JPS609183B2 - Combination roofing material using sulfur asphalt - Google Patents

Description

DETAILED DESCRIPTION OF THE INVENTION The present invention relates to roofing materials for flat or low-slope roofs, and in particular to "laminated roofing materials".
fing (stmctme); abbreviation "BUR"].

This laminated roof structure is a substantially rigid board covered with a plurality of asphalt-impregnated felt layers.
k) and in which the upper surface (also referred to as the top) of each felt layer is separately coated with asphalt. This roofing material is also often provided with a protective layer made of pebbles or other inert mineral aggregate (for example,
~2 layers), the protective layer comprising the top asphalt coating (topcoatin).
g)] and overlying the top asphalt coating. Laminated roofing materials are mainly used for commercial buildings,
For example, it is often used in "places where other types of roofing materials cannot be practically used," such as large industrial buildings with small cross sections.

This type of roofing is popular because it is relatively inexpensive, provides an effective weatherproof roof surface, and is durable. The main drawback of this type of roofing material is that it does not have sufficient resistance in the event of a disaster such as a fire. Fires quickly spread vertically, so in the case of a fire in a building with a small cross-section, the fire often quickly moves to the roof of the building. For example, if a part of a large building with a small cross section is constantly on fire, the fire may move to the roof, ignite the laminated roofing material, and cause the fire to spread laterally. . The fact that a roof catches fire and spreads laterally may not be a major problem in and of itself. This is because in this case the main frame or interior of the building may be in very bad condition. However, in the case of the above-mentioned laminated roofing material, the asphalt layer therein is flammable.
Moreover, this is caused by the heat of the fire liquefying the burning liquid asphalt, which drips onto the lower parts of the building or into the interior of the building, causing what was initially a localized fire to burn laterally within the building. It starts to spread. An example of such a dangerous fire is the devastating fire that occurred on August 12, 1953, at a General Motors plant in North Carolina, Michigan, USA. The fire destroyed the entire area under one roof of the one-story factory (34.5 acres in area). Regarding this fire, the National Fire
centre. Lotechion Association Quarterly” 1
The following information is included in the October issue of 953 Hitsuji. ``Flat roofs were closely related to the spread of fire.

The fire caused by the spark from the oxy-acetylene cutting torch transferred to the compare drip pan and ignited the fat and oil condensate present in the steel roofing components, which were used to heat the roof deck. The "fuel" and soon hot tar and asphalt flowed down through the gaps between the strips in the heat-bent roof shingles and ignited the fire. , spreads laterally through molten tar that oozes from the roof over a large area, and creates ``molten tar fall points'' on machinery, flammable liquid containers, floors (wooden floors), etc.
A small fire broke out at the same time. As firefighters scrambled to ensure safety, many suffered burns from hot tar droplets, and three people were engulfed in flames and died.

The number of casualties could have been higher if firefighters had delayed withdrawing until after the heat, smoke, and falling droplets of burning tar and asphalt made the building untenable. Dew. ``It has been found that the above-mentioned major drawbacks and deficiencies observed when using laminated roofing materials can be completely remedied according to the invention.

The present invention is an asphalt-based impregnating agent (saturating agent) (asph
a substantially rigid plate (rigddec) covered with a plurality of felts impregnated with
k), and a separate asphalt-based coating is applied to the upper surface of each felt layer, and at least one of the impregnating agent and the coating (preferably both) contains 90 to 45% by weight of asphalt. The invention relates to an asphalt-based laminated roofing material, characterized in that it is composed of a mixture consisting of 10 to 5% by weight of sulfur dispersed in the asphalt-based roofing material.

Further, the present invention has the above structure, and in addition,
It also relates to an asphalic laminated roofing material, characterized in that it has a protective layer made of inert mineral aggregate, and this protective layer is embedded in the top coating. . "Ratio" and "%" used herein are:
Unless otherwise specified, "weight ratio" and "wt %" are respectively meant. The specification of another patent application filed by the applicant discloses asphalt-based veneer roofings.

