AU675890B2

AU675890B2 - Weather sealing membrane

Info

Publication number: AU675890B2
Application number: AU80458/94A
Authority: AU
Inventors: Salvatore Scardigno
Original assignee: Individual
Current assignee: Individual
Priority date: 1993-12-14
Filing date: 1994-12-14
Publication date: 1997-02-20
Anticipated expiration: 2014-12-14
Also published as: AU8045894A

Description

43693 AWT:PFB P/00/011 Regulation 3.2

AUSTRALIA

Patents Act 1990 COMPLETE SPECIFICATION FOR A STANDARD PATENT

ORIGINAL

0* Name of Applicant: SALVATORE SCARDIGNO Name of inventor: SALVATORE SCARDIGNO Address for Service: COLLISON CO.,117 King William Street, Adelaide, S.A. 5000 Invention Title: WEATHER SEALING MEMBRANE Details of Associated Provisional Application: PM2983 Dated 14th December 1993 The following statement is a full description of this invention, including the best method of performing it known to me: This invention relates to dampcourse or flashing materials and particularly damp course and flashing materials which may have good weathering properties and hence which may have a wider application and more usefulness than those presently on the market for such purposes.

Weather seal flashing can be used on roofs, terraces, decks and areas like that which can be exposed to the weather particularly rain and sun and where sealing is necessary. Most products which have been used in the past are subject to weathering over time which can cause leakage and damage to building materials below a dampcourse or flashing.

1 0 It is the object of this invention to provide a weather sealing membrane which is particularly useful for sealing in the aforesaid situations and particularly a membrane which can be easily installed and adhered to building surfaces.

A problem with such adhesion has been solved in my earlier Australian Patent No. 485309 which proposed a plastics material having particulate material adhered to each surface thereof so that it could easily be adhered to existing building surfaces but this material does not have good weathering properties and hence this invention proposes a modification of such material to provide weathering properties.

In one form therefore although this may not necessarily be the only or S2 0 broadest form the invention is said to reside in a weather sealing membrane comprising a plastic sheet material base, a primer coating on each side thereof, on a first side of the sheet material base a particulate material adhered by means of a flexible adhesive material and on the second side of the sheet material base a metallic foil adhered by means of a flexible adhesive.

It will be seen that by this invention there is provided a weather sealing membrane which like my earlier invention has particulate material adhered to one surface thereof so it has very good joining ability with suitable adhesives to existing building structures and the other surface providing a metallic foil 3 0 which has very good sun and rain resistance to weathering.

Preferably, the particulate material is selected from sand or fine gravel and

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may have a size range of 0.1 mm up to perhaps 3 mm depending upon the type of application to which the weather sealing membrane is to be put.

The flexible adhesive may be selected from contact cements, latex adhesives, acrylic adhesives, polyester adhesives, synthetic rubber adhesives or bituminous adhesives.

In this specification the term flexible adhesive material is defined as a polymeric or pre-polymeric resin material which is in liquid form for application purposes in which cures to a flexible layer. Such a material may be cured by chemical means, solvent release, catalytic action or by water or oxygen or 1 0 some similar action or combination of actions or maybe a type which merely by release of solvent a flexible polymeric material is provided. The term bituminous compound used throughout this specification is herein defined as a liquid state bitumen solution or suspension which loses its solvent or dispersant by evaporation or other solvent or dispersant removal method or is 1 5 made into a liquid state by heating before application is required. Such a bituminous compound may also include fillers and other adhesives. In particular advantage of a bituminous compound is that it stays tacky when warm and hence is suitable over a range of temperatures. This may be of considerable advantage in situations where weathering by heating occurs.

2 0 Preferred adhesives for this invention are those which are based on water as a solvent such as bituminous and latex emulsion adhesives as these have minimal environmental effect during curing.

The primer coating may be by means of a flexible adhesive as discussed above particularly a bituminous adhesive.

