U.S. patent application number 17/702307 was filed with the patent office on 2022-09-29 for roofing membrane.
The applicant listed for this patent is BMIC LLC. Invention is credited to Adem Chich, Yixi Xiao, Yan Zheng.
Application Number | 20220307263 17/702307 |
Document ID | / |
Family ID | 1000006273128 |
Filed Date | 2022-09-29 |
United States Patent
Application |
20220307263 |
Kind Code |
A1 |
Chich; Adem ; et
al. |
September 29, 2022 |
ROOFING MEMBRANE
Abstract
A roofing membrane includes a plurality of resins present in an
amount of 30 wt. % to 100 wt. % based on a total weight of the
roofing membrane. The plurality of resins include a first resin and
a second resin. The first resin includes a resin present in an
amount of 20 wt. % to 80 wt. % based on a total weight of the
plurality of resins in the roofing membrane; that is not moisture
curable; and that is cured. The second resin includes a resin
present in an amount of 20 wt. % to 80 wt. % based on the total
weight of the plurality of resins in the roofing membrane; that is
moisture curable; that is uncured; and includes silicon. The
roofing membrane is flexible. The roofing membrane, when exposed to
moisture, exhibits a tear strength that meets ASTM D6878.
Inventors: |
Chich; Adem; (Kearny,
NJ) ; Zheng; Yan; (Livingston, NJ) ; Xiao;
Yixi; (Edison, NJ) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
BMIC LLC |
Dallas |
TX |
US |
|
|
Family ID: |
1000006273128 |
Appl. No.: |
17/702307 |
Filed: |
March 23, 2022 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
63164946 |
Mar 23, 2021 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
D06N 2211/06 20130101;
D06N 5/00 20130101; D06N 2203/066 20130101; E04D 5/10 20130101 |
International
Class: |
E04D 5/10 20060101
E04D005/10; D06N 5/00 20060101 D06N005/00 |
Claims
1. A rolled material, comprising: a roofing membrane, comprising: a
plurality of resins present in an amount of 30 wt. % to 100 wt. %
based on a total weight of the roofing membrane, wherein the
plurality of resins comprise a first resin and a second resin;
wherein the first resin comprises a resin: present in an amount of
20 wt. % to 80 wt. % based on a total weight of the plurality of
resins in the roofing membrane; that is not moisture curable; and
that is cured; wherein the second resin comprises a resin: present
in an amount of 20 wt. % to 80 wt. % based on the total weight of
the plurality of resins in the roofing membrane; that is moisture
curable; that is uncured; and comprising silicon; wherein the
roofing membrane is flexible; wherein the roofing membrane, when
exposed to moisture, exhibits a tear strength that meets ASTM
D6878; and wherein the tear strength is 55 lbf to 140 lbf.
2. The rolled material of claim 1, further comprising a filler
present in an amount of 1 wt. % to 70 wt. % based on the total
weight of the roofing membrane.
3. The rolled material of claim 2, wherein the filler is selected
from the group consisting of amorphous silica, precipitated silica,
fumed silica, calcium carbonate, barium sulfate, alumina
trihydrate, glass power, glass sphere, aluminum silicate, carbon
black, mica, clay, bentonite, or any combination thereof.
4. The rolled material of claim 1, further comprising an additive
present in an amount of 1 wt. % to 70 wt. % based on the total
weight of the roofing membrane.
5. The rolled material of claim 4, wherein the additive is selected
from the group consisting of diluents, crosslinkers, stabilizers,
adhesion promoters, dispersing agents, rheology modifiers,
coalescent agents, pigments, or any combination thereof.
6. The rolled material of claim 1, wherein the first resin is
selected from the group consisting of thermally curable resins,
epoxy curable resins, radical curable resins, ultraviolet curable
resins, polymer curable resins, or any combination thereof.
7. The rolled material of claim 1, wherein the first resin is
selected from the group consisting of polyether, polyethylene,
polypropylene, polystyrene, thermoplastic polyolefin (TPO),
polyvinyl chloride (PVC), polycarbonate, rosin, acrylate,
methylacrylate, vinyl silicone, isocyanate polymer, polyol,
polyamine, or any combination thereof.
8. The rolled material of claim 1, wherein the second resin is
selected from the group consisting of hydroxyl terminated
polysiloxane, oxime capped polysiloxane, alkoxyl capped
polysiloxane, acetyl capped polysiloxane, silane terminated
polyether, silane terminated polyethylene, silane terminated
polypropylene, silane terminated polyurethane, isocyanate
terminated polymer, or any combination thereof.
9. The rolled material of claim 1, further comprising an embedded
reinforcement, scrim, woven fabric, nonwoven fabric, mesh, or any
combination thereof.
10. The rolled material of claim 1, wherein the roofing membrane is
configured to seal a penetration therethrough.
11. A rolled roofing product, comprising: a moisture sealed
carrier, the moisture sealed carrier configured to prevent
moisture; and a roofing membrane, comprising: a plurality of resins
present in an amount of 30 wt. % to 100 wt. % based on a total
weight of the roofing membrane, wherein the plurality of resins
comprise a first resin and a second resin; wherein the first resin
comprises a resin: present in an amount of 20 wt. % to 80 wt. %
based on a total weight of the plurality of resins in the roofing
membrane; that is not moisture curable; and that is cured; wherein
the second resin comprises a resin: present in an amount of 20 wt.
% to 80 wt. % based on the total weight of the plurality of resins
in the roofing membrane; that is moisture curable; that is uncured;
and comprising silicon; wherein the roofing membrane is flexible;
wherein the roofing membrane, when exposed to moisture, exhibits a
tear strength that meets ASTM D6878; and wherein the tear strength
is 55 lbf to 140 lbf.
