Granted Patent B2

US 12,735,538 · App. 18/521,796 · Granted Sep 15, 2026

Inventors: Robert P. Harris (Tulsa, OK); Marlene Gomez (Tulsa, OK)

Assignee: MARCO INDUSTRIES INC.

C08J5/046C08J5/10C08J2333/08

Abstract

Claims (57)

1 . A composition comprising:

at least one polyester fiber, and

a binder mix comprising:

at least one acrylic emulsion, wherein the at least one acrylic emulsion is a self-crosslinking binder;

at least one fire retardant;

at least one surfactant, wherein the at least one surfactant is a nonionic surfactant derived from neutrally charged long-chain fatty acids;

at least one defoaming agent, wherein the at least one defoaming agent is present at about 0.024% to about 0.036% by weight of the binder mix, and wherein the defoaming agent is a water-based emulsion of wax and mineral oil; and

water.

2 . The composition of claim 1 , wherein the polyester fiber is present at about 25% to about 65% by weight of the composition.

3 . The composition of claim 1 , wherein the at least one acrylic emulsion is present at about 70% to about 95% by weight of the binder mix, and wherein the at least one acrylic emulsion is free of alkyl phenol ethoxylates.

4 . The composition of claim 1 , wherein the at least one fire retardant is present at about 2.90% to about 4.40% by weight of the binder mix, and wherein the at least one fire retardant is a water-soluble liquid having a density of 1.190, a pH of 8.0, and a flash point greater than 212 degrees.

5 . The composition of claim 1 , wherein the at least one surfactant is present at about 0.016% to about 0.024% by weight of the binder mix, and wherein the at least one surfactant includes long-chain polyoxyethylene or polyoxypropylene groups.

6 . The composition of claim 1 , wherein the water is present at about 10% to about 16% by weight of the binder mix.

7 . The composition of claim 1 , further comprising at least one pigment.

8 . The composition of claim 7 , wherein the at least one pigment is present at about 0.30% to about 0.45% by weight of the binder mix.

9 . The composition of claim 1 , wherein the composition includes about 0 ppm to about 16 ppm formaldehyde.

10 . The composition of claim 1 , wherein the composition is free of a terpolymer of vinyl chloride, vinyl acetate, ethylene, a crosslinking agent, and a crosslinking resin.

11 . A roofing strip comprising a roofing composition, the roofing composition comprising:

at least one polyester fiber, and

a binder mix comprising:

at least one acrylic emulsion, wherein the at least one acrylic emulsion is a self-crosslinking binder;

at least one fire retardant;

at least one surfactant, wherein the at least one surfactant is a nonionic surfactant derived from neutrally charged long-chain fatty acids;

at least one defoaming agent, wherein the at least one defoaming agent is present at about 0.024% to about 0.036% by weight of the binder mix, and wherein the defoaming agent is a water-based emulsion of wax and mineral oil; and

water,

wherein the composition is formed into a roofing strip.

12 . The roofing strip of claim 11 , wherein the roofing strip includes a first side having a flat and planar surface.

13 . The roofing strip of claim 11 , wherein the roofing strip includes a first side having a flat and planar surface, and a second side opposite the first side, the second side having a flat and planar surface.

14 . The roofing strip of claim 11 , wherein the roofing strip includes a first side having a flat and planar surface, and a second side opposite the first side, the second side configured to engage an uneven roof surface.

15 . The roofing strip of claim 11 , wherein the roofing strip includes a first side having a flat and planar surface, and a second side opposite the first side, the second side having a variable profile complimentary to an uneven roof surface.

16 . The roofing strip of claim 11 , wherein the roofing composition includes about 0 ppm to about 16 ppm formaldehyde.

17 . A roofing strip comprising:

a base defining a plurality of recesses along a length of the strip, each recess separated from another recess by a section of the base and each recess extending across a full width of the strip; and

an air permeable material received in the plurality of recesses defined in the base,

the strip having a first side opposite a second side, wherein one of the first side or the second side has a planar surface and the other of the first side or the second side is configured to engage an uneven roof surface; and

wherein the air permeable material comprises at least one polyester fiber and a binder mix, the binder mix comprising:

at least one acrylic emulsion, wherein the at least one acrylic emulsion is a self-crosslinking binder;

at least one fire retardant;

at least one surfactant, wherein the at least one surfactant is a nonionic surfactant derived from neutrally charged long-chain fatty acids;

at least one defoaming agent, wherein the at least one defoaming agent is present at about 0.024% to about 0.036% by weight of the binder mix, and wherein the defoaming agent is a water-based emulsion of wax and mineral oil; and

water.

18 . The roofing strip of claim 17 , wherein the air permeable material is formed as a plurality of discontinuous sections, each section received in one of the plurality of recesses defined in the base.

19 . The roofing strip of claim 17 , wherein the air permeable material forms a continuous strip from one recess to another recess.

20 . The roofing strip of claim 18 , wherein the air permeable material traverses a surface of the section of the base separating each recess.

21 . The roofing strip of claim 17 , wherein the roofing composition includes about 0 ppm to about 16 ppm formaldehyde.

22 . A method of installing a roofing strip, the method comprising:

applying a strip to a major roof panel, the strip including at least one material comprising:

at least one polyester fiber, and

a binder mix comprising:

at least one acrylic emulsion, wherein the at least one acrylic emulsion is a self-crosslinking binder;

at least one fire retardant;

at least one surfactant, wherein the at least one surfactant is a nonionic surfactant derived from neutrally charged long-chain fatty acids;

at least one defoaming agent, wherein the at least one defoaming agent is present at about 0.024% to about 0.036% by weight of the binder mix, and wherein the defoaming agent is a water-based emulsion of wax and mineral oil; and

water, and

attaching a minor roof panel to the major roof panel such that the strip is positioned between the minor and major roof panels,

wherein practicing the method results in an estimated total daily intake of up to about 25 μg/day formaldehyde.

23 . The method of claim 22 , wherein the estimated total daily intake of formaldehyde is less than performance of the same method except that the binder mix of the material includes a terpolymer of vinyl chloride, vinyl acetate, and ethylene instead of at least one acrylic emulsion.

Assignments (1)

Continuity (3)

References Cited (167)