# US 2010/0167013 A1 · Thermoplastic roofing membranes

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- Number: US 2010/0167013 A1
- Document ID: US20100167013A1
- Status: Published application
- Kind: A1
- Application number: 12/456,487
- Filed: 2009-06-17
- Published: 2010-07-01
- Earliest claimed: 2008-12-30
- Inventors: Carlos A. Cruz; Willi Lau; Joseph M. Rokowski
- Web page: https://patentgrep.com/patent/US20100167013A1

## CPC

- B32B 27/08: of synthetic resin
- B32B 27/304: {comprising vinyl halide (co)polymers, e.g. PVC, PVDC, PVF, PVDF}
- B32B 27/308: {comprising acrylic (co)polymers}
- E04D 5/10: by making use of compounded or laminated materials, e.g. metal foils or plastic films coated with bitumen
- B32B 2255/24: Organic non-macromolecular coating
- B32B 2272/00: Resin or rubber layer comprising scrap, waste or recycling material
- B32B 2307/7265: Non-permeable
- B32B 2419/06: Roofs, roof membranes
- Y10T 428/24405: Polymer or resin [e.g., natural or synthetic rubber, etc.]
- B32B: LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- E04D: ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS (coverings of outer walls by plaster or other porous material E04F13/00)
- Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION

## Abstract

The present invention provides thermoplastic roofing membranes comprising particles of crosslinked rubber and an aqueous (co)polymer dispersion. The thermoplastic roofing membranes are formed by combining particles of crosslinked rubber and a suspension polymer dispersion, or a coagulated aqueous latex (co)polymer dispersion, to form a mixture in aqueous dispersion, which aqueous dispersion mixture is subjected to solid state shear pulverization to form materials that can be processed as thermoplastics at crosslinked rubber concentrations of from 10 wt.% to as high as 95 wt.%, based on the total solids of the material. The method may further comprise kneading the pulverized product, followed by extrusion to form roofing membranes.

## Claims

### Claim 1

A roof membrane made by a process comprising:
(a) coagulating one or more aqueous polymer dispersion to produce a coagulated aqueous polymer dispersion with a weight average particle size of from about 1 micron to about 1,000 microns;
(b) combining particles of one or more crosslinked rubber with the aqueous polymer dispersion, before or after coagulating the aqueous polymer dispersion, to form an aqueous dispersion mixture in aqueous dispersion;
(c) subjecting the aqueous dispersion mixture to solid state shear pulverization and thereby producing a pulverized mixture;
(d) reducing the moisture content of the mixture; and
(e) forming the roof membrane;
wherein the coagulating of the one or more aqueous polymer dispersion may be carried out either prior to combining with the particles of crosslinked rubber, or in the presence of the particles of the crosslinked rubber.

### Claim 2 (depends on 1)

The roof membrane of claim 1 wherein the process further comprises extruding the pulverized mixture to form the roof membrane.

### Claim 3 (depends on 1)

The roof membrane of claim 1 wherein the particle size of the crosslinked rubber is 43 micron sieve particle size (325 mesh) or more, or 11,100 micron sieve particle size (2 mesh) or less.

### Claim 4 (depends on 1)

The roof membrane of claim 1 wherein the crosslinked rubber is obtained, at least in part, from recycled tires.

### Claim 5 (depends on 1)

The roof membrane of claim 1 wherein the aqueous polymer dispersion that is coagulated is obtained from an emulsion polymer dispersion.

### Claim 6 (depends on 1)

The roof membrane of claim 1 wherein the coagulated aqueous polymer dispersion is obtained from the waste stream of an emulsion polymer manufacturing facility.

### Claim 7 (depends on 1)

The roof membrane of claim 1 wherein reducing the moisture content of the pulverized mixture comprises isolating the solid content of the pulverized mixture.

### Claim 8 (depends on 1)

The roof membrane of claim 1 wherein the solid state shear pulverization comprises pan milling or disk milling.

### Claim 9 (depends on 1)

The roof membrane of claim 1 wherein the coagulated aqueous polymer dispersion comprises a copolymer having polymerized units of one or more functional monomers with functionality chosen from carboxy acid functionality, phosphorus acid functionality, hydroxy functionality, amine functionality, acetoacetoxy functionality, silyl functionality, epoxy functionality, cyano functionality, isocyanate functionality, and combinations thereof.

### Claim 10 (depends on 1)

The roof membrane of claim 1 wherein the roof membrane is further crosslinked during processing, which processing comprises one or more of kneading, or extrusion, or two-roll milling, or heat molding, or compression molding.

### Claim 11 (depends on 1)

The roof membrane of claim 1 wherein the process further comprises coating the membrane with a white coating or overlaying or laminating an acrylic sheet or PVC sheet or foil sheet on the roof membrane.

### Claim 12

A roof membrane made by a process comprising:
(a) combining particles of one or more crosslinked rubber with an aqueous polymer dispersion to form an aqueous dispersion mixture in aqueous dispersion;
(c) subjecting the aqueous dispersion mixture to solid state shear pulverization;
(d) reducing the moisture content of the mixture; and
(e) forming a roof membrane;
wherein the aqueous polymer dispersion is obtained by suspension polymerization.