Composite materials for roofing applications

Abstract

Composite materials and methods for making such materials are provided. These materials may be particularly useful as roofing materials for flat or low sloped roofs to protect the roof and building from water, heat, fire or other elements. A composite material comprises a water resistant layer comprising a polymer and a filler material incorporated into the water resistant layer. The filler material comprises a flame retardant material that limits heat transfer therethrough. This provides a watertight seal for a structure, such as a roof, while also providing adequate protection against fire or other sources of heat that may damage the building. The composite material may further include a non-woven layer bonded to the water resistant layer with a temperature sensitive adhesive to form a membrane roofing substrate.

Description

COMPOSITE MATERIALS FOR ROOFING APPLICATIONSTECHNICAL FIELD

[0001] This description generally relates to composite materials that reduce heat transfer andmore particularly to roofing materials for use on flat or low sloped roofs that include flame5 retardants and / or heat resistant materials.BACKGROUND

[0002] Continuous sheet roofing products have been used extensively in commercial andresidential building applications which involve large roof expanses, particularly with flat orshallow pitched roofs. This popularity of sheet roofing is due to a variety of factors, including10 convenience and speed of installation, reduced material and labor costs and longevity andreliability of the installed roof. Many sheet roofing products include synthetic rubber orthermoplastic sheets which are applied from rolls and attached to the roof via a variety ofadhesives and fasteners

[0003] Membrane roofing is a type of roofing system for buildings that creates a continuous15 watertight covering to protect the interior of a building. Membrane roofs are most commonlymade from cured or uncured elastomers, plastomers (e.¢., thermoplastics) or modified bitumen,or modified bitumen.

[0004] Membrane roofs provide distinct advantages over the previously more common flatroofing method of asphalt and gravel (commonly referred to as Built-Up-Roofs or "BUR"}. In20 asphalt and gravel applications, for example, it can be very difficult to create a proper seal atall seams and connection points. This can cause a roof to leak early in its lifespan, and requireruch more maintenance. When installed correctly, newer materials are either seamless, orhave seams as strong as the body. This eliminates most of the leakage concerns associated withflat roofing systems.25

[0005] While these membrane roofs provide a number of advantages, they also suffer fromcertain drawbacks. For example, the water resistant elastomer layer typically provides little tono resistance to heat transferring through the membrane. Thus, these membrane roofs are notas fire resistant as conventional asphait, gravel, concrete, slate or metal roofing materials and,itherefore, do not provide adequate protection from embers, firebrands, radiant heat exposureor direct flame contact.

[0006] What is needed, therefore, are roofing materials that provide the watertight benefitsof membrane roofing materials, while also providing adequate protection against fire or other5 sources of heat that may damage the building.SUMMARY

[0007] The following presents a simplified summary of the claimed subject matter in orderto provide a basic understanding of some aspects of the claimed subject matter. This summaryis not an extensive overview of the claimed subject matter. It is intended to neither identify key10 _ orcritical elements of the claimed subject matter nor delineate the scope of the claimed subjectmatter. Its sole purpose is to present some concepts of the claimed subject matter in a simplifiedform as a prelude to the more detailed description that is presented later.

[0008] Composite materials and methods for making such composite materials are provided.These materials may be particularly useful as roofing materials for flat or low sloped roofs to15. protect the roof and building or other structure from water, heat, fire or other elements.

[0009] In one aspect, a composite material comprises a water resistant layer comprising apolymer and a filler material incorporated into the water resistant layer. The filler materialcomprises a flame retardant material that limits heat transfer therethrough. This provides awatertight seal of a structure or substrate, such as a roof, while also providing adequate20 protection against fire or other sources of heat that may damage the building.

[0010] In embodiments, the polymer comprises an elastomer that provides sufficient waterresistance to maintain an adequate watertight seal. Suitable elastomers for use in the compositematerial include synthetic or natural rubbers, ethylene propylene diene monomer rubber(EPDM), butyl rubber, polyisobutylene (PIB), polyvinyl chloride (PVC), thermoplastic25 polyolefin (TPO) or combinations thereof. In an exemplary embodiment, the polymercomprises PIB.