2 5 The metallic foil may be any suitable metal foil for a particular application and may be selected from aluminium, zinc, copper, lead or other metal depending upon the requirements of a particular situation and a particular degree of flexibility required, the amount of traffic expected and the weathering expected. In a preferred embodiment of the invention the foil may be have a 3 0 size range of 0.01 mm to 0.08 mm. Preferably the foil is an aiumninium foil.

The foil is preferably adhered to the preferably primed plastics sheet material by means of an adhesive which is flexible and remains tacky when heated by the sun and other forms of heating. This may be a bituminous compound of the type referred to above may also include up to 30% by volume of a flexible adhesive. The particulate material may comprise sand or may comprise fine gravel having a size range of 0.5 mm to 3 mm. It will be realised of course that sand may have finer grain size than the sizes given.

The plastics sheet material base may have a thickness range of from 0.1 mm to 1.0 mm depending upon the flexibility requirements in a particular application.

In another form the invention may be said to reside in a weather sealing 1 0 membrane comprising a polyethylene plastics sheet material base, a primer coating of a water based emulsion bituminous adhesive on each side of the plastics sheet material base, on a first side of the sheet material base a particulate material adhered by means of a latex adhesive material and on the second side of the sheet material a aluminium metallic foil adhered by means 1 5 of a latex adhesive material.

In another form the invention may be said to reside in a weather sealing membrane comprising a polyethylene plastics sheet material base, a flexible adhesive coating of a mixture of a water based emulsion bituminous adhesive and a latex adhesive material on each side of the plastics sheet material base, S 2 0 on a first side of the sheet material base a particulate material adhered thereto .o by means of the mixture of adhesive materials and on the second side of the sheet material a aluminium metallic foil adhered by means of the mixture of adhesive materials.

In another form the invention may be said to reside in a method of applying a 2 5 coating on each side of a sheet plastics material to provide a weather sealing membrane, this method comprising the steps of applying a bituminous compound as hereinbefore defined on each side of a plastics sheet material, applying a flexible adhesive to a first side of the flexible sheet material and applying sand or fine gravel into the flexible adhesive before it cures and 3 0 further applying a flexible adhesive to a second side of the plastics sheet material and adhering sheet metallic foil to the flexible adhesive.

The sheet material may have an embossed or patterned surface to assist with adherence of the primer and flexible adhesive layers.

It will be realised that with thin foil sheets on the plastics sheet material the foil may be rolled on and the product rolled but for thicker coatings of foil the product may be kept in flat sheets.

In either embodiment the product may have edges adapted for joining where larger surfaces are required to be weather sealed and overlapping may be provided with the plastics sheet material and particulate material extending beyond the edge of the metallic foil on one side of a sheet and the metallic foil extending further than the plastics sheet material on the other side.

Overlapping will provide better weather sealing with suitable adhesives.

1 0 It will be realised that with relatively thin layers of the foil the weather sealing membrane as a whole may be conformable to the shape of a surface to be sealed while at the same time having good adhesion to the surface by the use of suitable adhesives such as bituminouw adhesives.

One particular application to which the invention may be applied is the 1 5 capping of wall tops and ridge caps on roofs. Other applications includes terraces and decking areas.

This then generally describes the invention but to assist with understanding of the invention reference will now be made to the accompanying drawings.

In the drawings: 2 0 FIG. 1 shows a part cross-sectional view of a weather sealing membrane according to one embodiment of this invention, FIG. 2 shows a part cross-sectional view of a weather sealing membrane according to another embodiment of this invention, FIG. 3 shows a preliminary stage of forming a join between two 2 5 weather sealing membranes of the invention, and FIG. 4 shows a completed joint between the two weather sealing membranes of FIG 3.

Now looking closely at the drawings and in particular FIG. 1 it will be seen that the weather sealing membrane comprises a base which is a plastics sheet material such as PVC, polyethylene or polypropylene 1. On each surface of the sheet material 1 is a primer coating 2 and 3.

Onto the primer coating 2 is applied a flexible adhesive 4 such as a bituminous adhesive and before this adhesive is set a metallic foil 5 is applied. The metallic foil 5 in this embodiment is an aluminium foil having a thickness of 0.02 mm.

