AU665445B2 - Laminate material - Google Patents
Laminate material Download PDFInfo
- Publication number
- AU665445B2 AU665445B2 AU44376/93A AU4437693A AU665445B2 AU 665445 B2 AU665445 B2 AU 665445B2 AU 44376/93 A AU44376/93 A AU 44376/93A AU 4437693 A AU4437693 A AU 4437693A AU 665445 B2 AU665445 B2 AU 665445B2
- Authority
- AU
- Australia
- Prior art keywords
- backing sheet
- foil
- layer
- sarking membrane
- membrane according
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Ceased
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/14—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers
- B32B37/16—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating
- B32B37/20—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by the properties of the layers with all layers existing as coherent layers before laminating involving the assembly of continuous webs only
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B15/00—Layered products comprising a layer of metal
- B32B15/14—Layered products comprising a layer of metal next to a fibrous or filamentary layer
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D12/00—Non-structural supports for roofing materials, e.g. battens, boards
- E04D12/002—Sheets of flexible material, e.g. roofing tile underlay
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
- E04G21/00—Preparing, conveying, or working-up building materials or building elements in situ; Other devices or measures for constructional work
- E04G21/32—Safety or protective measures for persons during the construction of buildings
- E04G21/3261—Safety-nets; Safety mattresses; Arrangements on buildings for connecting safety-lines
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04G—SCAFFOLDING; FORMS; SHUTTERING; BUILDING IMPLEMENTS OR AIDS, OR THEIR USE; HANDLING BUILDING MATERIALS ON THE SITE; REPAIRING, BREAKING-UP OR OTHER WORK ON EXISTING BUILDINGS
- E04G21/00—Preparing, conveying, or working-up building materials or building elements in situ; Other devices or measures for constructional work
- E04G21/32—Safety or protective measures for persons during the construction of buildings
- E04G21/3261—Safety-nets; Safety mattresses; Arrangements on buildings for connecting safety-lines
- E04G21/3266—Safety nets
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
- B32B37/1207—Heat-activated adhesive
- B32B2037/1215—Hot-melt adhesive
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2305/00—Condition, form or state of the layers or laminate
- B32B2305/10—Fibres of continuous length
- B32B2305/18—Fabrics, textiles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/30—Properties of the layers or laminate having particular thermal properties
- B32B2307/306—Resistant to heat
- B32B2307/3065—Flame resistant or retardant, fire resistant or retardant
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2311/00—Metals, their alloys or their compounds
- B32B2311/24—Aluminium
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2323/00—Polyalkenes
- B32B2323/10—Polypropylene
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Mechanical Engineering (AREA)
- Laminated Bodies (AREA)
Description
1_ 665445 -1
AUSTRALIA
PATENTS ACT 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT
ORIGINAL
Sr 4 4 000* 1*44 444* a,, O Ia Name of Applicant: Actual Inventor: CSR LIMITED, A.C.N. 000 001 276 Michael Frederick SMITH Address for Service: SHELSTON WATERS 55 Clarence Street SYDNEY NSW 2000 "LAMINATE MATERIAL" Invention Title: Details of Associated Provisional Application No: PL4048 dated 11th August, 1992 The following statement is a full description of this invention, including the best method of performing it known to us:- -2- The present invention relates to sarking membranes and in particular to an insulating flexible thin sheet laminate material suitable for use in roofing construction.
The invention has been developed primarily for use as a sarking membrane that: can withstand varied weather conditions; is a thermal insulator; and has sufficient strength to support the weight of a man and thus can also be used as a safety mesh, and will be described hereinafter with reference to this application.
The use of highly reflective foils as a thermal insulator is well known and there are a wide variety of products available on the market.
The nature and construction of these foil products varies. As foil is relatively expensive, it has been anld still is desirable to use a very thin foil layer. However, in order to make this viable it has been necessary to attach the foil to a substantially cheaper supporting substrate.
In the past, it has been common practice to adhere thin layers of aluminium foil to o S° 15 paper backing sheets which are relatively inexpensive and which provide added strength S to the foil.
