Thermoplastic roofing membranes adapted for adhesion to polar adhesives

Patent metadata

Field	Value
Publication number	US-2021300007-A1
Application number	US-201917266277-A
Country	US
Kind code	A1
Filing date	Aug 7, 2019
Priority date	Aug 8, 2018
Publication date	Sep 30, 2021
Grant date	—

Abstract

A method of preparing a thermoplastic roofing membrane, the method comprising (i) extruding a composition including a thermoplastic polymer and a mineral filler to form an extrudate; (ii) forming the extrudate into a sheet having first and second planar surfaces; (iii) allowing the sheet to at least partially cool; and (iv) mechanically treating the first planar surface of the sheet to thereby expose the mineral filler.

First claim

What is claimed is:

1 . A method of preparing a thermoplastic roofing membrane, the method comprising:
(i) extruding a composition including a thermoplastic polymer and a mineral filler to form an extrudate; (ii) forming the extrudate into a sheet having first and second planar surfaces; (iii) allowing the sheet to at least partially cool; and (iv) mechanically treating the first planar surface of the sheet to thereby expose the mineral filler.

2 . The method of claim 1 , where said step of extruding includes extruding a first polymeric sheet and a second polymeric sheet, where at least the first polymeric sheet includes mineral filler, and where said step of forming the extrudate into a sheet includes laminating the first and second sheets.

3 . The method of claim 1 , where said step of laminating includes sandwiching a reinforcing fabric between the first and second sheets.

4 . The method of claim 1 , where said step of mechanically treating includes abrading, sanding, or shaving the first planar surface of the sheet.

5 . The method of claim 1 , where said step of mechanically treating includes subjecting the first planar surface of the sheet to a sanding, abrading, or shaving element.

6 . The method of claim 1 , where said step of mechanically treating includes subjecting the first planar surface to an abrading element, and where said abrading element includes a file or knurled surface.

7 . The method of claim 1 , where the thermoplastic polymer is an olefinic polymer.

8 . The method of claim 1 , where the thermoplastic polymer is selected from the group consisting of thermoplastic olefinic polymers (TPOs), polyolefin blends, propylene-based elastomers, ethylene-based olefinic block copolymers, and/or functionalized polyolefin resins.

9 . The method of claim 1 , where the mineral filler is calcium carbonate.

10 . The method of claim 1 , where said step of allowing the sheet to cool allows the sheet to cool below 100° C.

11 . A thermoplastic roofing membrane comprising:
(i) a first thermoplastic layer, where said first thermoplastic layer includes first and second planar surfaces, and where said first thermoplastic layer includes mineral filler; (ii) an optional reinforcing fabric adjacent to said second planar surface of said first thermoplastic layer; (iii) a second thermoplastic layer laminated to said second planar surface of said first thermoplastic layer, where said first planar surface of said first thermoplastic layer is a mechanically-treated surface that exposes the mineral filler contained within the layer.

12 . The thermoplastic roofing membrane of claim 11 , where greater than 80% of the first planar surface of the first layer includes exposed mineral filler.

13 . The thermoplastic roofing membrane of claim 11 , where said first thermoplastic layer includes olefinic polymer.

14 . The thermoplastic roofing membrane of claim 11 , where said first thermoplastic layer includes polymer selected from the group consisting of thermoplastic olefinic polymers (TPOs), polyolefin blends, propylene-based elastomers, ethylene-based olefinic block copolymers, and/or functionalized polyolefin resins.

15 . The thermoplastic roofing membrane of claim 11 , where the mineral filler is calcium carbonate.

16 . A roofing system comprising a substrate; and a thermoplastic membrane adhesively mated to said substrate through a polar adhesive, said polar adhesive adhesively mating the membrane along a mechanically treated surface that exposes mineral filler within the membrane.

17 . The roofing system of claim 16 , where said polar adhesive is a silicon-terminated polymeric adhesive system.

18 . The roofing system of claim 16 , where said polar adhesive is a polyurethane adhesive.

Assignees

• Firestone Building Prod Co Llc

Inventors

• Wang Hao
• Tippmann Donna C

Classifications

• B32B37/206

  Laminating a continuous layer between two continuous plastic layers · CPC title

• B29K2023/08

  Copolymers of ethylene (B29K2023/16 takes precedence) · CPC title

• B29K2023/06

  PE, i.e. polyethylene · CPC title

• B29K2023/14

  Copolymers of polypropylene (B29K2023/16 takes precedence) · CPC title

• B29K2023/10

  Polymers of propylene · CPC title