US2249000A - Building material - Google Patents

Description

Jul 15, 1941. R T; JOHNSTON 2,249,000

BUILDING MATERIAL Original Filed Aug. 20. 1931 Patented July 15, 1941 BUILDING MATERIAL Robert T. Johnston, deceased, late of Plainfield, N. 1., by Clara E. Johnston, administratrix, Newark, N. 1., assignor, by mesne assignments, to Union Carbide and Carbon Corporation, New York, N. Y., a corporation of New York Original applicatiomAugust 20, 1931, Serial No.

Divided and this application September 25, 1936, Serial No. 102,543

2 Claims.

This invention relates to materials intended for exposure to weather and for that, purpose provided with protective coatings. The base material may be wood, cement, felt obtained from animal or vegetable fibers, paper, etc. or various compositions including them. More particularly the invention relates to coated base materials intended for roofing and the description which follows is therefore specifically addressed to this embodiment of the invention. The present application is a division of applicant's prior application Serial No, 558,247, now Patent No. 2,060,083 granted November 10, 1936.

Roofing base materials comprise in general shingles or other shapes of wood or felt and sometimes cement compositions. Wood shingles when coated are customarily dipped in an oil stain; however, the stain leaches out after a brief time dueto the action of rain and sun and the coating must therefore be frequently renewed. ,Felt base materials in the form of shingles or continuous strips have coatings of asphalt; but as asphalt-coated felt materials do not satisfactorily withstand changing weather conditions, it has been proposed to increase their durability by the application of crushed slate or the like. But this againpresents many serious faults, For one thing the absorption of heat by asphalt-coated materials when exposed to the summer sun causes the asphalt to soften and flow to a very marked degree, and this condition isgreatly accentuated by the weight of the superposed crushed slate; furthermore the heat in time dries the asphalt so that its grip on the slate particles is lost and they are readily separated from the base material. 0n the other hand in winter weather the asphalt shingle becomes porous and brittle, so that moisture penetrates and is absorbed to rot the felt base and result in rapiddeterioration, and the asphalt loses its cementing and gripping qualities. After a shingle has ab-, sorbed moisture in winter, the next high temperature resoftens the asphalt and seals the moisture within the shingle; then during the heat of summer the moisture expands to form blisters on the surface of the shingle as well as causing unequal contraction and expansion of the shingle which results in curling. On account of this loss and deterioration, the shingles become limp and flabby so that the wind can lift Particularly with reference to felt base materials it is found that the presentinvention not only counteracts to a large extent the destructive effects .of sun and rain, but imparts a strength and a stifiness to the material, that permits a thinner felt base and/or a greater proportionate exposure of the surface. These and other objects of the invention will be apparent from the description which follows.

The invention in one aspect comprises the application to abase material of a coating of granular material, which may be sand, crushed quartz; crushed slate or other suitable materials, secured to the base material by a cementing layer orbond which is waterproof and also non-softening under the action of a hot sun. The cementing layer may be any suitable oil composition containing extending material such as pigments or natural resin as copal, dammar, rosin, etc. which with tung oil, for example, can be made to yield compositions of greater durability and resistance than pigment-extended oils like linseed oil. Synthetic resin of the coumarone and ester gum types are also more or less suitable; but the syn-' thetic resins of the polyhydric alcohol type and more particularly those of the so-called oil-solu- I ble phenolic type are found to be greatly superior in durability and resistance to weather as well as showing very marked adhesive properties for superposed grains under all conditions of temperature and weather.

Oil-soluble phenolic resins, particularly some forms thereof, are likewise characterized by yielding films having a. flexibility, toughness and adhesiveness which render them suitable'as bonding agents per se for the objects herein indicated without the use of oils. pect of the invention comprises synthetic resins so characterized as bonding agents for securing granular coatings to base materials for use as roofing and the like.

Furthermore resins of this character. or compositions containing them, show a remarkable resistance to weather changes and freedom from destructive oxidation and therefore they in them- Therefore another asselves or oil compositions containing themcan be used as coatings without any protective layer of granular material showing marked improvement over coating compositions heretofore applied. The resins themselves in addition to being relatively non-oxidizing and non-softening under the heat of the sun form a flexible tough film that is continuous and non-penetrative by moisture; in addition they do not support combustion and are poor conductors of heat. In association with oils it is found that but small percentages of such phenolic resins profoundly modify the oil characteristics so that resistance to progressive oxidation, acids and alkalies is increased out of all proportion to the resin content, thereby rendering oil compositions of much improved utility as protective media for exposed base materials.

