Abstract:
Compositions of an aqueous emulsion of a bitumen and a drilling mud bentonite are especially adapted for cold application and provide many advantages.

Description:
BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     The use of bitumens (i.e., asphalt and cold tar) for roofing and other applications is well known. The advantage of cold applicability, e.g. on flat roofs so as to avoid working with a hot material at a job site is also well known. It is desirable to achieve improved formulations to increase the economy of the effort and improve the properties of the treated materials. 
     2. Description of the Background Art 
     U.S. Pat. No. 5,840,105 discloses the use of bentonite from drilling muds for sodium silicate and fine mica coatings. U.S. Pat. No. 5,970,893 discloses clay liners as barriers for the containment of pollutants or toxic waste. 
     SUMMARY OF THE INVENTION 
     It has now been found that aqueous emulsions of specific drilling mud bentonite with bitumen provide formulations that have markedly decreased costs and markedly improved properties for cold application. It is surprising to find that this specialty bentonite provides such superior results outside the petroleum drilling mud field. 
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT 
     The drilling bentonite mud conform to American Petroleum Institute (API) specification 13A which yield approximately 120 to 280 barrels of 15 centiposes mud per ton, preferably about 180 to 240 barrels per ton. Typical bentonites with their trademarks Hydraul-EZ; KWIK-THIK and Super-Gel-X. 
     Asphalt is a bitumen derived from a number of materials such as, for example, petroleum, shale oil, gilsonite and the like. Asphalt is a thick, viscous mixture of compounds such as, for example, paraffinic, cycloaliphatic and aromatic hydrocarbon and lesser amounts of heterocylic compound containing sulfur, nitrogen or oxygen. Although asphalt can be obtained from natural sources, it is primarily derived as the residue of petroleum distillation (e.g., the bottom product of a vacuum distillation of a topped crude). Although this invention is not limited thereto, it is preferred that the asphalt have a penetration (ASTM D5) at 77 degrees F. dmm: ranging from about 5 to about 300 dmm and more preferably from about 50 to about 200 dmm and conform in general to specification outlined by ASTM D312, D946 and/or D449. 
     The asphalt can be utilized in the form of an aqueous emulsion readily available in the trade, see ASTM D1227, and thus has a water content of about 40-60 wt.%. 
     Coal tar is a bitumen derived from crude coal tar, water gas tar, oil gas tar or from combination of such tars with their constituents. Coal tar is a black, viscous, naphthalene-like odor, amorphous residue mainly from distillation of coal. The majority of its composition is polynuclear aromatic compounds such a aromatic hydrocarbon, naphthalenic, phenolic, anthracenic, quinolinic compound with trace of insoluble materials. Different grades have different float tests and softening points. Although this invention is not constrained to, the preferred coal tars have a float test at 122 degrees F., seconds: ranging from about 75 to bout 230 seconds and more preferably from about 180 to 220 seconds and conform in general to specification outlined by RT-10 (Road tar-10) RT-11 and RT-12 in ASTM D490. 
     The coal tar can be utilized in the form of an aqueous emulsion readily available in the trade (see Federal Specification RP 355e) and thus has a maximum water content of about 53 wt. %. 
     At least one of asphalt and coal tar are employed, depending on desired final product. 
     Subject to the foregoing, the ranges of components are about: 
     
       
         
               
               
             
               
               
               
             
           
               
                   
                   
               
               
                   
                 wt. % of 
               
               
                   
                 Emulsion 
               
               
                   
                   
               
             
             
               
                   
               
             
          
           
               
                   
                 Bitumen 
                 5-50 
               
               
                   
                 Asphalt and/or Coal tar 
                 5-50 
               
               
                   
                 Drilling Mud Bentonite 
                 3-8  
               
               
                   
                 Water 
                 15-55  
               
               
                   
                 Specialty Additives 
                 0.1-2   
               
               
                   
                   
               
             
          
         
       
     
     The specialty additives include e.g. mineral salt to increase emulsability; complex organic acids such as acetic acid etc. to bring the pH to a range of 4-6, also to enhance emulsability, and polymers singly or in combination for a similar purpose, e.g. acrylic, vinyl polystyrene, etc. 
     Inert fillers such as pulverized limestone powder, talc, perlite, etc., can be used in an amount of about 0 to 50, wt. %. 
     Inert fibers such as cellulosic, asbestos, fiberglass, polyolefin, etc. can be used in an amount of from about 0-25 wt. %. 
     It should be noted that the amount of water listed above is in addition to that derived from asphalt and cold tar aqueous emulsions employed. 
     The process of producing the aqueous emulsified bitumens are as follows: 
     1. 3%-5% bentonite is added into water in the mixer. When dispersed after mixing, it turns into a slurry. The slurry temperature between 60-120 degrees Fahrenheit is preferred. 
     2. The bitumens (asphalt coal tar or both) are heated to 250-350 degree Fahrenheit. 
     3. The slurry and bitumen is then combined into a mixture of emulsified bitumen through process such as dispersing type (batch to batch) or colloid mill type (continuous) system. 
     The specifications of emulsified asphalt meet ASTM D 1227, Standard Specification for Emulsified Asphalt Used as Protective Coating for Roofing. The Specifications of emulsified coal tar meets ASTM D 5727 Standard Specification for Emulsified Refined Coal Tar and ASTM D3320 Standard Specification for Emulsified Coal-Tar Pitch. 
    
