CA1140443A - Waterproofing membranes - Google Patents
Waterproofing membranesInfo
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- CA1140443A CA1140443A CA000355413A CA355413A CA1140443A CA 1140443 A CA1140443 A CA 1140443A CA 000355413 A CA000355413 A CA 000355413A CA 355413 A CA355413 A CA 355413A CA 1140443 A CA1140443 A CA 1140443A
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Abstract
ABSTRACT OF THE DISCLOSURE
Improved waterproofing membranes of the pressure-sensitive or self-adhesive bituminous type particularly useful in roofing and for waterproofing substrates in general are described. The membranes are in the form of pre-formed, flexible, sheet-like laminates of (a) a layer of waterproofing pressure-sensitive bituminous adhesive such as a rubberized asphalt composition, and, (b) a flexible support sheet having an adhesive-promoting coating on one or both surfaces to improve its bonding to the bituminous adhesive to which it is laminated and/or to the bituminous adhesive layer of a like overlapping waterproofing membrane. The adhesion-promoting coating contains a polymer having a plurality of pendant carboxylate groups from its backbone (e.g. an acrylic polymer such as polymethylmethacrylate, or a polymer of a vinyl ester such as polyvinylacetate). Adhesion between such coating and the bituminous adhesive is promoted by subjecting the contacting portions to elevated temperature. The membrane is preferably provided further with a layer of removable protective material such as siliconized "release" paper placed adjacent the adhesive layer in order that the membrane is able to be transported to the job site.
Improved waterproofing membranes of the pressure-sensitive or self-adhesive bituminous type particularly useful in roofing and for waterproofing substrates in general are described. The membranes are in the form of pre-formed, flexible, sheet-like laminates of (a) a layer of waterproofing pressure-sensitive bituminous adhesive such as a rubberized asphalt composition, and, (b) a flexible support sheet having an adhesive-promoting coating on one or both surfaces to improve its bonding to the bituminous adhesive to which it is laminated and/or to the bituminous adhesive layer of a like overlapping waterproofing membrane. The adhesion-promoting coating contains a polymer having a plurality of pendant carboxylate groups from its backbone (e.g. an acrylic polymer such as polymethylmethacrylate, or a polymer of a vinyl ester such as polyvinylacetate). Adhesion between such coating and the bituminous adhesive is promoted by subjecting the contacting portions to elevated temperature. The membrane is preferably provided further with a layer of removable protective material such as siliconized "release" paper placed adjacent the adhesive layer in order that the membrane is able to be transported to the job site.
Description
Background Of The Inventi on This invention relates to laminates of pressure-sensitive-adhesive bituminous waterproofing layers adapted for waterproofing and sealing struc-tures. More particularly, this invention relates to improved pre-formed flexible sheet-like laminates of ~a3 a pressure-sensitive or "self-adhesive"
bituminous waterproofing adhesive layer and (b) a flexible supporting or carrying layer of sheet-like material or film non-releasable adhered thereto, which laminates are particularly useful as waterproofing membranes for sub-strates such as roofs and decks of buildings, concrete bridge decks and the like.
In United States Patent Nos. 3,741,856, 3,853,682 and 3,900,102 to John ~lurst, there are described flexible pre-formed laminates of a water-proofing pressure-sensitive bituminous adhesive layer and a flexible support layer of e~g. plastic film or metallic film. The pre-formed laminates are idealiy suited for forming waterproofing layers, for example upon or between substrates such as concrete buildings and road decks, in place of the conven-tionally utilized "built-up" waterproofing laminates constructed at the job-site from layers of bitumen-impregnated "felts" which are typically "plied"
together by hot-applied layers of bitumen adhesive. As discussed in particular 20 in United States Patent No. 3,900,102, such laminates may ideally be construc-ted in the plant in the form of a roll with a releasable layer of protective material such as siliconiæed paper applied against the pressure-sensitive bituminous adhesive, transported to the job site, and thereafter applied to the substrate adhesive side down, each laminate strip overlapping the edge of the previously-applied strip of laminate to insure a continuous waterproof seal.
The present invention concerns an improved waterproofing laminate ~L4i~q~43 of the type described in *he aforementioned }lurst pa~ents. The improved waterproofing laminate is a preformed flexible laminate of ~a) a layer of waterproofing pressure-sensitive bituminous adhesive composition and ~b) a flexible support sheet non-releasably adhered to the bituminous adhesive layer having a coating or layer ~a) on at least one edge portion of its upper surface remote from the adhesive and/or ~b) on its surface contacting such adhesive which coating or layer promotes the adhesion of the support sheet to the bituminous adhesive layer. The adhesion-promoting coa~T~s used herein contain polymers having a plurality of pendant carboxylate groups from their polymer backbone, for example acrylic polymers and polymers of vinyl esters.
It has been found that such coatings promote improved bondings to the bitumi-nous adhesive after the contacting portions have been subjected to elevated temperature.
DESCRIPTION OF T}IE DRAWINGS
Figure 1 is a perspective cross-sectional view of a waterproofing laminate according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
In Figure 1, the inventive laminate is shown as comprised of four layers, A flexible support sheet 1 is non-removably adhered to a layer of pressure-sensitive waterproofing bituminous adhesive 2, and has on its upper surface remote from adhesive 2, an adhesion-promoting coating or layer 3. A
removable protective layer 4, e.g. siliconized paper, is shown releasably-adhered to adhesive 2. The laminate as shown has a width ~"w"), e.g. 36 inches, less than its length ~t'l"), e.g. 30 fee~, and can conveniently be packaged in the form of a roll which is simply unrolled at the job-site, there-after layer 4 removed, and the exposed surface or adhesive 2 placed adjacent the substrate to be waterproofed. Another like strip of waterproofing 4.3 laminate ~not shown) is then placed adjacent the laminate, care being taken to overlap the laminate shown e.g. a distance "a" or "b" shown in Figure 1 in a manner such that the exposed surface of the adhesive layer of the like laminate is in contact with the surface of layer 3 along the area defined by width "a" or "b". Instead of fully covering the upper surface of sheet 1 with layer 3 as shown in Figure 1, one or more edges of the sheet 1, e.g. the areas "a" and/or "b" along the lateral edges of sheet 1 may be provided with coating 3 only, to promote adhesion between sheet 1 and the adhesive surface of the next-applied like laminate strip. Also coating 3 may be positioned between sheet 1 and adhesive 2.
