CA1252380A - Waterproof bonding membrane and method - Google Patents
Waterproof bonding membrane and methodInfo
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- CA1252380A CA1252380A CA000484213A CA484213A CA1252380A CA 1252380 A CA1252380 A CA 1252380A CA 000484213 A CA000484213 A CA 000484213A CA 484213 A CA484213 A CA 484213A CA 1252380 A CA1252380 A CA 1252380A
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Abstract
WATERPROOF BONDING MEMBRANE AND METHOD
ABSTRACT OF THE DISCLOSURE
A waterproof bonding membrane and method are provided to isolate and securely mount facing, such as tile, brick, terrazzo, stone, slate and the like, to various building surfaces in the construction of exterior and interior walls, floors, countertops, bathtub enclosures, fountains, shower stalls, and other similar structures. The membrane comprises a waterproof isolating sheet, with at least one bonding sheet, constructed of a non-woven, randomly distributed, continuous filament material, laminated to one side of the waterproof isolating sheet. A layer of membrane bonding agent attaches the other side of the waterproof isolating sheet to the building surface, and a layer of facing bonding agent attaches the facing to the exposed side of the bonding sheet. Both sides of the waterproof isolating sheet may have a bonding sheet laminated thereto to provide extra bond strength for certain types of building surfaces and constructions.
ABSTRACT OF THE DISCLOSURE
A waterproof bonding membrane and method are provided to isolate and securely mount facing, such as tile, brick, terrazzo, stone, slate and the like, to various building surfaces in the construction of exterior and interior walls, floors, countertops, bathtub enclosures, fountains, shower stalls, and other similar structures. The membrane comprises a waterproof isolating sheet, with at least one bonding sheet, constructed of a non-woven, randomly distributed, continuous filament material, laminated to one side of the waterproof isolating sheet. A layer of membrane bonding agent attaches the other side of the waterproof isolating sheet to the building surface, and a layer of facing bonding agent attaches the facing to the exposed side of the bonding sheet. Both sides of the waterproof isolating sheet may have a bonding sheet laminated thereto to provide extra bond strength for certain types of building surfaces and constructions.
Description
l ~ATERPROOF BOMDING MEMBRANE AND METHOD
BACKGROUND OF THE INVENTION
The present invention relates to faclng for buildings and the like, and in particular to a waterproof bonding membrane and method.
Various materials and methods that include waterprooE membranes, such as those disclosed in United States Patent 4,324,605 to Bethea, are available to mount facing articles to building substrates, and other similar surfaces. The term "facing" as used herein, is intended to include all exterior covering materials for walls, ceilings, floors, and the like, such as glazed wall tiles, ceramic and mozaic tiles, quarry tile, paver tile, marble, delftware, slate, brick, terrazzo and other similar finishing materials for both the interior and exterior of building constructions, and the like~ Such facing materials provide a very durable, easily cleaned, attractive construction which will not weather or deteriorate even in areas of high heat and humidity.
Hence, this type of builcling material is particularly adapted for use in all types of wet or moist areas, such as bath enclosures, shower stalls, kitchen floors, fountains, food processiny areas, breweries and other similar applications and environments.
Some facing materials, such as ceramic tile and the like, are relatively porous, at least with respect to water vapor. As a result, water vapor will penetrate the tile and surrouncling grout, and become absorbed in the bonding agent, which eventually ruins the bond holding the 1 tile to the substrate. Also, because the tiles and the grout are quite brittle, even slight structural shifting in the building walls or floors can cause the grout and/or tiles to become dislodged or cracked. In either of the above events, the tile substrate :is exposed to moisture, and in the case of drywall, plywood and the like, ultimately causes the substrate to lose its structural integrity. As a result, plywood, wallboard, and other such construction materials that are particularly susceptible to water damage are not commonly used as a substrate for ceramic tile installations.
Minor cracking of the building substrate caused by shrinkage, expansion, etc. is also a frequent occurrence, both before and after the facing is installedO Such cracking can damage the tile bedl and may propagate to the finished surface.
Hence, a need exists for an arrangement that will securely mount Eacing to different types of building substrates, including wood, cement, and the like, and that will form a waterproof barrier between the substrate and the facing. A need also exists for an arrangement that will isolate the facing bond from the effects of cracking that takes place in the building substrate.
SUMMARY OF THE INVENTION
-One aspect of the present invention is to provide a waterproof bonding membrane and method that isolates and securely rnounts facing to various building surfaces in the construction of floors, countertops, ceilings, bathtub enclosures, fountains, shower stalls, food processing stations, and other similar structures. The membrane comprises an imperforate waterproof isolating sheet, with 3~
1 at least one bonding sheet, constructed of a non-woven, randomly distributed, continuous filament material, laminated to one side of the waterproof isolating sheet.
A layer of membfane bonding agent attaches the other side of the waterproof isolating sheet to the building surface, and a layer of facing bonding agent attaches the facing to the exposed side of the bonding sheet. Preferably, both sides of the waterproof isolating sheet have a bonding sheet laminated thereto to provide extra bonding strength for certain types of building surfaces and constructions.
In one aspect of the present invention, the bonding sheets are constructed from spunbonded polyester, and the waterproof isolating sheet is constructed from chlorinated polyethylene. The waterproof isolating sheet is extruded from a die, with the sheet leaving the die at an elevated temperature, and the bonding sheets are laminated thereto by pressing the same against the opposite sides of the waterproof isolating sheet immediately ater the waterproof isolating sheet exits the die. Nip rollers may be used to press the three layers of the waterproof bonding rnembrane together, and pre~ferably physically presses each bonding sheet into the waterproof isolating sheet a distance in the range of .nO2 to .00 inches.
The principal objects of the present invention are to provide a triple function isolating, waterproofing and bonding membrane that isolates and securely attaches facing to a build:ing substrate, and forms a waterproof barrier therebetween. The waterproof bonding membrane is easy and economical to manufacture, and can be readily installed on various types of different building 1 substrates. The waterproof bonding membrane is particularly adapted for thin-bed tiling techniques, and can be used with a wide variety of different types of facing materials. In addition to waterproofing, the present invention may he used to protect the tile bed by minimizing the effect of any substrate that is cracked before installation of the tile or a substrate that cracks after the tile bed is installed. Minor cracking of the substrate is a frequent occurrence. When properly installed, tile will remain bonded to the membrane, even when the siæe or extent of cracking becomes unacceptable.
Since the present waterproofing membrane will stretch and remain in tact after the tile or grout have cracked, it can in effect protect the setting bed by isolating it from minute cracks.
The waterproof bonding membrane is particularly efficient in use, economical to manufacture, has a long effective life, and is particularly well adapted for the proposed use. These and other features, advantages and objects of the present invention will be further understood and appreciated by those skilled in the art by reference to the following specification, claims and appended drawings.
BRIEF D~SCRIPTION OF THE DRAWINGS
Fig. l is a partially schematic, fragmentary perspective view of a shower stall incorporating a waterproof bonding membrane and method embodying the present invention.
Fig. 2 is a partially schematic, fragmentary top plan view of the waterproof bonding membrane.
l Fig. 3 is a partially sehematie, enlarged fragmentary plan view of the waterproof bonding membrane.
Fig. 4 is a partially sehematic, fragmentary cross-sectional view of the waterproof bonding membrane, shown partially attached to a building substrate.
Fig. 5 is a partially schernatic, fragmentary cross-sectional view of the waterproof bonding membrane, shown fully attached to the building substrate, with facing partially attached to the exterior surface thereof.
Fig. 6 is a partially schematic, fragmentary cross-sectional view of the waterproof bonding membrane, with the facing completely attaehed to the exterior surfaee thereof and grouted in plaee.
Fig. 7 is a sehematic illustration of a method for manufacturing the waterproof bonding membrane.
Fig. 8 is a schematic illustration of the membrane manufacturing method, particularly showing nip rollers pressing bonding sheets into a waterproof isolating sheet of the waterproof bonding membrane.
Fig. 9 is a partially schematic front elevational view of the rnethod and structure of Fig. 8.
FicJ. lO is a partially schematic, fragmentary end elevational view of a sheet of waterproof bon~iny rnembrane constructed in accordance with the illustrated rnethod.
DF,TAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
For purposes of description herein, the terms "upper," nlower," nright," "left,n "rear,n "Eront,l1 "vertical," "horizontal," and derivatives thereof shall relate to the invention as oriented in Figs. 4, 5 and 6.
However, it is to be understood that the invention may assume various alternative orientations, and step 1 sequences, except where expressly specified to the contrary.
