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US-12617972-B2 - Roofing materials with asphalt shingle waste

US12617972B2US 12617972 B2US12617972 B2US 12617972B2US-12617972-B2

Abstract

A method comprises obtaining a virgin asphalt and obtaining an asphalt shingle waste. The asphalt shingle waste comprises 5 wt. % to 40 wt. % of asphalt based on the total weight of the asphalt shingle waste. The asphalt shingle waste comprises 60 wt. % to 95 wt. % of limestone, granules, and/or impurities based on the total weight of the asphalt shingle waste. The method comprises obtaining a phase modifier. The method comprises mixing the virgin asphalt, the asphalt shingle waste, and the phase modifier to form an asphalt mixture. The phase modifier is present in an amount of 0.25 wt. % to 25 wt. % based on the total weight of the asphalt mixture. The asphalt mixture is configured to be applied to a roof substrate to obtain a roofing shingle.

Inventors

  • Ann HAMER
  • Qian Qin
  • Cynthia SHAHA
  • Kevin Carr
  • Ramil MERCADO
  • Jarod KRAJCA
  • Aziel MEZA

Assignees

  • BMIC LLC

Dates

Publication Date
20260505
Application Date
20230926

Claims (20)

  1. 1 . A roofing shingle comprising: a substrate, wherein the substrate comprises a fiberglass mat; and an asphalt shingle waste filled coating, wherein the asphalt shingle waste filled coating is located on the substrate; wherein the asphalt shingle waste filled coating comprises an oxidized asphalt, an asphalt shingle waste, and a phase modifier, wherein the asphalt shingle waste comprises a waste asphalt, a limestone powder, granules, and impurities; wherein the phase modifier comprises at least one of a pine chemical additive, a renewable oil, or any combination thereof; wherein the oxidized asphalt, the asphalt shingle waste, and the phase modifier are present in an amount sufficient for the asphalt shingle waste filled coating to have at least one of: A) a penetration point of 16 dmm to 20 dmm, at 77° F., when tested according to ASTM 3462; or B) a softening point of 200° F. to 210° F. when tested according to ASTM D3461.
  2. 2 . The roofing shingle of claim 1 , wherein the asphalt shingle waste comprises: 60% to 95% by weight of the limestone powder, granules, and impurities based on a total weight of the asphalt shingle waste; and 5% to 40% by weight of the waste asphalt based on the total weight of the asphalt shingle waste.
  3. 3 . The roofing shingle of claim 1 , wherein the asphalt shingle waste filled coating further comprises: at least one filler, wherein the at least one filler comprises limestone.
  4. 4 . The roofing shingle of claim 1 , wherein the asphalt shingle waste filled coating has a softening point of 200° F. to 205° F. when tested according to ASTM D3461.
  5. 5 . The roofing shingle of claim 1 , wherein the asphalt shingle waste filled coating has a penetration point of 16 dmm to 19 dmm, at 77° F., when tested according to ASTM 3462.
  6. 6 . The roofing shingle of claim 1 , wherein the asphalt shingle waste filled coating has a penetration point of 16 dmm to 18 dmm, at 77° F., when tested according to ASTM 3462.
  7. 7 . The roofing shingle of claim 1 , wherein the asphalt shingle waste filled coating has a penetration point of 16 dmm to 17 dmm, at 77° F., when tested according to ASTM 3462.
  8. 8 . The roofing shingle of claim 1 , wherein the asphalt shingle waste filled coating has a penetration point of 17 dmm to 20 dmm, at 77° F., when tested according to ASTM 3462.
  9. 9 . The roofing shingle of claim 1 , wherein the asphalt shingle waste filled coating has a penetration point of 18 dmm to 20 dmm, at 77° F., when tested according to ASTM 3462.
  10. 10 . The roofing shingle of claim 1 , wherein the asphalt shingle waste filled coating has a penetration point of 19 dmm to 20 dmm, at 77° F., when tested according to ASTM 3462.