Phenolic resins of the oil-soluble type herein referred to, that is, resins which are suspensible r miscible with oils are in general obtained by reacting a phenolic body. which may be a phenol, eresol or higher substituted phenol or derivative. with a inethylcne-containing agent, such as formaldehyde or its polymers or compounds, furfural. benzaldchyde, etc. and a suitable catalyst. Lower phenol and similar resins which in themselves are not miscible with oils can be made so by blending them with sufficient proportions of rosin, ester gum or other natural resins; such additions, however, injuriously affect the desirable properties of the phenolic resins in proportion to the amount included and for that reason are not desirable. Oil-soluble or sus pensible resins can, however, be obtained from lower phenolswithout the necessity of including rosin or the like by adding an oil such as tung oilas an ingredient of the resin and preferably by reactin the oil first with the phenol and then with a methylene-containing agent. The higher phenlols, such as alkyl or phenyl substituted phenols, form resins which in themselves are miscible or suspensible and which therefore exhibit in a striking manner the properties heretofore mentioned. Accordingly the last type mentioned constitutes the preferred form of phenolic resins, particularly when associated with oils.

The oils found most suitable for the purposes of this invention are the drying oils, particular- 1y tung. linseed, rapeseed, etc. Non-drying oils, however, like castor oil, can be included; or oils including fatty acids as oleic, stearic, palmitlc, or the fatt acids themselves can be substituted. These oil when mixed with resins as described form mixtures which are soluble in the .usual volatile solvents such as alcohol. mineral spirits,

turpentine, etc. If desired the resins may be modified by the addition of high boiling solvents such as dibutyl phthalate, tricresyl phosphate.-

aniline, etc. Any desired color can be given the coatings or binding layers by suitable pigments which when added to resins as here described are found to substantially retain their original color quality due to the protecting influence of the resins.

The invention is found to be particularly useful in connection with the manufacture of roofings from felt base materials and specifically felt base materials impregnated with asphalt or other suitable bituminous material and havin applied thereto a layer of crushed slate or similar material of impervious nature. When such a treated base material is provided with a coating of the nature above described and particularly a coating including a synthetic phenolic resin in admixture with oils or their equivalents, it is found that the tendency for the asphalt to flow under the action of a hot sun is minimized and furthermore any shrinkage or contraction caused by cold weather is not sufficient to permit entrance of moisture and resulting deterioration. Furthermore with an-intermediate layer of crushed slate or the like, any tendency of the asphalt to blood into the applied coating is overcome.

As a. granular surfacing material the preferrcd form is fine, light colored silica sand. This crystalline mineral substance reflects a great deal of the light but, at the same time. is translucent and somewhat transparent so that the color of the underlying bonding layer is revealed to enhance the beauty and appearance of the roofing. Moreover it filters out actinic rays which are a cause of deterioration of roofing materials. Some of the sand grains may be entirely embedded in and coated by pressing them into the bonding layer during manufacture of the shingle, but preferably the surfacing layer of sand grains is only partially embedded therein. The projecting points of sand grains afford a protection from the abrading action of driving storms or sliding snow and ice to which all roofs are sub- Ject to thereby retain the gloss and freshness of the bonding layer which would otherwise become dulled. In the preferred type of roofing, enough sand 'is therefore used to form a substantially continuous layer for its outer surface. The surface which is exposed to the weather thereby becomes a silica surface which is one of the most weather resistant surfaces known. The appearance of the roofing then is due to the color of the pigment or dye in the bonding layer, and the gloss of the bonding layer combined with the transparency and reflectivity of the sand.

With a sand coating and intermediate bond applied to slate-asphalt-felt base the small sand granules get down in between the larger slate particles. This has a decidedly stiffening effect on the roofing in addition to the stiffening effect of the bonding agent. A felt base shingle tends to curl up under the force of the wind or the like to compress the upper surface; but with the spaces between the slate pieces filled with small sand granules there is less opportunity for the pieces of slate to approach each other and the shingle is thereby stiffened. The stiffening effect is further increased by the bonding agent particularly when of the resinous type heretofore described.

These, and other objects and features of the invention will more fully appear from the following descrlption and the accompanying drawing which, however, must be considered as merely illustrating and in no way limiting the invention, to the embodiment shown and described.