The reference numeral 1 (Fig. 4) generally designates a waterproof bonding membrane embodying the present invention. Waterproof bonding membrane 1 is particularly adapted to rnount facing materials, such as brick, stone, slate, et cetera, and the illustrated ceramic tile 2 (Figs. 1, 5 and 6) to various building surfaces in the construction of floors, walls, countertops, and the like, as well as the illustrated shower stall 3 Waterproof bonding membrane l comprises a waterproof isolating sheet 4 constructed of an imperforate, substantially waterproof material, and shaped to cover that portion of the building substrate on which facing 2 is to be mounted. WaterprooE bonding membrane l also includes a least one bonding sheet 5, constructed of a non-woven/ randomly distributed, continuous filament materiall and having a size and shape substantially commensurate with waterproof isolating sheet ~. sonding sheet 5 is laminated to one side of waterproof isolat:ing sheet ~. In the illustrated example, two bonding sheets 5 and 6 are larninated to the opposite side oE waterproof :isolating sheet ~. A layer of membrane bonding coat or agent 7 (Figs. 5 and 6) attaches one side of waterproof bonding membrane l to the building surface, and a layer of facing bonding coat or agent 8 attaches the facing 2 to the opposite side of waterproof bonding rnembrane 1, so as to securely mount the facing on the building surface~ and form a waterproof isolating barrier therebetween.
It is to be understood that shower stall 3 is rnerely exemplary of one application of the present 1 invention. ~laterproof bonding membrane 1 can be used on a wide variety of difEerent surfaces, on either the exterior or the interior of buildings, and the like. The illustrated shower stall 3 includes an end wall 14, a rear wall 15, a floor 16 and a front curb or dam 17. A
conventional drain 18 is positioned in the floor 16 of shower stall 3.
Waterproof bonding membrane 1 is preferably flexible, so that it will readily conform to diEferent shapes of building substrates and surfaces, as described in greater detail hereinafter. In the illustrated example, waterproof bonding membrane 1 has an overall final thickness in the range of .032 to .034 inches, a width of 60 inches, and is typically supplied in rolls of 100 foot length. As best illustrated in Figs. 9 and 10, bonding sheets 5 and 6 are preferably staggered or offset slightly on waterproof isolating sheet 4, so as to form exposed, bondings strips 23 and 24 along the side edges 25 and 26 of waterproof isolating sheet 4 to join two or more sheets of waterproof bonding membrane 1, in the manner described below. More specifically, with reference to Fig. 10, the left-hand side edge 27 of bonding sheet 5 is aligned with the corresponding left-hand side edge 25 of waterproof isolating sheet ~. In the illustrated example, bonding sheet 5 is approximately 2 inches narrower than waterproof isolating sheet ~, so as to form a 2 inch bonding strip 23 between the right-hand side edge 28 of bonding sheet 5, and the corresponding right-hand side edge 26 of waterproof isolating sheet 4. In a like manner, the right-hand edge 29 of bonding sheet 6 is aligned with the corresponding right-hand side edge 26 of ~S'~3~3 1 waterproof isolating sheet 4. The illustrated bonding sheet 6 is also approximately 2 inches narrower than waterproof isolating sheet 4, thereby forming bonding strip 24 between the left-hand side edge 30 of bonding sheet 6, and the left-hand side edge 25 of waterproof isolating sheet 4. ~ence, bonding strips 23 and 24 are located on opposite faces of waterproof bonding membrane 1, along the opposite side edges 25 and 26 thereof.
Waterproof isolating sheet 4 preferably comprises a relatively thin, continuous membrane constructed of a chlorinated polyethylene material. In the illustrated embodiment of the present invention, waterproof isolating sheet 4 has a thickness of approximately .023 to .024 inches, and a width of around 60 inches.
One example of a suitable waterproof isolating sheet 4 is made from a compound formulated from Chlorinated Polyethylene (CPE) resins that shall: (a) contain 38~ to 46~ chlorine; (b) be made from a linear polyethylene having a density of not less than 0.95 g/cm3;
(c) be substantially arnorphous having a heat o fusion oE
less than 0.4 cal/g (1.7 KJ/kg); and (d) have a melt viscosity of 1,700 ~ 500 Pa-sec when measured in an Instron Capillary Rheometer at a melt temperature of 190 -~/- 2 C, and a shear rate of 150 ~/- 10 sec-l.
Another example of a suitable chlorinated polyethylene material for waterproof isolating sheet 4 is disclosed in United States Patent 3,641,216, to Schnebelen et al.
Yet, another example of a suitable chlorinated polyethylene material for waterproof isolating sheet 4 has the following physical characteristics.
~25~
Hardness, Shore A ASTM D2240, points 76+/-6 ~5 second) Method A
Tensile Strength ASTM D412 psi 1500 min.
(transverse Meth. A, Die C
direction) Tensile Stress at ASTM D412 psi 400 min.
100% elongation Meth. A, Die C
(modulus) (transverse direction) ~ltimate Elongation ASTM D412 % 300 min.
at Break transverse direction) Tear Resistance ASTM D1004 lbs/in- 175 min.
(both directions) width Volatile ASTM D1203 ~ weight 1~ max.
Extraction loss Bonding sheets 5 and 6 are preferably constructed from relatively thin, continuous sheets of a non-woven material, such as spunbonded polyester. In the illustrated structure, bonding sheets 5 and 6 have a thickness of approximately .008 inches, a unit weight of 1 ounce per square yard (34 grams per square meter), and a width of approximately 58 inches. The bonding sheet material is constructed oE continuous filament polyester fibers that are randomly arranged, highly dispersecl, and bonded at the filament junctions. The chemical and thermal properties of the spunbonded material are essentially those of polyester fiber. ~ne such suitable material is known in the trade as "Reemay" (a registered trademark oE Dupont), which includes high tensile strength, coupled with a high elongation, high tear strength and toughness, high bulk and porosity, non-raveling edges, and good dimensional stability. The non-woven nature of the bonding sheets 5 and 6 permits adhesives to readily saturate or permeate the same in _g_ ~s~
1 order to obtain a very strong mechanical bond Reemay brand spunbonded polyester style 2014 is illustrative of one working example of bonding sheets 5 and 6. The bonding sheet material illustrated in Fig. 2 has generally straight fibers.
Another example of a suitable material for bonding sheets 5 and 6 is disclosed in U.S. Patent 3,341,394 to Kinney, rlxample No. 10.
As best illustrated in Figs. 7-10, waterproof bonding membrane 1 is preferably constructed by laminating bonding sheets 5 and 6 to the opposite sides of waterproof isolating sheet 4. In the illustrated example, waterproof isolating sheet 4 is extruded from a die 35. A pair of compression or nip rollers 36 and 37 are positioned immediately downstream from extruding die 35, and preferably include an exterior layer or coating of silicon 38 for purposes to be described in greater detail hereinafter. Waterproof isolating sheet 4 is pulled or tensed slightly in the longitudinal direction between die 35 and nip rollers 36 and 37. In one working example of the present invention, wherein waterproof isolating sheet 4 has a thickness of approximately .023 to .024 inches, and bonding sheets 5 and 6 have a thickness in the nature of .008 inches, nip rollers 36 and 37 are spaced apart a distance of approximately .n23 inches. A pair of dispensing rollers or drums 39 and 40 are positioned on opposite sides of nip rollers 36 and 37, and feed bonding sheets 5 and 6 respectively between nip rollers 36 and 37. A water cooled idler roller 41 is located directly below the lower nip roller 37, and receives the laminated waterproof bonding membrane 1 thereover. A takeup drum 42 ~2~
1 is located downstream of nip rollers 36 and 37, and collects the fully larninated waterproof bonding membrane 1 onto a suitable core Eor storage and transport.
In one exarnple of the present invention, S waterproof isolatiny sheet 4 exits extruding die 35 at an elevated temperature, in the range of 250 to 350 degrees F., preferably approximately 290 to 300 degrees F. Nip rollers 36 and 37 are preferably located immediately downstream from extrusion die 35, so that bonding sheets 5 and 6 are pressed firmly into the opposite sides of waterproof isolating sheet 4 while the ~aterproof isolating sheet is at the elevated, extruded temperature of approximately 290 to 300 degrees F. The elevated temperature of waterproof isolating sheet 4, in combination with the compressive forces applied by nip rollers 36 and 37, securely laminate bonding sheets 5 and 6 to waterproof isolating sheet 4 to form an integral construction. The fully laminated waterproof bonding membrane 1 then exits nip rollers 36 and 37, and is cooled as it travels over idler roller 41.
As best illustrated in Fig. 8, during the laminating step, both the bondiny sheets 5 and 6, and the waterproof isolatiny sheet 4 are elastically deformed inwardly in a compressive fashion. The compressive force applied by nip rollers 36 and 37 physically presses each bonding sheet 5 into waterproof isolating sheet 4 a distance of approximately .002 to .004 inches. Mence, in the illustrated example, the final thickness of waterproof bonding membrane 1 is .032 to .034 inches, whereas the original thickness of the three layers is approximately .039 to ~040 inchesO The total thickness of finished o~
1 waterproof bonding rnembrane l is 79% to 87% of the total thickness of bonding sheets 5 and 6 and waterproof isolating sheet ~ before being laminated together. In one exarnple oE the present invention, bonding sheets 5 and 6 include a binder, which when heated during the laminating process, assists in bonding sheets 5 and 6 to waterproof isolating sheet 4. The silicon coating 35 on nip rollers 36 and 37 keeps the bonding sheets 5 and 6 from sticking to the rollers as they pass thereover.
