claim 1 , wherein the first intermediate mixture comprises about 1:1 to about 1.5:1 polyisocyanate:asphalt.
9. The method of claim 1 , wherein the polyol is an amino-based polyol.
10. The method of claim 1 , wherein the blowing agent is selected from the group consisting of water, halocarbons, and mixture of ethanol and dibutylpthalate.
11. A method of forming a ridge cap or roofing tile comprising the steps of:
providing a conveyor belt;
applying a granule layer to said conveyor belt;
providing a mold with a top side open;
filling the mold with a reaction mixture produced by a method of claim 1 ;
applying the mold with the open side down on said granule layer; and
curing the asphaltic foam; thereby forming the ridge cap or roofing tile.
12. The method of claim 11 , additionally comprising the step of forming an indentation on said granule layer after applying the granule layer on said conveyor belt.
13. The method of claim 11 , additionally comprising the step of applying a second granule layer having a contrasting color compared to the color of said first granule layer.
14. The method of claim 11 , wherein said mold comprises an indentation.
15. The method of claim 11 , further comprising applying a strip of modified asphalt onto the granule layer before applying the asphaltic foam.
16. The method of claim 15 , further comprising applying a fire resistant roofing underlayment onto the strip of modified asphalt.
17. The method of claim 16 , wherein the fire resistant roofing underlayment is a coated substrate product with fire-resistant qualities.
18. The method of claim 11 , wherein the second intermediate mixture comprises at least one additional ingredient selected from the group consisting of catalyst and fire retardant. .
19. The method of claim 18 , wherein the catalyst is a curing catalyst.
20. The method of claim 11 , wherein the surfactant is a silicone surfactant.
21. The method of claim 11 , wherein the isocyanate is polymeric methylene diphenyl diisocyanate (MDI).
22. The method of claim 11 , wherein the first intermediate mixture comprises about 1:1 to about 1.5:1 polyisocyanate:asphalt.
23. The method of claim 11 , wherein the polyol is an amino-based polyol.
24. The method of claim 11 , wherein the blowing agent is selected from the group consisting of water, halocarbons, and mixture of ethanol and dibutylpthalate.
25. The method of claim 1 , wherein the mixing step produces an initial cream time in which the final reaction mixture thickens.
26. The method of claim 1 , wherein the initial cream time lasts for about 15 to 20 seconds.
27. The method of claim 1 , wherein the mixing step lasts about 2 to 6 seconds.
28. The method of claim 25 , wherein the initial cream time is followed by an expansion stage in which production of CO 2 causes expansion of the final reaction mixture.
29. The method of claim 1 , wherein the blowing agent volatizes during the expansion stage.
30. The method of claim 1 , further comprising placing said final reaction mixture in a mold or placing a mold around the final reaction mixture;
expanding the final reaction mixture in the mold; and
curing the expanded final reaction mixture.