It is generally further required that roofing materials of this nature also act as a i| sarking membrane, sealing out dust and wind driven rain. Accordingly, to meet this requirement the laminate material must also have a water resistant outer surface. This has 20 been achieved in a number of ways, the most common of which are to include either some J to a supporting paper substrate. If such an additional layer of foil is used, it is usually ,necessary to coat this surface with an anti-glare finish which is a further additional cost.
S, Furthermore, as the safety requirements of roofing construction have become more stringent, it has also become necessary to provide some form of safety mesh that will support, for example, a tiler should he lose his footing during construction of the roof.
As insulating foil materials do not generally meet this strength requirement, it has been necessary in many construction circumstances to use arn additional safety mesh.
i h This practice is very expensive as not only is there the additional cost of installing the 6M&MMWMM mesh, it is often impractical to try and remove the mesh once the roof covering has been installed. In this way the safety mesh may also constitute an additional material cost.
There are now a limited range of insulating foil products available on the market that meet these strength and safety requirements. H-owever, such products can be heavy and expensive. Products meeting these strength requirements generally comprise multiple layers of foil, paper and reinforcing mesh, making such products expensive to produce.
Furthermore, the layers of papcr used in such products are known to fail after repeated folds. Therefore, the strength of such products can be significantly affected if not handled correctly.
Accordingly, there is a need for a strong, light weight and relatively inexpensive sarking material able to function as a thermal roof insulator and a roofing safety mesh if required. that will also comply with the abovementioned stringent safety requirements.
According to a first aspect of the invention there is provided a sarking membrane 00:comprising an insulating flexible thin sheet laminate material including: o 15 a reinforcing polymeric backing sheet adhesively bonded on one side to an outer 0.0!layer of -foil having a thickniess of 50 microns or less, said reinforcing backing sheet having a water resistant coating on its outer side remote from said layer of foil that is selected from the group comprising polypropylene, 0: polyethylene and PVC, and wherein said laminate material is adapted for use as a safety mesh and is capable *I Preferably the water resistant coating also resists water vapour transmission.
i':o uprtn h egh famn In an embodiment the reinforced backing sheet comprises a woven fabric of polymeric fibres.
More preferably, the backing sheet comprises a woven fabric of polymeric fibres selected from the group including polypropylenes, polyethylenes and polyesters.
In another embodiment the reinforcing backing sheet may be an unwoven fabric of polyester scrim or spun bonded material. Woven materials are preferred.
-4- The overall density of the coated backing sheet may be approximately 150gsm, typically comprising a 116gsm fabric with a 32gsm coating. The coating may be 25 to microns thick.
Desirably, the foil is aluminium foil, which in a preferred embodiment is about 6.35 microns in thickness.
Preferably, the total density of the laminate material is around 400gsm.
It is also preferred that the reinforced backing sheet be adhered to the layer of aluminium foil by use of a hot melt fire retardant adhesive having, for example, a thermoplastic polymer base.
According to a second aspect of the invention there is provided a method of making a sarking membrane comprising a flexible thin sheet insulating laminate material, i said method comprising the steps of: adhesively bonding an outer layer of foil having a thickness of 50 microns or less 'to a reinforcing polymeric backing sheet that has a water resistant coating on its outer side 15 remote from said layer of foil, and wherein said laminate material is adapted for use as a safety mesh and is capable of supporting the weight of a man.
In a preferred embodiment the method comprises the steps of: applying to a polymeric reinforced backing sheet that has been pre-coated on one side with a water resistant coating a layer of adhesive on the surface remote from said coating; feeding said backing sheet with layer of adhesive to a pair of nip rollers; S simultaneously feeding to said nip rollers a layer of foil in an orientation so as to align directly adjacent the layer of adhesive on said backing sheet; and laminating said foil to said backing sheet under heat and pressure applied to said nip rollers.
Desirably, the laminate is then passed through a cooling drum and is then wound onto rolls.
