Highly-filled Sealant Composition with Polymer-Modified Binder
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Solution Overview
Problem
Existing waterproofing and sealant compositions face challenges in achieving high filler loadings while maintaining low temperature flexibility and ease of manufacturing and application, due to the limitations of asphalt/rubber compositions, which become difficult to handle with increased filler content.
Innovation Solution
A sealant composition comprising a binder with an elastomeric material, residual pitch product, and optional asphalt, microcrystalline wax, and oil, allowing for higher filler material volumes without increasing viscosity, thereby maintaining flexibility and ease of application.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Quantity of substance
If additional filler material is added to asphalt/rubber compositions to reduce cost, then material cost decreases, but the composition becomes more difficult to manufacture and apply
Solution Approach 1:
The patent changes the chemical composition parameters of the binder by introducing a specific polymer-modified asphalt binder with controlled molecular weight and composition. This modified binder maintains fluidity and workability even at high filler loadings (up to 70% by weight), thereby enabling cost reduction through increased filler content without compromising manufacturing ease or application performance
2Quantity of substance
If additional filler material is added to asphalt/rubber compositions to reduce cost, then material cost decreases, but the composition becomes difficult or impossible to effectively apply
Solution Approach 1:
The patent modifies the binder parameters by using a polymer-modified asphalt composition with specific viscosity characteristics and flexibility properties. This allows the composition to maintain adequate workability and application characteristics even with high filler loadings, enabling effective application while reducing material costs through increased filler content
3Reliability
If filler material is added to enhance certain properties of the coating, then coating performance improves, but the composition becomes more difficult to manufacture and apply
Solution Approach 1:
The patent optimizes the binder parameters by selecting a polymer-modified asphalt with specific molecular weight, composition, and viscosity characteristics. This optimized binder serves as an effective dispersion medium that maintains coating performance and reliability even at high filler loadings, while avoiding the manufacturing difficulties that arise with conventional asphalt/rubber compositions
4Reliability
If asphalt/rubber compositions are used to provide weather resistance, then weather resistance improves, but the composition becomes more expensive due to petroleum cost increases
Solution Approach 1:
The patent changes the composition parameters by using a polymer-modified asphalt binder that achieves equivalent or superior weather resistance at lower asphalt content. The modified binder provides enhanced flexibility and durability, allowing reduction of expensive petroleum-based asphalt while maintaining or improving weather resistance performance
Solution Approach 2:
The patent employs a composite binder system combining polymer modifiers with asphalt to create a material that provides weather resistance more efficiently than pure asphalt/rubber compositions. This composite approach reduces dependence on expensive petroleum products while maintaining protective performance
Data Source
AI summary
A sealant composition comprising a binder and a filler material. The binder comprising a residual pitch product and an elastomeric material and, optionally, asphalt, a microcrystalline wax, and/or oil. The filler material is present in an amount of between about 11 vol. % and about 67 vol. % of the sealant composition. In one embodiment, the filler material is present in an amount of between about 25 wt. % and about 70 wt. % of the sealant composition.