Preferably, both bonding sheets 5 and 6 are tensed laterally (in the direction of the arrows illustrated in Fig. ~) as they enter nip rollers 36 and 37. This tensing step insures maximum contact between the bonding sheets 5 and 6 and the waterproof isolating sheet 4, and thereby prevents wrinkles, and other such formations, that can cause improper lamination between the three layers of waterproof bonding membrane l. In the illustrated method, bonding sheets 5 and 6 are stretched laterally an amount less than 1% oE the overall width of bonding sheets 5 and 6.
Waterproof bonding rnernbrane l is typically used in the following fashion. The building surfaces to which the facing 2 is to be applied, such as shower stall surfaces l~, 15, 16 and 17, must be clean, reasonably smooth and free of holes, cracks and sharp projections.
The surfaces should be cleaned in accordance with those directions provided by the manufacturer of membrane bonding agent 7. New concrete should be free of foreign release, curing compounds, oil, wax, and the like.
Adequate ventilation should be provided when working with solvent cement or adhesive in confined spaces.
~12-3~
1 Once the substrate surfaces have been properly prepared, a thin coat of membrane bonding agent 7 is applied thereover at a width slightly greater than the width o waterproof bonding membrane 1. Bonding agent 7 may comprise PortlancJ cement mortar, epoxy, or organic type adhesives, which are the normal bonding agents used in the "trowel trades,~ and are suitable to attach waterproof bonding membrane 1 to conventional building surfacesO Special adhesives may be required to adhere waterproof bonding membrane 1 to metal or other non-porous surfaces. WaterprooE bonding membrane 1 is immediately pressed into the layer of membrane bonding agent 7, before a skin forms on the same, so that the fibers of bonding sheet 5 are fully embedded in the layer of bonding agent 7~ On the floor 16 of the illustrated shower stall 3, the edges of waterproof honding membrane 1 are turned upwardly along the end and rear walls 1~ and 15 approximately 3 inches higher than the finished elevation of curb 17 r WaterprooE bonding membrane 1 may be securely embecdded into the layer of membrane bonding agent 7 by rneans such as a roller, or the like. It is preferred that waterproof bonding membrane 1 be lifted periodically Erom the building substrate to verify proper coverage and quality of the bond.
In the event that the building surface to be covered is wider or taller than the width oE waterproof bonding membrane 1, two sheets of waterproof bonding membrane 1 must be joined together before they are attached to the building surEace. Two sheets of waterproof bonding membrane 1 are preferably joined in the following fashion. The two sheets of waterproof bonding ~5~
I membrane 1 are arranged with their bonding strips 23 and
BACKGROUND OF THE INVENTION
The present invention relates to faclng for buildings and the like, and in particular to a waterproof bonding membrane and method.
Various materials and methods that include waterprooE membranes, such as those disclosed in United States Patent 4,324,605 to Bethea, are available to mount facing articles to building substrates, and other similar surfaces. The term "facing" as used herein, is intended to include all exterior covering materials for walls, ceilings, floors, and the like, such as glazed wall tiles, ceramic and mozaic tiles, quarry tile, paver tile, marble, delftware, slate, brick, terrazzo and other similar finishing materials for both the interior and exterior of building constructions, and the like~ Such facing materials provide a very durable, easily cleaned, attractive construction which will not weather or deteriorate even in areas of high heat and humidity.
Hence, this type of builcling material is particularly adapted for use in all types of wet or moist areas, such as bath enclosures, shower stalls, kitchen floors, fountains, food processiny areas, breweries and other similar applications and environments.
Some facing materials, such as ceramic tile and the like, are relatively porous, at least with respect to water vapor. As a result, water vapor will penetrate the tile and surrouncling grout, and become absorbed in the bonding agent, which eventually ruins the bond holding the 1 tile to the substrate. Also, because the tiles and the grout are quite brittle, even slight structural shifting in the building walls or floors can cause the grout and/or tiles to become dislodged or cracked. In either of the above events, the tile substrate :is exposed to moisture, and in the case of drywall, plywood and the like, ultimately causes the substrate to lose its structural integrity. As a result, plywood, wallboard, and other such construction materials that are particularly susceptible to water damage are not commonly used as a substrate for ceramic tile installations.
Minor cracking of the building substrate caused by shrinkage, expansion, etc. is also a frequent occurrence, both before and after the facing is installedO Such cracking can damage the tile bedl and may propagate to the finished surface.
Hence, a need exists for an arrangement that will securely mount Eacing to different types of building substrates, including wood, cement, and the like, and that will form a waterproof barrier between the substrate and the facing. A need also exists for an arrangement that will isolate the facing bond from the effects of cracking that takes place in the building substrate.
SUMMARY OF THE INVENTION
-One aspect of the present invention is to provide a waterproof bonding membrane and method that isolates and securely rnounts facing to various building surfaces in the construction of floors, countertops, ceilings, bathtub enclosures, fountains, shower stalls, food processing stations, and other similar structures. The membrane comprises an imperforate waterproof isolating sheet, with 3~
1 at least one bonding sheet, constructed of a non-woven, randomly distributed, continuous filament material, laminated to one side of the waterproof isolating sheet.
A layer of membfane bonding agent attaches the other side of the waterproof isolating sheet to the building surface, and a layer of facing bonding agent attaches the facing to the exposed side of the bonding sheet. Preferably, both sides of the waterproof isolating sheet have a bonding sheet laminated thereto to provide extra bonding strength for certain types of building surfaces and constructions.
In one aspect of the present invention, the bonding sheets are constructed from spunbonded polyester, and the waterproof isolating sheet is constructed from chlorinated polyethylene. The waterproof isolating sheet is extruded from a die, with the sheet leaving the die at an elevated temperature, and the bonding sheets are laminated thereto by pressing the same against the opposite sides of the waterproof isolating sheet immediately ater the waterproof isolating sheet exits the die. Nip rollers may be used to press the three layers of the waterproof bonding rnembrane together, and pre~ferably physically presses each bonding sheet into the waterproof isolating sheet a distance in the range of .nO2 to .00 inches.
The principal objects of the present invention are to provide a triple function isolating, waterproofing and bonding membrane that isolates and securely attaches facing to a build:ing substrate, and forms a waterproof barrier therebetween. The waterproof bonding membrane is easy and economical to manufacture, and can be readily installed on various types of different building 1 substrates. The waterproof bonding membrane is particularly adapted for thin-bed tiling techniques, and can be used with a wide variety of different types of facing materials. In addition to waterproofing, the present invention may he used to protect the tile bed by minimizing the effect of any substrate that is cracked before installation of the tile or a substrate that cracks after the tile bed is installed. Minor cracking of the substrate is a frequent occurrence. When properly installed, tile will remain bonded to the membrane, even when the siæe or extent of cracking becomes unacceptable.
Since the present waterproofing membrane will stretch and remain in tact after the tile or grout have cracked, it can in effect protect the setting bed by isolating it from minute cracks.
The waterproof bonding membrane is particularly efficient in use, economical to manufacture, has a long effective life, and is particularly well adapted for the proposed use. These and other features, advantages and objects of the present invention will be further understood and appreciated by those skilled in the art by reference to the following specification, claims and appended drawings.
BRIEF D~SCRIPTION OF THE DRAWINGS
Fig. l is a partially schematic, fragmentary perspective view of a shower stall incorporating a waterproof bonding membrane and method embodying the present invention.
Fig. 2 is a partially schematic, fragmentary top plan view of the waterproof bonding membrane.
l Fig. 3 is a partially sehematie, enlarged fragmentary plan view of the waterproof bonding membrane.
Fig. 4 is a partially sehematic, fragmentary cross-sectional view of the waterproof bonding membrane, shown partially attached to a building substrate.
Fig. 5 is a partially schernatic, fragmentary cross-sectional view of the waterproof bonding membrane, shown fully attached to the building substrate, with facing partially attached to the exterior surface thereof.
Fig. 6 is a partially schematic, fragmentary cross-sectional view of the waterproof bonding membrane, with the facing completely attaehed to the exterior surfaee thereof and grouted in plaee.
Fig. 7 is a sehematic illustration of a method for manufacturing the waterproof bonding membrane.
Fig. 8 is a schematic illustration of the membrane manufacturing method, particularly showing nip rollers pressing bonding sheets into a waterproof isolating sheet of the waterproof bonding membrane.
Fig. 9 is a partially schematic front elevational view of the rnethod and structure of Fig. 8.
FicJ. lO is a partially schematic, fragmentary end elevational view of a sheet of waterproof bon~iny rnembrane constructed in accordance with the illustrated rnethod.
DF,TAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS
For purposes of description herein, the terms "upper," nlower," nright," "left,n "rear,n "Eront,l1 "vertical," "horizontal," and derivatives thereof shall relate to the invention as oriented in Figs. 4, 5 and 6.
