The development and characterization of a new plastomer designed as the primary building block for single-ply roofing are reviewed. An improvement in mechanical properties over existing soft plastomers having similar flexibility was achieved through the incorporation of various monomers, resulting in the creation of bipolymers which provide toughness and softness performance. A higher total level of the combined bipolymers within a polypropylene random c9polymer (RACO) matrix was utilized to achieve the unique properties in comparison to the existing plastomer currently used in single-ply roofing. Controlled blending of two plastomers compounded on standard single screw compounding equipment completed development of the final product. The result of the blending study was then simulated and scaled up to a continuous three-loop gas phase pilot reactor. The final mechanical, thermal, and rheological property profile of these new resins is presented.
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