Polyvinyl ester formulations, methods of making the same roofing materials and roofing systems including the same

1. A roofing material comprising:

a substrate,

wherein the substrate comprises at least one of a fiberglass mat, a polyester mat, or any combination thereof;

at least one reinforcement material; and

at least one polyvinyl ester,

wherein the at least one polyvinyl ester is interspersed with the at least one reinforcement material,

wherein the at least one polyvinyl ester comprises the following polymer chain segments:

wherein R is an ester group, and

wherein the polymer chain segment B′ is different from the polymer chain segment C; and

wherein the roofing material exhibits at least one of the following:

an elongation of 50% to 500% based on ASTM D828,

a tensile strength of 35 lbf to 130 lbf, based on ASTM D828,

a tear of 500 gf to 2500 gf, based on ASTM D1922, or

any combination thereof.

2. The roofing material of claim 1 ,

wherein the at least one reinforcement material is present in an amount of 1 wt % to 50 wt % based on a total weight of the roofing material, and

wherein the at least one polyvinyl ester is present in an amount of 50 wt % to 99 wt % based on the total weight of the roofing material.

3. The roofing material of claim 1 , wherein the at least one reinforcement material comprises at least one of ground tire rubber, asphalt shingle waste, at least one organic filler, at least one mineral filler, at least one antioxidant, at least one fire retardant, or any combination thereof.

4. The roofing material of claim 1 , wherein the ester group of the polymer chain segment B′ of the at least one polyvinyl ester is at least one of a carboxylate group, a fatty acid ester group, or any combination thereof.

5. The roofing material of claim 1 , wherein the ester group of the polymer chain segment B′ of the at least one polyvinyl ester is at least one of a lactate group, a formate group, a citrate group, an oxalate group, a maleate group, a tartrate group, an oleate group, or any combination thereof.

6. A roofing system comprising:

a roof substrate; and

a roofing material on the roof substrate,

wherein the roofing material comprises:

a substrate,

wherein the substrate comprises at least one of a fiberglass mat, a polyester mat, or any combination thereof,

at least one reinforcement material; and

at least one polyvinyl ester,

wherein the at least one polyvinyl ester is interspersed with the at least one reinforcement material,

wherein the at least one polyvinyl ester comprises the following polymer chain segments:

 wherein R is an ester group, and

wherein the polymer chain segment B′ is different from the polymer chain segment C; and

wherein the roofing material exhibits at least one of the following:

an elongation of 50% to 500% based on ASTM D828,

a tensile strength of 35 lbf to 130 lbf, based on ASTM D828,

a tear of 500 gf to 2500 gf, based on ASTM D1922, or

any combination thereof.

7. The roofing system of claim 6 , wherein the roof substrate comprises a roof deck.

8. The roofing system of claim 6 ,

wherein the at least one reinforcement material is present in an amount of 1 wt % to 50 wt % based on a total weight of the roofing material, and

wherein the at least one polyvinyl ester is present in an amount of 50 wt % to 99 wt % based on the total weight of the roofing material.

9. The roofing system of claim 6 , wherein the at least one reinforcement material comprises at least one of ground tire rubber, asphalt shingle waste, at least one organic filler, at least one mineral filler, at least one antioxidant, at least one fire retardant, or any combination thereof.

10. The roofing system of claim 6 , wherein the ester group of the polymer chain segment B′ of the at least one polyvinyl ester is at least one of carboxylate group, a fatty acid ester group, or any combination thereof.

11. The roofing system of claim 6 , wherein the ester group of the polymer chain segment B′ of the at least one polyvinyl ester is at least one of a lactate group, a formate group, a citrate group, an oxalate group, a maleate group, a tartrate group, an oleate group, or any combination thereof.

12. A method comprising:

obtaining a substrate,

wherein the substrate comprises at least one of a fiberglass mat, a polyester mat, or any combination thereof;

obtaining a mixture,

wherein the mixture comprises:

at least one vinyl polymer,

wherein the at least one vinyl polymer comprises the following polymer chain segments:

at least one organic acid, and

at least one hydronium ion donor; and

reacting the —OH group of the B polymer chain segment with the at least one organic acid in the presence of the at least one hydronium ion donor, so as to form at least one polyvinyl ester,

wherein the at least one polyvinyl ester comprises the following polymer chain segments:

wherein R is an ester group, and

wherein the polymer chain segment B′ is different from the polymer chain segment C; and

applying the at least one polyvinyl ester onto the substrate, so as to form a roofing material, wherein the at least one polyvinyl ester is interspersed with at least one reinforcement material.

13. The method of claim 12 , wherein the at least one organic acid comprises at least one of a carboxylic acid, a fatty acid, or any combination thereof.

14. The method of claim 13 ,

wherein the carboxylic acid is at least one of lactic acid, citric acid, oxalic acid, malic acid, tartaric acid, acid anhydride, or any combination thereof;

wherein the fatty acid is at least one of a saturated fatty acid, an unsaturated fatty acid, or any combination thereof.

15. The method of claim 14 ,

wherein the saturated fatty acid is at least one of caprylic acid, capric acid, lauric acid, myristic acid, palmitic acid, stearic acid, arachidic acid, behenic acid, lignoceric acid, cerotic acid, or any combination thereof;

wherein the unsaturated fatty acid is at least one of myristoleic acid, palmitoleic acid, sapienic acid, oleic acid, elaidic acid, vaccenic acid, linoleic acid, linoelaidic acid, α-linolenic acid, arachidonic acid, eicosapentaenoic acid, erucic acid, docosahexaenoic acid, or any combination thereof.

16. The method of claim 12 , wherein the at least one hydronium ion donor comprises at least one of water, an acid, an aqueous solution, an alcohol, or any combination thereof.

17. The method of claim 16 ,

wherein the acid comprises at least one of hydrochloric acid, nitric acid, phosphoric acid, sulfuric acid, hydrobromic acid, boric acid, hydrofluoric acid, perchloric acid, hydroiodic acid, or any combination thereof;

wherein the aqueous solution is a salt solution comprising at least one of alkaline metal ions, alkaline earth metal ions, transition metal ions, ammonium ions, halide ions, carbonate ions, nitrate ions, nitrite ions, phosphate ions, sulfate ions, or any combination thereof;

wherein the alcohol is at least one of methanol, ethanol, butanol, isopropyl alcohol, or any combination thereof.

18. The method of claim 12 , wherein the at least one vinyl polymer is present in the mixture an amount of 30 wt % to 90 wt % based on a total weight of the mixture.

19. The method of claim 12 , wherein the at least one organic acid is present in an amount of 5 wt % to 60 wt % based on a total weight of the mixture.

20. The method of claim 12 , wherein the at least one hydronium ion donor is present in an amount of 0.1 wt % to 10 wt % based on a total weight of the mixture.