For the purpose of illustrating the invention. a felt base shingle is shown on the accompanying drawing, it being understood that the invention may be applied to shingles of other materials and to other forms of roofing materials such as roll or strip roofing. In the drawing:

Fig. 1 is a perspective view of one form of a finished shingle;

Fig. 2 is an enlarged detailed section through the coating and a part of the body of the shingle shown in Fig. 1;

Fig. 3 is a perspective view of the under-side of the shingle of Fig. 1, illustrating the way in which a reinforcing strip can be made part of the edge of the shingle;

Fig.4 is a view similar to Fig. 3 but showing the shingle before a forward edge of a flap made part of the shingle'blank has been folded .to form the reinforcing strip; and

Fig. 5 is a section on line 5-5 of Fi 3. The body 2 of the shingle illustrated is of felt whichmay be in the form of layers 4. Follow-- ,ing the usual procedure the .surface portion of the body 2, can be impregnated with a thinly fluid or low melting point asphalt 6, and a layer 8, of heavier or higher melting point asphalt is applied on the surface of the body. Where the shingle body is not specially impregnated with .an asphalt-6, impregnationoccurs when the asphalt layer 8 is applied on the surface of the shingle. Rather large pieces ill, of slate, for instance, pieces about 1*; of an inch or somewhat larger in breadth are thereupon applied as usual to the asphalt layer 8. Up to this point the practice customarily followed in the manufacture of felt base rooiings is applied. a

A bonding layer I! of the nature hereindescribed-is applied over the slate pieces l0 and exposed portions of the asphalt layer 8. For example the bonding agent can be a synthetic resin.obtained by reacting a phenyl-substituted phenol with an aldehyde and thereafter digested with tungoil, or tung oil and linseed oil. The bonding agent is preferably dissolved in a suitable volatile solvent such as mineral spirits or .others as previously mentioned, so that the bonding agent not only coats-the base of slate but works down into the crevices and contacts 2.

with the asphalt layer 8. The solvent also softens somewhat theexposed portions of the asphalt-so that the resin forms a substantial union with the asphaltbut on account oftherestricted areas of contact caused by the interposed slate particles neither the asphalt nor the resin bleed materially into each other. The resulting shingle is one which has a surface completely covered with a continuous impervious non-softening film, modified by color pigments or the'like.

In the manufacture of the shingle the asphalt layer 8 is applied to the bodywhile the asphalt, and sometimes the body, are warm enough so that the asphalt will'run, whereupon the pieces of slate are spread over the asphalt, and the shingle is passed in contact with rollers,- which cause the slate pieces to embed themselves inthe -asphalt layer 8. Although the bonding or film-forming agent may .be applied to a cold shingle, it is deemed preferable that the shingle I be somewhat warm; The hot and somewhat soft:

' exposed area. This leaves the majority of the but only partially embedded. With granules projecting above the bonding agent surface there is no tendency for shingles to stick together, even though one is stacked on top of another unexposed area in.a pliablecondition to mold itself to -the roof deck and seal-the roof from driving rain. However, the entire shingle sur face may be coated if desired.

If desired, the shingle may be used with the film as the exposed surface but preferably relatively small particles or granules ll, of silica sand, quartz sand, or other mineral substance, or ground'glass are embedded in the resin. These are applied before all of the solvent has left the agent eitherby driving them into the resin,

of slate and even partially into the asphalt in v the crevices between the pieces of slate. The granuleswithin the agent are therefore completelycoyered by it and firmly bonded together thereby when it hardens. The resulting article is a base carrying an asphalti'c covering with large and small granules all bonded and ce-. mented together into a solid mass by the bonding material with sand granules forming an outermost layer, preferably not entirely coated as they come from the machine before the agent is, dry. This is highly desirable from a manufacturing point of view as it removes the necessity of waiting for the bonding agent to dry before the shingles are stacked or bundled. "Different color effects maybe obtained, if de sired, by forming rows or other designs of translucent, transparent or colored sand particles.

' Sand grains previously dyed, coated or otherwise colored may be used. Thecolored coated sandgrains mayeasily be produced by thoroughly mixing. the sand with colored weather resistant agents ofthe types previously described herein. Enough sand can be so mixed to form a plastic mass which is then rolled relatively thin-and permitted to harden, after which 'it' is crushed and screened to obtain the colored granules of- J the desired size.

by the sand particles lying between the larger pieces of slate is thus obtained, further increase are held together with a material .which is 'unv affected by the weather and will not gradually yield or rub oil as will soft asphalt, nor will it strip in cold weather as will'hard asphalt.