[0011] In embodiments, the filler material comprises a material suitable for resisting heattransfer and / or retarding flames. In certain embodiments, the filler material comprises fibersthat are mixed with the elastomer to form the water resistant layer. Suitable filler materials foruse with the composite material include melamine, melamine polyphosphate, aluminumtrihydroxide, antimony trihydroxide, phosphorous, ammonium polyphosphate, halogenatedorganic materials, PBDE, TBBPA, mica and mica derivatives, vermiculite and vermiculitederivatives, polybutylene terephthalate, chalk, silica, or combinations thereof. In an exemplary5 embodiment, the filler material comprises aluminum trihydroxide or a combination of chalkand silica.

[0012] In embodiments, the composite material further includes a non-woven layer bondedto the water resistant layer. The non-woven layer may comprise a fleece, felt or other suitablematerial for contacting a substrate or structure, such as a roof substrate.10

[0013] The composite material may further comprise an adhesive between the non-wovenlayer and the water resistant layer. The adhesive may comprise a temperature resistantadhesive and at least some of the adhesive may be disposed within the non-woven layer tobond the composite material to a substrate or structure, such as a roof substrate. Suitabletemperature resistant adhesives include butyl glue, hot melt adhesives, silicone glue and the15 like.

[0014] The composite material may include a release liner removably coupled to the waterresistant layer. The release liner allows the composite material to be handled prior to adheringit to the roof substrate.

[0015] In certain embodiments, the water resistant layer further comprises a polymer having20 a percentage of total weight of the water resistant layer that provides a sufficient hardness tothe water resistant layer to allow the layer to be walked on without being substantially indented.In certain embodiments, the hardness of the water resistant layer is at least about 60 Shore O.In an exemplary embodiment, the hardness is at least about 78 Shore O.

[0016] The polymer is preferably about 40% to about 75%, or about 50% to about 60%25 percent by weight of the overall water resistant layer. Suitable polymers include ultra-lowdensity polyethylene (ULDPE), low density polyethylene (LDPE), high density polyethylene(HDPE), polypropylene (PP), polyvinyl chloride and vinyl derivatives, polystyrene,polyethylene terephthalate (polyester), polyamides or combinations thereof. In an exemplaryembodiment, the polymer comprises ULDPE.30

[0017] In another aspect, a method for making a composite material comprises providingfibers of a flame retardant filler material and mixing the fibers with a polymer to form a waterresistant layer. The polymer may comprise an elastomer that provides sufficient waterresistance to maintain an adequate watertight seal.

[0018] In embodiments, the fibers and the elastomer are ground together with one or more5 moving blades through a shearing process. In an exemplary embodiment, the fibers andelastomer are mixed together in a robust mixing device, such as a Branbury mixer or the like,that includes a series of rams and rotators that provide the mixing action and compresses thefibers into the polymer to form the water resistant layer.

[0019] In one embodiment, a polymer, such as ULDPE or the like, is mixed and ground10 together with the fibers and the elastomer in the same process. Alternatively, the polymermay be added to the water resistant layer after the fibers and elastomer have been mixedtogether.

[0020] Incertain embodiments, the fibers and the polymers may be extruded together to formthe water resistant layer. In one embodiment, the extrusion occurs after the mixing described15. above. In another embodiment, the extrusion replaces the mixing step and serves to mix theelastomer with the fibers into the water resistant layer. In this embodiment, the method furthercomprises mixing a plasticizer with the fibers and the polymer to facilitate extrusion of theelastomer. Once the fibers are suitably mixed with the elastomer, the composite may becalendared to form a moderately incompressible layer.20

[0021] Incertain embodiments, the method further comprises bonding a non-woven layer tothe water resistant layer. The layers may be bonded together with, for example, a temperatureresistant adhesive.

[0022] In embodiments, a release liner may be removably coupled to the water resistantlayer. The release liner allows the composite material to be handled prior to adhering it to the25 roof substrate.

[0023] The recitation herein of desirable objects which are met by various embodiments ofthe present description is not meant to imply or suggest that any or all of these objects arepresent as essential features, either individually or collectively, in the most generalembodiment of the present description or in any of its more specific embodiments.BRIEF DESCRIPTION OF THE DRAWINGS

[0024] FIG. 1 is a schematic of the layers of a composite material for a structure, such as aroof; and

[0025] FIG. 2 illustrates the composite material of FIG. 1 with the layers bonded to each5 other.DETAILED DESCRIPTION

[0026] This description and the accompanying drawings illustrate exemplary embodimentsand should not be taken as limiting, with the claims defining the scope of the presentdescription, including equivalents. Various mechanical, compositional, structural, and10 operational changes may be made without departing from the scope of this description and theclaims, including equivalents. In some instances, well-known structures and techniques havenot been shown or described in detail so as not to obscure the description. Like numbers in twoor more figures represent the same or similar elements. Furthermore, elements and theirassociated aspects that are described in detail with reference to one embodiment may,15. whenever practical, be included in other embodiments in which they are not specifically shownor described. For example, if an element is described in detail with reference to oneembodiment and is not described with reference to a second embodiment, the element maynevertheless be claimed as included in the second embodiment. Moreover, the depictionsherein are for illustrative purposes only and do not necessarily reflect the actual shape, size, or20 dimensions of the system or illustrated components.

