Self-healing impact resistant roofing materials and methods of making thereof

Abstract

This invention, in embodiments, relates to a roofing material comprising (a) a substrate having a top surface and a back surface, (b) a plurality of self-healing particles embedded into the substrate, and (c) a coating applied onto the substrate having the plurality of self-healing particles embedded therein, to provide a coated substrate. The plurality of self-healing particles can be embedded into the top surface and/or the back surface of the substrate. The roofing material can further include a plurality of roofing granules applied to a top surface of the coating of the coated substrate. This invention, in embodiments, further relates to a method of preparing such a roofing material.

21 . A roofing material comprising:
 (a) a substrate having a top surface and a back surface, the substrate being uncoated and comprising one of a fiberglass mat, a polyester mat, a scrim, or a combination thereof;   (b) a plurality of self-healing particles embedded into the back surface of the uncoated substrate, such that the plurality of self-healing particles directly contact the back surface of the uncoated substrate, wherein each self-healing particle of the plurality of self-healing particles comprises an external shell and a film-forming material within the external shell; and   (c) a single coating applied onto the back surface of the substrate having the plurality of self-healing particles embedded therein, to provide a coated substrate, wherein the coating comprises one of an asphaltic coating, a non-asphaltic coating, a polymer-modified asphaltic coating, or a combination thereof.   
     
     
         22 . The roofing material according to  claim 21 , wherein the roofing material further includes a plurality of roofing granules applied to a top surface of the coating of the coated substrate. 
     
     
         23 . The roofing material according to  claim 21 , wherein the self-healing particles further comprise one or more additives. 
     
     
         24 . The roofing material according to  claim 21 , wherein the back surface of the substrate has an average surface coverage amount of the plurality of self-healing particles of between 50% and 100%. 
     
     
         25 . The roofing material according to  claim 21 , wherein the back surface of the substrate has an average surface coverage amount of the plurality of self-healing particles of between 70% and 100%. 
     
     
         26 . The roofing material according to  claim 21 , wherein the back surface of the substrate has an average surface coverage amount of the plurality of self-healing particles of greater than 50%. 
     
     
         27 . The roofing material according to  claim 21 , wherein the back surface of the substrate has an average surface coverage amount of the plurality of self-healing particles of greater than 75%. 
     
     
         28 . The roofing material according to  claim 21 , wherein the roofing material having the plurality of self-healing particles achieves one of a Class 3 rating or a Class 4 rating for impact resistance, according to UL 2218. 
     
     
         29 . The roofing material according to  claim 21 , wherein the roofing material is one of a roofing shingle, a roofing membrane, and a roofing tile. 
     
     
         30 . The roofing material according to  claim 21 , wherein the roofing material is one of (i) an asphaltic shingle, (ii) a non-asphaltic shingle, and (ii) a polymer-modified asphalt shingle. 
     
     
         31 . The roofing material according to  claim 21 , wherein the roofing material exhibits an improved impact resistance as compared to a roofing material prepared without self-healing particles. 
     
     
         32 . The roofing material according to  claim 21 , wherein one or more self-healing particles of the plurality of self-healing particles is configured to rupture upon impact to the substrate, to thereby dispense the film-forming material to help repair any damage to the roofing material.