Use of thermoplastic polyurethanes in rubber modified bitumen roofing membranes

1. A prefabricated flexible membrane having high stability to ultraviolet (UV) exposure, said prefabricated flexible membrane comprising a fabric or mat material that includes a coating composition, said coating composition coated on at least one outer surface of said fabric or mat material, at least partially impregnated in said fabric or mat material, or combinations thereof, said coating composition comprising a petroleum liquid, polymer, and thermoplastic polyurethane, said petroleum liquid including one or more materials selected from the group consisting of asphalt, modified asphalt, bitumen, modified bitumen, coal-tar and modified coal tar, said polymer including one or more compounds selected from the group constituting of block polymer and plastomer, said polymer includes one or more compounds selected from the group consisting of Amorphous Poly-Alpha-Olefin (APAO), Atactic Polypropylene (APP), Ethylene-Vinyl Acetate (EVA), Polyphthalamide (PPA), Polymeric Polyisocyanate (PPI), Styrene-Ethylene/Butylene-Styrene (SEBS), Styrene-Butadiene-Styrene (SBS) and Styrene-Isoprene-Styrene(SIS), said thermoplastic polyurethane includes one or more compounds selected from the group consisting of polyether backbone Thermoplastic Polyurethane (TPU), polyester backbone TPU, polyether/polyester backbone TPU and polycarbonate backbone TPU.

2. The prefabricated flexible membrane as defined in claim 1 , wherein said fabric or mat material is substantially fully impregnated with said coating material.

3. The prefabricated flexible membrane as defined in claim 1 , wherein said polymer includes oil extended SBS.

4. The prefabricated flexible membrane as defined in claim 1 , wherein said coating composition includes a filler, said filler includes one or more compounds selected from the group consisting of alumina trihydrate (ATH), calcium carbonate, chalk, clay, dolomite, kaolin, reinforced fibers, silica, talc, coloring agents, metal flakes, UV resistance agents, adhesion enhancers, fire retardants, biocides, oils and softening agents.

5. The prefabricated flexible membrane as defined in claim 1 , wherein a weight percent of said petroleum liquid being greater than a weight percent of said polymer, said weight percent of said petroleum liquid being greater than a weight percent of said thermoplastic polyurethane.

6. The prefabricated flexible membrane as defined in claim 5 , wherein said weight percent of said polymer is greater than said weight percent of said thermoplastic polyurethane, said weight percent of said petroleum liquid is greater than a combined weight percent of said polymer and said thermoplastic polyurethane.

7. The prefabricated flexible membrane as defined in claim 1 , comprising by weight percent:

Petroleum Liquid

30-80

wt. %

Polymer

0.5-40

wt. %

Thermoplastic polyurethane

0.1-25

wt. %

Filler and/or additives

0-69.4

wt. %.

8. The prefabricated flexible membrane as defined in claim 1 , comprising by weight percent:

Petroleum Liquid

30-80 wt. %

Polymer

1-40 wt. %

Thermoplastic polyurethane

0.1-15 wt. %

Filler and/or additives

0-68.9 wt. %.

9. The prefabricated flexible membrane as defined in claim 1 , comprising by weight percent:

Petroleum Liquid

30-80 wt. %

Polymer

1-40 wt. %

Thermoplastic polyurethane

0.1-9 wt. %

Filler and/or additives

0-68.9 wt. %.

10. The prefabricated flexible membrane as defined in claim 1 , comprising by weight percent:

Petroleum Liquid

30 to less than 40 wt. % 

Polymer

1-40 wt. % 

Thermoplastic polyurethane

0.1-15 wt. % 

Filler and/or additives

6-68.9 wt. %.

11. The prefabricated flexible membrane as defined in claim 1 , comprising by weight percent:

Petroleum Liquid

30-80 wt. % 

Polymer

1-25 wt. % 

Thermoplastic polyurethane

0.5-15 wt. % 

Filler and/or additives

0-68.5 wt. %.

12. The prefabricated flexible membrane as defined in claim 1 , comprising by weight percent:

Asphalt

30-75 wt. % 

APP, SEBS, SBS and/or SIS

5-20 wt. % 

Thermoplastic polyurethane

0.5-10 wt. % 

Filler and/or additives

0-64.5 wt. %.

13. The prefabricated flexible membrane as defined in claim 1 , comprising by weight percent:

Asphalt

30-70 wt. % 

SEBS and/or SBS

8-18 wt. % 

Polyether backbone TPU

1-9 wt. % 

Filler and/or additives

4-50 wt. %.

14. The prefabricated flexible membrane as defined in claim 1 , comprising by weight percent:

Asphalt

35-65 wt. % 

SBS

10-16 wt. % 

Polyether backbone TPU

2-8 wt. % 

Filler and/or additives

12-50 wt. %.

15. The prefabricated flexible membrane as defined in claim 1 ,

wherein a weight percent ratio of said petroleum liquid to said polymer is about 1.05-40:1.

16. The prefabricated flexible membrane as defined in claim 1 , wherein a weight percent ratio of said polymer to said TPU is about 1.01-20:1.

17. The prefabricated flexible membrane as defined in claim 15 , wherein a weight percent ratio of said polymer o said TPU is about 1.01-20:1.