    
     This invention will be better understood by reference to the following examples: 
     EXAMPLE 1 
     The Preparation of Emulsified Asphalt Using Bentonite Slurry With AC-250 Type Asphalt 
     
       
         
               
               
             
               
               
               
             
           
               
                   
                   
               
               
                   
                 % By weight 
               
               
                   
                   
               
             
             
               
                   
               
             
          
           
               
                   
                 Water 
                 51.0 
               
               
                   
                 Drilling Mud Bentonite 
                 1.5-2.5 
               
               
                   
                 AC-20 Asphalt (115 deg. F. melting point) 
                 46.3-47.3 
               
               
                   
                 Ph Adjuster 
                  0.2 
               
               
                   
                   
                 100.0  
               
               
                   
                   
               
             
          
         
       
     
     EXAMPLE 2 
     The Preparation of Emulsified Asphalt Using Bentonite Slurry With PPA Hard Asphalt. 
     
       
         
               
               
             
               
               
               
             
           
               
                   
                   
               
               
                   
                 % By weight 
               
               
                   
                   
               
             
             
               
                   
               
             
          
           
               
                   
                 Water 
                 51.0 
               
               
                   
                 Drilling Mud Bentonite Slurry 
                 2.5-3.5 
               
               
                   
                 Hard PPA Asphalt (185 deg. F. melting point) 
                 45.3-46.3 
               
               
                   
                 Ph Adjuster 
                  0.2 
               
               
                   
                   
                 100.0  
               
               
                   
                   
               
             
          
         
       
     
     EXAMPLE 3 
     Preparation of Emulsified Coal Tar Using Bentonite Slurry. 
     
       
         
               
               
             
               
               
               
             
           
               
                   
                   
               
               
                   
                 % By weight 
               
               
                   
                   
               
             
             
               
                   
               
             
          
           
               
                   
                 Water 
                 52.0 
               
               
                   
                 Drilling Mud Bentonite 
                 7.0 
               
               
                   
                 Coal Tar 
                 41.0 
               
               
                   
                   
                 100.0 
               
               
                   
                   
               
             
          
         
       
     
     EXAMPLE 4 
     Preparation of Emulsified Asphalt Using Polymer(s) Added Asphalt and Bentonite Slurry. 
     
       
         
               
               
             
               
               
               
             
           
               
                   
                   
               
               
                   
                 % By weight 
               
               
                   
                   
               
             
             
               
                   
               
             
          
           
               
                   
                 Water 
                 52.0 
               
               
                   
                 Drilling Mud Bentonite 
                 2.5-3.5 
               
               
                   
                 Asphalt with Polymer(s) 
                 44.3-45.3 
               
               
                   
                 Ph Adjusters 
                  0.2 
               
               
                   
                   
                 100.0  
               
               
                   
                   
               
             
          
         
       
     
     The following examples employ the drilling mud bentonite and bitumen of preceding examples. 
     EXAMPLE 5 
     Asphalt Emulsion Roofing Composition. 
     
       
         
               
               
             
               
               
               
             
           
               
                   
                   
               
               
                   
                 % By weight 
               
               
                   
                   
               
             
             
               
                   
               
             
          
           
               
                   
                 Example 1 or 2 
                  20-60 
               
               
                   
                 Reinforced Fibers 
                 0.5-10 
               
               
                   
                 Fillers/Extenders 
                 1.0-20 
               
               
                   
                 Water 
                 0.0-20 
               
               
                   
                 Specialty Additives 
                 0.1-10 
               
               
                   
                   
               
             
          
         
       
     
     EXAMPLE 6 
     Asphalt Emulsion Reflective Aluminum Composition 
     
       
         
               
               
             
               
               
               
             
           
               
                   
                   
               
               
                   
                 % By weight 
               
               
                   
                   
               
             
             
               
                   
               
             
          
           
               
                   
                 Example 1, 2 or 3 
                 20-60  
               
               
                   
                 Special treated aluminum paste 
                 5-15 
               
               
                   
                 Fillers/Extenders 
                 2-20 
               
               
                   
                 Water 
                 3-20 
               
               
                   
                 Specialty additives 
                 0.2-5   
               
               
                   
                   
               
             
          
         
       
     
     EXAMPLE 7 
     Bituminous Black Top Driveway Sealers 
     
       
         