12. The rolled roofing product of claim 11, wherein the roofing
membrane further comprises a filler present in an amount of 1 wt. %
to 70 wt. % based on the total weight of the roofing membrane.
13. The rolled roofing product of claim 12, wherein the filler is
selected from the group consisting of amorphous silica,
precipitated silica, fumed silica, calcium carbonate, barium
sulfate, alumina trihydrate, glass power, glass sphere, aluminum
silicate, carbon black, mica, clay, bentonite, or any combination
thereof.
14. The rolled roofing product of claim 11, wherein the roofing
membrane further comprises an additive present in an amount of 1
wt. % to 70 wt. % based on the total weight of the roofing
membrane.
15. The rolled roofing product of claim 14, wherein the additive is
selected from the group consisting of diluents, crosslinkers,
stabilizers, adhesion promoters, dispersing agents, rheology
modifiers, coalescent agents, pigments, or any combination
thereof.
16. The rolled roofing product of claim 11, wherein the first resin
is selected from the group consisting of polyether, polyethylene,
polypropylene, polystyrene, thermoplastic polyolefin (TPO),
polyvinyl chloride (PVC), polycarbonate, rosin, acrylate,
methylacrylate, vinyl silicone, isocyanate polymer, polyol,
polyamine, or any combination thereof.
17. The rolled roofing product of claim 11, wherein the second
resin is selected from the group consisting of hydroxyl terminated
polysiloxane, oxime capped polysiloxane, alkoxyl capped
polysiloxane, acetyl capped polysiloxane, silane terminated
polyether, silane terminated polyethylene, silane terminated
polypropylene, silane terminated polyurethane, isocyanate
terminated polymer, or any combination thereof.
18. A method, comprising: obtaining a rolled roofing product,
wherein the rolled roofing product comprises a roofing membrane
contained within a moisture sealed carrier; wherein the roofing
membrane comprises: a plurality of resins present in an amount of
30 wt. % to 100 wt. % based on a total weight of the roofing
membrane, wherein the plurality of resins comprise a first resin
and a second resin; wherein the first resin comprises a resin:
present in an amount of 20 wt. % to 80 wt. % based on a total
weight of the plurality of resins in the roofing membrane; that is
not moisture curable; and that is cured; wherein the second resin
comprises a resin: present in an amount of 20 wt. % to 80 wt. %
based on the total weight of the plurality of resins in the roofing
membrane; that is moisture curable; that is uncured; and comprising
silicon; wherein the roofing membrane is flexible; and installing
the roofing membrane on a roofing substrate to form an installed
roofing membrane, wherein, in response to installing the roofing
membrane, the second resin cures so as to result in the installed
roofing membrane exhibiting a tear strength that meets ASTM D6878,
wherein the tear strength is 55 lbf to 140 lbf.
19. The method of claim 18, wherein the second resin cures in a
time range of 1 to 72 hours after the installing.
20. The method of claim 18, wherein installing the roofing membrane
on the roofing substrate comprises removing the roofing membrane
from the moisture sealed carrier, and exposing the roofing membrane
to ambient humidity.
Description
RELATED APPLICATIONS
[0001] This application claims priority to U.S. Provisional
Application No. 63/164,946, filed on Mar. 23, 2021, and titled
"ROOFING MEMBRANE," the entire contents of which is hereby
incorporated by reference.
FIELD
[0002] This disclosure relates generally to roofing membranes. More
specifically, this disclosure relates to silicon roofing
membranes.
BACKGROUND
[0003] Roofing membranes, such as roofing membranes made from
thermoplastic polyolefins (TPO), can be installed on a roofing
substrate. The roofing membranes are secured to the roofing
substrate via, for example, adhesives, fasteners, or the like.
Roofing membranes may lack flexibility to cover various roof
topologies. However, increasing flexibility can reduce mechanical
strength, which provides rigidity for durability and
protection.
SUMMARY
[0004] In some embodiments, a rolled material includes a roofing
membrane includes a plurality of resins present in an amount of 30
wt. % to 100 wt. % based on a total weight of the roofing membrane.
In some embodiments, the plurality of resins include a first resin
and a second resin. In some embodiments, the first resin includes a
resin present in an amount of 20 wt. % to 80 wt. % based on a total
weight of the plurality of resins in the roofing membrane. In some
embodiments, the first resin is not moisture curable. In some
embodiments, the first resin is cured. In some embodiments, the
second resin includes a resin present in an amount of 20 wt. % to
80 wt. % based on the total weight of the plurality of resins in
the roofing membrane. In some embodiments, the second resin is
moisture curable. In some embodiments, the second resin is uncured.
In some embodiments, the second resin includes silicon. In some
embodiments, the roofing membrane is flexible. In some embodiments,
the roofing membrane, when exposed to moisture, exhibits a tear
strength that meets ASTM D6878. In some embodiments, the tear
strength is 55 lbf to 140 lbf.
[0005] In some embodiments, a rolled roofing product includes a
moisture sealed carrier configured to prevent moisture. In some
embodiments, the rolled roofing product includes a roofing
membrane. In some embodiments, a roofing membrane includes a
plurality of resins present in an amount of 30 wt. % to 100 wt. %
based on a total weight of the roofing membrane. In some
embodiments, the plurality of resins include a first resin and a
second resin. In some embodiments, the first resin includes a resin
present in an amount of 20 wt. % to 80 wt. % based on a total
weight of the plurality of resins in the roofing membrane. In some
embodiments, the first resin is not moisture curable. In some
embodiments, the first resin is cured. In some embodiments, the
second resin includes a resin present in an amount of 20 wt. % to
80 wt. % based on the total weight of the plurality of resins in
the roofing membrane. In some embodiments, the second resin is
moisture curable. In some embodiments, the second resin is uncured.