The pressure-sensitive bituminous waterproofing adhesive layer 2 useful herein is of the type described in the aforementioned United States patents to John Hurst. The adhesive composition comprises a mixture of ~a) a bituminous material and ~b) natural or synthetic polymer preferably a rub-ber or other elastomeric polymer. The amount of polymer employed in such compositions is typically from about 1 to 100, preferably about 20 to 50, percent by weight of the bituminous material. The term "bituminous material"
as used herein includes compositions containing asphalt, tar, or pitch. The adhesive may be reinforced with fibers and/or particulate fillers. The ad-hesive composition may also contain a conventional extender component suchas mineral oil. Suitable polymers include thermoplastic polymers such as polyethylene and the like. As aforementioned, the preferred polymer component is rubber which may be a virgin rubber or reclaimed rubber which is blended into the bitumen and optionally the extender component preferably at elevated temperature to form a smooth mix. Generally, suitable adhesive compositions have softening points ~measured by the Ring and Ball method) of 70 to 120C., preferably 75 to 100C., and penetration valuec~ Of 50 to 400, preferably 50 to 100 dmm. at 25C.(150 g/5 secs-ASTM-D217).
In order to give optimum sealin~ and waterproofing performance es-pecially where the substrate to be waterprooed is concrete, the adhesive layer should be at least 0.010 inch thick, preferably about 0.025 to about 0.200 inch thicX. The adhesive layer can be comprised of one or more layers of the aforemen~ioned bituminous adhesive, not necessarily of the same compo-sition, to give an adhesive layer within the overall aforementioned thickness range. Further, the adhesive layer can have a reinforcement such as an open weave fabric, gauze, scrim or the like located therein to strengthen it. The adhesive layer 2 at least at its surface remote from support sheet 1 is pres-sure-sensitive and tacky at normal ambient temperature in order that it be self-adhesive to the substrate.
A wide variety of materials can be used as the sheet-like support 1.
It is generally desirable that the support be substantially impermeable to water. For many purposes it is desirable that the support should be such that after application of the laminate to a substrate it is capable of stretching with movement of the substrate, e.g. as a result of shrinkage, with main-tenance of a moisture and moisture-vapor-proof seal. However, where stretch-ability and flexibility are less important than other properties, supports not fulfilling these requirements can be utilized. For example, it is de-sirable for some purposes to use a metallic foil, particularly of copper or aluminum, as the support 1~
The preferred sheet supports 1 are films of synthetic organic poly-mer such as polyethylene, polypropylene or other polyolefin, polyamide, poly-ester, e.g. polyethylene terephthalate, polyurethane, polyvinyl chloride, a copolymer of vinyl chloride and vinylidene chloride, synthetic rubber such as polychloroprene or butyl rubber, etc.
4~3 Other sheet-like supports include woven and non-woven fabrics of inorganic or organic natural or synthetic fibers ~staple fibers or continuous filaments), e.g. a woven fabric or fabrics of one of the synthetic organic polymers already referred to: glass, tissue, hessian, cotton or other fiber scrim, or bituminous roofing felt.
In applications where the laminate of the invention is to be exposed to the weather, for example where strips of the laminate are to be applied so as to form a continuous waterproofing membrane at the exposed surface of roofs of buildings and the like, it is desirable that the support sheet 1 have op-timum weatherabilîty characteristics. Thus the support sheet may be renderedopaque, for example by the incorporation therein of a material such as carbon black to render the support sheet non-translucent. Alternatively, a trans-lucent support sheet, e.g. a clear synthetic polymer film may be rendered opaque by a top-coating of non-trans~cent material, for example a carbon black containing coating. The support sheet may be a single sheet or film layer, or may itself comprise a plurality of such layers, not necessarily identical, laminated together to form a unitary support sheet layer 1. The support sheet 1 preferably is at least 0.001 inch in thickness, more preferably at least about 0.004 inch thick. As in the case of the adhesive layer 2 described above, the support sheet layer may have a fabric, gau~e or scrim reinforce-ment therein to strengthen it.
Cross-laminated polymeric films and biaxially oriented polymeric films are desirable support sheets 1 for use herein. As mentioned in Canadian Patent No. 1,008,738 to Everett R. Davis, support sheets for lamin-ates of the type herewith concerned comprised for example of cross-laminated high-density polyethylene and biaxially-oriented polypropylene are desirable support sheets to avoid wrinkling when the laminate is applied to a substrate 3~4~3 and exposed to direct sunlight. Any film-forming synthetic polymer or copoly-mer which can be oriented ~biaxially or cross-laminated) is useful. Biaxially oriented films of such polymers as polyolefins, e.g. high and low density polyethylene, vinylidene chloride, polystyrene, polyvinyl chloride~ rubber hydrochloride, polyethylene terephthalate, etc. are commercially available.
Particularly useful films are biaxially oriented polyolefin and cross-lamin-ated polyolefins. Preferred polymeric films for use as the flexible support material in the invention are cross-laminated high density polyethylene film and biaxially oriented polyesters such as polyethylene terephthalate desirably containing a filler such as carbon black to render such opaque. Another pre-ferred oriented film for use as the support sheet 1 in the invention is biaxlally oriented polypropylene.
The adhesion-promoting coating or layer is of a material different from that constituting sheet 1 and is employed herein to enhance the bonding between bituminous adhesive 2 and support sheet 1. In the drawing, the sur-face of sheet 1 remote from adhesive layer 2 is coated with such adhesion-promoting layer (3) to improve bonding with an overlapping like membrane.
However, the adhesion-promoting coating 3 may be applied to the opposite sur-face of sheet 1 to improve the bond between sheet 1 and adhesive layer 2 of the laminate shown in the drawing. In another preferred embodiment (not shown), both the upper and lower surfaces of sheet 1 are provided with coating or layer 3.