However, it is to be understood that the invention may assume various alternative orientations, and step 1 sequences, except where expressly specified to the contrary.
The reference numeral 1 (Fig. 4) generally designates a waterproof bonding membrane embodying the present invention. Waterproof bonding membrane 1 is particularly adapted to rnount facing materials, such as brick, stone, slate, et cetera, and the illustrated ceramic tile 2 (Figs. 1, 5 and 6) to various building surfaces in the construction of floors, walls, countertops, and the like, as well as the illustrated shower stall 3 Waterproof bonding membrane l comprises a waterproof isolating sheet 4 constructed of an imperforate, substantially waterproof material, and shaped to cover that portion of the building substrate on which facing 2 is to be mounted. WaterprooE bonding membrane l also includes a least one bonding sheet 5, constructed of a non-woven/ randomly distributed, continuous filament materiall and having a size and shape substantially commensurate with waterproof isolating sheet ~. sonding sheet 5 is laminated to one side of waterproof isolat:ing sheet ~. In the illustrated example, two bonding sheets 5 and 6 are larninated to the opposite side oE waterproof :isolating sheet ~. A layer of membrane bonding coat or agent 7 (Figs. 5 and 6) attaches one side of waterproof bonding membrane l to the building surface, and a layer of facing bonding coat or agent 8 attaches the facing 2 to the opposite side of waterproof bonding rnembrane 1, so as to securely mount the facing on the building surface~ and form a waterproof isolating barrier therebetween.
It is to be understood that shower stall 3 is rnerely exemplary of one application of the present 1 invention. ~laterproof bonding membrane 1 can be used on a wide variety of difEerent surfaces, on either the exterior or the interior of buildings, and the like. The illustrated shower stall 3 includes an end wall 14, a rear wall 15, a floor 16 and a front curb or dam 17. A
conventional drain 18 is positioned in the floor 16 of shower stall 3.
Waterproof bonding membrane 1 is preferably flexible, so that it will readily conform to diEferent shapes of building substrates and surfaces, as described in greater detail hereinafter. In the illustrated example, waterproof bonding membrane 1 has an overall final thickness in the range of .032 to .034 inches, a width of 60 inches, and is typically supplied in rolls of 100 foot length. As best illustrated in Figs. 9 and 10, bonding sheets 5 and 6 are preferably staggered or offset slightly on waterproof isolating sheet 4, so as to form exposed, bondings strips 23 and 24 along the side edges 25 and 26 of waterproof isolating sheet 4 to join two or more sheets of waterproof bonding membrane 1, in the manner described below. More specifically, with reference to Fig. 10, the left-hand side edge 27 of bonding sheet 5 is aligned with the corresponding left-hand side edge 25 of waterproof isolating sheet ~. In the illustrated example, bonding sheet 5 is approximately 2 inches narrower than waterproof isolating sheet ~, so as to form a 2 inch bonding strip 23 between the right-hand side edge 28 of bonding sheet 5, and the corresponding right-hand side edge 26 of waterproof isolating sheet 4. In a like manner, the right-hand edge 29 of bonding sheet 6 is aligned with the corresponding right-hand side edge 26 of ~S'~3~3 1 waterproof isolating sheet 4. The illustrated bonding sheet 6 is also approximately 2 inches narrower than waterproof isolating sheet 4, thereby forming bonding strip 24 between the left-hand side edge 30 of bonding sheet 6, and the left-hand side edge 25 of waterproof isolating sheet 4. ~ence, bonding strips 23 and 24 are located on opposite faces of waterproof bonding membrane 1, along the opposite side edges 25 and 26 thereof.
Waterproof isolating sheet 4 preferably comprises a relatively thin, continuous membrane constructed of a chlorinated polyethylene material. In the illustrated embodiment of the present invention, waterproof isolating sheet 4 has a thickness of approximately .023 to .024 inches, and a width of around 60 inches.
One example of a suitable waterproof isolating sheet 4 is made from a compound formulated from Chlorinated Polyethylene (CPE) resins that shall: (a) contain 38~ to 46~ chlorine; (b) be made from a linear polyethylene having a density of not less than 0.95 g/cm3;
(c) be substantially arnorphous having a heat o fusion oE
less than 0.4 cal/g (1.7 KJ/kg); and (d) have a melt viscosity of 1,700 ~ 500 Pa-sec when measured in an Instron Capillary Rheometer at a melt temperature of 190 -~/- 2 C, and a shear rate of 150 ~/- 10 sec-l.
Another example of a suitable chlorinated polyethylene material for waterproof isolating sheet 4 is disclosed in United States Patent 3,641,216, to Schnebelen et al.
Yet, another example of a suitable chlorinated polyethylene material for waterproof isolating sheet 4 has the following physical characteristics.
~25~
Hardness, Shore A ASTM D2240, points 76+/-6 ~5 second) Method A
Tensile Strength ASTM D412 psi 1500 min.
(transverse Meth. A, Die C
direction) Tensile Stress at ASTM D412 psi 400 min.
100% elongation Meth. A, Die C
(modulus) (transverse direction) ~ltimate Elongation ASTM D412 % 300 min.
at Break transverse direction) Tear Resistance ASTM D1004 lbs/in- 175 min.
(both directions) width Volatile ASTM D1203 ~ weight 1~ max.
Extraction loss Bonding sheets 5 and 6 are preferably constructed from relatively thin, continuous sheets of a non-woven material, such as spunbonded polyester. In the illustrated structure, bonding sheets 5 and 6 have a thickness of approximately .008 inches, a unit weight of 1 ounce per square yard (34 grams per square meter), and a width of approximately 58 inches. The bonding sheet material is constructed oE continuous filament polyester fibers that are randomly arranged, highly dispersecl, and bonded at the filament junctions. The chemical and thermal properties of the spunbonded material are essentially those of polyester fiber. ~ne such suitable material is known in the trade as "Reemay" (a registered trademark oE Dupont), which includes high tensile strength, coupled with a high elongation, high tear strength and toughness, high bulk and porosity, non-raveling edges, and good dimensional stability. The non-woven nature of the bonding sheets 5 and 6 permits adhesives to readily saturate or permeate the same in _g_ ~s~
1 order to obtain a very strong mechanical bond Reemay brand spunbonded polyester style 2014 is illustrative of one working example of bonding sheets 5 and 6. The bonding sheet material illustrated in Fig. 2 has generally straight fibers.
Another example of a suitable material for bonding sheets 5 and 6 is disclosed in U.S. Patent 3,341,394 to Kinney, rlxample No. 10.
As best illustrated in Figs. 7-10, waterproof bonding membrane 1 is preferably constructed by laminating bonding sheets 5 and 6 to the opposite sides of waterproof isolating sheet 4. In the illustrated example, waterproof isolating sheet 4 is extruded from a die 35. A pair of compression or nip rollers 36 and 37 are positioned immediately downstream from extruding die 35, and preferably include an exterior layer or coating of silicon 38 for purposes to be described in greater detail hereinafter. Waterproof isolating sheet 4 is pulled or tensed slightly in the longitudinal direction between die 35 and nip rollers 36 and 37. In one working example of the present invention, wherein waterproof isolating sheet 4 has a thickness of approximately .023 to .024 inches, and bonding sheets 5 and 6 have a thickness in the nature of .008 inches, nip rollers 36 and 37 are spaced apart a distance of approximately .n23 inches. A pair of dispensing rollers or drums 39 and 40 are positioned on opposite sides of nip rollers 36 and 37, and feed bonding sheets 5 and 6 respectively between nip rollers 36 and 37. A water cooled idler roller 41 is located directly below the lower nip roller 37, and receives the laminated waterproof bonding membrane 1 thereover. A takeup drum 42 ~2~
1 is located downstream of nip rollers 36 and 37, and collects the fully larninated waterproof bonding membrane 1 onto a suitable core Eor storage and transport.
In one exarnple of the present invention, S waterproof isolatiny sheet 4 exits extruding die 35 at an elevated temperature, in the range of 250 to 350 degrees F., preferably approximately 290 to 300 degrees F. Nip rollers 36 and 37 are preferably located immediately downstream from extrusion die 35, so that bonding sheets 5 and 6 are pressed firmly into the opposite sides of waterproof isolating sheet 4 while the ~aterproof isolating sheet is at the elevated, extruded temperature of approximately 290 to 300 degrees F. The elevated temperature of waterproof isolating sheet 4, in combination with the compressive forces applied by nip rollers 36 and 37, securely laminate bonding sheets 5 and 6 to waterproof isolating sheet 4 to form an integral construction. The fully laminated waterproof bonding membrane 1 then exits nip rollers 36 and 37, and is cooled as it travels over idler roller 41.