A preferred embodiment of the invention will now be described, by way of iU example only, with reference to the accompanying drawings in which: Figure 1 is a schematic cross-sectional view of the sarking membrane according to the invention.
Figure 2 is a schematic side view of the apparatus for making the sarking membrane shown in Figure 1.
Referring to Figure 1 the sarking membrane comprises insulating laminate material 1 formed from a reinforced backing sheet 2 attached by means of a layer of adhesive 3 to an outer layer of aluminium foil 4.
The thickness of the layer of foil 4 is about 6.35 microns. Similarly, the preferred adhesive is a fire retardant hot melt formulation having a thermoplastic polymer base such as ethylene vinyl acetate including a chloroparrafin and antimony trioxide fire retardant system. The adhesive is applied as a layer of approximai.ly 180 to 240 gsm.
The backing sheet 2 comprises a layer of woven polypropylene fabric 6 having an extruded polypropylene coating 7.
S. One such suitable material is a material produced by RHEEM and sold under the 15 trade name "BRADTUFF" that has 79 yarns per 10cm of 88 Tex in the warp direction and 31 yarns per 10cm of 140 Tex in the weft direction and which includes an extruded polypropylene coating of approximately 25 to 75 microns thickness. An alternative material has 40 x 43 yarns per 10cm, both of 115 Tex. The density of the former preferred reinforcing is approximately 116gsm and the coating 32gsm resulting in an overall density of the backing sheet of approximately 150gsm.
I Referring now to Figure 2, there is shown an apparatus on which the sarking S membrane according to the invention may be made.
The apparatus 10 includes an unwind station 11 at which is placed a roll of the reinforced backing sheet 2. Adjacent the unwind station 11 is a hot melt adhesive coating station 12 comprising a heated melt pot and rollers, above which is located the nip combining set of rollers 13.
Situated to the left of the hot melt adhesive coating station 12 is a second unwind station 14 at which are located rolls of aluminium foil 4.
t nj 3 *i
I-
i| i _ii=il~i~TL~ 44 a. a 4 4444 a 4 44 4i -6- A set of cooling drum rollers are provided at 15 which connect to a set of tension control rollers 16 to a rewind station 17 at the far right which houses the finished laminate 1.
In use, pre-coated woven polypropylene backing fabric 2 is unwound from a roll on unwind station 11 and drawn through the hot melt adhesive coating station 12. Here molten fire retardant adhesive is applied to the woven fabric side 6 of the backing sheet 2 remote from the polypropylene coating 7.
The resulting web of backing fabric 2 with applied adhesive 3 is then drawn through the nip combining set of rollers 13.
Simultaneously, aluminium foil 4 is drawn from the roll on unwind station 14 and laminated under heat and pressure at the nip combining set of rollers 13.
The combined laminate 1 is then passed through the cooling drum set 15 and travels via tension control set 16 to rewind station 17, where it is wound up to "jumbo" sized rolls.
Jumbo sized rolls are then transferred to slitter/rewinders where sd.ss are trinmmed and the product wound to consumer size rolls of 20, 30 or 40 meters length. Finally, these rolls are shrinkwrapped and packaged on pallets for sale.
It will be appreciated that other laminating methods are likely to be suitable.
The company or customer logo can conveniently be printed on the uncovered surface of the backing sheet as required.
The sarking membrane according to the invention is lightweight, weighing from about 25% to 30% less than the previously available equivalent materials. Furthermore, the product is very strong, being readily capable of supporting the weight of a man and complying with the applicable stringent safety stindards.
The material will also provide more than adequate protection should a roof tile be dislodged or broken, or in the event of generally inclement weather. This new sarking membrane also meets the necessary fire protection requirements.
C 1 I I -7- Furthermore, the sarking membrane is substantially more fold resistant and generally more durable than previously known equivalent products incorporating layers of paper.
The new sarking membrane is also less expensive to produce as it can be made in a single-pass laminating operation, thereby saving time and reducing waste.