The adhesion-promoting coatings used herein contain polymers found to effect strong adhesive bondings between the bituminous waterproofing ad-hesive and the support sheet upon subjection of the contacting bonded sur-faces to elevated temperature. Such polymers contain a plurality of carboxy-late groups COOR ~R being alkyl of for example, 1 to about 10 carbon atoms) , ~04~3 pending from ~heir polymeric backbone. Such polymers include for example, acrylate type polymers which have pending carboxylate groups linked to the polymer backbone by way of carbon atoms (-COOR), and polymers of vinyl esters such as polyvinylacetate which have pendant carboxylate groups linked to the polymer backbone by way of oxygen atoms (-OOCR). In such polymers the car-boxylate groups form part of substituent entities pendant from the backbone or skeletal structure of the polymer, as opposed to polymers such as poly-esters wherein the carboxylate groups are components of the skeletal struc-ture.
Suitable acrylic type polymers useful in the adhesion-promoting coatings herein include homopolymers and copolymers of monomers having the structural formula CH2 C (Rl) COOR2, wherein Rl is hydrogen or alkyl con-taining 1 to about 10 carbon atoms and R2 is alkyl containing 1 to about 10 carbon atoms. Exemplary acrylic polymers include homopolymers and copolymers of methyl acrylate, ethyl acrylate, butyl acrylate, methyl methacrylate, ethyl methacrylate, butyl methacrylate, etc., and mixtures thereof. Prefer-red acrylic polymers or resins for use in the adhesion-promoting layer are polymers and copolymers of monomers which are esters having the above struc-tural formula wherein Rl is hydrogen or methyl and R2 is an alkyl group containing 1 to about 5 carbon atoms, and mixtures of such. Exemplary poly-mers of vinyl esters suitable for use in the adhesion-promoting layer include polymers and copolymers of vinyl esters of carboxylic acids such as monocar-boxylic acids containing for example 2 to about 20 carbon atoms such as vinyl acetate, vinyl propionate, vinyl butyrate, etc., as well as mixtures thèreof. Layers containing such polymers are preferably applied to the sur-face of sheet 1 in the form of fluid adherent coatings of the aforementioned polymers. Thus a fluid solution, dispersion or emulsion of the polymer e.g.
a solvent solution or a colloidal dispersion or emulsion of the polymer in water, can be deposi~ed upon the surface of the support sheet 1 followed by drying or otherwise removing the solvent or medium in which the polymer is dispersed or emulsified. To promote bonding of the polymeric adhesion-pro-moting layer to the surface of the support sheet, it may be desirable to in-terpose between the coating and the sheet a layer of material having good bonding characteristics to both the support sheet surface and the adhesion-promoting polymeric coating, or to mix such a material in the adhesion-pro-moting coating itself.
The thickness of the adhesion-promoting coating 3 will generally range between about 0.05 mils and about 5 mils. The adhesion-promoting polymeric layer further may contain one or more optional additives such as particulate fillers, for example finely divided carbon black to enhance the weatherability of the coating and/or to reduce the passage of ultraviolet light therethrough. Further, the adhesion-promoting layer may contain ad-ditives such as plasticizers, etc. to modify or enhance the physical proper-ties thereof such as flexibility and elongation.
The enhanced bonding between the bituminous adhesive, the adhesion-promoting coating, and the support sheet is achieved by subjecting the con-tacting surfaces of such to elevated temperature, that is to a temperaturegreater than about 70F, and preferably greater than about 100F. Good results have been obtained by heating the contacting portions to a tempera-ture range of about 120F to 200F over a time period of about 1 to 30 days.
In practice, successive strips of the laminate of the invention may be ap-plied to a substrate for example in overlapping fashion, and heat thereafter applied to the portions of sheet 1 having coating 3 and in contact with the adhesive layer 2. When the laminate is to be utili~ed in an environment where it will be exposed to elevated temperature, for example in the forma-tion of a continuous waterproofing membrane on the tops of roofs of buildings and the like, the requisite heating is supplied by exposure of the laminates to the heat from the sun which can cause the laminates to be heated to tem-peratures as high as 170F.
The waterproofing laminates of the invention as aforementioned are conveniently produced in the factory9 stored and transported to the job site preferably in the form of a roll comprising alternate layers of the adhesive layer 2, support mate~al 1, adhesion-promoting coating 3 and a protective layer 4. A wide variety of materials can be used to provide the protective layer. Paper having a release coating thereon, e.g. siliconized paper, or paper having a coating thereon of a vinyl chloride polymer, is satisfactory.
Other materials include films of organic polymers such as vinyl chloride polymers.
The following detailed examples further illustrate the invention:
EXAMPLE I
Several laminates of ~a) a layer of rubberiæed-asphalt pressure-sensitive waterproofing adhesive, and (b) differing support films were pre-pared for testing of the strength of overlap bonds formed between like laminates according to a "lap peel" adhesion test procedure. In the test, two like laminates are superposed (exposed adhesive side of one laminate is placed over the exposed surface of the support film of another like laminate).
The two superposed laminates are rolled with a 26 lb. weight four times to bond the two together. The bonded laminates are then stored at a constant temperature and after a recorded period of time removed from storage and pulled apart by the jaws of an "Instron" test device at room temperature.
The Instron device separates the laminates at an angle of 180 to each other _g _ 1~4''~4~3 at a rate of 2 inches per minute. The force required to separate the adhesive surface of one laminate from the surface of the support film of the like lam-inate is recorded in pounds per inch of overlapped width of the test sample.
In the test results recorded in Table I below, the laminates tested were pre-pared by adhering a layer of rubberized asphalt in an approximate thickness of between 40 and 60 mils to one side of rectangular-shaped support films measuring approximately three inches by six inches. One of the support films ~Film "D" in Table I) had a polymeric coating on its surface overlapped by the like laminate. The rubberized asphalt pressure-sensitive adhesive com-position used contained approximately 45 to 52 parts by weight of asphalt, 16 to 20 parts by weight of styrene-butadiene rubber, 26 parts by weight of mineral oil and 6 to 13 parts by weight of filler. The laminates tested and the results of the tests are given in Table I.