[0027] It is noted that, as used in this specification and the appended claims, the singularforms “a,” “an,” and “the,” and any singular use of any word, include plural referents unlessexpressly and unequivocally limited to one referent. As used herein, the term “include” and itsgrammatical variants are intended to be non-limiting, such that recitation of items in a list is25 not to the exclusion of other like items that can be substituted or added to the listed items.

[0028] Except as otherwise noted, any quantitative values are approximate whether the word“about” or “approximately” or the like are stated or not. The materials, methods, and examplesdescribed herein are illustrative only and not intended to be limiting.

[0029] Composite materials are provided for resisting heat transfer through the material.These materials may be particularly useful as waterproof sheeting layers or membranes forcovering roof substrates on flat or low sloped roofs. The composite materials may, forexample replace lead for roofing materials and / or may be used for flashing waterproof areas.

[0030] Referring now to FIGS. 1 and 2, a composite material 10 for roofing substrates5 comprises a water resistant layer 20. In some embodiments, the material 10 may furthercomprise an adhesive layer 30 and a non-woven layer 40. The adhesive layer 30 bonds nonwoven layer 40 to water resistant layer 20. In other embodiments, composite material 10does not comprise the non-woven layer 40.

[0031] Water resistant layer 20 comprises an elastomer that provides sufficient water10 resistance to maintain an adequate watertight seal. Suitable elastomers for use in the compositematerial include synthetic or natural rubbers, ethylene propylene diene monomer rubber(EPDM), butyl rubber, polyisobutylene (PIB), polyvinyl chloride (PVC), thermoplasticpolyolefin (TPO) or combinations thereof. I

[0032] nan exemplary embodiment, the polymer comprises PIB. The PIB layer may have a15 thickness of about 1 mm to about 2 mm, preferably about 1.3 mm.

[0033] The water resistant layer 20 further includes one or more filler materials incorporatedtherein. The filler material(s) comprise a flame retardant material that limits heat transfertherethrough. The filler material is typically about 25% to about 60%, or about 40% to about50% percent by weight of the water resistant layer.20

[0034] . Suitable filler materials for use with the composite material include melamine,melamine polyphosphate, aluminum trihydroxide, antimony trihydroxide, chalk, silica,phosphorous, ammonium polyphosphate, halogenated organic materials, PBDE, TBBPA, micaand mica derivatives, vermiculite and vermiculite derivatives, polybutylene terephthalate,chalk, silica, or combinations thereof. In an exemplary embodiment, the filler material25 comprises aluminum trihydroxide or a combination of chalk and silica.

[0035] In one embodiment, the filler material comprises chalk and silica.

[0036] The adhesive is preferably a weather, aging, and temperature resistant adhesive, andmay have a thickness of about 0.05 mm to about 0.2 mm, preferably about 0.1 mm. Suitabletemperature resistant adhesives include butyl glue, hot melt adhesives, silicone glue and thelike. A suitable butyl glue for use herein is manufactured by Isoltema Group, with headquartersin Gambettoia (FC), Italy.

[0037] The adhesive may include pigments that impart viscosity and mechanically reinforcethe cured adhesive. The adhesive may also include a plasticizer to impart elastomeric5 properties to the cured adhesive.

[0038] The non-woven layer preferably comprises a material that is durable, resistant tofraying and relatively easy to cut. Suitable non-woven layers include fleece, felt or the like.The non-woven layer may have a thickness of about 0.5 to about 2 mm, preferably about 1mm.10

[0039] The composite material may include a release liner removably coupled to the waterresistant layer. The release liner allows the composite material to be handled prior to adheringit to the roof substrate. Suitable release liners include polyvinyl chloride (PVC), polyethylene,low density polyethylene (LDPE) and the like.