This veneer roofing material has a felt layer impregnated with an asphalt-based impregnation agent and coated with a mineral filler-binder mixture on top of which the binder is coated with asphalt 90~ 45% and 10% sulfur present in dispersed form.
55% by weight of a homogeneous sulfur-asphalt dispersion composition (mixture). In addition, the specification of the patent application states that the above-mentioned single-panel roofing material has excellent flame retardancy (flammability retardation), and that the single-panel roofing material is held at a 45-degree angle to allow fire to ignite. It is stated that there is little or no loss of liquid asphalt from the edges of this roofing material when burned next to it. The asphalt-based impregnating agent composition impregnated into the felt layer of the preferred veneer-type roofing material disclosed in the specification has an asphalt-based ape-containing agent of 90 to 45%.
% and 10-55% sulfur dispersed therein. Similarly, the asphalt-based impregnant composition for felt house impregnation used in preferred embodiments of the present invention is a homogeneous dispersion comprising 90-45% asphalt-based impregnant and 10-55% sulfur dispersed therein. It is a composition (mixture). In the present invention, the amount of sulfur dispersed in the asphalt is between 20 and 4% by weight (based on the total amount of the mixture).
It is more preferable that Preferably, the sulfur present in undissolved form in this mixture is in the form of finely dispersed particles having a particle size within a particle size range of substantially less than 50 microns. This laminated roofing material can generally be manufactured according to the following conventional manufacturing method.

That is, '1) Hard roof base material (roof seam)
On top of which several layers in the form of parallel strips (platelets) of asphalt-impregnated felt are installed in sequence, and these strips (i.e. strips used to form a single layer from a roll of felt) The strips shall be attached so that they overlap each other appropriately at the border with the adjacent strip. ■For each felt layer,
Coats of hot liquid asphalt of the appropriate grade are applied in sequence, and subsequent felt layers are applied over the coats before the asphalt has cooled and solidified. When the rigid roofing board is made of wood such as plywood, the bottom felt layer (lowest felt layer) is usually fixed to the board using suitable nails. Will. If the slab is concrete, gypsum board, or other non-nailable material, a primary asphalt is applied to it to form a bottom sheath (bottom sheath) through which the slab is coated. A bottom felt layer can be affixed to the shaped body. The entire operation of applying a coating of asphalt onto a felt layer or slab and coating it with another layer of felt must be carried out very quickly, i.e. each felt layer is coated with asphalt. If overcoated, the felt layer coating operation must be carried out while the asphalt coating is still sufficiently hot to ensure that the top felt layer adheres strongly to the underlying asphalt coating. A final asphalt coating is applied over the top felt layer, if desired, with a loose asphalt coating applied to protect the latter asphalt coating.
e) A protective layer of aggregate can be provided embedded in the asphalt coating and over the latter coating. The selection of the grade (variety) of asphalt used in the manufacture of laminated roofing materials should be made in consideration of various conditions such as the slope of the roof and the local weather conditions (e.g. temperature).

Of course, the grade of asphalt is closely related to "its combination of physical properties." Among these properties, the most important property for this purpose is the softening point. The greater the slope of the roof or the higher the temperature around the roof, the more it is necessary to use asphalt with a higher softening point. The sulfur content of the asphalt-containing mixture used in the present invention is
It does not substantially change the properties (softening point) of asphalt. Generally, sulfur will slightly lower the softening point, but in the case of certain asphalts, the presence of some amount of sulfur can even slightly increase the softening point of the mixture. On the other hand, the presence of sulfur in the sulfur-asphalt mixture used in the present invention has a significant effect on the viscosity of the mixture in a fluid state.