TABLE I
LAP PEEL ADHESION
~Samples stored at 120F) ~Pounds per inch) SUPPORT FILM
Stored A~l) B~2) C~3) D~4) 7 2~3 2-3 2-3 5-6 )Uncoated polymeric film ~film having no coating applied tO its overlapped surface).
, 4~`3 )Clear biaxially-oriented polyester (polyethylene terephthalate) film having no coating applied to its overlapped surface.
~3)Carbon black-filled biaxially oriented polyester film having no coating applied to its overlapped surface.
(4)Same as ~3) above, except that the overlapped surface of the film Y ~ had an acrylic resin coating deposited thereon ("Elvacite"
methacrylate polymer hydrosol, product of E. I. DuPont de Nemours ~ Co.~ in an amount of about 10-14 milligrams per square decimeter of film. A vinylidene chloride resin under-coating was employed for the acrylic resin.
The test results shown in Table I evidence that whereas the strength of the heat-treated overlap bonds of the uncoated films "A-C" decreased over a period of time, the strength of the overlap bonds to the acrylic-coated film "D" improved with time.
EXAMPLE II
Various coatings were applied to aluminum foil and also to the films "A" and "B" of Table I to investigate the effect of such coatings on "lap peel" adhesion of the coated surfaces to a rubberized-asphalt pressure sen-sitive adhesive as in Example I. The coatings were obtained by depositing and drying each of the following on the film surfaces;
~1) Solvent solution of polymethylmethacrylate resin ~"Elvacite 2041") ~2) Solvent solution of polyethylmethacrylate resin ~"Elvacite 2042") (3) Solvent solution of methacrylate copolymer resin ("Elvacite 2013") (4) Solvent solution of acrylonitrile rubber ~ rr&lcle ~n~rk ~5) Solvent solution of styrene/butadiene rubber ~40/60) ~6) Polyvinylidene chloride aqueous latex (7) Polyvinyl acetate aqueous dispersion (8) Solvent solution of rubberized asphalt composition.
The overlap bond strengths between the surfaces coated with tha above coatings 1-8 and the rubberized-asphalt waterproofing adhesive layer were tested as in Example I. Prior to testing in the Instron device, the lapped surfaces were first stored at elevated temperatures (120F. and higher). The acrylic coated films (coatings 1-3) and the films coated with polyvinyl acetate (coating 7) showed a marked increase in lap adhesion as did the films coated with the solvent solution of rubberized asphalt (coating 8). The latter coating ~8) is impractical as an adhesion-promoting coating in the present invention however as it is tacky after deposition upon the film and would require an additional protective coating during shipping.
The acrylonitrile rubber coated surfaces, the surfaces coated with polyviny-lidene chloride, and the surfaces coated with styrene-butadiene rubber ~coatings 4, 5 and 6) showed no major improvement in lap bond strength. In addition to the laboratory coated films tested above, commercially coated films were also tested. A polypropylene film commercially coated with acrylic resin showed marked increase in lap bond strength. A film commercially coated with polyvinylidene chloride did not show increased lap-bond strength.
EXA~IPLE III
Coatings 1J 7 and 8 f.om Example II were deposited upon samples of the support film "A" of Table I and the "lap Peel" adhesion tests of Example I performed on overlap bonds of the coated surfaces to a rubberized asphalt pressure-sensitive adhesive composition as in Example I. The tests were performed at 72F. after storage of the test samples for 24 hours at (a) ~4~14~3 70F.; ~b) 120F.; and ~c) 138F. The results are shown in Table II below.
TABLE II
ADHESION-PROMOTING LAP PEEL ADHESION
COATING (Pounds per Inch) NO. 70F 120F 138F
None 2.7 2.7 2.3 7 2.7 6.7 6.7 1 2.7 3.0 5.7 8 1.7 3.0 4.0 The test results shown in Table II evidence that all three coatings enhanced lap-bond strengths after storage at elevated temperatures.
:
bituminous waterproofing adhesive layer and (b) a flexible supporting or carrying layer of sheet-like material or film non-releasable adhered thereto, which laminates are particularly useful as waterproofing membranes for sub-strates such as roofs and decks of buildings, concrete bridge decks and the like.
In United States Patent Nos. 3,741,856, 3,853,682 and 3,900,102 to John ~lurst, there are described flexible pre-formed laminates of a water-proofing pressure-sensitive bituminous adhesive layer and a flexible support layer of e~g. plastic film or metallic film. The pre-formed laminates are idealiy suited for forming waterproofing layers, for example upon or between substrates such as concrete buildings and road decks, in place of the conven-tionally utilized "built-up" waterproofing laminates constructed at the job-site from layers of bitumen-impregnated "felts" which are typically "plied"
together by hot-applied layers of bitumen adhesive. As discussed in particular 20 in United States Patent No. 3,900,102, such laminates may ideally be construc-ted in the plant in the form of a roll with a releasable layer of protective material such as siliconiæed paper applied against the pressure-sensitive bituminous adhesive, transported to the job site, and thereafter applied to the substrate adhesive side down, each laminate strip overlapping the edge of the previously-applied strip of laminate to insure a continuous waterproof seal.
The present invention concerns an improved waterproofing laminate ~L4i~q~43 of the type described in *he aforementioned }lurst pa~ents. The improved waterproofing laminate is a preformed flexible laminate of ~a) a layer of waterproofing pressure-sensitive bituminous adhesive composition and ~b) a flexible support sheet non-releasably adhered to the bituminous adhesive layer having a coating or layer ~a) on at least one edge portion of its upper surface remote from the adhesive and/or ~b) on its surface contacting such adhesive which coating or layer promotes the adhesion of the support sheet to the bituminous adhesive layer. The adhesion-promoting coa~T~s used herein contain polymers having a plurality of pendant carboxylate groups from their polymer backbone, for example acrylic polymers and polymers of vinyl esters.
It has been found that such coatings promote improved bondings to the bitumi-nous adhesive after the contacting portions have been subjected to elevated temperature.
DESCRIPTION OF T}IE DRAWINGS
Figure 1 is a perspective cross-sectional view of a waterproofing laminate according to the invention.
