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.

Description

RELATED APPLICATIONS

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

This disclosure relates generally to roofing membranes. More specifically, this disclosure relates to silicon roofing membranes.

BACKGROUND

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

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.

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.

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.

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.

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.

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.

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.

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.

In some embodiments, the roofing membrane includes an embedded reinforcement, scrim, woven fabric, nonwoven fabric, mesh, or any combination thereof.

In some embodiments, the roofing membrane is configured to seal a penetration therethrough.

In some embodiments, the roofing membrane is more flexible than a TPO roofing membrane.

In some embodiments, the second resin cures in a time range of 1 to 72 hours after being installed.

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

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.

FIG. 1 is a flowchart of a method for preparing a roofing membrane, according to some embodiments.

FIG. 2 is a flowchart of a method for installing a roofing membrane, according to some embodiments.

Like reference numbers represent the same or similar parts throughout.

DETAILED DESCRIPTION

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.

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.

All prior patents, publications, and test methods referenced herein are incorporated by reference in their entireties.

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.

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.

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.

In some embodiments, the first resin is not moisture curable.

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.

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.

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.

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.

In some embodiments, thermally curable resins include polyether, polyethylene, polypropylene, polystyrene, thermoplastic polyolefin (TPO), polyvinyl chloride (PVC), polycarbonate, rosin, or any combination thereof.

In some embodiments, radical curable resins include acrylate, methylacrylate, vinyl silicone, or any combination thereof.

In some embodiments, polymer curable resins include isocyanate polymer, polyol, polyamine, or any combination thereof.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

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.

In some embodiments, the roofing membrane includes an embedded reinforcement, scrim, woven fabric, nonwoven fabric, mesh, or any combination thereof.

In some embodiments, the roofing membrane is configured to seal a penetration therethrough.

In some embodiments, the roofing membrane is more flexible than a TPO roofing membrane.

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. 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.

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.

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.

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.

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.