  11. 11 . A roofing system comprising: a roofing substrate; and a plurality of roofing shingles, wherein the plurality of roofing shingles is located on the roofing substrate; wherein each of the plurality of roofing shingles comprises: a substrate, wherein the substrate comprises a fiberglass mat; and an asphalt shingle waste filled coating, wherein the asphalt shingle waste filled coating is located on the substrate; wherein the asphalt shingle waste filled coating comprises an oxidized asphalt, an asphalt shingle waste, and a phase modifier, wherein the asphalt shingle waste comprises a waste asphalt, a limestone powder, granules, and impurities; wherein the phase modifier comprises at least one of a pine chemical additive, a renewable oil, or any combination thereof; wherein the oxidized asphalt, the asphalt shingle waste, and the phase modifier are present in an amount sufficient for the asphalt shingle waste filled coating to have at least one of: A) a penetration point of 16 dmm to 20 dmm, at 77° F., when tested according to ASTM 3462; or B) a softening point of 200° F. to 210° F. when tested according to ASTM D3461.
  12. 12 . The roofing system of claim 11 , wherein the asphalt shingle waste filled coating has a softening point of 200° F. to 205° F. when tested according to ASTM D3461.
  13. 13 . The roofing system of claim 11 , wherein the asphalt shingle waste filled coating has a penetration point of 16 dmm to 19 dmm, at 77° F., when tested according to ASTM 3462.
  14. 14 . The roofing system of claim 11 , wherein the asphalt shingle waste filled coating has a penetration point of 16 dmm to 18 dmm, at 77° F., when tested according to ASTM 3462.
  15. 15 . The roofing system of claim 11 , wherein the asphalt shingle waste filled coating has a penetration point of 16 dmm to 17 dmm, at 77° F., when tested according to ASTM 3462.
  16. 16 . The roofing system of claim 11 , wherein the asphalt shingle waste filled coating has a penetration point of 17 dmm to 20 dmm, at 77° F., when tested according to ASTM 3462.
  17. 17 . The roofing system of claim 11 , wherein the asphalt shingle waste filled coating has a penetration point of 18 dmm to 20 dmm, at 77° F., when tested according to ASTM 3462.
  18. 18 . The roofing system of claim 11 , wherein the asphalt shingle waste filled coating has a penetration point of 19 dmm to 20 dmm, at 77° F., when tested according to ASTM 3462.
  19. 19 . A roofing shingle comprising: a substrate, wherein the substrate comprises a fiberglass mat; and an asphalt shingle waste filled coating, wherein the asphalt shingle waste filled coating is located on the substrate; wherein the asphalt shingle waste filled coating comprises an asphalt shingle waste and a phase modifier, wherein the asphalt shingle waste comprises a waste asphalt, a limestone powder, granules, and impurities; wherein the phase modifier comprises at least one of a pine chemical additive, a renewable oil, or any combination thereof; wherein the asphalt shingle waste and the phase modifier are present in an amount sufficient for the asphalt shingle waste filled coating to have at least one of: A) a penetration point of 16 dmm to 20 dmm, at 77° F., when tested according to ASTM 3462; and B) a softening point of 200° F. to 210° F. when tested according to ASTM D3461.
  20. 20 . The roofing shingle of claim 19 , wherein the asphalt shingle waste filled coating further comprises: at least one filler, wherein the at least one filler comprises limestone.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS The present application is a continuation of U.S. patent application Ser. No. 18/088,361, filed Dec. 23, 2022, now U.S. Pat. No. 11,802,219 entitled “ROOFING MATERIALS WITH ASPHALT SHINGLE WASTE,” which claims priority of U.S. Provisional Patent Application No. 63/309,284, filed Feb. 11, 2022, entitled “ROOFING SHINGLES WITH ASPHALT SHINGLE WASTE,” and U.S. Provisional Patent Application No. 63/420,958, filed Oct. 31, 2022, entitled “ROOFING SHINGLES WITH ASPHALT SHINGLE WASTE,” all of which are incorporated herein by reference in their respective entirety for all purposes. FIELD At least some embodiments disclosed herein relate generally to roofing shingles. More particularly, at least some embodiments disclosed herein relate to methods for making roofing shingles from asphalt shingle waste, asphalt recovered