DETAILED DESCRIPTION OF THE INVENTION
In Figure 1, the inventive laminate is shown as comprised of four layers, A flexible support sheet 1 is non-removably adhered to a layer of pressure-sensitive waterproofing bituminous adhesive 2, and has on its upper surface remote from adhesive 2, an adhesion-promoting coating or layer 3. A
removable protective layer 4, e.g. siliconized paper, is shown releasably-adhered to adhesive 2. The laminate as shown has a width ~"w"), e.g. 36 inches, less than its length ~t'l"), e.g. 30 fee~, and can conveniently be packaged in the form of a roll which is simply unrolled at the job-site, there-after layer 4 removed, and the exposed surface or adhesive 2 placed adjacent the substrate to be waterproofed. Another like strip of waterproofing 4.3 laminate ~not shown) is then placed adjacent the laminate, care being taken to overlap the laminate shown e.g. a distance "a" or "b" shown in Figure 1 in a manner such that the exposed surface of the adhesive layer of the like laminate is in contact with the surface of layer 3 along the area defined by width "a" or "b". Instead of fully covering the upper surface of sheet 1 with layer 3 as shown in Figure 1, one or more edges of the sheet 1, e.g. the areas "a" and/or "b" along the lateral edges of sheet 1 may be provided with coating 3 only, to promote adhesion between sheet 1 and the adhesive surface of the next-applied like laminate strip. Also coating 3 may be positioned between sheet 1 and adhesive 2.
The pressure-sensitive bituminous waterproofing adhesive layer 2 useful herein is of the type described in the aforementioned United States patents to John Hurst. The adhesive composition comprises a mixture of ~a) a bituminous material and ~b) natural or synthetic polymer preferably a rub-ber or other elastomeric polymer. The amount of polymer employed in such compositions is typically from about 1 to 100, preferably about 20 to 50, percent by weight of the bituminous material. The term "bituminous material"
as used herein includes compositions containing asphalt, tar, or pitch. The adhesive may be reinforced with fibers and/or particulate fillers. The ad-hesive composition may also contain a conventional extender component suchas mineral oil. Suitable polymers include thermoplastic polymers such as polyethylene and the like. As aforementioned, the preferred polymer component is rubber which may be a virgin rubber or reclaimed rubber which is blended into the bitumen and optionally the extender component preferably at elevated temperature to form a smooth mix. Generally, suitable adhesive compositions have softening points ~measured by the Ring and Ball method) of 70 to 120C., preferably 75 to 100C., and penetration valuec~ Of 50 to 400, preferably 50 to 100 dmm. at 25C.(150 g/5 secs-ASTM-D217).
In order to give optimum sealin~ and waterproofing performance es-pecially where the substrate to be waterprooed is concrete, the adhesive layer should be at least 0.010 inch thick, preferably about 0.025 to about 0.200 inch thicX. The adhesive layer can be comprised of one or more layers of the aforemen~ioned bituminous adhesive, not necessarily of the same compo-sition, to give an adhesive layer within the overall aforementioned thickness range. Further, the adhesive layer can have a reinforcement such as an open weave fabric, gauze, scrim or the like located therein to strengthen it. The adhesive layer 2 at least at its surface remote from support sheet 1 is pres-sure-sensitive and tacky at normal ambient temperature in order that it be self-adhesive to the substrate.
A wide variety of materials can be used as the sheet-like support 1.
It is generally desirable that the support be substantially impermeable to water. For many purposes it is desirable that the support should be such that after application of the laminate to a substrate it is capable of stretching with movement of the substrate, e.g. as a result of shrinkage, with main-tenance of a moisture and moisture-vapor-proof seal. However, where stretch-ability and flexibility are less important than other properties, supports not fulfilling these requirements can be utilized. For example, it is de-sirable for some purposes to use a metallic foil, particularly of copper or aluminum, as the support 1~
The preferred sheet supports 1 are films of synthetic organic poly-mer such as polyethylene, polypropylene or other polyolefin, polyamide, poly-ester, e.g. polyethylene terephthalate, polyurethane, polyvinyl chloride, a copolymer of vinyl chloride and vinylidene chloride, synthetic rubber such as polychloroprene or butyl rubber, etc.
4~3 Other sheet-like supports include woven and non-woven fabrics of inorganic or organic natural or synthetic fibers ~staple fibers or continuous filaments), e.g. a woven fabric or fabrics of one of the synthetic organic polymers already referred to: glass, tissue, hessian, cotton or other fiber scrim, or bituminous roofing felt.
In applications where the laminate of the invention is to be exposed to the weather, for example where strips of the laminate are to be applied so as to form a continuous waterproofing membrane at the exposed surface of roofs of buildings and the like, it is desirable that the support sheet 1 have op-timum weatherabilîty characteristics. Thus the support sheet may be renderedopaque, for example by the incorporation therein of a material such as carbon black to render the support sheet non-translucent. Alternatively, a trans-lucent support sheet, e.g. a clear synthetic polymer film may be rendered opaque by a top-coating of non-trans~cent material, for example a carbon black containing coating. The support sheet may be a single sheet or film layer, or may itself comprise a plurality of such layers, not necessarily identical, laminated together to form a unitary support sheet layer 1. The support sheet 1 preferably is at least 0.001 inch in thickness, more preferably at least about 0.004 inch thick. As in the case of the adhesive layer 2 described above, the support sheet layer may have a fabric, gau~e or scrim reinforce-ment therein to strengthen it.
Cross-laminated polymeric films and biaxially oriented polymeric films are desirable support sheets 1 for use herein. As mentioned in Canadian Patent No. 1,008,738 to Everett R. Davis, support sheets for lamin-ates of the type herewith concerned comprised for example of cross-laminated high-density polyethylene and biaxially-oriented polypropylene are desirable support sheets to avoid wrinkling when the laminate is applied to a substrate 3~4~3 and exposed to direct sunlight. Any film-forming synthetic polymer or copoly-mer which can be oriented ~biaxially or cross-laminated) is useful. Biaxially oriented films of such polymers as polyolefins, e.g. high and low density polyethylene, vinylidene chloride, polystyrene, polyvinyl chloride~ rubber hydrochloride, polyethylene terephthalate, etc. are commercially available.