That is, the viscosity of the mixture is significantly different from the viscosity of asphalt alone (at the same temperature). The viscosity of the fluid consisting of a mixture of sulfur and asphalt used in the present invention is considerably lower than that of a fluid consisting only of asphalt at temperatures above the melting point of sulfur. However, it is completely unnecessary to heat the mixture to such high temperatures that the material consisting solely of asphalt can exist as a fluid. For example, a fluid consisting of a mixture of sulfur and asphalt may be used at a temperature at least 500 F (30 oo) below the temperature at which asphalt alone would be used in the manufacture of laminated roofing. ~ This is convenient and preferable.The difference in processing temperature is mainly defined as "temperature A at which molten asphalt of a certain viscosity can exist" and "temperature A at which molten asphalt of a certain viscosity can exist" and "temperature A at which molten asphalt of a certain viscosity can exist" and "temperature A at which molten asphalt of a certain viscosity can exist" and "temperature A at which molten asphalt of a certain viscosity can exist" and "temperature A at which molten asphalt of a certain viscosity can exist" and "temperature A at which molten asphalt of a certain viscosity can exist"
This is to cover the difference between the temperature B and the temperature B at which the melt of the mixture obtained by mixing at a mixing ratio of 5% to 75% asphalt can exist at the same viscosity. substantially lower. In this way, molten sulfur-
Because asphalt mixtures have different viscosity values~
Mopping of the roofing material with the mixture during the manufacture of laminated roofing materials can be carried out at lower temperatures. Generally required when covering ordinary asphalt.
Harmful polluting vapors emanating from the sulfur-asphalt mixture at "higher temperatures" are largely prevented from occurring in the present invention, since operations can be carried out at "lower temperatures" as described above. It is. The laminated roofing material of the present invention is produced by applying an asphalt-based roofing coating to the felt during the manufacturing of the roofing material (if desired, this asphalt is impregnated into the felt as an asphalt-based impregnant to create an impregnated felt). A conventional process for the production of laminated roofing materials known in the art, except that it is a mixture of 90-45% of such suitable asphalt and 10-55% of sulfur dispersed therein. The mixture used in the present invention preferably contains 20 to 40% of sulfur dispersed in asphalt.The sulfur particles dispersed in the mixture have a diameter of 50%. Preferably, the diameter is less than a micron, and more preferably an average diameter of 1 to 10 microns.The above-mentioned "another patent application"
As stated in the specification, mixtures of elemental sulfur and roofing grade or similar grade asphalt are prepared by dispersing the sulfur into the asphalt at a temperature not substantially exceeding 3500F (i76oo). It can be easily produced by mixing liquid sulfur and liquid asphalt at the desired mixing ratio under appropriate conditions for imparting trout shearing force.The appropriate shearing force corresponds to the amount of materials to be mixed. This can be satisfactorily applied when using a high-speed sill-probera type mixer "pipeline mixer" or other type of cutting force application mixing equipment having dimensions of Sulfur dispersed in asphalt by the above-mentioned dispersion method "generally dissolves in asphalt when its amount (abundance ratio) is substantially 15 to 25% by weight (based on the total amount of the mixture) or less". Or it will mix homogeneously with asphalt.The amount that can be homogeneously dispersed (abundance ratio) will mainly depend on the properties of asphalt.When a larger amount of liquid sulfur is mixed with liquid asphalt, Excess sulfur other than the amount that can be homogeneously dispersed is
When the total amount of sulfur in the total mixture is substantially 50 to 6% by weight or less, "
It will become heterogeneously dispersed as "droplets of liquid sulfur." As the amount of sulfur increases, the mixture will undergo a phase inversion and become a mixture of liquid asphalt dispersed in liquid sulfur. Therefore, the amount of sulfur is 55
% by weight (based on the total amount of the mixture of sulfur and asphalt) are also unsuitable for the present invention and do not fall within the scope of the present invention. When a dispersion of liquid sulfur droplets dispersed heterogeneously in liquid asphalt is cooled, this sulfur also solidifies or crystallizes and forms dispersoids in the form of "small particles dispersed in asphalt". remains as. An example of a laboratory test on flammability and fire spread of samples made according to known techniques and samples made according to the present invention is shown.

This known sample was a laminated roofing material (test pseudo-roofing material) made using an impregnating agent that contained roofing asphalt but not dispersed sulfur. On the other hand, the samples according to the invention contained sulfur 25% in the above impregnating agent and roofing asphalt.
(per 75 parts of asphalt). These laboratory samples (i.e., pseudo-laminated roofing samples) were manufactured through the following series of manufacturing steps. 1. Soak unimpregnated dry paper felt, 0.019 inch (0.48 skin) thick, with impregnation agent.

This impregnation operation is carried out according to the following method. That is, the felt was hand impregnated in the impregnation agent at 3000F (149C) for approximately 49 stages, an operation similar to the following. That is, a continuous web of felt is passed over rollers and into an impregnating tank, and the felt sheet is soaked in sand between 19 and 220 to 2500F (104 to
A hydraulic press (12100) maintained at a temperature range of
Silicone coated quick release paper in heated platen of hydraulic press
A squeezing operation is carried out between the sheets of felt, thereby squeezing out the excess impregnating agent, resulting in an impregnating agent with an impregnating agent content of essentially 170% (based on the "original weight" of the sheet of felt). Make a felt sheet. 2 Place these two impregnated sheets together in a hydraulic press (hydra mountain ic).
anneal by passing through the press
al), which gives a thickness of 0.040 inches (1
．． Make an impregnated felt sheet.