Other embodiments of the invention use a variety of reinforcing mesh materials, both woven and unwoven, including, for example, polyester scrim or spun bonded fabric.
Polyethylene fabrics may also be used. Similarly, other water resistant coatings can be used such as polyvinylchloride (PVC). In a further embodiment a second layer of foil is applied, such that foil is provided on both sides of the reinforced backing sheet.
Although the invention has been described with reference to specific examples, it will be appreciated by those skilled in the art that the invention may be embodied in many other forms.
t t I t
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Claims (14)
1. A sarking membrane comprising an insulating flexible thin sheet laminate material including: a reinforcing polymeric backing sheet adhesively bonded on one side to an outer layer of foil having a thickness of 50 microns or less, said reinforcing backing sheet having a water resistant coating on its outer side remote from said layer of foil that is selected from the group comprising polypropylene, polyethylene and PVC, and wherein said laminate material is adapted for use as a safety mesh and is capable of supporting the weight of a man.
2. A sarking membrane according to claim 1 wherein the water resistant coating also resists water vapour transmission.
3. A sarking membrane according to claim 1 or claim 2 wherein said reinforcing backing sheet comprises a woven fabric of polymeric fibres.
4. A sarking membrane according to claim 3 wherein the fibres are made of one or more polymeric materials selected from the group including polypropylene, polyethylene and polyester. A sarking membrane according to claim 3 or claim 4 wherein the woven backing sheet has either 79 yarns per 10 cm of 88 Tex in a warp direction and 31 yarns per 10 cm 4 t t I of 140 Tex in a weft direction or 40 yarns per 10 cm of 115 Tex in a warp direction and S43 yarns per 10 cm of 115 Tex in a weft direction. i 6. A sarking membrane according to claim 1 or claim 2 wherein said reinforcing backing sheet comprises an unwoven fabric of polyester scrim or spun bonded material.
7. A sarking membrane according to any one of the preceding claims wherein the overall density of the coated backing sheet is approximately 150gsm.
8. A sarking membrane according to claim 7 wherein the coated backing sheet comprises a 116gsm fabric with a coating of approximately 32gsm.
9. A sarking membrane according to any one of the preceding claims wherein the if Y\water resisting coating is 25 to 75 microns in thickness. II -9- A sarking membrane according to any one of the preceding claims wherein the foil is aluminium foil.
11. A sarking membrane according to claim 10 wherein the thickness of the foil is approximately 6 to 6.5 microns in thickness.
12. A sarking membrane according to any one of the preceding claims wherein the total density of the laminate material is approximately 400gsm.
13. A sarking membrane according to any one of the preceding claims wherein the reinforced backing sheet is adhesively bonded to an outer layer of foil by a hot melt fire 00 0 0 0 retardant adhesive. S 10 14. A sarking membrane according to claim 13 wherein the hot melt fire retardant 000o: adhesive is of a kind having a thermoplastic polymer base. A sarking membrane according to claim 12 or claim 13 wherein the adhesive is 0:0, 0 applied as a layer of approximately 160 to 260 gsm in weight. 0 o S 15 insulating laminate material adapted for use as a safety mesh and capable of supporting o the weight of a man, said method comprising the steps of: adhesively bonding an outer layer of foil having a thickness of 50 microns or less to a reinforcing polymeric backing sheet that has a water resistant coating on its outer side remote from said layer of foil, and wherein said laminate material is adapted for use as a safety mesh and is capable of supporting the weight of a man.
17. A method of making a sarking membrane comprising a flexible thin sheet insulating laminate material adapted for use as a safety mesh and capable of supporting the weight of a man, said method comprising the steps of: i0% I I QI- Pr -i 00 0 0 o eo 0 0 S 10 00 0 OoD 000 0~4e 115 o o oo o a oa 4 e04 a 20 oo oo o o a or ou 0 a t o o o a« 0 2 applying to a polymeric reinforcing backing sheet that has been pre-coated on one side with a water resisLant coating a layer of adhesive on the surface remote from said coating; feeding said backing sheet with layer of adhesive to a pair of nip rollers; simultaneously feeding to said nip rollers a layer of foil having a thickness of microns or less in an orientation so as to align directly adjacent the layer of adhesive on said backing sheet; and laminating said foil to said backing sheet under heat and pressure applied to said nip rollers.