18. The prefabricated flexible membrane as defined in claim 1 , wherein a weight percent ratio of said petroleum liquid to a combined weight percent of said polymer and said TPU is about 1.01-10:1.

19. The prefabricated flexible membrane as defined in claim 17 , wherein a weight percent ratio of said petroleum liquid to a combined weight percent of said polymer and said TPU is about 1.01-10:1.

20. A prefabricated flexible membrane having high stability to ultraviolet (UV) exposure, said prefabricated flexible membrane comprising a fabric or mat material that includes a coating composition, said fabric or mat material is substantially fully impregnated with said coating material, said coating composition comprising a petroleum liquid, polymer, and thermoplastic polyurethane, said petroleum liquid including one or more materials selected from the group consisting of asphalt, modified asphalt, bitumen, modified bitumen, coal-tar and modified coal tar, said polymer including one or more compounds selected from the group constituting of block polymer and plastomer, said polymer includes one or more compounds selected from the group consisting of Amorphous Poly-Alpha-Oletin (APAO), Atactic Polypro ylene (APP), Ethylene-Vinyl Acetate (EVA), Polyphthalamide (PPA), Polymeric Polyisocyanate (PPI), Styrene-Ethylene/Butyl ene-Styrene (SEBS), Styrene-Butadiene-Styrene (SBS) and Styrene-Isoprene-Styrene(SIS), said thermoplastic polyurethane includes one or more compounds selected from the group consisting of polyether backbone Thermoplastic Polyurethane (TPU), polyester backbone TPU, polyether/polyester backbone TPU and polycarbonate backbone TPU, a weight percent ratio of said petroleum liquid to said polymer is about 1.05-40:1, a weight percent ratio of said polymer to said TPU is about 1.01-20:1, a weight percent ratio of said petroleum liquid to a combined weight percent of said polymer and said TPU is about 1.01-10:1.

21. The prefabricated flexible membrane as defined in claim 20 , wherein said coating composition includes a tiller, said tiller includes one or more compounds selected from the group consisting of alumina trihydrate (ATH), calcium carbonate, chalk, clay, dolomite, kaolin, reinforced fibers, silica, talc, coloring agents, metal flakes, UV resistance agents, adhesion enhancers, fire retardants, biocides, oils and softening agents.

22. The prefabricated flexible membrane as defined in claim 20 , comprising by weight percent:

Petroleum Liquid

30-80

wt. %

Polymer

0.5-40

wt. %

Thermoplastic polyurethane

0.1-25

wt. %

Filler and/or additives

0-69.4

wt. %.

23. The prefabricated flexible membrane as defined in claim 20 , comprising by weight percent:

Petroleum Liquid

30-80 wt. % 

Polymer

1-40 wt. % 

Thermoplastic polyurethane

0.1-15 wt. % 

Filler and/or additives

0-68.9 wt. %.

24. The prefabricated flexible membrane as defined in claim 20 , comprising by weight percent:

Petroleum Liquid

30-80 wt. % 

Polymer

1-40 wt. % 

Thermoplastic polyurethane

0.1-9 wt. % 

Filler and/or additives

0-68.9 wt. %.

25. The prefabricated flexible membrane as defined in claim 20 , comprising by weight percent:

Petroleum Liquid

30 to less than 40 wt. % 

Polymer

1-40 wt. % 

Thermoplastic polyurethane

0.1-15 wt. % 

Filler and/or additives

6-68.9 wt. %.

26. The prefabricated flexible membrane as defined in claim 20 , comprising by weight percent:

Petroleum Liquid

30-80 wt. % 

Polymer

1-25 wt. % 

Thermoplastic polyurethane

0.5-15 wt. % 

Filler and/or additives

0-68.5 wt. %.

27. The prefabricated flexible membrane as defined in claim 20 , comprising by weight percent:

Asphalt

30-75 wt. % 

APP, SEBS, SBS and/or SIS

5-20 wt. % 

Thermoplastic polyurethane

0.5-10 wt. % 

Filler and/or additives

0-64.5 wt. %.

28. The prefabricated flexible membrane as defined in claim 20 , comprising by weight percent:

Asphalt

30-70 wt. % 

SEBS and/or SBS

8-18 wt. % 

Polyether backbone TPU

1-9 wt. % 

Filler and/or additives

4-50 wt. %.

29. The prefabricated flexible membrane as defined in claim 20 , comprising by weight percent:

Asphalt

35-65 wt. % 

SBS

10-16 wt. % 

Polyether backbone TPU

2-8 wt. % 

Filler and/or additives

12-50 wt. %.

30. The prefabricated flexible membrane as defined in claim 20 , wherein said weight percent ratio of said petroleum liquid to said polymer is about 1.6-5:1.

31. The prefabricated flexible membrane as defined in claim 20 , wherein said weight percent of said polymer to said TPU is about 1.4-8:1.

32. The prefabricated flexible membrane as defined in claim 31 wherein said weight percent of said polymer to said TPU is about 1.4-8:1.

33. The prefabricated flexible membrane as defined in claim 20 , wherein said weight percent of said petroleum liquid to said combined weight percent of said polymer and said TPU is about 1.4-5:1.

34. The prefabricated flexible membrane as defined in claim 33 , wherein said weight percent of said petroleum liquid to said combined weight percent of said polymer and said TPU is about 1.4-5:1.