As best illustrated in Fig. 8, during the laminating step, both the bondiny sheets 5 and 6, and the waterproof isolatiny sheet 4 are elastically deformed inwardly in a compressive fashion. The compressive force applied by nip rollers 36 and 37 physically presses each bonding sheet 5 into waterproof isolating sheet 4 a distance of approximately .002 to .004 inches. Mence, in the illustrated example, the final thickness of waterproof bonding membrane 1 is .032 to .034 inches, whereas the original thickness of the three layers is approximately .039 to ~040 inchesO The total thickness of finished o~
1 waterproof bonding rnembrane l is 79% to 87% of the total thickness of bonding sheets 5 and 6 and waterproof isolating sheet ~ before being laminated together. In one exarnple oE the present invention, bonding sheets 5 and 6 include a binder, which when heated during the laminating process, assists in bonding sheets 5 and 6 to waterproof isolating sheet 4. The silicon coating 35 on nip rollers 36 and 37 keeps the bonding sheets 5 and 6 from sticking to the rollers as they pass thereover.
Preferably, both bonding sheets 5 and 6 are tensed laterally (in the direction of the arrows illustrated in Fig. ~) as they enter nip rollers 36 and 37. This tensing step insures maximum contact between the bonding sheets 5 and 6 and the waterproof isolating sheet 4, and thereby prevents wrinkles, and other such formations, that can cause improper lamination between the three layers of waterproof bonding membrane l. In the illustrated method, bonding sheets 5 and 6 are stretched laterally an amount less than 1% oE the overall width of bonding sheets 5 and 6.
Waterproof bonding rnernbrane l is typically used in the following fashion. The building surfaces to which the facing 2 is to be applied, such as shower stall surfaces l~, 15, 16 and 17, must be clean, reasonably smooth and free of holes, cracks and sharp projections.
The surfaces should be cleaned in accordance with those directions provided by the manufacturer of membrane bonding agent 7. New concrete should be free of foreign release, curing compounds, oil, wax, and the like.
Adequate ventilation should be provided when working with solvent cement or adhesive in confined spaces.
~12-3~
1 Once the substrate surfaces have been properly prepared, a thin coat of membrane bonding agent 7 is applied thereover at a width slightly greater than the width o waterproof bonding membrane 1. Bonding agent 7 may comprise PortlancJ cement mortar, epoxy, or organic type adhesives, which are the normal bonding agents used in the "trowel trades,~ and are suitable to attach waterproof bonding membrane 1 to conventional building surfacesO Special adhesives may be required to adhere waterproof bonding membrane 1 to metal or other non-porous surfaces. WaterprooE bonding membrane 1 is immediately pressed into the layer of membrane bonding agent 7, before a skin forms on the same, so that the fibers of bonding sheet 5 are fully embedded in the layer of bonding agent 7~ On the floor 16 of the illustrated shower stall 3, the edges of waterproof honding membrane 1 are turned upwardly along the end and rear walls 1~ and 15 approximately 3 inches higher than the finished elevation of curb 17 r WaterprooE bonding membrane 1 may be securely embecdded into the layer of membrane bonding agent 7 by rneans such as a roller, or the like. It is preferred that waterproof bonding membrane 1 be lifted periodically Erom the building substrate to verify proper coverage and quality of the bond.
In the event that the building surface to be covered is wider or taller than the width oE waterproof bonding membrane 1, two sheets of waterproof bonding membrane 1 must be joined together before they are attached to the building surEace. Two sheets of waterproof bonding membrane 1 are preferably joined in the following fashion. The two sheets of waterproof bonding ~5~
I membrane 1 are arranged with their bonding strips 23 and
2~ overlapping. Both of the bonding strips 23 and 24 are cleaned, such as with a light application of xylene, alcohol, or the like. The exposed surfaces oE bonding strips 23 and 24 are then roughened by means such as a copper scrub pad, or a clean wire brush. ~ waterproof isolating sheet solvent, which in the present example is for chlorinated polyethylene, is then applied liberally to both of the bondinc3 strips 23 and 24. Before the solvent 1() is allowecl to dry, the bonding strips 23 and 24 are pressecl firmly against one another, and the seam is closed while the waterproof isolating sheet 4 is soft and wet. A
roller may he used along the seam to insure proper contact between bonding strips 23 and 24, and eliminate any air L5 bubbles that might have formed. Heat may be applied to the seam to speed up curing time. All completed seams should be fully cured before the waterproof bonding membrane 1 is applied to the building substrateO
After the waterproof bonding membrane 1 has been applied to the building substrate, and mernbrane bonding agent 7 is fully cured, the facing, such as ceramic tiles 2, may be applied with a thin bed technique. Tile bonding agent ~ is rnanually appliecl or troweled over the exposed side oE waterprooE bonding membrane 1 to Eorm a layer having a thickness in the nature oE 1/~ to 1/4 inches.
Tile bonding agent ~ preferably ;ncludes a liquid laytex and Portland cement mortar. Preferably, tile bondinq agent ~ is sufficiently liquid or flowable that it can be applied manually by a trowel, and will saturate the fibers 3n oE bonding sheet 6.
--1'1--
roller may he used along the seam to insure proper contact between bonding strips 23 and 24, and eliminate any air L5 bubbles that might have formed. Heat may be applied to the seam to speed up curing time. All completed seams should be fully cured before the waterproof bonding membrane 1 is applied to the building substrateO
After the waterproof bonding membrane 1 has been applied to the building substrate, and mernbrane bonding agent 7 is fully cured, the facing, such as ceramic tiles 2, may be applied with a thin bed technique. Tile bonding agent ~ is rnanually appliecl or troweled over the exposed side oE waterprooE bonding membrane 1 to Eorm a layer having a thickness in the nature oE 1/~ to 1/4 inches.
Tile bonding agent ~ preferably ;ncludes a liquid laytex and Portland cement mortar. Preferably, tile bondinq agent ~ is sufficiently liquid or flowable that it can be applied manually by a trowel, and will saturate the fibers 3n oE bonding sheet 6.
--1'1--
3~3~
1 The illustrated ceramic tiles 2 are then set by hand into the uncured tile honding agent 8, as shown in Figs. 5 and 6, in a conventional fashion, wherein the tiles 2 are pressed firmly toward the wall, sinking them slightly into the layer of wet bonding agent 8. After all of the tiles 2 have been pressed into place, tile bonding agent ~ is allowed to fully cure. After tile bonding agent 8 is fully cured, the gaps Eormed between adjacent side edges of the ceramic tiles 2 are filled with grout 48, using conventional rnethods.
With its inherent flexibility and crack bridging ability, waterproof bonding membrane 1 protects against both moisture penetration into the substrate, and crack propagation from the substrate to the finished surface.
In addition to water, waterproof bonding membrane 1 also resists oils, chemicals, brines and other severe environmental conditions.
Waterproof bonding membrane 1 can be installed both horizontally and vertically over all common construction substrates including wood and tile backer boards with the same bonding agent recommended for the tile. Seams are sealed by chemical fusion, or thermal fusion. No special tools are required and only normal job site skills are needed. Waterproof bonding membrane 1 is a uniform, homogeneous sheet and is suited to both new and renovation projects, whether commercial or residential.
Waterproo~ bonding membrane 1 isolates and securely rnounts a wide variety of facing materials to different types of building substrates and surfaces, and also forms a waterproof barrier. The non-woven fibers of bonding sheets 5 and 6 are embedded in or saturated by the ;~S23~
1 associated layers of bonding agent 7 and ~, so as to form a very strong, secure mechanical bond or attachment. This bond is so strong that the Eacing tiles 2 cannot be removed frorn waterproof bonding mernbrane 1 without tearing the membrane apart. By larninating bonding sheets 5 and 6 to the opposite sides oE waterproof isolating sheet 4, the three sheets cannot be separated. Once the facing articles 2 are mounted in place, they cannot be removed without tearing apart or shearing the fibers in the center of the exterior bonding sheet 6. When properly installed, the facing articles 2 will remain bonded to the waterproof bonding membrane 1, even when the size and/or extent of cracking in the building substrate becomes unacceptable.
The waterproof bonding membrane 1 will stretch and remain in tact even after facing tile and/or grout have cracked, thereby protecting the setting bed by isolating it from such cracks. Waterproof bonding membrane 1 is not only uncomplicated and economical to manufacture, but it can be readily installed in a wide variety of different applications.
It is to be understood that while certain specific orms and examples of the present invention are illustrated and described herein, the invention is not to be limited to the specific examples noted hereinabove.
Further, it will be Eully appreciated by those skilled in the art that modifications may be made to the invention without departing from the concepts disclosed herein.
Such rnodifications are to be considered as included in the following claims, unless these claims by their language expressly state otherwise.
1 The illustrated ceramic tiles 2 are then set by hand into the uncured tile honding agent 8, as shown in Figs. 5 and 6, in a conventional fashion, wherein the tiles 2 are pressed firmly toward the wall, sinking them slightly into the layer of wet bonding agent 8. After all of the tiles 2 have been pressed into place, tile bonding agent ~ is allowed to fully cure. After tile bonding agent 8 is fully cured, the gaps Eormed between adjacent side edges of the ceramic tiles 2 are filled with grout 48, using conventional rnethods.