18. A method according to claim 19 further comprising the steps of: passing the laminate through a cooling drum; and winding the laminate on to rolls.
19. A sarking membrane substantially as herein described with reference to Figure 1 of the accompanying drawings.
20. A method of making a sarking membrane substantially as herein described with reference to the accompanying drawings. Dated this 17th Day of October, 1995 CSR Limited Attorney: CAROLINE M. BOMMER Fellow Institute of Patent Attorneys of Australia of SHELSTON WATERS U I- i I 6 9, Co 690 46 64 6 6,s 9. 9060Q 404 ABSTRACT The invention relates to an insulating laminate material for use as a sarking membrane and roofing safety mesh and a method of making the same. The laminate material includes a reinforced backing sheet (2) attached by means of a layer of adhesive to an outer layer of foil In the preferred form, the reinforced backing sheet comprises a layer of woven polypropylene fabric having an extruded polypropylene coating The preferred adhesive is fire retardant hot melt formulation having a thermoplastic polymer base. The preferred method of making the insulating laminate material comrrises the steps of applying to the reinforced backing sheet that has been precoated on one side with a water resistant coating a layer 15 of adhesive on a surface remote from the coating The backing sheet with the layer of adhesive is then fed to a pair of nip rollers (13) to which is simultaneously fed a layer of foil in an orientation so as to align the foil directly adjacent the layer of 20 adhesive on the backing sheet The foil is thereby laminated to the backing sheet under heat and pressure applied to the nip rollers (13). V I I o a 9 t I t I'4 II 4 4444 44 6
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| AUPL404892 | 1992-08-11 | ||
| AUPL4048 | 1992-08-11 |
Related Child Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| AU66002/94A Division AU655571C (en) | 1992-08-11 | 1994-06-27 | Laminate material |
Publications (3)
| Publication Number | Publication Date |
|---|---|
| AU4437693A AU4437693A (en) | 1994-02-17 |
| AU665445B2 true AU665445B2 (en) | 1996-01-04 |
| AU665445C AU665445C (en) | 1998-02-26 |
Family
ID=
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP1063345A2 (en) * | 1999-06-24 | 2000-12-27 | Johns Manville International, Inc. | Reinforced membranes for roofing and other applications |
| CN105329555A (en) * | 2015-11-24 | 2016-02-17 | 安徽美翔塑业有限公司 | Thermal-insulating packaging bag |
Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| AU523379B3 (en) * | 1982-03-11 | 1982-08-05 | Australian Gypsum Limited | Method of making insulfoil |
| WO1991018738A1 (en) * | 1990-05-25 | 1991-12-12 | Renouf Industries Pty. Ltd. | Improvements in reflective foil insulation |
Patent Citations (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| AU523379B3 (en) * | 1982-03-11 | 1982-08-05 | Australian Gypsum Limited | Method of making insulfoil |
| WO1991018738A1 (en) * | 1990-05-25 | 1991-12-12 | Renouf Industries Pty. Ltd. | Improvements in reflective foil insulation |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP1063345A2 (en) * | 1999-06-24 | 2000-12-27 | Johns Manville International, Inc. | Reinforced membranes for roofing and other applications |
| EP1063345A3 (en) * | 1999-06-24 | 2002-03-20 | Johns Manville International, Inc. | Reinforced membranes for roofing and other applications |
| CN105329555A (en) * | 2015-11-24 | 2016-02-17 | 安徽美翔塑业有限公司 | Thermal-insulating packaging bag |
Also Published As
| Publication number | Publication date |
|---|---|
| AU4437693A (en) | 1994-02-17 |
| NZ248312A (en) | 1995-12-21 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| MK14 | Patent ceased section 143(a) (annual fees not paid) or expired |