In some embodiments, the second resin includes silicon. In some
embodiments, the roofing membrane is flexible. In some embodiments,
the roofing membrane, when exposed to moisture, exhibits a tear
strength that meets ASTM D6878. In some embodiments, the tear
strength is 55 lbf to 140 lbf.
[0006] In some embodiments, a method includes obtaining a rolled
roofing product. In some embodiments, the rolled roofing product
includes a roofing membrane contained within a moisture sealed
carrier. In some embodiments, the roofing membrane includes a
plurality of resins present in an amount of 30 wt. % to 100 wt. %
based on a total weight of the roofing membrane. In some
embodiments, the plurality of resins include a first resin and a
second resin. In some embodiments, the first resin includes a resin
present in an amount of 20 wt. % to 80 wt. % based on a total
weight of the plurality of resins in the roofing membrane. In some
embodiments, the first resin is not moisture curable. In some
embodiments, the first resin is cured. In some embodiments, the
second resin includes a resin present in an amount of 20 wt. % to
80 wt. % based on the total weight of the plurality of resins in
the roofing membrane. In some embodiments, the second resin is
moisture curable. In some embodiments, the second resin is uncured.
In some embodiments, the second resin includes silicon. In some
embodiments, the roofing membrane is flexible. In some embodiments,
the method includes installing the roofing membrane on a roofing
substrate to form an installed roofing membrane. In some
embodiments, in response to installing the roofing membrane, the
second resin cures so as to result in the installed roofing
membrane exhibiting a tear strength that meets ASTM D6878. In some
embodiments, the tear strength is 55 lbf to 140 lbf.
[0007] In some embodiments, the roofing membrane includes a filler
present in an amount of 1 wt. % to 70 wt. % based on the total
weight of the roofing membrane. In some embodiments, the filler is
selected from the group consisting of amorphous silica,
precipitated silica, fumed silica, calcium carbonate, barium
sulfate, alumina trihydrate, glass power, glass sphere, aluminum
silicate, carbon black, mica, clay, bentonite, or any combination
thereof.
[0008] In some embodiments, the roofing membrane includes an
additive present in an amount of 1 wt. % to 70 wt. % based on the
total weight of the roofing membrane. In some embodiments, the
additive is selected from the group consisting of diluents,
crosslinkers, stabilizers, adhesion promoters, dispersing agents,
rheology modifiers, coalescent agents, pigments, or any combination
thereof.
[0009] In some embodiments, the first resin is selected from the
group consisting of thermally curable resins, epoxy curable resins,
radical curable resins, ultraviolet curable resins, polymer curable
resins, or any combination thereof.
[0010] In some embodiments, the first resin is selected from the
group consisting of polyether, polyethylene, polypropylene,
polystyrene, TPO, polyvinyl chloride (PVC), polycarbonate, rosin,
acrylate, methylacrylate, vinyl silicone, isocyanate polymer,
polyol, polyamine, or any combination thereof.
[0011] In some embodiments, the second resin is selected from the
group consisting of hydroxyl terminated polysiloxane, oxime capped
polysiloxane, alkoxyl capped polysiloxane, acetyl capped
polysiloxane, silane terminated polyether, silane terminated
polyethylene, silane terminated polypropylene, silane terminated
polyurethane, isocyanate terminated polymer, or any combination
thereof.
[0012] In some embodiments, the roofing membrane includes an
embedded reinforcement, scrim, woven fabric, nonwoven fabric, mesh,
or any combination thereof.
[0013] In some embodiments, the roofing membrane is configured to
seal a penetration therethrough.
[0014] In some embodiments, the roofing membrane is more flexible
than a TPO roofing membrane.
[0015] In some embodiments, the second resin cures in a time range
of 1 to 72 hours after being installed.
[0016] In some embodiments, installing the roofing membrane on the
roofing substrate includes removing the roofing membrane from the
moisture sealed carrier, and exposing the roofing membrane to
ambient humidity.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] Reference is made to the drawings that form a part of this
disclosure, and which illustrate embodiments in which the devices
and methods described herein can be practiced.
[0018] FIG. 1 is a flowchart of a method for preparing a roofing
membrane, according to some embodiments.
[0019] FIG. 2 is a flowchart of a method for installing a roofing
membrane, according to some embodiments.
[0020] Like reference numbers represent the same or similar parts
throughout.
DETAILED DESCRIPTION
[0021] Among those benefits and improvements that have been
disclosed, other objects and advantages of this disclosure will
become apparent from the following description taken in conjunction
with the accompanying figures. Detailed embodiments of the present
disclosure are disclosed herein; however, the disclosed embodiments
are merely illustrative of the disclosure that may be embodied in
various forms. In addition, each of the examples given regarding
the various embodiments of the disclosure are intended to be
illustrative, and not restrictive.
[0022] Throughout the specification and claims, the following terms
take the meanings explicitly associated herein, unless the context
clearly dictates otherwise. The phrases "in one embodiment," "in an
embodiment," and "in some embodiments" as used herein do not
necessarily refer to the same embodiment(s), though it may.