With its inherent flexibility and crack bridging ability, waterproof bonding membrane 1 protects against both moisture penetration into the substrate, and crack propagation from the substrate to the finished surface.
In addition to water, waterproof bonding membrane 1 also resists oils, chemicals, brines and other severe environmental conditions.
Waterproof bonding membrane 1 can be installed both horizontally and vertically over all common construction substrates including wood and tile backer boards with the same bonding agent recommended for the tile. Seams are sealed by chemical fusion, or thermal fusion. No special tools are required and only normal job site skills are needed. Waterproof bonding membrane 1 is a uniform, homogeneous sheet and is suited to both new and renovation projects, whether commercial or residential.
Waterproo~ bonding membrane 1 isolates and securely rnounts a wide variety of facing materials to different types of building substrates and surfaces, and also forms a waterproof barrier. The non-woven fibers of bonding sheets 5 and 6 are embedded in or saturated by the ;~S23~
1 associated layers of bonding agent 7 and ~, so as to form a very strong, secure mechanical bond or attachment. This bond is so strong that the Eacing tiles 2 cannot be removed frorn waterproof bonding mernbrane 1 without tearing the membrane apart. By larninating bonding sheets 5 and 6 to the opposite sides oE waterproof isolating sheet 4, the three sheets cannot be separated. Once the facing articles 2 are mounted in place, they cannot be removed without tearing apart or shearing the fibers in the center of the exterior bonding sheet 6. When properly installed, the facing articles 2 will remain bonded to the waterproof bonding membrane 1, even when the size and/or extent of cracking in the building substrate becomes unacceptable.
The waterproof bonding membrane 1 will stretch and remain in tact even after facing tile and/or grout have cracked, thereby protecting the setting bed by isolating it from such cracks. Waterproof bonding membrane 1 is not only uncomplicated and economical to manufacture, but it can be readily installed in a wide variety of different applications.
It is to be understood that while certain specific orms and examples of the present invention are illustrated and described herein, the invention is not to be limited to the specific examples noted hereinabove.
Further, it will be Eully appreciated by those skilled in the art that modifications may be made to the invention without departing from the concepts disclosed herein.
Such rnodifications are to be considered as included in the following claims, unless these claims by their language expressly state otherwise.
Claims
The embodiments of the invention in which an exclusive property or privilege is claimed are defined as follows:
A method for mounting facing on a building substrate, comprising:
providing a waterproof isolating sheet, constructed of an imperforate, substantially waterproof material, and shaped to cover that portion of the building substrate on which the facing is to be mounted;
providing a bonding sheet, constructed of a randomly distributed continuous filament material, and having a size and shape substantially commensurate with the waterproof isolating sheet;
positioning the bonding sheet overlying one side of the waterproof isolating sheet in a predetermined orientation therewith;
laminating the bonding sheet to the one side of the waterproof isolating sheet to form a waterproof bonding membrane;
bonding the other side of the waterproof isolating sheet to the building substrate; and bonding the facing to the exposed side of the waterproof bonding membrane.
A method as set forth in claim 1, wherein:
said bonding sheet comprises a first bonding sheet, and including:
providing a second bonding sheet, constructed of a randomly distributed continuous filament material, and having a size and shape substantially commensurate with the waterproof isolating sheet;
positioning the second bonding sheet overlying the other side of the waterproof isolating sheet in a predetermined orientation therewith; and laminating the second bonding sheet to the other side of the waterproof isolating sheet, and wherein;
said second bonding sheet is adhered to the building substrate.
A method as set forth in claim 2, wherein:
said waterproof isolating sheet providing step comprises extruding said waterproof isolating sheet from a die, whereby said waterproof isolating sheet exits the die at a temperature substantially above ambient temperature;
and said laminating step comprises pressing said first and second bonding sheets against the opposite sides of the waterproof isolating sheet immediately after said extruding step, while said waterproof isolating sheet is still at a temperature substantially above ambient temperature.
A method as set forth in claim 3, wherein:
said bonding sheet material comprises spunbonded polyester; and said waterproof isolating sheet material comprises chlorinated polyethylene.
A method as set forth in claim 4, wherein:
the temperature of the waterproof isolating sheet at the beginning of said laminating step is in the range of 250 to 350 degrees F.
A method as set forth in claim 5, wherein said laminating step comprises:
tensing the first and second bonding sheets laterally before pressing the same against the opposite sides of the waterproof isolating sheet.
A method as set forth in claim 6, wherein said bonding sheet pressing step comprises:
providing nip rollers between which the waterproof bonding membrane is passed; and adjusting the nip rollers to press each of the first and second bonding sheets into the waterproof isolating sheet a distance in the range of .002 to .004 inches.
A method as set forth in claim 7, wherein-said nip roller adjusting step comprises adjusting the nip rollers to reduce the overall thickness of the waterproof bonding membrane to an amount equal to 79% to 87%. of the original thickness of the waterproof bonding membrane.
A method as set forth in claim 8, wherein said laminating step comprises:
coating the nip rollers with a layer of silicon.
A method as set forth in claim 9, including:
providing a second waterproof bonding membrane shaped to cover that protion of the building substrate that is not covered by the first named waterproof bonding membrane, and joining adjacent side edges of the first and second named waterproof bonding membranes before adhering the same to the building substrate.
A method as set forth in claim 10, wherein:
said waterproof isolating sheet has a predetermined width, and includes first and second side edges;
said first and second bonding sheets each have a predetermined width that is narrower than the width of the waterproof isolating sheet, and includes first and second side edges.
A method as set forth in claim 11, wherein said sheet positioning step comprises:
aligning the first side edge of the first bonding sheet with the first side edge of the waterproof isolating sheet, thereby forming a first open strip of waterproof isolating sheet on one side thereof between the second side edge of the first bonding sheet and the second side edge of the waterproof isolating sheet; and aligning the second side edge of the second bonding sheet with the second side edge of the waterproof isolating sheet, thereby forming a second open strip of waterproof isolating sheet on the other side thereof between the first side edge of the second bonding sheet and the first side edge of the waterproof isolating sheet.
A method as set forth in claim 12, wherein said sheet joining step comprises:
positioning the first open strip of the first named waterproof bonding membrane over the second open strip of the second named waterproof bonding membrane and adhering the same together.
A method as set forth in claim 13, wherein said open strip adhering step comprises:
cleaning the first open strip of the first named waterproof bonding membrane and the second open strip of the second named waterproof bonding membrane;
roughening the first open strip of the first named waterproof bonding membrane and the second open strip of the second named waterproof bonding membrane;
applying a waterproof isolating sheet solvent to the first open strip of the first named waterproof bonding membrane and the second open strip of the second named waterproof bonding membrane; and pressing the first open strip of the first named waterproof bonding membrane and the second open strip of the second named waterproof bonding membrane together.
A method as set forth in claim 14, wherein:
said facing comprises a plurality of individual articles, such as the tiles, bricks, stones, slate pieces and the like; and said facing bonding step comprises positioning the individual facing articles on the building substrate and individually bonding the same thereto.
A method as set forth in claim 15, wherein said membrane bonding step comprises:
smoothing the surface of the building substrate to which the facing is to be mounted;
cleaning the surface of the building substrate to which the facing is to be mounted;
applying a layer of membrane bonding agent to the substrate surface;
pressing the waterproof bonding membrane into the layer of membrane bonding agent; and curing the membrane bonding agent.
A method as set forth in claim 16, wherein said facing bonding step further comprises:
applying a layer of tile bonding agent to the other side of the waterproof bonding membrane;
pressing the facing articles into the layer of tile bonding agent; and curing the tile bonding agent.
A method as set forth in claim 17, wherein:
said tile bonding agent comprises a mixture having a trowelable consistence, and includes Portland cement mortar; and said tile bonding agent applying step comprises manually trowelling a thin bed layer of the tile bonding agent onto the other side of the waterproof bonding membrane.
A method as set forth in claim 18, wherein:
said waterproof bonding membrane is flexible to conform to the shape of the building substrate, and isolate the facing and tile bonding agent from the effects of cracks in the building substrate.
A method as set forth in claim 19, wherein:
said first and second bonding sheets comprise straight fibers.
A method as set forth in claim 1, wherein:
said waterproof isolating sheet providing step comprises extruding said waterproof isolating sheet from a die, whereby said waterproof isolating sheet exits the die at a temperature substantially above ambient temperature;
and said laminating step comprises pressing said bonding sheet against the one side of the waterproof isolating sheet immediately after said extruding step, while said waterproof isolating sheet is still at a temperature substantially above ambient temperature.
A method as set forth in claim 1, wherein:
said bonding sheet material comprises spunbonded polyester;
said waterproof isolating sheet material comprises chlorinated polyethylene; and said temperature of the waterproof isolating sheet at the beginning of said laminating step is in the range of 250 to 350 degrees F.
A method as set forth in claim 1, wherein said laminating step comprises:
tensing the bonding sheet laterally before pressing the same against the one side of the waterproof isolating sheet.