3. The uppermost surface or top surface (topsm) of the sheet.
A coating of roofing asphalt or a sulfur-asphalt mixture is applied to the roof and the resulting coated sheet is pressed to flatten the coating.

This pressing operation is carried out by covering both sides of the sheet with silicone-coated quick-release paper and placing it in the □ section (ja boat) of a hydraulic press and pressing it. Incidentally, a metal spacer is disposed at the mouth portion, and this spacer exists near each side of the sheet and plays the role of adjusting the thickness of the coating. 4. Heat the abdominal surface of this coated sheet using a small heat source to soften the toasphalt.

The softened asphalt-bearing side of the sheet is placed in the mouth of a press together with another similar coated sheet and applied a slight pressure for a few seconds to form a laminate. A laminated structure having a thickness of 0.11 inches (2.8 willows) is obtained.5 The thickness and dimensions of this laminated structure are measured, and a size of 3×1 with a uniform thickness is obtained.
Select a structure of 0 inches (7.6 x 25.4),
This was cut into the above-mentioned dimensions, and the product thus obtained was used as the pseudo-laminated roof material sample described above.

According to the above manufacturing method, a set of two laminated roof village samples were
I made seeds. These five samples differed in the composition of the impregnating agent in the felt or in the coating, as described below. Sample 1...This set of samples had felt impregnated with commercially available asphalt for felt impregnation, which is sold under the registered trade name "420 Saturant" and has the following physical properties. Ta.

Specific gravity (600F; 15.6℃) 1.0
209 Softening Point (ASTM-D-36) 1490F (
6500) Penetration (770F; 2500) (ASTM-
D-5) 35 ductility (77F; 25oo) (ASTM-
D-113) 11 The coating applied on the impregnated felt is
It was commercially available under the trade name "BUR-3, Roofing Compound" and consisted of asphalt for roofing material having the following physical properties.

API-Gravity (600F: 15.6Q○)
5.8 specific gravity (6piF; 15.600)
1.0306 Softening Point (ASTM-○-36) 20
00F (93.3oo) Penetration (770F; 25qo)
(ASTM-D-5) 15 ductility (770F; 25qo
) (ASTM-D-113) 3.2 Sample 2 This set of samples consisted of 75% asphalt, the same grade of impregnating asphalt used in Sample 1, and a liquid dispersed therein. It had felt impregnated with an impregnating agent that was a mixture with 25% sulfur. The sulfur droplets dispersed therein did not exceed 50 microns in diameter. The coating on the felt consisted of the same "BUR-3, Roofing, Compound" as in Sample 1. Sample 3: This set of samples had felt impregnated with the same impregnating agent as Sample 1.

The coating on the felt, on the other hand, consisted of a mixture of 75% BUR-3 Roofing Compound and 25% liquid sulfur dispersed therein. The diameter did not exceed 50 microns.Sample 4...This set of samples had felts impregnated with the same sulfur-asphalt mixture used in Sample 2. The above coating consisted of the same sulfur-asphalt mixture coated onto the felt in Sample 3, i.e. each of the impregnant and coating asphalt compositions contained ~dispersed liquid sulfur. Sample 5: This set of samples had a commercially available impregnated felt. On the other hand, the coating on the felt consisted of the same sulfur-asphalt mixture used in Sample 3. The thickness of this commercial felt was 0.035 inches (0.89 mm). ) and “
The impregnating agent contained therein was completely unknown except that it was a commercially available impregnating agent. TEST EXAMPLE The flammability of the five samples described above was also tested according to the improved flammability test method as described in the specification of the above-mentioned "Another Patent Application" filed by the applicant.