Particularly useful films are biaxially oriented polyolefin and cross-lamin-ated polyolefins. Preferred polymeric films for use as the flexible support material in the invention are cross-laminated high density polyethylene film and biaxially oriented polyesters such as polyethylene terephthalate desirably containing a filler such as carbon black to render such opaque. Another pre-ferred oriented film for use as the support sheet 1 in the invention is biaxlally oriented polypropylene.
The adhesion-promoting coating or layer is of a material different from that constituting sheet 1 and is employed herein to enhance the bonding between bituminous adhesive 2 and support sheet 1. In the drawing, the sur-face of sheet 1 remote from adhesive layer 2 is coated with such adhesion-promoting layer (3) to improve bonding with an overlapping like membrane.
However, the adhesion-promoting coating 3 may be applied to the opposite sur-face of sheet 1 to improve the bond between sheet 1 and adhesive layer 2 of the laminate shown in the drawing. In another preferred embodiment (not shown), both the upper and lower surfaces of sheet 1 are provided with coating or layer 3.
The adhesion-promoting coatings used herein contain polymers found to effect strong adhesive bondings between the bituminous waterproofing ad-hesive and the support sheet upon subjection of the contacting bonded sur-faces to elevated temperature. Such polymers contain a plurality of carboxy-late groups COOR ~R being alkyl of for example, 1 to about 10 carbon atoms) , ~04~3 pending from ~heir polymeric backbone. Such polymers include for example, acrylate type polymers which have pending carboxylate groups linked to the polymer backbone by way of carbon atoms (-COOR), and polymers of vinyl esters such as polyvinylacetate which have pendant carboxylate groups linked to the polymer backbone by way of oxygen atoms (-OOCR). In such polymers the car-boxylate groups form part of substituent entities pendant from the backbone or skeletal structure of the polymer, as opposed to polymers such as poly-esters wherein the carboxylate groups are components of the skeletal struc-ture.
Suitable acrylic type polymers useful in the adhesion-promoting coatings herein include homopolymers and copolymers of monomers having the structural formula CH2 C (Rl) COOR2, wherein Rl is hydrogen or alkyl con-taining 1 to about 10 carbon atoms and R2 is alkyl containing 1 to about 10 carbon atoms. Exemplary acrylic polymers include homopolymers and copolymers of methyl acrylate, ethyl acrylate, butyl acrylate, methyl methacrylate, ethyl methacrylate, butyl methacrylate, etc., and mixtures thereof. Prefer-red acrylic polymers or resins for use in the adhesion-promoting layer are polymers and copolymers of monomers which are esters having the above struc-tural formula wherein Rl is hydrogen or methyl and R2 is an alkyl group containing 1 to about 5 carbon atoms, and mixtures of such. Exemplary poly-mers of vinyl esters suitable for use in the adhesion-promoting layer include polymers and copolymers of vinyl esters of carboxylic acids such as monocar-boxylic acids containing for example 2 to about 20 carbon atoms such as vinyl acetate, vinyl propionate, vinyl butyrate, etc., as well as mixtures thèreof. Layers containing such polymers are preferably applied to the sur-face of sheet 1 in the form of fluid adherent coatings of the aforementioned polymers. Thus a fluid solution, dispersion or emulsion of the polymer e.g.
a solvent solution or a colloidal dispersion or emulsion of the polymer in water, can be deposi~ed upon the surface of the support sheet 1 followed by drying or otherwise removing the solvent or medium in which the polymer is dispersed or emulsified. To promote bonding of the polymeric adhesion-pro-moting layer to the surface of the support sheet, it may be desirable to in-terpose between the coating and the sheet a layer of material having good bonding characteristics to both the support sheet surface and the adhesion-promoting polymeric coating, or to mix such a material in the adhesion-pro-moting coating itself.
The thickness of the adhesion-promoting coating 3 will generally range between about 0.05 mils and about 5 mils. The adhesion-promoting polymeric layer further may contain one or more optional additives such as particulate fillers, for example finely divided carbon black to enhance the weatherability of the coating and/or to reduce the passage of ultraviolet light therethrough. Further, the adhesion-promoting layer may contain ad-ditives such as plasticizers, etc. to modify or enhance the physical proper-ties thereof such as flexibility and elongation.
The enhanced bonding between the bituminous adhesive, the adhesion-promoting coating, and the support sheet is achieved by subjecting the con-tacting surfaces of such to elevated temperature, that is to a temperaturegreater than about 70F, and preferably greater than about 100F. Good results have been obtained by heating the contacting portions to a tempera-ture range of about 120F to 200F over a time period of about 1 to 30 days.
In practice, successive strips of the laminate of the invention may be ap-plied to a substrate for example in overlapping fashion, and heat thereafter applied to the portions of sheet 1 having coating 3 and in contact with the adhesive layer 2. When the laminate is to be utili~ed in an environment where it will be exposed to elevated temperature, for example in the forma-tion of a continuous waterproofing membrane on the tops of roofs of buildings and the like, the requisite heating is supplied by exposure of the laminates to the heat from the sun which can cause the laminates to be heated to tem-peratures as high as 170F.
The waterproofing laminates of the invention as aforementioned are conveniently produced in the factory9 stored and transported to the job site preferably in the form of a roll comprising alternate layers of the adhesive layer 2, support mate~al 1, adhesion-promoting coating 3 and a protective layer 4. A wide variety of materials can be used to provide the protective layer. Paper having a release coating thereon, e.g. siliconized paper, or paper having a coating thereon of a vinyl chloride polymer, is satisfactory.
Other materials include films of organic polymers such as vinyl chloride polymers.
The following detailed examples further illustrate the invention:
EXAMPLE I
Several laminates of ~a) a layer of rubberiæed-asphalt pressure-sensitive waterproofing adhesive, and (b) differing support films were pre-pared for testing of the strength of overlap bonds formed between like laminates according to a "lap peel" adhesion test procedure. In the test, two like laminates are superposed (exposed adhesive side of one laminate is placed over the exposed surface of the support film of another like laminate).