               
               
             
               
               
               
             
           
               
                   
                   
               
               
                   
                 % By weight 
               
               
                   
                   
               
             
             
               
                   
               
             
          
           
               
                   
                 Example 1 to 4 
                 15-50 
               
               
                   
                 Fillers/Extenders 
                  2-20 
               
               
                   
                 Sand 
                 0.5-20  
               
               
                   
                 Water 
                 10-40 
               
               
                   
                 Specialty Additives 
                 0.2-5   
               
               
                   
                   
               
             
          
         
       
     
     EXAMPLE 8 
     Bituminous Patching Compound 
     
       
         
               
               
             
               
               
               
             
           
               
                   
                   
               
               
                   
                 % By weight 
               
               
                   
                   
               
             
             
               
                   
               
             
          
           
               
                   
                 Example 1 to 4 
                 50-80 
               
               
                   
                 Fillers/Extenders 
                  5-15 
               
               
                   
                 Fibers 
                 1-5 
               
               
                   
                 Water 
                  1-10 
               
               
                   
                 Specialty Additives 
                 0.2-2.0 
               
               
                   
                   
               
             
          
         
       
     
     EXAMPLE 9 
     Bituminous Bonding Adhesives 
     
       
         
               
               
             
               
               
               
             
           
               
                   
                   
               
               
                   
                 % By weight 
               
               
                   
                   
               
             
             
               
                   
               
             
          
           
               
                   
                 Example 1 to 4 
                 30-60  
               
               
                   
                 Adhesive Enhancer Polymer Resins 
                 1-20 
               
               
                   
                 Water 
                 1-10 
               
               
                   
                 Fillers/Extenders 
                 2-10 
               
               
                   
                 Fibers 
                 0.5-5   
               
               
                   
                 Specialty Additives 
                 0.2-5   
               
               
                   
                   
               
             
          
         
       
     
     EXAMPLE 10 
     Bituminous Roof Mastic 
     
       
         
               
               
             
               
               
               
             
           
               
                   
                   
               
               
                   
                 % By weight 
               
               
                   
                   
               
             
             
               
                   
               
             
          
           
               
                   
                 Example 1 to 4 
                 40-70 
               
               
                   
                 Bituminous Cutback Solvent 
                  0-30 
               
               
                   
                 Fillers/Extenders 
                  2-20 
               
               
                   
                 Specialty Additives 
                 0.5-30  
               
               
                   
                   
               
             
          
         
       
     
     EXAMPLE 11 
     Bituminous Waterproofer or Vapor Barriers 
     
       
         
               
               
             
               
               
               
             
           
               
                   
                   
               
               
                   
                 % By weight 
               
               
                   
                   
               
             
             
               
                   
               
             
          
           
               
                   
                 Example 1 to 4 
                 70-90  
               
               
                   
                 Wax Emulsion 
                 0-15 
               
               
                   
                 Silicon Emulsion 
                 0-15 
               
               
                   
                 Water 
                 0-10 
               
               
                   
                 Specialty Additives 
                 0.1-5   
               
               
                   
                   
               
             
          
         
       
     
     EXAMPLE 12 
     Primer/Weed Controller/Road Dust Suppressor 
     
       
         
               
               
             
               
               
               
             
           
               
                   
                   
               
               
                   
                 % By weight 
               
               
                   
                   
               
             
             
               
                   
               
             
          
           
               
                   
                 Example 1 to 4 
                 10-50 
               
               
                   
                 Water 
                 10-60 
               
               
                   
                 Surface Active Additives 
                 0.3-3   
               
               
                   
                 Specialty Additives 
                 0.1-6   
               
               
                   
                   
               
             
          
         
       
     
     The advantages of this invention will be apparent to the skilled in the art higher solids emulsions, higher melt point when using harder asphalts; no coalescing solvent needed despite high glass transition temperature; no water sensitive surface active agents needed; superior binding and wetting of pigments; fibers and fillers; non porous; harder films; no setting or separation in package; excellent wetting of substrate and adhesion to old substrates; easier more uniform application due to their thixotropic nature; fast dry; superior color wetness); superior hydrophobic nature, superior abrasion resistance; superior “track” resistance (less softening when hot); much longer useful life and weather resistance; presents good sealed surface for recoat when necessary. 
     For economy of operation and ease of use, the compositions are transported and usually marketed as concentrates. They can then be diluted with other materials for related applications. The methods of application are well-known and need not be elaborated here. 
     The present disclosure includes that contained in the appended claims, as well as that of the foregoing description. Although this invention has been described in its preferred form with a certain degree of particularity, it is understood that the present disclosure of the preferred form has been made only by way of example and that numerous changes in the details of construction and the combination and arrangement of parts may be resorted to without departing from the spirit and scope of the invention. 
     Now that the invention has been described,