from asphalt shingle waste, or any combination thereof. BACKGROUND Significant amounts of asphalt shingle waste are generated in the U.S. each year. SUMMARY In some embodiments, a method comprises obtaining a virgin asphalt. In some embodiments, the method comprises obtaining an asphalt shingle waste. In some embodiments, the asphalt shingle waste comprises 5 wt. % to 40 wt. % of asphalt based on a total weight of the asphalt shingle waste. In some embodiments, the asphalt shingle waste comprises 60 wt. % to 95 wt. % of limestone, granules, and/or impurities based on the total weight of the asphalt shingle waste. In some embodiments, the method comprises obtaining a phase modifier. In some embodiments, the method comprises mixing the virgin asphalt, the asphalt shingle waste, and the phase modifier to form an asphalt mixture. In some embodiments, the phase modifier is present in an amount of 0.25 wt. % to 25 wt. % based on a total weight of the asphalt mixture. In some embodiments, the asphalt mixture is configured to be applied to a roof substrate to obtain a roofing shingle. In some embodiments, the phase modifier is selected from the group consisting of pine chemical additives, renewable oils, and any combination thereof. In some embodiments, the impurities are selected from the group consisting of fiberglass mat sand, fines, marker paint, sealant, one or more adhesives, tape, plastic debris, paper debris, soil, wood, nails, and any combination thereof. In some embodiments, the phase modifier is present in an amount of 0.25 wt. % to 5 wt. % based on the total weight of the asphalt mixture. In some embodiments, the phase modifier is present in an amount of 0.25 wt. % to 3 wt. % based on the total weight of the asphalt mixture. In some embodiments, the phase modifier is present in an amount of 0.25 wt. % to 2 wt. % based on the total weight of the asphalt mixture. In some embodiments, the virgin asphalt is present in an amount of 50 wt. % to 85 wt. % based on the total weight of the asphalt mixture. In some embodiments, the virgin asphalt is present in an amount of 60 wt. % to 80 wt. % based on the total weight of the asphalt mixture. In some embodiments, the virgin asphalt is present in an amount of 70 wt. % to 75 wt. % based on the total weight of the asphalt mixture. In some embodiments, the asphalt shingle waste is present in an amount of 10 wt. % to 35 wt. % based on the total weight of the asphalt mixture. In some embodiments, the asphalt shingle waste is present in an amount of 20 wt. % to 30 wt. % based on the total weight of the asphalt mixture. In some embodiments, a method comprises obtaining an unoxidized asphalt that has a penetration point at 77° F. of 15 dmm or less when tested according to ASTM D5. In some embodiments, the method comprises obtaining a phase modifier; and mixing the unoxidized asphalt with the phase modifier to form an asphalt mixture. In some embodiments, the phase modifier is present in an amount of 0.25 wt. % to 25 wt. % based on a total weight of the asphalt mixture. In some embodiments, the method comprises oxidizing the asphalt mixture. In some embodiments, the asphalt mixture as oxidized is configured to be applied to a roof substrate to obtain a roofing shingle. In some embodiments, the unoxidized asphalt is present in an amount of 75 wt. % to 99 wt. % based on the total weight of the asphalt mixture. In some embodiments, the oxidized asphalt is present in an amount of 85 wt. % to 99 wt. % based on the total weight of the asphalt mixture. In some embodiments, the oxidized asphalt is present in an amount of 90 wt. % to 99 wt. % based on the total weight of the asphalt mixture. In some embodiments, the oxidized asphalt is present in an amount of 95 wt. % to 99 wt. % based on the total weight of the asphalt mixture. In some embodiments, a method comprises obtaining an oxidized asphalt that has a penetration point at 77° F. of 15 dmm or less when tested according to ASTM D5. In some embodiments, the method comprises obtaining a phase modifier and mixing the oxidized asphalt with the phase modifier to form an asphalt mixture.