The coated area may be only the edges" and in the stiffness of the shingle, particularly'at the exposed butt edge, is secured by fastening a re- I inforcing strip It, to the edge. The reinforcing strip furthermore gives the appearance of a much thicker shingle. For convenience in manufacture, and tomost effectively seal the'butt edge H, the reinforcing strip It, may be a part of the shingle body which is folded under so as to lie flat preferably cut into or otherwise formed in, the body of the shingle" across the line 20, on. which the strip I8, is folded. The elongated scores the surface-which is exposed when the shingle preferably do not extend entirely through the shingle body, in order not to destroy the surface of the felt, and. lie at a slant to theline of fold 2|.

The angular position of the scores ll, renders the shingle body somewhat yieldabie on the line of fold but yet the scores do not weaken the body too much as they would if parallel to the line of fold. Scores which lie at a right angle to the line of fold are not desirable because they do not overcome the tendency of the outer surface to break when the fold is made and to spring back into the flat position. The slanting scores combine the advantages of'both of the other types of scores and lessen the tension of the folded fibers so that there is less tension on the bonding material which bonds the reinforcing strip to the shingle. It will readily be understood that the reinforcing strip it, need not be a folded part of the shingle body but may be a separate piece of material. However, it is preferably bonded to the shingle in the manner just described.

A bonding medium preferably of the synthetic resin type is used to fasten the reinforcing strip It, in position against the under surface of the shingle. The binder is applied to the two adja cent surfaces in a thinly fluid condition so that it runs into the openings of the scores l8 and spreads out into the body of both the shingle and reinforcing strip, as is shown in Fig. 5. The binder thoroughly impregnates and holds fast to the fibers of the body and enters into the interstices thereof, or bonds with the asphalt wherever the felt is impregnated with asphalt, and thereafter hardens, forming what may conveniently be likened to mushroom heads or anchors 22, within the bodies of both the shingle and the reinforcing strip. The heads 22, are joined by solid masses or rods 24, of binder thus firmly bonding the reinforcing strip to the shingle. In addition there is the usual junction formed by the layer 28, of binder between the contacting surfaces. The bonds 24, occur at the points where the scores l8, cross each other, as is shown in Fig. 3.

- Although'the previous description has dealt specifically with the application of a coating to an asphalt and felt shingle, it is obvious that the invention may beapplied to other articles and materials, for instance strip materials, as well as wood and cement shingles or tiles or siding and the like which are comprised in the term "roofing." A resin-containing coating as described either colored or not and with or without a sand facing, greatly improves the appearance and/or life of wood and cement roofings, as it more or less enters the pores of the wood or cement and forms an extremely tight bond as well as a continuous durable film to seal them from entry of moisture. etc. When wood shingles are exposed to rain, the moisture enters the shingle causing it to split. check and curl and eventually to decay, while in the case of cement-asbestos shingles the absorption of moisture weakens the cementasbestos structure. Moreover the usual colored shingles of either wood or cement are very costly and the colors do not last. 7 In the case of colored cement shingles the expensive pigments are mixed with the plastic cement magma and are distributed throughout it, but the colors fade from the outer surface and the shingles have a poor appearance although the colors may be brilliant just under the surface. With a colored resinous coating, however, the colors are on only the exposed surface where they are needed and they will hold their brilliancy because they are protected both by the binder from the weather and the active rays of the sun as well as by sand when so surfaced. It is therefore recognized that these and various other modifications and applications may be made and it is to be understood that the invention is to be construed as broadly as the claims. taken in conjunction with the prior art, may allow.

What is claimed is:

1. Roofing comprising a body formed with a fold and having a plurality of scores on the adjacent portions of the fold and crossing the line of fold, said scores being disposed obliquely to the line of fold with the scores on the adjacent contacting surfaces criss-crossing.

2. Roofing comprising a base having an inturncd edge to form a reinforcing strip and scores cut across the line of fold on the contacting surfaces, said scores being disposed obliquely to the line of fold with the scores on adjacent contacting surfaces criss-crossing, and a bonding medium extending into the scores for securing the strip to the base.

CLARA E. JOHNSTON. Administmfrix of the Estate of Robert T. Johnston, Deceased.

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