Source: http://www.google.com/patents/US7749924?dq=6,073,142
Timestamp: 2017-11-18 18:39:51
Document Index: 266903

Matched Legal Cases: ['§371', 'Application No. 60', 'Application No. 60', 'Application No. 60', 'Application No. 60', 'Application No. 60']

Patent US7749924 - Thermoplastic roofing membranes - Google Patents
A membrane comprising at least one polymeric layer including i) a plastomer, ii) a low density polyethylene, iii) a propylene-based polymer, and optionally iv) flame retardant....http://www.google.com/patents/US7749924?utm_source=gb-gplus-sharePatent US7749924 - Thermoplastic roofing membranes
Publication number US7749924 B2
Application number US 11/991,231
PCT number PCT/US2006/033522
Also published as CA2621207A1, CA2621207C, US20090137168, WO2007027602A1
Publication number 11991231, 991231, PCT/2006/33522, PCT/US/2006/033522, PCT/US/2006/33522, PCT/US/6/033522, PCT/US/6/33522, PCT/US2006/033522, PCT/US2006/33522, PCT/US2006033522, PCT/US200633522, PCT/US6/033522, PCT/US6/33522, PCT/US6033522, PCT/US633522, US 7749924 B2, US 7749924B2, US-B2-7749924, US7749924 B2, US7749924B2
Inventors Richard Peng
Patent Citations (83), Non-Patent Citations (2), Referenced by (3), Classifications (12), Legal Events (3)
US 7749924 B2
26. The membrane of claim 1, further comprising a scrim positioned between the first and second polymeric layers.
This application is a §371 application of PCT/2006/033522 filed Aug. 29, 2006, which claims the benefit of U.S. Provisional Application No. 60/712,070, filed Aug. 29, 2005, U.S. Provisional Application No. 60/774,349, filed Feb. 17, 2006, U.S. Provisional Application No. 60/775,128, filed Feb. 21, 2006, U.S. Provisional Application No. 60/800,110, filed May 12, 2006, and U.S. Provisional Application No. 60/801,450, filed May 18, 2006, which are incorporated herein by reference.
In one or more embodiments, the plastomer may be characterized by a DSC melting point curve that exhibits the occurrence of a single melting point break occurring in the region of 50 to 110° C.
The propylene-based polymers employed in one or more embodiments of this invention may be characterized by a melt flow rate of from about 0.5 to about 15 dg/min, in other embodiments from about 0.7 to about 12 dg/min, in other embodiments from about 1 to about 10 dg/min, and in other embodiments from about 1.5 to about 3 dg/min per ASTM D-1238 at 230° C. and 2.16 kg load. In these or other embodiments, the propylene-based polymers may have a weight average molecular weight (Mw) of from about 1×105 to about 5×105 g/mole, in other embodiments from about 2×105 to about 4×105 g/mole, and in other embodiments from about 3×105 to about 4×105 g/mole, as measured by GPC with polystyrene standards. The molecular weight distribution of these propylene-based copolymer may be from about 2.5 to about 4, in other embodiments from about 2.7 to about 3.5, and in other embodiments from about 2.8 to about 3.2.
In one or more embodiments, propylene-based polymers may be characterized by a melt temperature (Tm) that is from about 165° C. to about 130° C., in other embodiments from about 160 to about 140° C., and in other embodiments from about 155° C. to about 140° C. In one or more embodiments, particularly where the propylene-based polymer is a copolymer of propylene and a comonomer, the melt temperature may be below 160° C., in other embodiments below 155° C., in other embodiments below 150° C., and in other embodiments below 145° C. In one or more embodiments, they may have a crystallization temperature (Tc) of about at least 90° C., in other embodiments at least about 95° C., and in other embodiments at least 100° C., with one embodiment ranging from 105° to 115° C.
In one or more embodiments, the at least one polymeric layer may include from about 5 to about 50% by weight, in other embodiments from about 10 to about 45% by weight, and in other embodiments from about 15 to about 38% by weight plastomer, based upon the total weight of the polymeric component of the polymeric layer, where the polymeric component refers to all polymeric constituents of the layer, (e.g., plastomer, low density polyethylene, and propylene-based polymer). In these or other embodiments, the polymeric layer may include at least 5% by weight, in other embodiments at least 10% by weight, and in other embodiments at least 15% by weight plastomer, based upon the total weight of the polymeric component of the polymeric layer; in these or other embodiments, the polymeric layer may include less than 50% by weight, in other embodiments less than 45% by weight, and in other embodiments less than 38% by weight plastomer based upon the total weight of the polymeric component of the polymeric layer. In one or more embodiments, the polymeric layer of the membranes of this invention includes sufficient plastomer so as to be flexible at −40° C. In one or more embodiments, the layer includes sufficient plastomer so as to pass the brittle-point test of ASTM D-2137.