Furthermore, the phrases "in another embodiment" and "in some other
embodiments" as used herein do not necessarily refer to a different
embodiment, although it may. All embodiments of the disclosure are
intended to be combinable without departing from the scope or
spirit of the disclosure.
[0023] All prior patents, publications, and test methods referenced
herein are incorporated by reference in their entireties.
[0024] In some embodiments, a rolled material includes a roofing
membrane. In some embodiments, the roofing membrane includes a
plurality of resins present in an amount of 30 wt. % to 100 wt. %
based on a total weight of the roofing membrane. In some
embodiments, the roofing membrane includes a plurality of resins
present in an amount of 30 wt. % to 95 wt. % based on a total
weight of the roofing membrane. In some embodiments, the roofing
membrane includes a plurality of resins present in an amount of 30
wt. % to 90 wt. % based on a total weight of the roofing membrane.
In some embodiments, the roofing membrane includes a plurality of
resins present in an amount of 30 wt. % to 85 wt. % based on a
total weight of the roofing membrane. In some embodiments, the
roofing membrane includes a plurality of resins present in an
amount of 30 wt. % to 80 wt. % based on a total weight of the
roofing membrane. In some embodiments, the roofing membrane
includes a plurality of resins present in an amount of 30 wt. % to
75 wt. % based on a total weight of the roofing membrane. In some
embodiments, the roofing membrane includes a plurality of resins
present in an amount of 30 wt. % to 70 wt. % based on a total
weight of the roofing membrane. In some embodiments, the roofing
membrane includes a plurality of resins present in an amount of 30
wt. % to 65 wt. % based on a total weight of the roofing membrane.
In some embodiments, the roofing membrane includes a plurality of
resins present in an amount of 30 wt. % to 60 wt. % based on a
total weight of the roofing membrane. In some embodiments, the
roofing membrane includes a plurality of resins present in an
amount of 30 wt. % to 55 wt. % based on a total weight of the
roofing membrane. In some embodiments, the roofing membrane
includes a plurality of resins present in an amount of 30 wt. % to
50 wt. % based on a total weight of the roofing membrane. In some
embodiments, the roofing membrane includes a plurality of resins
present in an amount of 30 wt. % to 45 wt. % based on a total
weight of the roofing membrane. In some embodiments, the roofing
membrane includes a plurality of resins present in an amount of 30
wt. % to 40 wt. % based on a total weight of the roofing membrane.
In some embodiments, the roofing membrane includes a plurality of
resins present in an amount of 30 wt. % to 35 wt. % based on a
total weight of the roofing membrane.
[0025] In some embodiments, the roofing membrane includes a
plurality of resins present in an amount of 35 wt. % to 100 wt. %
based on a total weight of the roofing membrane. In some
embodiments, the roofing membrane includes a plurality of resins
present in an amount of 40 wt. % to 100 wt. % based on a total
weight of the roofing membrane. In some embodiments, the roofing
membrane includes a plurality of resins present in an amount of 45
wt. % to 100 wt. % based on a total weight of the roofing membrane.
In some embodiments, the roofing membrane includes a plurality of
resins present in an amount of 50 wt. % to 100 wt. % based on a
total weight of the roofing membrane. In some embodiments, the
roofing membrane includes a plurality of resins present in an
amount of 55 wt. % to 100 wt. % based on a total weight of the
roofing membrane. In some embodiments, the roofing membrane
includes a plurality of resins present in an amount of 60 wt. % to
100 wt. % based on a total weight of the roofing membrane. In some
embodiments, the roofing membrane includes a plurality of resins
present in an amount of 65 wt. % to 100 wt. % based on a total
weight of the roofing membrane. In some embodiments, the roofing
membrane includes a plurality of resins present in an amount of 70
wt. % to 100 wt. % based on a total weight of the roofing membrane.
In some embodiments, the roofing membrane includes a plurality of
resins present in an amount of 75 wt. % to 100 wt. % based on a
total weight of the roofing membrane. In some embodiments, the
roofing membrane includes a plurality of resins present in an
amount of 80 wt. % to 100 wt. % based on a total weight of the
roofing membrane. In some embodiments, the roofing membrane
includes a plurality of resins present in an amount of 85 wt. % to
100 wt. % based on a total weight of the roofing membrane. In some
embodiments, the roofing membrane includes a plurality of resins
present in an amount of 90 wt. % to 100 wt. % based on a total
weight of the roofing membrane. In some embodiments, the roofing
membrane includes a plurality of resins present in an amount of 95
wt. % to 100 wt. % based on a total weight of the roofing
membrane.
[0026] In some embodiments, the plurality of resins in the roofing
membrane includes a first resin and a second resin. In some
embodiments, the plurality of resins in the roofing membrane
includes a plurality of first resins and a second resin. In some
embodiments, the plurality of resins in the roofing membrane
includes a first resin and a plurality of second resins. In some
embodiments, the roofing membrane includes a plurality of first
resins and a plurality of second resins.
[0027] In some embodiments, the first resin is not moisture
curable.
[0028] As used herein, "not moisture curable" includes resins that
utilize a curing mechanism other than via moisture. Examples of
curing mechanisms other than via moisture include, but are not
limited to, thermal curing, adhesive curing, polymer curing,
radiation curing, or any combination thereof.
[0029] As used herein, "thermal curing" includes curing that
involves heating a resin to cure the resin, cooling the resin to
cure the resin, or any combination thereof.
[0030] In some embodiments, the first resin is cured. For example,
after producing the roofing membrane having the plurality of
resins, the roofing membrane can be exposed to curing mechanisms
other than moisture curing so that the first resin is cured.