The two superposed laminates are rolled with a 26 lb. weight four times to bond the two together. The bonded laminates are then stored at a constant temperature and after a recorded period of time removed from storage and pulled apart by the jaws of an "Instron" test device at room temperature.
The Instron device separates the laminates at an angle of 180 to each other _g _ 1~4''~4~3 at a rate of 2 inches per minute. The force required to separate the adhesive surface of one laminate from the surface of the support film of the like lam-inate is recorded in pounds per inch of overlapped width of the test sample.
In the test results recorded in Table I below, the laminates tested were pre-pared by adhering a layer of rubberized asphalt in an approximate thickness of between 40 and 60 mils to one side of rectangular-shaped support films measuring approximately three inches by six inches. One of the support films ~Film "D" in Table I) had a polymeric coating on its surface overlapped by the like laminate. The rubberized asphalt pressure-sensitive adhesive com-position used contained approximately 45 to 52 parts by weight of asphalt, 16 to 20 parts by weight of styrene-butadiene rubber, 26 parts by weight of mineral oil and 6 to 13 parts by weight of filler. The laminates tested and the results of the tests are given in Table I.
TABLE I
LAP PEEL ADHESION
~Samples stored at 120F) ~Pounds per inch) SUPPORT FILM
Stored A~l) B~2) C~3) D~4) 7 2~3 2-3 2-3 5-6 )Uncoated polymeric film ~film having no coating applied tO its overlapped surface).
, 4~`3 )Clear biaxially-oriented polyester (polyethylene terephthalate) film having no coating applied to its overlapped surface.
~3)Carbon black-filled biaxially oriented polyester film having no coating applied to its overlapped surface.
(4)Same as ~3) above, except that the overlapped surface of the film Y ~ had an acrylic resin coating deposited thereon ("Elvacite"
methacrylate polymer hydrosol, product of E. I. DuPont de Nemours ~ Co.~ in an amount of about 10-14 milligrams per square decimeter of film. A vinylidene chloride resin under-coating was employed for the acrylic resin.
The test results shown in Table I evidence that whereas the strength of the heat-treated overlap bonds of the uncoated films "A-C" decreased over a period of time, the strength of the overlap bonds to the acrylic-coated film "D" improved with time.
EXAMPLE II
Various coatings were applied to aluminum foil and also to the films "A" and "B" of Table I to investigate the effect of such coatings on "lap peel" adhesion of the coated surfaces to a rubberized-asphalt pressure sen-sitive adhesive as in Example I. The coatings were obtained by depositing and drying each of the following on the film surfaces;
~1) Solvent solution of polymethylmethacrylate resin ~"Elvacite 2041") ~2) Solvent solution of polyethylmethacrylate resin ~"Elvacite 2042") (3) Solvent solution of methacrylate copolymer resin ("Elvacite 2013") (4) Solvent solution of acrylonitrile rubber ~ rr&lcle ~n~rk ~5) Solvent solution of styrene/butadiene rubber ~40/60) ~6) Polyvinylidene chloride aqueous latex (7) Polyvinyl acetate aqueous dispersion (8) Solvent solution of rubberized asphalt composition.
The overlap bond strengths between the surfaces coated with tha above coatings 1-8 and the rubberized-asphalt waterproofing adhesive layer were tested as in Example I. Prior to testing in the Instron device, the lapped surfaces were first stored at elevated temperatures (120F. and higher). The acrylic coated films (coatings 1-3) and the films coated with polyvinyl acetate (coating 7) showed a marked increase in lap adhesion as did the films coated with the solvent solution of rubberized asphalt (coating 8). The latter coating ~8) is impractical as an adhesion-promoting coating in the present invention however as it is tacky after deposition upon the film and would require an additional protective coating during shipping.
The acrylonitrile rubber coated surfaces, the surfaces coated with polyviny-lidene chloride, and the surfaces coated with styrene-butadiene rubber ~coatings 4, 5 and 6) showed no major improvement in lap bond strength. In addition to the laboratory coated films tested above, commercially coated films were also tested. A polypropylene film commercially coated with acrylic resin showed marked increase in lap bond strength. A film commercially coated with polyvinylidene chloride did not show increased lap-bond strength.
EXA~IPLE III
Coatings 1J 7 and 8 f.om Example II were deposited upon samples of the support film "A" of Table I and the "lap Peel" adhesion tests of Example I performed on overlap bonds of the coated surfaces to a rubberized asphalt pressure-sensitive adhesive composition as in Example I. The tests were performed at 72F. after storage of the test samples for 24 hours at (a) ~4~14~3 70F.; ~b) 120F.; and ~c) 138F. The results are shown in Table II below.
TABLE II
ADHESION-PROMOTING LAP PEEL ADHESION
COATING (Pounds per Inch) NO. 70F 120F 138F
None 2.7 2.7 2.3 7 2.7 6.7 6.7 1 2.7 3.0 5.7 8 1.7 3.0 4.0 The test results shown in Table II evidence that all three coatings enhanced lap-bond strengths after storage at elevated temperatures.
:
Claims (29)
PROPERTY OR PRIVILEGE IS CLAIMED ARE DEFINED AS FOLLOWS:
1. A pre-formed, flexible pressure-sensitive adhesive waterproofing laminate comprising (a) a waterproofing layer of pressure-sensitive adhesive bituminous composition; (b) a layer of flexible support material non-releas-ably adhered to said layer (a); and (c) an adhesion-promoting coating layer upon at least a portion of the surface of said support material (b) remote from said adhesive layer (a) and/or between said support material (b) and said adhesive layer (a), said adhesion-promoting coating layer containing a polymer having a plurality of carboxylate groups COOR wherein R is alkyl of 1 to about 10 carbon atoms pendant from its polymeric backbone, said adhesion-promoting coating layer acting to enhance the adhesive bond between the sup-port material (b) and the adhesive layer (a) upon subjection of such adhesive bond to elevated temperature.