In one or more embodiments, the at least one layer of the membranes of this invention may include from about 5 to about 50% by weight, in other embodiments from about 10 to about 45% by weight, and in other embodiments from about 15 to about 35% by weight propylene-based polymer, based upon the total weight of the polymeric component of the polymeric layer. In these or other embodiments, the at least one polymeric layer may include at least 5% by weight, in other embodiments at least 10% by weight, and in other embodiments at least 15% by weight propylene-based polymer, based upon the total weight of the polymeric component of the polymeric layer; in these or other embodiments, the polymeric layer may include less than 50%, in other embodiments less than 49% by weight, and in other embodiments less than 45% by weight propylene-based polymer based upon the total weight of the polymeric component of the polymeric layer. In one or more embodiments, the at least one polymeric layer of the membranes of this invention include sufficient propylene polymer so as to withstand 116° C. aging for 7 days, where membranes or layers that do not withstand these conditions will flow or deform.
In one or more embodiments, the at least one polymeric layer includes less than 10% by weight, in other embodiments less than 5% by weight, in other embodiments less than 2% by weight, and in other embodiments less than 1% by weight rubber based upon the total weight of the layer. In these or other embodiments, the polymeric sheet is substantially devoid of rubber, which refers to an amount that is less than that amount that would have an appreciable impact on the polymeric sheet. In certain embodiments, the polymeric sheet is devoid of rubber. In one or more embodiments, a rubber may include a polymer or polymeric compound having a glass transition temperature that is less than 10° C., in other embodiments less than 0° C., in other embodiments less than −10° C., and in other embodiments less than −20° C. In these or other embodiments, rubbers include those polymers or polymeric compounds that will not crystallize. In these or other embodiments, rubbers include those polymers or polymeric compounds that exhibit less than 10% by weight, in other embodiments less than 5% by weight, in other embodiments less than 2% by weight, in other embodiments less than 1% by weight, and in other embodiments less than 0.5% by weight crystallinity. Exemplary rubber polymers include ethylene-propylene rubber (e.g., propylene content in excess of 30%), ethylene-propylene-diene rubber, isobutylene-paramethylstyrene copolymer, and brominated isobutylene-paramethylstyrene copolymer.
In one or more embodiments, the number of warp and weft yarns can include from about 1 to about 20 yarns in the machine direction and from about 1 to about 20 yarns in the cross-machine direction per square inch, in other embodiments from about 5 to about 15 yarns in the machine direction and from about 5 to 15 yarns in the cross machine direction per square inch, and in other embodiments from about 8 to 12 yarns in the machine direction and from about 8 to 12 yarns in the cross machine direction per square inch. In one particular embodiment, the reinforcing scrim may include a 9×9 1,000 denier scrim that is weft inserted.
EXAMPLES Prophetic Example
Ingredient Weight Commercial Source
LLDPE 30 LX ™ 177 (Huntsman)
m-PE 18.5 Engage ™ 8180 (Dow)
PP-random 12.5 TR ™ 3020F (Sunoco)
AO 0.15 Mayzo ™ BNX 1225 (Mayzo)
AO 0.15 Mayzo ™ BNX 1900 Mayzo)
UV 0.15 Mayzo ™ BLS 1770 (Mayzo)
UV 0.1 Ciba ™ EB 40-70 (Ciba)
Antiblock 0.3 Struktol ™ TR016 (Struktol)
TiO2 4.8 Kronos ™ 2160 (Kronos)
Mag 32 Vertex ™ St (J. M. Huber)
Talc 1.35 Microtuff ™ AG609-D (Specialty Minerals)
The foregoing ingredients can be mixed within a twin screw extruder or a Farrel™ continuous mixer. The mixer can be operated at a temperature up to about 450° to about 470° F. In the case of a twin-crew extruder, the temperature may be ramped up across sequential barrels so as to reach a final barrel temperature of about 450-470° F. The residence time of mixing may be from about 5 to about 10 minutes. Where a Farrel™ continuous mixer is employed, all ingredients can be added at one interval, and the sequence of addition may not be critical. Where a twin-screw extruder is employed, addition of the various ingredients can occur simultaneously or sequentially by employing side feeders.
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U.S. Classification 442/38
Cooperative Classification B32B27/32, C08L23/0815, C08L2205/02, C08L23/10, Y10T428/31909, Y10T428/31938, Y10T442/164, Y10T442/10
Owner name: BFS DIVERSIFIED PRODUCTS, LLC, OHIO
Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:PENG, LICHIH RICHARD, MR.;REEL/FRAME:022069/0112