A further flexible adhesive 6 is applied to the primer coating 3 and fine particulate materials such as sand or fine gravel 7 is adhered into the 1 0 adhesive. The result is a weather sealing membrane which is flexible and conformable but has excellent weather properties owing particularly to the nature of the metallic foil.

FIG 2 shows an alternative embodiment of a weather sealing membrane :according to this invention. The weather sealing membrane comprises a base 1 5 which is a plastics sheet material such as PVC, polyethylene or polypropylene Onto one surface of the base 10 is applied a flexible adhesive 11 such as o a mixture of a latex and bituminous adhesive and before this adhesive is set a metallic foil 12 is applied. The metallic foil 12 in this embodiment is an aluminium foil having a thickness of 0.02 mm. A further flexible adhesive 14 is applied to the other side of the base 10 and fine particulate materials such as sand or fine gravel 15 is adhered into the adhesive. The result is a weather S° sealing membrane which is flexible and conformable but has excellent S• weather properties owing particularly to the nature of the metallic foil.

FIG. 3 and 4 show a cross section of a join between two sheets of the weather S 2 5 sealing membrane of the present invention. A first portion of weather sealing membrane 20 has a foil 21 extending beyond the end 22 of the membrane. A second sheet of membrane 25 has the foil 26 cut back from the end 27 of the membrane. When the two ends are joined together and a suitable adhesive 28 applied to fill the spaces at the junction a good weather sealing join is produced.

It will be seen that by this invention a weather sealing membrane is produced which has a good combination of flexibility to allow it to be applied any desired surface, good adhesion capability because of the particulate material surface and good weather sealing because of the metal foil front surface.

Throughout this specification and the claims that follow unless the context requires otherwise, the words 'comprise' and 'include' and variations such as 'comprising' and 'including' will be understood to imply the inclusion of a stated integer or group of integers but not the exclusion of any other integer or group of integers.

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Claims

1. A weather sealing membrane comprising a plastics sheet material base, on a first side of the sheet material base a particulate material adhered by means of a flexible adhesive material and on the second side of the sheet material base a metallic foil adhered by means of a flexible adhesive.

2. A weather sealing membrane as in Claim 1 wherein there is further included a primer coating on each side of the plastics sheet material base.

3. A weather sealing membrane as in Claim 2 wherein the primer coating is a bituminous adhesive. 1 0

4. A weather sealing membrane as in Claim 1 wherein the particulate material is selected from sand or fine gravel.

A weather sealing membrane as in Claim 4 wherein the particulate material has a size range of from 0.1 mm up to 3 mm.

6. A weather sealing membrane as in Claim 1 wherein the flexible 1 5 adhesive is selected from contact cements, latex adhesives, acrylic adhesives, polyester adhesives, synthetic rubber adhesives or bituminous adhesives.

7. A weather sealing membrane as in Claim 1 wherein the flexible S" adhesive is a mixture of a water based bituminous adhesive emulsion and a 000000 latex adhesive. 0000

8. A weather sealing membrane as in any one preceding claim wherein the metallic foil is be selected from aluminium, zinc, copper, lead or other metal depending upon the requirements of a particular situation and a particular degree of flexibility required, the amount of traffic expected and the weathering expected.

9. A weather sealing membrane as in Claim 8 wherein the foil has a thickness range of 0.01 mm to 0.08 mm.

A weather sealing membrane as in any one preceding claim wherein the plastics sheet material is selected from polyvinyl chloride, polyethylene of polypropylene.

11. A weather sealing membrane as in any one preceding claim wherein the plastics sheet material base has a thickness range of from 0.1 mm to 1.0 mm depending upon the flexibility requirements in a particular application.

12. A weather sealing membrane comprising a polyethylene plastics sheet material base, a primer coating of a water based emulsion bituminous 1 0 adhesive on each side of the plastics sheet material base, on a first side of the sheet material base a particulate material adhered by means of a latex adhesive material and on the second side of the sheet material a aluminium metallic foil adhered by means of a latex adhesive material.