2. The laminate of Claim 1 wherein said waterproofing layer comprises a mixture of bitumen and polymer.
3. The laminate of Claim 2 wherein said polymer in said mixture is thermoplastic.
4. The laminate of Claim 2 wherein said polymer in said mixture is elastomeric.
5. The laminate of Claim 1 wherein said layer (a) comprises a mixture of asphalt, rubber and mineral oil.
6. The laminate of Claim 1 wherein said support material is a film of organic polymer, a metallic foil, or a woven or non-woven fabric or mesh.
7. The laminate of Claim 1 wherein said pendant carboxylate groups are linked to said polymeric backbone by bonds between either a carbon atom or an oxygen atom in said groups and the polymeric backbone.
8. The laminate of Claim 1 wherein said polymer having pendant car-boxylate groups is an acrylic polymer, a polymer of a vinyl ester, or mixture thereof.
9. The laminate of Claim 1 wherein said layer (b) comprises a plurality of layers of differing materials.
10. The laminate of Claim 1 wherein said waterproofing layer (a) is at least 0.010 inch thick.
11. The laminate of Claim 1 wherein said layer (b) is at least 0.001 inch thick.
12. The laminate of Claim 1 wherein the surface of the waterproofing pressure-sensitive adhesive layer remote from said layer (b) has a protective coating or covering which can be physically separated therefrom without sub-stantially damaging the adhesive layer.
13. A pre-formed, flexible, pressure-sensitive adhesive waterproofing laminate comprising (a) a waterproofing layer at least 0.010 inch thick of pressure-sensitive adhesive composition containing bitumen and an elastomeric polymer, the amount of said polymer present being from about 1 to 50 percent by weight of said bitumen, (b) a layer of flexible support material at least 0.001 inch thick non-releasably adhered to one surface of said waterproofing adhesive layer, said support material comprising one or more layers of mater-ial selected from the group consisting of synthetic polymer films, metallic foils, and woven or non-woven fabric; and (c) an adhesion-promoting coating layer located upon at least a portion of the surface of said support layer (b) remote from said adhesive layer (a), said adhesion-promoting coating layer containing a polymer having a plurality of carboxylate groups COOR wherein R
is alkyl of 1 to about 10 carbon atoms pendant from its polymeric backbone, said adhesive-promoting coating layer acting to enhance the adhesive bond between the support material and the adhesive (a) of a like, overlapping water-proofing membrane upon subjection of said adhesive bond to elevated tempera-ture.
is alkyl of 1 to about 10 carbon atoms pendant from its polymeric backbone, said adhesive-promoting coating layer acting to enhance the adhesive bond between the support material and the adhesive (a) of a like, overlapping water-proofing membrane upon subjection of said adhesive bond to elevated tempera-ture.
14. The laminate of Claim 13 wherein said adhesive layer (a) comprises a mixture of asphalt, rubber and mineral oil.
15. The laminate of Claim 14 wherein said rubber is a copolymer of styrene and butadiene.
16. The laminate of Claim 14 wherein said support of layer (b) is com-prised of a polyester film.
17. The laminate of Claim 16 wherein said film is opaque.
18. The laminate of Claim 16 wherein said film comprises biaxially-oriented polyethylene terephthalate.
19. The laminate of Claim 13 wherein said support layer (b) comprises cross-laminated polyolefin film.
20. The laminate of Claim 13 wherein said adhesion-promoting coating layer contains a polymer of one or more monomers having the structural for-mula:
wherein R1 is hydrogen or alkyl of 1 to about 10 carbon atoms and R2 is alkyl of 1 to about 10 carbon atoms.
wherein R1 is hydrogen or alkyl of 1 to about 10 carbon atoms and R2 is alkyl of 1 to about 10 carbon atoms.
21. The laminate of Claim 14 wherein said adhesion-promoting coating layer is a dried adherent deposit from a solution, dispersion or emulsion of said polymer containing said pendant carboxyl groups.
22. The laminate of Claim 14 wherein said polymer containing said pen-dant carboxy groups is selected from the group consisting of acrylate and methacrylate polymers, polymers of vinyl esters, and mixtures thereof.
23. The laminate of Claim 14 wherein said adhesion-promoting coating layer contains a filler rendering it opaque.
24. The laminate of Claim 14 wherein said polymer in said adhesion-promoting coating layer is a polymer of a polymerizable vinyl ester.
25. The laminate of Claim 24 wherein said polymer is polyvinyl acetate.
26. The laminate of Claim 20 wherein said alkyl contains, 1 to about 5 carbon atoms.
27. The method of waterproofing a substrate comprising the steps of ap-plying a plurality of the laminates of Claim 1 to said substrate and subject-ing the contacting portions of said adhesive and said adhesion-promoting coating layers to elevated temperature.
28. The method of Claim 27 wherein said overlapped portion is heated to temperature in excess of 70°F.
29. The method of Claim 27 wherein said overlapping portion is heated to temperature of from about 120 to 200°F.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US5476879A | 1979-07-05 | 1979-07-05 | |
| US54,768 | 1979-07-05 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1140443A true CA1140443A (en) | 1983-02-01 |
Family
ID=21993407
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000355413A Expired CA1140443A (en) | 1979-07-05 | 1980-07-04 | Waterproofing membranes |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1140443A (en) |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP1075938A1 (en) * | 1999-08-13 | 2001-02-14 | Premark RWP Holdings, Inc. | Liquid resistant laminate |
| CN113134879A (en) * | 2021-04-20 | 2021-07-20 | 中国林业科学研究院木材工业研究所 | Fragrance-releasing decorative artificial board and preparation method thereof |
-
1980
- 1980-07-04 CA CA000355413A patent/CA1140443A/en not_active Expired
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| EP1075938A1 (en) * | 1999-08-13 | 2001-02-14 | Premark RWP Holdings, Inc. | Liquid resistant laminate |
| SG92710A1 (en) * | 1999-08-13 | 2002-11-19 | Premark Rwp Holdings Inc | Liquid resistant laminate with strong backer |
| CN113134879A (en) * | 2021-04-20 | 2021-07-20 | 中国林业科学研究院木材工业研究所 | Fragrance-releasing decorative artificial board and preparation method thereof |
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