[0031] In some embodiments, the first resin is selected from the
group consisting of thermally curable resins (thermoplastic
resins), epoxy curable resins, radical curable resins, ultraviolet
curable resins, polymer curable resins, or any combination
thereof.
[0032] In some embodiments, thermally curable resins include
polyether, polyethylene, polypropylene, polystyrene, thermoplastic
polyolefin (TPO), polyvinyl chloride (PVC), polycarbonate, rosin,
or any combination thereof.
[0033] In some embodiments, radical curable resins include
acrylate, methylacrylate, vinyl silicone, or any combination
thereof.
[0034] In some embodiments, polymer curable resins include
isocyanate polymer, polyol, polyamine, or any combination
thereof.
[0035] In some embodiments, the first resin is present in an amount
of 20 wt. % to 80 wt. % based on a total weight of the plurality of
resins in the roofing membrane. In some embodiments, the first
resin is present in an amount of 20 wt. % to 75 wt. % based on a
total weight of the plurality of resins in the roofing membrane. In
some embodiments, the first resin is present in an amount of 20 wt.
% to 70 wt. % based on a total weight of the plurality of resins in
the roofing membrane. In some embodiments, the first resin is
present in an amount of 20 wt. % to 65 wt. % based on a total
weight of the plurality of resins in the roofing membrane. In some
embodiments, the first resin is present in an amount of 20 wt. % to
60 wt. % based on a total weight of the plurality of resins in the
roofing membrane. In some embodiments, the first resin is present
in an amount of 20 wt. % to 55 wt. % based on a total weight of the
plurality of resins in the roofing membrane. In some embodiments,
the first resin is present in an amount of 20 wt. % to 50 wt. %
based on a total weight of the plurality of resins in the roofing
membrane. In some embodiments, the first resin is present in an
amount of 20 wt. % to 45 wt. % based on a total weight of the
plurality of resins in the roofing membrane. In some embodiments,
the first resin is present in an amount of 20 wt. % to 40 wt. %
based on a total weight of the plurality of resins in the roofing
membrane. In some embodiments, the first resin is present in an
amount of 20 wt. % to 35 wt. % based on a total weight of the
plurality of resins in the roofing membrane. In some embodiments,
the first resin is present in an amount of 20 wt. % to 30 wt. %
based on a total weight of the plurality of resins in the roofing
membrane. In some embodiments, the first resin is present in an
amount of 20 wt. % to 25 wt. % based on a total weight of the
plurality of resins in the roofing membrane.
[0036] In some embodiments, the first resin is present in an amount
of 25 wt. % to 80 wt. % based on a total weight of the plurality of
resins in the roofing membrane. In some embodiments, the first
resin is present in an amount of 30 wt. % to 80 wt. % based on a
total weight of the plurality of resins in the roofing membrane. In
some embodiments, the first resin is present in an amount of 35 wt.
% to 80 wt. % based on a total weight of the plurality of resins in
the roofing membrane. In some embodiments, the first resin is
present in an amount of 40 wt. % to 80 wt. % based on a total
weight of the plurality of resins in the roofing membrane. In some
embodiments, the first resin is present in an amount of 45 wt. % to
80 wt. % based on a total weight of the plurality of resins in the
roofing membrane. In some embodiments, the first resin is present
in an amount of 50 wt. % to 80 wt. % based on a total weight of the
plurality of resins in the roofing membrane. In some embodiments,
the first resin is present in an amount of 55 wt. % to 80 wt. %
based on a total weight of the plurality of resins in the roofing
membrane. In some embodiments, the first resin is present in an
amount of 60 wt. % to 80 wt. % based on a total weight of the
plurality of resins in the roofing membrane. In some embodiments,
the first resin is present in an amount of 65 wt. % to 80 wt. %
based on a total weight of the plurality of resins in the roofing
membrane. In some embodiments, the first resin is present in an
amount of 70 wt. % to 80 wt. % based on a total weight of the
plurality of resins in the roofing membrane. In some embodiments,
the first resin is present in an amount of 75 wt. % to 80 wt. %
based on a total weight of the plurality of resins in the roofing
membrane.
[0037] In some embodiments, the second resin is moisture curable.
As used herein, "moisture curable" includes resins that utilize
moisture as a curing mechanism. Moisture can be applied to drive
the curing via, for example, ambient humidity, spraying with water,
or any combination thereof.
[0038] In some embodiments, the second resin is uncured. For
example, after producing the roofing membrane having the plurality
of resins, the roofing membrane can be exposed to curing mechanisms
other than moisture curing so that the first resin is cured, and
prevented from being exposed to moisture so the second resin
remains uncured. In some embodiments, the roofing membrane can be
packaged in a moisture sealed carrier that prevents moisture from
entering into the moisture sealed carrier, thus keeping the second
resin uncured until the roofing membrane is removed from the
moisture sealed carrier.
[0039] In some embodiments, the second resin includes silicon. In
some embodiments, the second resin includes hydroxyl terminated
polysiloxane, oxime capped polysiloxane, alkoxyl capped
polysiloxane, acetyl capped polysiloxane, silane terminated
polyether, silane terminated polyethylene, silane terminated
polypropylene, silane terminated polyurethane, isocyanate
terminated polymer, or any combination thereof.