[0040] In certain embodiments, the water resistant layer further comprises a polymer having15 a percentage of total weight of the water resistant layer that provides a sufficient hardness tothe water resistant layer. This may, for example, allow the layer to be walked on without beingindented. In certain embodiments, the hardness of the water resistant layer is at least about 60Shore O. In an exemplary embodiment, the hardness is at least about 78 Shore O.

[0041] The polymer is preferably about 40% to about 75%, or about 50% to about 60%20 percent by weight of the overall water resistant layer. Suitable polymers include ultra-lowdensity polyethylene (ULDPE), low density polyethylene (LDPE), high density polyethylene(HDPE), polypropylene (PP), polyvinyl chloride and vinyl derivatives, polystyrene,polyethylene terephthalate (polyester) and polyamides. In an exemplary embodiment, thepolymer comprises ULDPE.25

[0042] Methods for making the composite materials described above are also provided inthis description. In one method, components of a flame retardant filler material are mixed withthe elastomer to form the water resistant layer. These components may include, for example,powders, fibers, or other granulated materials. The powder and the polymer are groundtogether with one or more moving blades through a shearing process. In an exemplary30 embodiment, the powder and polymer are mixed together in a robust mixing device, such as aBranbury mixer or the like, that includes a series of rams and rotators that provide the mixingaction and compress the powder into the polymer to form the water resistant layer.

[0043] The powder and the polymers may be extruded together to form the water resistantlayer. In one embodiment, the extrusion occurs after the mixing described above. In another5 embodiment, the extrusion replaces the mixing step and serves to mix the elastomer with thepowder into the water resistant layer. In this embodiment, the method further comprisesmixing a plasticizer with the powder and the polymer to facilitate extrusion of the polymer.Once the powder is suitably mixed with the polymer, the composite may be calendared to forma moderately incompressible layer.10

[0044] In certain embodiments, the method further comprises bonding a non-woven layer tothe water resistant layer. The layers may be bonded together with, for example, a temperatureresistant adhesive.

[0045] In embodiments, a release liner may be removably coupled to the water resistantlayer. The release liner allows the composite material to be handled prior to adhering it to the15 roof substrate.

[0046] While the devices, systems and methods have been described in detail herein inaccordance with certain preferred embodiments thereof, many modifications and changestherein may be effected by those skilled in the art. Accordingly, the foregoing descriptionshould not be construed to be limited thereby but should be construed to include such20 aforementioned obvious variations and be limited only by the spirit and scope of the followingclaims.

[0047] For example, in a first aspect, a first embodiment is a composite material comprisinga water resistant layer comprising a polymer and a filler material incorporated into the waterresistant layer. The filler material comprises a flame retardant material that limits heat transfer25 therethrough.

[0048] A second embodiment is the first embodiment, wherein the polymer comprises anelastomer.

[0049] A third embodiment is any combination of the first two embodiments, wherein thepolymer comprises a material selected from the group consisting of synthetic or naturalrubbers, ethylene propylene diene monomer rubber (EPDM), butyl rubber, polyisobutylene(PIB), polyvinyl chloride (PVC) and thermoplastic polyolefin (TPO).

[0050] <A 4 embodiment is any combination of the first 3 embodiments, wherein thepolymer comprises polyisobutylene (PIB).5

[0051] A 5" embodiment is any combination of the first 4 embodiments, wherein the fillermaterial comprises a material selected from the group consisting of melamine, melaminepolyphosphate, aluminum trihydroxide, antimony trihydroxide, chalk, silica, phosphorous,ammonium polyphosphate, halogenated organic materials, PBDE, TBBPA, mica and micaderivatives, vermiculite and vermiculite derivatives, polybutylene terephthalate and10 combinations thereof.

[0052] A 6" embodiment is any combination of the first 5 embodiments, wherein the fillermaterial comprises aluminum trihydroxide.

[0053] A 7 embodiment is any combination of the first 6 embodiments, wherein the fillermaterial comprises chalk, silica, or a combination thereof.15

[0054] An 8 embodiment is any combination of the first 7 embodiments, wherein the fillermaterial comprises one or more fibers that are mixed into the PIB.

[0055] A 9" embodiment is any combination of the first 8 embodiments, further comprisinga non-woven layer bonded to the water resistant layer.

[0056] A 10 embodiment is any combination of the first 9 embodiments, further comprising20 an adhesive between the non-woven layer and the water resistant layer.