A method as set forth in claim 1, wherein said laminating step comprises:
providing nip rollers between which the waterproof bonding membrane is passed; and adjusting the nip rollers to press the bonding sheet into the waterproof isolating sheet an amount in the range of .002 to .004 inches.
A method as set forth in claim 24, wherein:
said nip roller adjusting step comprises adjusting the nip rollers to reduce the overall thickness of the waterproof bonding membrane to an amount equal to 79% to 87% of the original thickness of the waterproof bonding membrane.
A method as set forth in claim 1, including:
providing a second waterproof bonding membrane shaped to cover that protion of the building substrate that is not covered by the first named waterproof bonding membrane; and joining adjacent side edges of the first and second named waterproof bonding membranes before adhering the same to the building substrate.
A method as set forth in claim 2, wherein:
said waterproof isolating sheet has a predetermined width, and includes first and second side edges;
said first and second bonding sheets each have a predetermined width that is narrower than the width of the waterproof isolating sheet, and includes first and second side edges.
A method as set forth in claim 27, wherein said sheet positioning step comprises:
aligning the first side edge of the first bonding sheet with the first side edge of the waterproof isolating sheet, thereby forming a first open strip of waterproof isolating sheet on one side thereof between the second side edge of the first bonding sheet and the second side edge of the waterproof isolating sheet; and aligning the second side edge of the second bonding sheet with the second side edge of the waterproof isolating sheet, thereby forming a second open strip of waterproof isolating sheet on the other side thereof between the first side edge of the second bonding sheet and the first side edge of the waterproof isolating sheet.
A method as set forth in claim 28 wherein said sheet joining step comprises:
positioning the first open strip of the first named waterproof bonding membrane over the second open strip of the second named waterproof bonding membrane and adhering the same together.
A method as set forth in claim 29, wherein said open strip adhering step comprises:
cleaning the first open strip of the first named waterproof bonding membrane and the second open strip of the second named waterproof bonding membrane;
roughening the first open strip of the first named waterproof bonding membrane and the second open strip of the second named waterproof bonding membrane;
applying a waterproof isolating sheet solvent to the first open strip of the first named waterproof bonding membrane and the second open strip of the second named waterproof bonding membrane; and pressing the first open strip of the first named waterproof bonding membrane and the second open strip of the second named waterproof bonding membrane together.
A method as set forth in claim 1, wherein:
said facing comprises a plurality of individual articles, such as the tiles, bricks, stones, slate pieces and the like; and said facing bonding step comprises positioning the individual facing articles on the building substrate and individually bonding the same thereto.
A method as set forth in claim 1, wherein said membrane bonding step comprises:
smoothing the surface of the building substrate to which the facing is to be mounted;
cleaning the surface of the building substrate to which the facing is to be mounted;
applying a layer of membrane bonding agent to the building substrate surface;
pressing the waterproof bonding membrane into the layer of membrane bonding agent; and curing the membrane bonding agent.
A method as set forth in claim 1, wherein said facing bonding step comprises:
applying a layer of facing bonding agent to the exposed side of the bonding sheet;
pressing the facing into the layer of facing bonding agent; and curing the facing bonding agent.
A method as set forth in claim 33, wherein:
said facing bonding agent comprises a mixture having a trowelable consistence, and includes Portland cement mortar; and said facing bonding agent applying step comprises manually trowelling a thin bed set layer of the facing bonding agent onto the other side of the waterproof bonding membrane.
A waterproof facing construction for building surfaces and the like, comprising:
a waterproof isolating sheet, constructed of an imperforate, substantially waterproof material, and shaped to cover a predetermined building surface;
a bonding sheet, constructed of a randomly distibuted continuous filament material, and having first and second sides, and a size and shape substantially commensurate with said waterproof isolating sheet; said bonding sheet first side being positioned overlying and laminated to one side of said waterproof isolating sheet in a predetermined orientation therewith to form a waterproof bonding membrane;
a facing shaped to cover the predetermined building surface;
a first layer of bonding agent positioned between and bonding the other side of said waterproof isolating sheet to the predetermined building surface; and a second layer of bonding agent positioned between and bonding said facing to the second side of said bonding sheet, whereby said waterproof bonding membrane securely isolates and mounts said facing on the predetermined building surface, and forms a waterproof membrane therebetween.
A facing construction as set forth in claim 35, wherein:
said bonding sheet material comprises spunbonded polyester.
A facing construction as set forth in claim 36, wherein:
said waterproof isolating sheet material comprises chlorinated polyethylene.
A facing construction as set forth in claim 37, wherein:
said waterproof isolating sheet is extruded from a die, whereby said waterproof isolating sheet exits the die at a temperature substantially above ambient temperature; and said bonding sheet is pressed against the one side of said waterproof isolating sheet immediately after the same exits the die, while said waterproof isolating sheet is still at a temperature substantially above ambient temperature to form a heat laminated construction.
A facing construction as set forth in claim 38, wherein:
said waterproof isolating sheet has a predetermined width, and includes first and second side edges;
said bonding sheet has a predetermined width that is narrower than the width of said waterproof isolating sheet, and includes first and second side edges;
said first side edge of said bonding sheet is aligned with the first side edge of said waterproof isolating sheet, thereby forming a first open strip of waterproof isolating sheet on one side thereof between the second side edge of said bonding sheet and the second side edge of said waterproof isolating sheet.
A waterproof facing construction for building surfaces and the like; comprising:
a waterproof isolating sheet, constructed of an imperforate, substantially waterproof material, and shaped to cover a predetermined building surface;
first and second bonding sheets, constructed of a randomly distibuted continuous filament material, and having first and second sides, and a size and shape substantially commensurate with said waterproof isolating sheet; said first and second bonding sheets being positioned overlying and laminated to the opposite sides of said waterproof isolating sheet in a predetermined orientation therewith to form a waterproof bonding membrane;
a facing shaped to cover the predetermined building surface;
a first layer of bonding agent positioned between and bonding one side of said waterproof bonding membrane to the predetermined building surface; and a second layer of bonding agent positioned between and bonding said facing to the other side of said waterproof bonding membrane, whereby said waterproof bonding membrane isolates and securely mounts said facing on the predetermined building surface, and forms a waterproof membrane therebetween.
A facing construction as set forth in claim 40, wherein:
said bonding sheet material comprises spunbonded polyester.
A facing construction as set forth in claim 41, wherein:
said waterproof isolating sheet material comprises chlorinated polyethylene.
A construction as set forth in claim 42, wherein:
said waterproof isolating sheet is extruded from a die, whereby said waterproof isolating sheet exits the die at a temperature substantially above ambient temperature; and said first and second bonding sheets are pressed against the sides of said waterproof isolating sheet immediately after the same exits the die, while said waterproof isolating sheet is still at a temperature substantially above ambient temperature to form a heat laminated construction.
A construction as set forth in claim 43, wherein:
said waterproof isolating sheet has a predetermined width and includes first and second side edges;
said first and second bonding sheets each have a predetermined width that is narrower than the width of the waterproof isolating sheet, and include first and second side edges;
said first side edge of said first bonding sheet is aligned with the first side edge of said waterproof isolating sheet, thereby forming a first open strip of waterproof isolating sheet on one side thereof between the second side edge of said first bonding sheet and the second side edge of said waterproof isolating sheet; and said second side edge of said second bonding sheet is aligned with the second side edge of said waterproof isolating sheet, thereby forming a second open strip of waterproof isolating sheet on the other side thereof between the first side edge of said second bonding sheet and the first side edge of said waterproof isolating sheet.
A waterproof bonding membrane for mounting facing on a building substrate, comprising:
a waterproofing sheet, constructed of an imperforate, substantially waterproof material, and shaped to cover that portion of the building substrate on which the facing is to be mounted;
a bonding sheet, constructed of a randomly distributed continuous filament material, and having a size and shape substantially commensurate with the waterproofing sheet; said bonding sheet being positioned overlying and laminated to one side of the waterproofing sheet, whereby the other side of said waterproofing sheet is bonded to the building substrate, and the facing is bonded to the exposed side of the bonding sheet to securely mount the facing to the building substrate and form a waterproof membrane therebetween.
A waterproof bonding membrane as set forth in claim 45, wherein:
said bonding sheet compises a first bonding sheet; and including a second bonding sheet, constructed of a randomly distributed continuous filament material, and having a size and shape substantially commensurate with the waterproofing sheet; said second bonding sheet being positioned overlying and laminated to the other side of the waterproofing sheet, whereby said second bonding sheet is bonded to the building substrate.
A waterproof bonding membrane as set forth in claim 46, wherein:
said bonding sheet material comprises spunbonded polyester.
A waterproof bonding membrane as set forth in claim 47, wherein:
said waterproofing sheet material comprises chlorinated polyethylene.