[0040] In some embodiments, the second resin is present in an
amount of 20 wt. % to 80 wt. % based on a total weight of the
plurality of resins in the roofing membrane. In some embodiments,
the second resin is present in an amount of 20 wt. % to 75 wt. %
based on a total weight of the plurality of resins in the roofing
membrane. In some embodiments, the second resin is present in an
amount of 20 wt. % to 70 wt. % based on a total weight of the
plurality of resins in the roofing membrane. In some embodiments,
the second resin is present in an amount of 20 wt. % to 65 wt. %
based on a total weight of the plurality of resins in the roofing
membrane. In some embodiments, the second resin is present in an
amount of 20 wt. % to 60 wt. % based on a total weight of the
plurality of resins in the roofing membrane. In some embodiments,
the second resin is present in an amount of 20 wt. % to 55 wt. %
based on a total weight of the plurality of resins in the roofing
membrane. In some embodiments, the second resin is present in an
amount of 20 wt. % to 50 wt. % based on a total weight of the
plurality of resins in the roofing membrane. In some embodiments,
the second resin is present in an amount of 20 wt. % to 45 wt. %
based on a total weight of the plurality of resins in the roofing
membrane. In some embodiments, the second resin is present in an
amount of 20 wt. % to 40 wt. % based on a total weight of the
plurality of resins in the roofing membrane. In some embodiments,
the second resin is present in an amount of 20 wt. % to 35 wt. %
based on a total weight of the plurality of resins in the roofing
membrane. In some embodiments, the second resin is present in an
amount of 20 wt. % to 30 wt. % based on a total weight of the
plurality of resins in the roofing membrane. In some embodiments,
the second resin is present in an amount of 20 wt. % to 25 wt. %
based on a total weight of the plurality of resins in the roofing
membrane.
[0041] In some embodiments, the second resin is present in an
amount of 25 wt. % to 80 wt. % based on a total weight of the
plurality of resins in the roofing membrane. In some embodiments,
the second resin is present in an amount of 30 wt. % to 80 wt. %
based on a total weight of the plurality of resins in the roofing
membrane. In some embodiments, the second resin is present in an
amount of 35 wt. % to 80 wt. % based on a total weight of the
plurality of resins in the roofing membrane. In some embodiments,
the second resin is present in an amount of 40 wt. % to 80 wt. %
based on a total weight of the plurality of resins in the roofing
membrane. In some embodiments, the second resin is present in an
amount of 45 wt. % to 80 wt. % based on a total weight of the
plurality of resins in the roofing membrane. In some embodiments,
the second resin is present in an amount of 50 wt. % to 80 wt. %
based on a total weight of the plurality of resins in the roofing
membrane. In some embodiments, the second resin is present in an
amount of 55 wt. % to 80 wt. % based on a total weight of the
plurality of resins in the roofing membrane. In some embodiments,
the second resin is present in an amount of 60 wt. % to 80 wt. %
based on a total weight of the plurality of resins in the roofing
membrane. In some embodiments, the second resin is present in an
amount of 65 wt. % to 80 wt. % based on a total weight of the
plurality of resins in the roofing membrane. In some embodiments,
the second resin is present in an amount of 70 wt. % to 80 wt. %
based on a total weight of the plurality of resins in the roofing
membrane. In some embodiments, the second resin is present in an
amount of 75 wt. % to 80 wt. % based on a total weight of the
plurality of resins in the roofing membrane.
[0042] In some embodiments, the second resin cures in a time range
of 1 to 72 hours after being installed (e.g., after being exposed
to moisture such as ambient humidity). In some embodiments, the
second resin cures in a time range of 1 to 48 hours after being
installed. In some embodiments, the second resin cures in a time
range of 1 to 24 hours after being installed. In some embodiments,
the second resin cures in a time range of 1 to 12 hours after being
installed. In some embodiments, the second resin cures in a time
range of 1 to 6 hours after being installed. In some embodiments,
the second resin cures in a time range of 1 to 3 hours after being
installed.
[0043] In some embodiments, the second resin cures in a time range
of 3 to 72 hours after being installed. In some embodiments, the
second resin cures in a time range of 6 to 72 hours after being
installed. In some embodiments, the second resin cures in a time
range of 12 to 72 hours after being installed. In some embodiments,
the second resin cures in a time range of 24 to 72 hours after
being installed. In some embodiments, the second resin cures in a
time range of 48 to 72 hours after being installed.
[0044] In some embodiments, the roofing membrane has a peel
strength of 0 before curing. In some embodiments, the roofing
membrane has a peel strength of 6 lbs to 9 lbs after curing. In
some embodiments, the roofing membrane has a peel strength of 7 lbs
to 8 lbs after curing. In some embodiments, the roofing membrane
has a peel strength of 6 lbs to 8 lbs after curing. In some
embodiments, the roofing membrane has a peel strength of 6 lbs to 7
lbs after curing. In some embodiments, the roofing membrane has a
peel strength of 7 lbs to 9 lbs after curing. In some embodiments,
the roofing membrane has a peel strength of 8 lbs to 9 lbs after
curing.
[0045] In some embodiments, the roofing membrane further includes a
filler. In some embodiments, the filler is selected from the group
consisting of amorphous silica, precipitated silica, fumed silica,
calcium carbonate, barium sulfate, alumina trihydrate, glass power,
glass sphere, aluminum silicate, carbon black, mica, clay,
bentonite, or any combination thereof.
[0046] In some embodiments, the filler is present in an amount of 1
wt. % to 70 wt. % based on a total weight of the roofing membrane.