[0057] An 11" embodiment is any combination of the first 10 embodiments, wherein thenon-woven layer comprises a material selected from the group consisting of fleece and felt.

[0058] A 12 embodiment is any combination of the first 11 embodiments, wherein theadhesive comprises a temperature resistant adhesive.25

[0059] A 13 embodiment is any combination of the first 12 embodiments, wherein theadhesive comprises butyl glue.

[0060] A 14" embodiment is any combination of the first 13 embodiments, furthercomprising a release liner removably coupled to the water resistant layer.

[0061] A 15 embodiment is any combination of the first 14 embodiments, furthercomprising a second polymer in the water resistant layer, the second polymer selected from5 the group consisting of ultra-low density polyethylene (ULDPE), low density polyethylene(LDPE), high density polyethylene (HDPE), polypropylene (PP), polyvinyl chloride and vinylderivatives, polystyrene, polyethylene terephthalate (polyester) and polyamides.

[0062] A 16" embodiment is any combination of the first 15 embodiments, wherein thecomposite material has a hardness of at least about 60 Shore O.10

[0063] A 17" embodiment is any combination of the first 16 embodiments, wherein thecomposite material is configured for attachment to a structure.

[0064] An 18" embodiment is any combination of the first 17 embodiments, wherein thestructure is a roof of a building.

[0065] In another aspect, a first embodiment is a roof membrane comprising a water resistant15 layer comprising a polymer and a filler material incorporated into the water resistant layer.The filler material comprises a flame retardant material that limits heat transfer therethrough.

[0066] A second embodiment is the first embodiment, wherein the polymer comprises anelastomer.

[0067] A third embodiment is any combination of the first 2 embodiments, wherein polymer20 comprises a material selected from the group consisting of synthetic or natural rubbers,ethylene propylene diene monomer rubber (EPDM), butyl rubber, polyisobutylene (PIB),polyvinyl chloride (PVC) and thermoplastic polyolefin (TPO).

[0068] A 4 embodiment is any combination of the first 3 embodiments, wherein thepolymer comprises polyisobutylene (PIB).25

[0069] A 5 embodiment is any combination of the first 4 embodiments, wherein the fillermaterial comprises a material selected from the group consisting of melamine, melaminepolyphosphate, aluminum trihydroxide, antimony tnhydroxide, phosphorous, ammoniumpolyphosphate, halogenated organic materials, PBDE, TBBPA, mica and mica derivatives,vermiculite and vermiculite derivatives, polybutylene terephthalate and combinations thereof.

[0070] A 6" embodiment is any combination of the first 5 embodiments, further comprisinga non-woven layer bonded to the water resistant layer.5

[0071] A 7" embodiment is any combination of the first 6 embodiments, wherein the fillermaterial comprises aluminum trihydroxide.

[0072] An 8" embodiment is any combination of the first 7 embodiments, wherein the fillermaterial comprises chalk, silica, or a combination thereof.

[0073] A 9 embodiment is any combination of the first 8 embodiments, wherein the filler10 material comprises one or more fibers that are mixed into the PIB.

[0074] A 10 embodiment is any combination of the first 9 embodiments, further comprisinga non-woven layer bonded to the water resistant layer.

[0075] An 11 embodiment is any combination of the first 10 embodiments, furthercomprising an adhesive between the non-woven layer and the water resistant layer.15

[0076] A 12 embodiment is any combination of the first 11 embodiments, wherein the nonwoven layer comprises a material selected from the group consisting of fleece and felt.

[0077] A 13 embodiment is any combination of the first 12 embodiments, wherein theadhesive comprises a temperature resistant adhesive.

[0078] A 14 embodiment is any combination of the first 13 embodiments, wherein the20 adhesive comprises butyl glue.

[0079] A 15 embodiment is any combination of the first 14 embodiments, furthercomprising a release liner removably coupled to the water resistant layer.

[0080] A 16" embodiment is any combination of the first 15 embodiments, furthercomprising a second polymer in the water resistant layer, the second polymer selected from25 the group consisting of ultra-low density polyethylene (ULDPE), low density polyethylene(LDPE), high density polyethylene (HDPE), polypropylene (PP), polyvinyl chloride and vinylderivatives, polystyrene, polyethylene terephthalate (polyester) and polyamides.

[0081] A 17" embodiment is any combination of the first 16 embodiments, wherein thewater resistant layer has a hardness of at least about 60 Shore O.

