Roofing product including roofing-grade asphalt mixture and methods of making the roofing product and the roofing-grade asphalt mixture
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Solution Overview
Problem
Conventional roofing-grade asphalt mixtures often rely on petroleum-based asphalt, which is non-renewable and can have unsuitable characteristics, leading to waste and environmental concerns, while also being susceptible to supply fluctuations and high production costs.
Innovation Solution
The use of a bio-asphalt, partially oxidized from bio-source materials like recycled vegetable oil, combined with other bitumen source materials to create a roofing-grade asphalt mixture with improved softening points, penetration distances, and viscosities, allowing for the incorporation of off-spec bitumen sources and reducing environmental impact.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If petroleum-based asphalt is used in roofing mixtures, then production costs are high and supply is subject to fluctuations, but the asphalt provides consistent performance characteristics
Solution Approach 1:
The patent changes the chemical composition parameters of the asphalt by incorporating bio-asphalt (5-50% by weight) and oxidized asphalt (0-40% by weight) alongside petroleum-based asphalt. This parameter modification allows the use of alternative, more stable, and potentially lower-cost materials while maintaining the required performance characteristics through controlled oxidation and blending ratios.
Solution Approach 2:
The patent creates a composite asphalt material system combining four distinct components: petroleum-based asphalt, bio-asphalt, oxidized asphalt, and filler materials. This composite approach diversifies the material supply base, reducing dependence on any single source while achieving consistent performance through the synergistic interaction of components with complementary properties.
2Reliability
If conventional asphalt mixtures are used, then performance specifications can be met, but environmental impact is negative and waste is generated
Solution Approach 1:
The patent modifies the chemical composition by incorporating bio-asphalt derived from renewable resources (5-50% by weight) and controlled oxidation products. This changes the environmental profile of the asphalt mixture while maintaining performance specifications through careful control of oxidation level (0-40%) and blending ratios, reducing dependence on non-renewable petroleum-based materials.
Solution Approach 2:
The patent recovers and utilizes oxidized asphalt that would otherwise be considered waste or off-spec material. By intentionally controlling the oxidation process and incorporating oxidized asphalt (0-40% by weight) into the mixture, the patent transforms a waste stream into a valuable component that contributes to the final product's performance while reducing environmental impact.
3Ease of manufacture
If off-spec bitumen sources are incorporated, then supply costs are stabilized and waste is reduced, but the asphalt mixture may not meet performance specifications
Solution Approach 1:
The patent systematically adjusts multiple composition parameters to compensate for variations in off-spec bitumen materials. By controlling the ratios of bio-asphalt (5-50%), oxidized asphalt (0-40%), and filler materials (10-50%), the patent creates a buffered system where the collective properties of the mixture maintain performance specifications even when individual components vary.
Solution Approach 2:
The patent employs a multi-component composite system where petroleum-based asphalt, bio-asphalt, oxidized asphalt, and filler materials work together to achieve consistent performance. This composite approach allows the use of off-spec or variable-quality materials while the overall mixture maintains required specifications through the synergistic contribution of each component.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach enables the production of roofing products that meet performance specifications while utilizing renewable resources, reducing waste, and stabilizing supply costs, as the bio-asphalt mixture can incorporate a variety of bitumen sources, including off-spec materials, thus offering a more sustainable and cost-effective solution.
Implementation Method 1
The use of a bio-asphalt, partially oxidized from bio-source materials like recycled vegetable oil
Data Source
AI summary
A method of forming a roofing-grade asphalt mixture can include mixing a bio-asphalt including a partially oxidized bio-source material, a bitumen source material different from the bio-asphalt, and particles to form the roofing-grade asphalt mixture. In an embodiment, the bitumen source material can have a softening point of at least approximately 102° C. and a penetration distance no greater than approximately 20 dmm. In another embodiment, the roofing-grade asphalt mixture can have a softening point of at least approximately 104° C., a penetration distance no greater than approximately 12 dmm, a viscosity of at least approximately 3000 cps at a temperature of 177° C., or any combination thereof. The roofing-grade asphalt mixture can be applied to a base material to form a roofing product.