In some embodiments, the filler is present in an amount of 1 wt. %
to 65 wt. % based on a total weight of the roofing membrane. In
some embodiments, the filler is present in an amount of 1 wt. % to
60 wt. % based on a total weight of the roofing membrane. In some
embodiments, the filler is present in an amount of 1 wt. % to 55
wt. % based on a total weight of the roofing membrane. In some
embodiments, the filler is present in an amount of 1 wt. % to 50
wt. % based on a total weight of the roofing membrane. In some
embodiments, the filler is present in an amount of 1 wt. % to 45
wt. % based on a total weight of the roofing membrane. In some
embodiments, the filler is present in an amount of 1 wt. % to 40
wt. % based on a total weight of the roofing membrane. In some
embodiments, the filler is present in an amount of 1 wt. % to 35
wt. % based on a total weight of the roofing membrane. In some
embodiments, the filler is present in an amount of 1 wt. % to 30
wt. % based on a total weight of the roofing membrane. In some
embodiments, the filler is present in an amount of 1 wt. % to 25
wt. % based on a total weight of the roofing membrane. In some
embodiments, the filler is present in an amount of 1 wt. % to 20
wt. % based on a total weight of the roofing membrane. In some
embodiments, the filler is present in an amount of 1 wt. % to 15
wt. % based on a total weight of the roofing membrane. In some
embodiments, the filler is present in an amount of 1 wt. % to 10
wt. % based on a total weight of the roofing membrane. In some
embodiments, the filler is present in an amount of 1 wt. % to 5 wt.
% based on a total weight of the roofing membrane.
[0047] In some embodiments, the filler is present in an amount of 5
wt. % to 70 wt. % based on a total weight of the roofing membrane.
In some embodiments, the filler is present in an amount of 10 wt. %
to 70 wt. % based on a total weight of the roofing membrane. In
some embodiments, the filler is present in an amount of 15 wt. % to
70 wt. % based on a total weight of the roofing membrane. In some
embodiments, the filler is present in an amount of 20 wt. % to 70
wt. % based on a total weight of the roofing membrane. In some
embodiments, the filler is present in an amount of 25 wt. % to 70
wt. % based on a total weight of the roofing membrane. In some
embodiments, the filler is present in an amount of 30 wt. % to 70
wt. % based on a total weight of the roofing membrane. In some
embodiments, the filler is present in an amount of 35 wt. % to 70
wt. % based on a total weight of the roofing membrane. In some
embodiments, the filler is present in an amount of 40 wt. % to 70
wt. % based on a total weight of the roofing membrane. In some
embodiments, the filler is present in an amount of 45 wt. % to 70
wt. % based on a total weight of the roofing membrane. In some
embodiments, the filler is present in an amount of 50 wt. % to 70
wt. % based on a total weight of the roofing membrane. In some
embodiments, the filler is present in an amount of 55 wt. % to 70
wt. % based on a total weight of the roofing membrane. In some
embodiments, the filler is present in an amount of 60 wt. % to 70
wt. % based on a total weight of the roofing membrane. In some
embodiments, the filler is present in an amount of 65 wt. % to 70
wt. % based on a total weight of the roofing membrane.
[0048] In some embodiments, the roofing membrane includes an
additive. In some embodiments, the additive is selected from the
group consisting of diluents, crosslinkers, stabilizers, adhesion
promoters, dispersing agents, rheology modifiers, coalescent
agents, pigments, or any combination thereof.
[0049] In some embodiments, the additive is present in an amount of
1 wt. % to 70 wt. % based on a total weight of the roofing
membrane. In some embodiments, the additive is present in an amount
of 1 wt. % to 65 wt. % based on a total weight of the roofing
membrane. In some embodiments, the additive is present in an amount
of 1 wt. % to 60 wt. % based on a total weight of the roofing
membrane. In some embodiments, the additive is present in an amount
of 1 wt. % to 55 wt. % based on a total weight of the roofing
membrane. In some embodiments, the additive is present in an amount
of 1 wt. % to 50 wt. % based on a total weight of the roofing
membrane. In some embodiments, the additive is present in an amount
of 1 wt. % to 45 wt. % based on a total weight of the roofing
membrane. In some embodiments, the additive is present in an amount
of 1 wt. % to 40 wt. % based on a total weight of the roofing
membrane. In some embodiments, the additive is present in an amount
of 1 wt. % to 35 wt. % based on a total weight of the roofing
membrane. In some embodiments, the additive is present in an amount
of 1 wt. % to 30 wt. % based on a total weight of the roofing
membrane. In some embodiments, the additive is present in an amount
of 1 wt. % to 25 wt. % based on a total weight of the roofing
membrane. In some embodiments, the additive is present in an amount
of 1 wt. % to 20 wt. % based on a total weight of the roofing
membrane. In some embodiments, the additive is present in an amount
of 1 wt. % to 15 wt. % based on a total weight of the roofing
membrane. In some embodiments, the additive is present in an amount
of 1 wt. % to 10 wt. % based on a total weight of the roofing
membrane. In some embodiments, the additive is present in an amount
of 1 wt. % to 5 wt. % based on a total weight of the roofing
membrane.