[0082] In another aspect, a first embodiment is a method for making a composite material.The method comprises providing fibers of a flame retardant filler material and mixing the5 fibers with a polymer to form a water resistant layer.

[0083] A second embodiment is the first embodiment, wherein the fibers and the polymerare ground together with one or more moving blades.

[0084] A 3" embodiment is any combination of the first 2 embodiments, wherein the fibersand the polymer are ground together through a shearing process.10

[0085] A 4™ embodiment is any combination of the first 3 embodiments, further comprisingextruding the fibers and the polymer.

[0086] A 5 embodiment is any combination of the first 4 embodiment, further comprisingmixing a plasticizer with the fibers and the polymer.

[0087] A 6" embodiment is any combination of the first 5 embodiments, further comprising15 calendaring the fibers and the polymer to form the water resistant layer.

[0088] A 7" embodiment is any combination of the first 6 embodiments, further comprisingbonding a non-woven layer to the water resistant layer.

[0089] An 8 embodiment is any combination of the first 7 embodiments, wherein thepolymer comprises an elastomer.20

[0090] A 9 embodiment is any combination of the first 8 embodiments, wherein thepolymer comprises a material selected from the group consisting of synthetic or naturalrubbers, ethylene propylene diene monomer rubber (EPDM), butyl rubber, polyisobutylene(PIB), polyvinyl chloride (PVC) and thermoplastic polyolefin (TPO).

[0091] A 10" embodiment is any combination of the first 9 embodiments, wherein the filler25 material comprises a material selected from the group consisting of melamine, melaminepolyphosphate, aluminum trihydroxide, antimony tnhydroxide, phosphorous, ammoniumpolyphosphate, halogenated organic materials, PBDE, TBBPA, mica and mica derivatives,vermiculite and vermiculite derivatives, polybutylene terephthalate and combinations thereof.

[0092] An 11 embodiment is any combination of the first 10 embodiments, furthercomprising removably coupling a release liner to the water resistant layer.

Claims

What is Claimed is:

1. A composite material comprising:a water resistant layer comprising a polymer; and5 a filler material incorporated into the water resistant layer, the filler materialcomprising a flame retardant material that limits heat transfer therethrough.

2. The composite material of claim 1, wherein the polymer comprises an elastomer.10 3. The composite material of claim 1, wherein the polymer comprises a materialselected from the group consisting of synthetic or natural rubbers, ethylene propylene dienemonomer rubber (EPDM), butyl rubber, polyisobutylene (PIB), polyvinyl! chloride (PVC)and thermoplastic polyolefin (TPO).15 4. The composite material of claim 1, wherein the polymer comprises polyisobutylene(PIB).

5. The composite material of claim 1, wherein the filler material comprises a materialselected from the group consisting of melamine, melamine polyphosphate, aluminum20 trihydroxide, antimony trihydroxide, chalk, silica, phosphorous, ammonium polyphosphate,halogenated organic materials, PBDE, TBBPA, mica and mica derivatives, vermiculite andvermiculite derivatives, polybutylene terephthalate and combinations thereof,6. The composite material of claim 1, wherein the filler material comprises aluminum25 trihydroxide.

7. The composite material of claim 1, wherein the filler material comprises chalk, silica,or a combination thereof.30 8. The composite material of claim 1, wherein the filler material comprises one or morefibers that are mixed into the PIB.WO 2025 / 235339 PCT / US2025 / 0276769. The composite material of claim 1, further comprising a non-woven layer bonded tothe water resistant layer.

10. The composite material of claim 9, further comprising an adhesive between the non5 woven layer and the water resistant layer.

11. The composite material of claim 9, wherein the non-woven layer comprises a materialselected from the group consisting of fleece and felt.

12. The composite material of claim 10, wherein the adhesive comprises a temperatureresistant adhesive.

13. The composite material of claim 10, wherein the adhesive comprises butyl glue.

14. The composite material of claim 1, further comprising a release liner removablycoupled to the water resistant layer.

15. The composite material of claim 1, further comprising a second polymer in the water20 resistant layer, the second polymer selected from the group consisting of ultra-low densitypolyethylene (ULDPE), low density polyethylene (LDPE), high density polyethylene(HDPE), polypropylene (PP), polyvinyl chloride and vinyl derivatives, polystyrene,polyethylene terephthalate (polyester) and polyamides.25 16. The composite material of claim 1, wherein the composite material has a hardness ofat least about 60 Shore O.