To conduct this test, first a 1/8 inch thick (
I made an inverted U-shaped rectangular frame using Shinchiyumura (3.2 legs) and 1'2 (13 legs). The net end-to-end distance of the inner space between the sides of this frame was 2 inches (51 ribs). The net end-to-end distance of the inner space between the top and bottom of this inverted U-shaped frame was 10 inches (254 ribs). Each side of a sample measuring 3 x 10 inches (76 x 254 sails) was clamped between two frames of this shape. Therefore, the sample piece in this case was flat and its edges were exposed.
The specimen was kept in an orientation at a 20 degree angle to the horizontal and held firmly in the frame with the bottom edge exposed. A clean Cleveland, open, cup igniter (flash device) taper was used.
The flame length of the napper was adjusted to 3 inches (7.6 mm), the tip of the taper was 2 inches (2 inches) from the surface of the specimen, and 2 inches (13 mm) from the lower edge. Therefore, the flame was approximately 1 inch (25 skins) above the felt surface.The flame was present between 6 inkstone sands to ensure that the sample ignited.
The flame was then removed. The weight of the sample, which is the material to be combusted, is measured before ignition, and after the fire is naturally extinguished, the weight of the carbonized part to the ashed part and the unburned remaining part of the sample is measured. The degree of weight loss was calculated. Sample 1'3 is the side piece of the frame (
s;dep;eces) and the combustion air could not reach that far, so it did not burn. In other words, at most only 2'3 of each sample was placed in a "potential combustion position". The liquid asphalum that softened, flowed, and dripped from each sample during the combustion test was collected in a drip pan and its weight was measured. The weight standard of the "combustible part") was calculated. In other words, this weight reduction rate simply represented the loss rate of liquid asphalt. Each set of samples was tested twice, and the average weight loss (%; based on the weight of the "combustible part" of the samples) is shown in Table 1 below. The first column of this table lists the sample number of each set of samples mentioned above, and the second and third columns list the amount of sulfur added to the impregnating agent and covering asphalt in the sample. The fourth column contains the degree of weight loss of the sample due to the loss of asphalt or sulfur-asphalt mixture during the combustion test, and the fifth column shows the degree of weight loss of the sample due to the loss of asphalt or sulfur-asphalt mixture during the combustion test. The total weight loss of the sample due to sample combustion until
The value is expressed as a percentage based on the weight of the "potentially combustible part" of the sample before the test. Table 1 In addition to the above quantitative data, the following qualitative results were also obtained.

In other words, Sample 1, in which sulfur was not added to either the impregnating agent in the felt or the cumulative asphalt coating, spontaneously extinguished only after the sample ignited and was completely combusted by the flame from bottom to top. . When sample 1 ignites L, the asphalt that becomes a fluid in front of the combustion flame moves from the bottom edge to the surface, flows through the flame, ignites, and heats the bottom edge of the sample. ignited ~ and dripped from the edge. As a result of heating the bottom edge of this sample (i.e., the control sample),
After removing the tapered flame, the sample burned continuously from the bottom towards the edge of the specimen. In contrast, in samples where sulfur was added to the impregnating asphalt and/or coating asphalt, very little liquid asphalt exited the top of the sample and passed through the flame. Also, the expansion and scorching of the flame path "prevented the flow of fluid asphalt to the bottom edge. Therefore, the amount of asphalt lost from these samples was negligible, and in each case the amount of asphalt lost on the sample Combustion did not occur due to insufficient heat propagation. The flame transferred to these specimens was extinguished within seconds after the flammable taber was removed. In addition, another comparative experiment was conducted. I did it.

Claims (1)

[Scope of Claims] 1. A substantially rigid plate-like body covered with a plurality of felt layers impregnated with an asphalt-based impregnating agent, and an asphalt-based coating is separately applied to the upper surface of each felt layer. the bottom felt layer is fixed to the rigid plate;
Each impregnated felt layer in the stack is tightly adhered to an asphaltic coating applied to the felt layer below it, the impregnating agent and at least one of the coating being comprised of 90 to 45% by weight of asphalt. sulfur 10-55
An asphalt-based laminated roofing material characterized in that it is composed of a mixture containing % by weight in a dispersed state. 2. In the laminated roofing material according to claim 1, both the asphalt-based impregnating agent and the asphalt-based coating contain 10 to 10% of sulfur in 90 to 50% of asphalt.
A roofing material comprising a mixture containing 55% in a dispersed state. 3. In the laminated roofing material according to claim 2, the impregnating agent and coating are made of asphalt 80-60
1. A roofing material comprising a mixture containing 20 to 40% of sulfur in a dispersed state. 4. A laminated roofing material according to any one of claims 1 to 3, additionally comprising a protective layer consisting of an inert mineral aggregate, and this protective layer covers the uppermost coating. A roofing material that is embedded in the material. 5. In the laminated roofing material according to claim 3, the sulfur dispersed in the asphalt is substantially
A roofing material characterized in that it is dispersed as particles with a particle size smaller than 0 microns. 6. The laminated roofing material according to claim 5, wherein the dispersed sulfur has an average particle size of 1 to 10 microns.