[0050] In some embodiments, the additive is present in an amount of
5 wt. % to 70 wt. % based on a total weight of the roofing
membrane. In some embodiments, the additive is present in an amount
of 10 wt. % to 70 wt. % based on a total weight of the roofing
membrane. In some embodiments, the additive is present in an amount
of 15 wt. % to 70 wt. % based on a total weight of the roofing
membrane. In some embodiments, the additive is present in an amount
of 20 wt. % to 70 wt. % based on a total weight of the roofing
membrane. In some embodiments, the additive is present in an amount
of 25 wt. % to 70 wt. % based on a total weight of the roofing
membrane. In some embodiments, the additive is present in an amount
of 30 wt. % to 70 wt. % based on a total weight of the roofing
membrane. In some embodiments, the additive is present in an amount
of 35 wt. % to 70 wt. % based on a total weight of the roofing
membrane. In some embodiments, the additive is present in an amount
of 40 wt. % to 70 wt. % based on a total weight of the roofing
membrane. In some embodiments, the additive is present in an amount
of 45 wt. % to 70 wt. % based on a total weight of the roofing
membrane. In some embodiments, the additive is present in an amount
of 50 wt. % to 70 wt. % based on a total weight of the roofing
membrane. In some embodiments, the additive is present in an amount
of 55 wt. % to 70 wt. % based on a total weight of the roofing
membrane. In some embodiments, the additive is present in an amount
of 60 wt. % to 70 wt. % based on a total weight of the roofing
membrane. In some embodiments, the additive is present in an amount
of 65 wt. % to 70 wt. % based on a total weight of the roofing
membrane.
[0051] In some embodiments, the roofing membrane includes an
embedded reinforcement, scrim, woven fabric, nonwoven fabric, mesh,
or any combination thereof.
[0052] In some embodiments, the roofing membrane is configured to
seal a penetration therethrough.
[0053] In some embodiments, the roofing membrane is more flexible
than a TPO roofing membrane.
[0054] In some embodiments, the roofing membrane, when exposed to
moisture, exhibits a tear strength that meets ASTM D6878.
[0055] In some embodiments, the tear strength is 55 lbf to 140 lbf.
In some embodiments, the tear strength is 60 lbf to 140 lbf. In
some embodiments, the tear strength is 65 lbf to 140 lbf. In some
embodiments, the tear strength is 70 lbf to 140 lbf. In some
embodiments, the tear strength is 75 lbf to 140 lbf. In some
embodiments, the tear strength is 80 lbf to 140 lbf. In some
embodiments, the tear strength is 85 lbf to 140 lbf. In some
embodiments, the tear strength is 90 lbf to 140 lbf. In some
embodiments, the tear strength is 95 lbf to 140 lbf. In some
embodiments, the tear strength is 100 lbf to 140 lbf. In some
embodiments, the tear strength is 105 lbf to 140 lbf. In some
embodiments, the tear strength is 110 lbf to 140 lbf. In some
embodiments, the tear strength is 115 lbf to 140 lbf. In some
embodiments, the tear strength is 120 lbf to 140 lbf. In some
embodiments, the tear strength is 125 lbf to 140 lbf. In some
embodiments, the tear strength is 130 lbf to 140 lbf. In some
embodiments, the tear strength is 135 lbf to 140 lbf.
[0056] In some embodiments, the tear strength is 55 lbf to 135 lbf.
In some embodiments, the tear strength is 55 lbf to 130 lbf. In
some embodiments, the tear strength is 55 lbf to 125 lbf. In some
embodiments, the tear strength is 55 lbf to 120 lbf. In some
embodiments, the tear strength is 55 lbf to 115 lbf. In some
embodiments, the tear strength is 55 lbf to 110 lbf. In some
embodiments, the tear strength is 55 lbf to 105 lbf. In some
embodiments, the tear strength is 55 lbf to 100 lbf. In some
embodiments, the tear strength is 55 lbf to 95 lbf. In some
embodiments, the tear strength is 55 lbf to 90 lbf. In some
embodiments, the tear strength is 55 lbf to 85 lbf. In some
embodiments, the tear strength is 55 lbf to 80 lbf. In some
embodiments, the tear strength is 55 lbf to 75 lbf. In some
embodiments, the tear strength is 55 lbf to 70 lbf. In some
embodiments, the tear strength is 55 lbf to 65 lbf. In some
embodiments, the tear strength is 55 lbf to 60 lbf.
[0057] FIG. 1 is a flowchart of a method 10 for preparing a roofing
membrane, according to some embodiments. At block 12, an uncured
roofing membrane that includes a plurality of resins is produced.
Producing the roofing membrane includes, for example, blade
coating, printing, calendaring, extrusion, or any combination
thereof. In some embodiments, the roofing membrane can include a
plurality of discrete layers of material. In some embodiments, the
plurality of resins can be mixed such that they are combined into a
layer of material. At block 14, the non-moisture curable resins in
the uncured roofing membrane are cured to form a partially cured
roofing membrane. The partially cured roofing membrane includes one
or more moisture curable resins that are uncured. At block 16, the
partially cured roofing membrane is prevented from moisture curing.
At block 16, the method 10 can include, for example, sealing the
partially cured roofing membrane in a moisture sealed carrier to
prevent the partially cured roofing membrane from being exposed to
moisture. In some embodiments, the moisture sealed carrier can be a
release liner. In some embodiments, the moisture sealed carrier can
be a package configured to prevent ingress of moisture. In some
embodiments, the partially cured roofing membrane can be rolled
into a rolled form.
[0058] FIG. 2 is a flowchart of a method 50 for installing a
roofing membrane, according to some embodiments. At block 52, a
roofing membrane contained within a moisture sealed carrier is
obtained. In some embodiments, the roofing membrane within the
moisture sealed carrier is in a rolled form. At block 54, the
roofing membrane is installed on a roofing substrate to form an
installed roofing membrane. In some embodiments, the installing at
block 54 can include removing the roofing membrane from the
moisture sealed carrier and exposing the roofing membrane to
ambient humidity. In some embodiments, the installing at block 54
can include unrolling the rolled roofing membrane. As a result of
the installing, the moisture curable resin(s) of the roofing
membrane are driven to cure by the moisture in ambient humidity
within, for example, 1 to 72 hours.
* * * * *