S13. A weather sealing membrane comprising a polyethylene plastics 1 5 sheet material base, a flexible adhesive coating of a mixture of a water based emulsion bituminous adhesive and a latex adhesive material on each side of the plastics sheet material base, on a first side of the sheet material base a particulate material adhered thereto by means of the mixture of adhesive materials and on the second side of the sheet material a aluminium metallic 2 0 foil adhered by means of the mixture of adhesive materials.

14. A weather sealing membrane as in any one preceding claim wherein the sheet material base has an embossed or patterned surface to too assist with adherence of the adhesive layers. A method of applying a coating on each side of a sheet plastics 2 5 material base to provide a weather sealing membrane, this method comprising the steps of applying a flexible adhesive to a first side of the flexible sheet material base and applying sand or fine gravel into the flexible adhesive before it cures and further applying a flexible adhesive to a second side of the plastics sheet material base and adhering sheet metallic foil to the 3 0 flexible adhesive.

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16. A method of applying a coating on each side of a sheet plastics material base to provide a weather sealing membra:., this method comprising the steps of applying a bituminous con ;pound emulsion as hereinbefore defined on each side of the plastics sheet material base, applying a flexible adhesive to a first side of the flexible sheet material base and applying sand or fine gravel into the f axibl., adhesive before it cures and further applying a flexible adhesive to a ,r'nd sic a of the plastics sheet material base and adhering sheet metallic ioil cu the flexible adhesive.

17. A method of applying a coating as in Claim 15 or Claim 16 wherein 1 0 the sheet material base has an embossed or patterned surface to assist with adherence of the adhesive layers.

18. A method of applying a coating as in Claim 16 wherein the primer coating is a bituminous adhesive.

19. A method of applying a coating as in Claim 15 or Claim 16 wherein o 1 5 the particulate material is selected from sand or fine gravel.

A method of applying a coating as in Claim 19 wherein the particulate material has a size range of from 0.1 mm up to 3 mm.

21. A method of applying a coating as in Claim 15 or Claim 16 wherein o the flexible adhesive is selected from contact cements, latex adhesives, acrylic oo* 20 adhesives, polyester adhesives, synthetic rubber adhesives or bituminous adhesives. 0000

22. A method of applying a coating as in Claim 15 wherein the flexible adhesive is a mixture of a water based bituminous adhesive emulsion and a latex adhesive.

23. A method of applying a coating as in Claim 15 or Claim 16 wherein the metallic foil is be selected from aluminium, zinc, copper, lead or other metal depending upon the requirements of a particular situation and a particular degree of flexibility required, the amount of traffic expected and the weathering expected. ~I I I 11

24. A method of applying a coating as in Claim 23 wherein the foil has a thickness range of 0.01 mm to 0.08 mm.

A method of applying a coating as in Claim 15 or Claim 16 wherein the plastics sheet material base is selected from polyvinyl chloride, polyethylene of polypropylene.

26. A method of applying a coating as in Claim 15 or Claim 16 wherein the plastics sheet material base has a thickness range of from 0.1 mm to mm depending upon the flexibility requirements in a particular application. 1 0

27. A weather sealing membrane substantially as hereinbefore described with reference to and as illustrated in the accompanying drawings.

28. A method of applying a coating on each side of a sheet plastics 15 material base to provide a weather sealing membrane substantially as hereinbefore described with reference to and as illustrated in the accompanying drawings. o Dated this 14 th day of December 1994 20 SALVATORE SCARDIGNO By his Patent Attorneys, COLLISON CO. I, SSSO f/ s ABSTRACT A weather sealing membrane comprising a plastics sheet material base, on a first side of the sheet material base a particulate material adhered by means of a flexible adhesive material and on the second side of the sheet material base a metallic foil adhered by means of a flexible adhesive. There may be a primer layer applied before the flexible adhesive. The weather sealing membrane is conformable to be applied to curved and angular surfaces for flashing purposes. C «o*o*o