Composite shingle including polyketone
Various embodiments disclosed relate to a composite shingle. The composite shingle includes a particle layer and a polyketone layer proximate to the particle layer.
1. A composite shingle comprising:
a particle layer; and
a polyketone copolymer layer proximate to the particle layer,
wherein
the polyketone copolymer layer comprises a polyketone copolymer in a range of from about 20 wt % to about 100 wt % of the polyketone copolymer layer,
the polyketone comprises a repeating unit having the structure according to Formula I:
wherein R 1 and R 2 are independently chosen from —H, —OH substituted or unsubstituted (C 1 -C 20 ) hydrocarbyl chosen from (C 1 -C 20 )alkyl, (C 1 -C 20 )alkenyl, (C 1 -C 20 )alkynyl, (C 1 -C 20 )acyl, (C 1 -C 20 )cycloalkyl, (C 1 -C 20 )aryl, and (c 1 -C 20 )alkoxy, combinations thereof.
2. The composite shingle of claim 1 , further comprising an adhesive between the particle layer and the polyketone copolymer layer.
3. The composite shingle of claim 2 , wherein the adhesive comprises asphalt.
4. The composite shingle of claim 1 , wherein the polyketone comprises repeating units according to Formula II:
wherein
R 3 , R 4 , R 5 , R 6 , R 7 , R 8 , R 9 , and R 10 are independently chosen from —H, —OH, substituted or unsubstituted (C 1 -C 20 )hydrocarbyl,
a degree of polymerization of m and n are independently between 0 and 1 and the repeating are in random, block, or alternating configuration.
5. The composite shingle of claim 4 , wherein the (C 1 -C 20 )hydrocarbyl is chosen from (C 1 -C 20 )alkyl, (C 1 -C 20 )alkenyl, (C 1 -C 20 )alkynyl, (c 1 -C 20 )acyl, (C 1 -C 20 )cycloalkyl, (C 1 -C 20 )aryl, and (C 1 -C 20 )alkoxy, combinations thereof.
6. The composite shingle of claim 4 , wherein R 10 is —CH 3 .
7. The composite shingle of claim 4 , wherein R 3 , R 4 , R 5 , R 6 , R 7 , R 8 , and R 9 are each —H.
8. The composite shingle of claim 1 , further comprising an asphalt layer located between the particle layer and the polyketone copolymer layer.
9. The composite shingle of claim 1 , further comprising a reinforcing layer at least partially embedded in the polyketone copolymer layer.
10. A roof comprising the composite shingle of claim 1 .
11. A composite shingle comprising:
a particle layer comprising a plurality of particles disposed substantially in a plane;
an asphalt layer in direct contact with the particle layers;
a polyketone copolymer layer in direct contact with the asphalt layer, a thickness of the polyketone layer is in a range of from about 0.5 mm to about 10 mm; and
an adhesive layer contacting the polyketone copolymer layer,
wherein the polyketone layer is substantially free of at least one of a polyethylene, a polypropylene, and a mixture thereof, wherein
the polyketone copolymer layer comprises a polyketone copolymer in a range of from about 20 wt % to about 100 wt % of the polyketone copolymer layer,
the polyketone comprises a repeating unit having the structure according to Formula I:
wherein R 1 and R 2 are independently chosen from —H, —OH, substituted or unsubstituted (C 1 -C 20 ) hydrocarbyl chosen from (C 1 -C 20 )alkyl, (C 1 -C 20 )alkenyl, (C 1 -C 20 )alkynyl, (C 1 -C 20 )acyl, (C 1 -C 20 )cycloalkyl, (C 1 -C 20 )aryl, and (C 1 -C 20 )alkoxy, combinations thereof.
12. The composite shingle claim 11 , wherein the polyketone comprises repeating units according to Formula II:
wherein
R 3 , R 4 , R 5 , R 6 , R 7 , R 8 , R 9 , and R 10 are independently chosen from —H, —OH, substituted or unsubstituted (C 1 -C 20 )hydrocarbyl,
a degree of polymerization of m and n are independently between 0 and land the repeating are in random, block, or alternating configuration.
13. The composite shingle of claim 12 , wherein the asphalt layer comprises asphalt in a range of from about 30 wt % to about 100 wt % of the asphalt layer.
14. A method of making a composite shingle, the method comprising contacting a polyketone copolymer layer with at least one of a particle layer, an asphalt layer, a reinforcing layer, and an adhesive layer, wherein
the polyketone copolymer layer comprises a polyketone copolymer in a range of from about 20 wt % to about 100 wt % of the polyketone copolymer layer,
the polyketone comprises a repeating unit having the structure according to Formula I:
wherein R 1 and R 2 are independently chosen from —H, —OH, substituted or unsubstituted (C 1 -C 20 ) hydrocarbyl chosen from (C 1 -C 20 )alkyl, (C 1 -C 20 )alkenyl, (C 1 -C 20 )alkynyl, (C 1 -C 20 )acyl, (C 1 -C 20 )cycloalkyl, (C 1 -C 20 )aryl, and (C 1 -C 20 )alkoxy, combinations thereof.
15. The method of claim 14 , further comprising at least partially embedding the reinforcing layer in the polyketone copolymer layer.
16. The method of claim 14 , further comprising at least partially embedding the reinforcing layer in the asphalt layer.