17. The composite material of claim 1, wherein the composite material is configured forattachment to a structure.

18. The composite material of claim 17, wherein the structure is a roof of a building.

19. A roof membrane comprising:a water resistant layer comprising a polymer; andWO 2025 / 235339 PCT / US2025 / 027676a filler material incorporated into the water resistant layer, the filler materialcomprising a flame retardant material that limits heat transfer therethrough.

20. The roof membrane of claim 19, wherein the polymer comprises an elastomer.

21. The roof membrane of claim 19, wherein polymer comprises a material selected fromthe group consisting of synthetic or natural rubbers, ethylene propylene diene monomerrubber (EPDM), butyl rubber, polyisobutylene (PIB), polyvinyl chloride (PVC) andthermoplastic polyolefin (TPO).

22. The roof membrane of claim 19, wherein the polymer comprises polyisobutylene(PIB).

23. The roof membrane of claim 19, wherein the filler material comprises a material15 selected from the group consisting of melamine, melamine polyphosphate, aluminumtrihydroxide, antimony trihydroxide, phosphorous, ammonium polyphosphate, halogenatedorganic materials, PBDE, TBBPA, mica and mica derivatives, vermiculite and vermiculitederivatives, polybutylene terephthalate and combinations thereof.20 24. The roof membrane of claim 19, further comprising a non-woven layer bonded to thewater resistant layer.

25. The roof membrane of claim 19, wherein the filler material comprises aluminumtrihydroxide.

26. The roof membrane of claim 19, wherein the filler material comprises chalk, silica, ora combination thereof.

27. The roof membrane of claim 19, wherein the filler material comprises one or more30 fibers that are mixed into the PIB.

28. The roof membrane of claim 19, further comprising a non-woven layer bonded to thewater resistant layer.WO 2025 / 235339 PCT / US2025 / 02767629. The roof membrane of claim 28, further comprising an adhesive between the nonwoven layer and the water resistant layer.

30. The roof membrane of claim 28, wherein the non-woven layer comprises a materialselected from the group consisting of fleece and felt.

31. The roof membrane of claim 29, wherein the adhesive comprises a temperature10 resistant adhesive.

32. The roof membrane of claim 31, wherein the adhesive comprises butyl! glue.

33. The roof membrane of claim 19, further comprising a release liner removably coupled15 to the water resistant layer.

34. The roof membrane of claim 19, further comprising a second polymer in the waterresistant layer, the second polymer selected from the group consisting of ultra-low densitypolyethylene (ULDPE), low density polyethylene (LDPE), high density polyethylene20 (HDPE), polypropylene (PP), polyvinyl chloride and vinyl derivatives, polystyrene,polyethylene terephthalate (polyester) and polyamides.

35. The roof membrane of claim 19, wherein the water resistant layer has a hardness of atleast about 60 Shore O.

36. A method for making a composite material, the method comprising:providing fibers of a flame retardant filler material; andmixing the fibers with a polymer to form a water resistant layer.30 37. The method of claim 36, wherein the fibers and the polymer are ground together withone or more moving blades.

38. The method of claim 36, wherein the fibers and the polymer are ground togetherthrough a shearing process.WO 2025 / 235339 PCT / US2025 / 02767639. The method of claim 36, further comprising extruding the fibers and the polymer.

40. The method of claim 39, further comprising mixing a plasticizer with the fibers and5 the polymer.

41. The method of claim 36, further comprising calendaring the fibers and the polymer toform the water resistant layer.10 42. The method of claim 36, further comprising bonding a non-woven layer to the waterresistant layer.

43. The method of claim 36, wherein the polymer comprises an elastomer.15 44. The method of claim 36, wherein the polymer comprises a material selected from thegroup consisting of synthetic or natural rubbers, ethylene propylene diene monomer rubber(EPDM), butyl rubber, polyisobutylene (PIB), polyvinyl chloride (PVC) and thermoplasticpolyolefin (TPO).20 45. The method of claim 36, wherein the filler material comprises a material selectedfrom the group consisting of melamine, melamine polyphosphate, aluminum trihydroxide,antimony trihydroxide, phosphorous, ammonium polyphosphate, halogenated organicmaterials, PBDE, TBBPA, mica and mica derivatives, vermiculite and vermiculitederivatives, polybutylene terephthalate and combinations thereof.

46. The method of claim 36, further comprising removably coupling a release liner to thewater resistant layer.

Images