Coating for granulated products to improve granule adhesion, staining, and tracking

Abstract

A building material product and a method of making building material products, having increased resistance to granule rub off and staining. The building material product comprises a substrate having embedded granules and an acrylic latex coating positioned on the granules, where the polymer of the acrylic latex coating has the repeating structural unit [CH 2 —C(R 1 )(R 2 )], where R 1 is hydrogen or C 1 -C 8 alkyl; R 2 is hydrogen, cyano or —COOR; and R is a linear or branched hydrocarbon containing 1-22 carbon atoms, with the proviso that R 1 and R 2 are both not hydrogen. The method includes applying this acrylic latex water based composition to a granule embedded substrate.

1 . A building product comprising: 
 a substrate;    granules embedded in said substrate; and    an acrylic latex coating said granules, a polymer of said acrylic latex coating includes the repeating structural unit [CH 2 —C(R 1 )(R 2 )], where R 1  is hydrogen or C 1 -C 8  alkyl; R 2  is hydrogen, cyano or —COOR, where R is a linear branched hydrocarbon containing 1-22 carbon atoms, with the proviso that R 1  and R 2  are not both hydrogen.    
     
     
         2 . The building product of  claim 1  wherein said acrylic latex coating comprises a homopolymer or copolymer of methacrylic acid, a methacrylate ester, an acrylate ester or acrylonitrile.  
     
     
         3 . The building product of  claim 1  wherein said acrylic latex coating is applied such that its concentration is in the range of between about 0.5 grams/square foot and about 20 grams/square foot.  
     
     
         4 . The building product of  claim 3  wherein said acrylic latex coating concentration is in the range of between about 1 grams/square foot and about 10 grams per square foot.  
     
     
         5 . The building product of  claim 1  wherein said granules are greenstone, nephelene syeniate, common gravel, slate, ganister, quartz, sand, quartzite, greystone, argillite, coal slag, copper slag, or nickel slag.  
     
     
         6 . The building product of  claim 5  wherein said granules are coated with a ceramic coating comprising a reaction product of an alkali metal silicate and an aluminosilicate.  
     
     
         7 . The building product of  claim 5  wherein said granules are encapsulated in a coating comprising said polymer.  
     
     
         8 . The building product of  claim 1  wherein said substrate is coated with an asphalt coating.  
     
     
         9 . The building product of  claim 8  wherein said building product is rolled roofing and said asphalt coating is a modified bitumen having a polymer additive.  
     
     
         10 . The building product of  claim 8  wherein said building material product is a shingle and said asphalt coating is a non-modified bitumen.  
     
     
         11 . The building product of  claim 1  wherein said substrate comprises a glass fiber web or polymeric web bound by a resin binder.  
     
     
         12 . The building product of  claim 11  wherein said resin binder comprises a urea-formaldehyde resin, a phenol-formaldehyde resin, a phenolic resin, polyvinyl alcohol, polyvinyl acetate, an acrylic resin, polyvinyl acetate, or bone glue.  
     
     
         13 . The building product of  claim 1  wherein said substrate comprises a plastic material.  
     
     
         14 . The building product of  claim 13  wherein said plastic material comprises polyolefin, polycarbonate, polyvinyl chloride, polyvinyl flouride, acrylic resins, acrylonitrile, butadiene, styrene, copolymers of acrylonitrile, butadiene or styrene.  
     
     
         15 . The building of product of  claim 14  wherein said substrate further comprises a filler.  
     
     
         16 . The building product of  claim 15  wherein said filler comprises calcium carbonate, talc, asbestos, silicates, or wood flour.  
     
     
         17 . The building product of  claim 1  wherein said substrate comprises glass fibers, polyester fibers, cellulosic fibers, asbestos, steel fibers, alumina fibers, ceramic fibers, nylon fibers, graphite fibers, wool fibers, boron fibers, carbon fibers, jute fibers, polyolefin fibers, polystyrene fibers, acrylic fibers, phenolformaldehyde resin fibers, aromatic polyamide fibers, aliphatic polyamide fibers, polyacrylamide fibers, polyacrylimide fibers or mixtures thereof.  
     
     
         18 . The building product of  claim 1  wherein said building product is flexible flooring, floor tiles, siding, roofing panels, rolled roofing, or roofing shingles.  
     
     
         19 . A method for coating a building product comprising applying an acrylic latex water based composition, a polymer of said acrylic latex coating including the repeating structural unit [CH 2 —C(R 1 )(R 2 )], where R 1  is hydrogen or R is a linear or branched hydrocarbon containing 1-22 carbon atoms, with the proviso that R 1  and R 2  are both not hydrogen, to a substrate on which granules are embedded.  
     
     
         20 . The method of  claim 19  wherein said acrylic latex water based composition comprises between about 10% and about 90% polymer and about 90% to about 10% water, said percentages being by weight based on the total weight of the composition.  
     
     
         21 . The method of  claim 19  wherein said polymer comprises a homopolymer or a copolymer of methacrylic acid, a methacrylate ester, an acrylate ester or acrylonitrile.  
     
     
         22 . The method of  claim 19  wherein said acrylic latex water based composition comprises less than 200 ppm styrene and 200 ppm butyl acrylate.  
     
     
         23 . The method of  claim 19  wherein said acrylic latex water based composition is applied by dipping, roller application brushing, or spraying.  
     
     
         24 . The method of  claim 19  wherein said acrylic latex water based composition is applied such that said polymer is present on said substrate in an amount ranging from about 0.5 g/ft 2  to about 20 g/ft 2 .  
     
     
         25 . The method of  claim 19  wherein said polymer is present in an amount ranging from about 1 g/ft 2  to about 10 g/ft 2 .  
     
     
         26 . The method of  claim 19  wherein said substrate further comprises asphalt.  
     
     
         27 . The method of  claim 26  wherein said asphalt comprises modified bitumen having a polymer additive.  
     
     
         28 . The method of  claim 26  wherein said asphalt comprises a non-modified asphalt.  
     
     
         29 . The method of  claim 19  wherein said substrate comprises polyolefin, polycarbonate, polyvinyl chloride, polyvinyl flouride, acrylic resins, acrylonitrile, butadiene, styrene, copolymers of acrylonitrile, butadiene or styrene.  
     
     
         30 . The method of  claim 29  wherein said substrate further comprises a filler.  
     
     
         31 . The method of  claim 30  wherein said filler comprises calcium carbonate, talc, asbestos, silicates, or wood flour.  
     
     
         32 . The method of  claim 19  wherein said substrate comprises glass fibers, polyester fibers, cellulosic fibers, asbestos, steel fibers, alumina fibers, ceramic fibers, nylon fibers, graphite fibers, wool fibers, boron fibers, carbon fibers, jute fibers, polyolefin fibers, polystyrene fibers, acrylic fibers, phenolformaldehyde resin fibers, aromatic and aliphatic polyamide fibers, polyacrylamide fibers, polyacrylimide fibers or mixtures thereof.  
     
     
         33 . The method of  claim 19  wherein said granules comprise greenstone, nephelene syeniate, common gravel, slate, ganister, quartz, sand, quartzite, greystone, argillite, coal slag, copper slag, or nickel slag.  
     
     
         34 . The method of  claim 33  wherein said granules are coated with said polymer prior to being embedded into said substrate.