A waterproof bonding membrane as set forth in claim 48, wherein:
said waterproofing sheet is extruded from a die, whereby said waterproofing sheet exits the die at a temperature substantially above ambient temperature; and said first and second bonding sheets are pressed against the opposite sides of the waterproofing sheet immediately after the same exits the die, while said waterproofing sheet is still at a temperature substantially above ambient temperature to form a heat laminated construction.
A waterproof bonding membrane as set forth in claim 49, wherein:
said waterproofing sheet has a predetermined width and includes first and second side edges;
said first and second bonding sheets each have a predetermined width that is narrower than the width of the waterproofing sheet, and include first and second side edges;
said first side edge of said first bonding sheet is aligned with the first side edge of said waterproofing sheet, thereby forming a first open strip of waterproofing sheet on one side thereof between the second side edge of said first bonding sheet and the second side edge of said waterproofing sheet; and said second side edge of said second bonding sheet is aligned with the second side edge of said waterproofing sheet, thereby forming a second open strip of waterproofing sheet on the other side thereof between the first side edge of said second bonding sheet and the first side edge of said waterproofing sheet.
A waterproof bonding membrane as set forth in claim 5n, wherein:
said waterproof bonding membrane is flexible to conform to the shape of the building substrate.
A waterproof bonding membrane as set forth in claim 45, wherein:
said bonding sheet material comprises spunbonded polyester.
waterproof bonding membrane as set forth in claim 52, wherein:
said bonding sheet material comprises straight fibers.
A waterproof bonding membrane as set forth in claim 45, wherein:
said waterproofing sheet material comprises chlorinated polyethylene.
A waterproof bonding membrane as set forth in claim 45, wherein:
said waterproofing sheet is extruded from a die, whereby said waterproofing sheet exits the die at a temperature substantially above ambient temperature; and said bonding sheet is pressed against the one side of the waterproofing sheet immediately after the same exits the die, while said waterproofing sheet is still at a temperature substantially above ambient temperature to form a heat laminated construction.
A waterproof bonding membrane as set forth in claim 46, wherein:
said waterproofing sheet has a predetermined width and includes first and second side edges;
said first and second bonding sheets each have a predetermined width that is narrower than the width of the waterproofing sheet, and includes first and second side edges;
said first side edge of said first bonding sheet is aligned with the first side edge of said waterproofing sheet, thereby forming a first open strip of waterproofing sheet on one side thereof between the second side edge of said first bonding sheet and the second side edge of said waterproofing sheet; and said second side edge of said second bonding sheet is aligned with the second side edge of said waterproofing sheet, thereby forming a second open strip of waterproofing sheet on the other side thereof between the first side edge of said second bonding sheet and the first side edge of said waterproofing sheet.
A method for mounting facing on a building substrate, comprising:
providing a waterproof isolating sheet, constructed of an imperforate, substantially waterproof material, and shaped to cover that portion of the building substrate on which the facing is to be mounted;
providing a bonding sheet, constructed of a randomly distributed continuous filament material, and having a size and shape substantially commensurate with the waterproof isolating sheet;
positioning the bonding sheet overlying one side of the waterproof isolating sheet in a predetermined orientation therewith;
laminating the bonding sheet to the one side of the waterproof isolating sheet to form a waterproof bonding membrane;
bonding the other side of the waterproof isolating sheet to the building substrate; and bonding the facing to the exposed side of the waterproof bonding membrane.
A method as set forth in claim 1, wherein:
said bonding sheet comprises a first bonding sheet, and including:
providing a second bonding sheet, constructed of a randomly distributed continuous filament material, and having a size and shape substantially commensurate with the waterproof isolating sheet;
positioning the second bonding sheet overlying the other side of the waterproof isolating sheet in a predetermined orientation therewith; and laminating the second bonding sheet to the other side of the waterproof isolating sheet, and wherein;
said second bonding sheet is adhered to the building substrate.
A method as set forth in claim 2, wherein:
said waterproof isolating sheet providing step comprises extruding said waterproof isolating sheet from a die, whereby said waterproof isolating sheet exits the die at a temperature substantially above ambient temperature;
and said laminating step comprises pressing said first and second bonding sheets against the opposite sides of the waterproof isolating sheet immediately after said extruding step, while said waterproof isolating sheet is still at a temperature substantially above ambient temperature.
A method as set forth in claim 3, wherein:
said bonding sheet material comprises spunbonded polyester; and said waterproof isolating sheet material comprises chlorinated polyethylene.
A method as set forth in claim 4, wherein:
the temperature of the waterproof isolating sheet at the beginning of said laminating step is in the range of 250 to 350 degrees F.
A method as set forth in claim 5, wherein said laminating step comprises:
tensing the first and second bonding sheets laterally before pressing the same against the opposite sides of the waterproof isolating sheet.
A method as set forth in claim 6, wherein said bonding sheet pressing step comprises:
providing nip rollers between which the waterproof bonding membrane is passed; and adjusting the nip rollers to press each of the first and second bonding sheets into the waterproof isolating sheet a distance in the range of .002 to .004 inches.
A method as set forth in claim 7, wherein-said nip roller adjusting step comprises adjusting the nip rollers to reduce the overall thickness of the waterproof bonding membrane to an amount equal to 79% to 87%. of the original thickness of the waterproof bonding membrane.
A method as set forth in claim 8, wherein said laminating step comprises:
coating the nip rollers with a layer of silicon.
A method as set forth in claim 9, including:
providing a second waterproof bonding membrane shaped to cover that protion of the building substrate that is not covered by the first named waterproof bonding membrane, and joining adjacent side edges of the first and second named waterproof bonding membranes before adhering the same to the building substrate.
A method as set forth in claim 10, wherein:
said waterproof isolating sheet has a predetermined width, and includes first and second side edges;
said first and second bonding sheets each have a predetermined width that is narrower than the width of the waterproof isolating sheet, and includes first and second side edges.
A method as set forth in claim 11, wherein said sheet positioning step comprises:
aligning the first side edge of the first bonding sheet with the first side edge of the waterproof isolating sheet, thereby forming a first open strip of waterproof isolating sheet on one side thereof between the second side edge of the first bonding sheet and the second side edge of the waterproof isolating sheet; and aligning the second side edge of the second bonding sheet with the second side edge of the waterproof isolating sheet, thereby forming a second open strip of waterproof isolating sheet on the other side thereof between the first side edge of the second bonding sheet and the first side edge of the waterproof isolating sheet.
A method as set forth in claim 12, wherein said sheet joining step comprises:
positioning the first open strip of the first named waterproof bonding membrane over the second open strip of the second named waterproof bonding membrane and adhering the same together.
A method as set forth in claim 13, wherein said open strip adhering step comprises:
cleaning the first open strip of the first named waterproof bonding membrane and the second open strip of the second named waterproof bonding membrane;
roughening the first open strip of the first named waterproof bonding membrane and the second open strip of the second named waterproof bonding membrane;
applying a waterproof isolating sheet solvent to the first open strip of the first named waterproof bonding membrane and the second open strip of the second named waterproof bonding membrane; and pressing the first open strip of the first named waterproof bonding membrane and the second open strip of the second named waterproof bonding membrane together.
A method as set forth in claim 14, wherein:
said facing comprises a plurality of individual articles, such as the tiles, bricks, stones, slate pieces and the like; and said facing bonding step comprises positioning the individual facing articles on the building substrate and individually bonding the same thereto.
A method as set forth in claim 15, wherein said membrane bonding step comprises:
smoothing the surface of the building substrate to which the facing is to be mounted;
cleaning the surface of the building substrate to which the facing is to be mounted;
applying a layer of membrane bonding agent to the substrate surface;
pressing the waterproof bonding membrane into the layer of membrane bonding agent; and curing the membrane bonding agent.
A method as set forth in claim 16, wherein said facing bonding step further comprises:
applying a layer of tile bonding agent to the other side of the waterproof bonding membrane;
pressing the facing articles into the layer of tile bonding agent; and curing the tile bonding agent.
A method as set forth in claim 17, wherein:
said tile bonding agent comprises a mixture having a trowelable consistence, and includes Portland cement mortar; and said tile bonding agent applying step comprises manually trowelling a thin bed layer of the tile bonding agent onto the other side of the waterproof bonding membrane.
A method as set forth in claim 18, wherein:
said waterproof bonding membrane is flexible to conform to the shape of the building substrate, and isolate the facing and tile bonding agent from the effects of cracks in the building substrate.
A method as set forth in claim 19, wherein:
said first and second bonding sheets comprise straight fibers.
A method as set forth in claim 1, wherein:
said waterproof isolating sheet providing step comprises extruding said waterproof isolating sheet from a die, whereby said waterproof isolating sheet exits the die at a temperature substantially above ambient temperature;
and said laminating step comprises pressing said bonding sheet against the one side of the waterproof isolating sheet immediately after said extruding step, while said waterproof isolating sheet is still at a temperature substantially above ambient temperature.
A method as set forth in claim 1, wherein:
said bonding sheet material comprises spunbonded polyester;
said waterproof isolating sheet material comprises chlorinated polyethylene; and said temperature of the waterproof isolating sheet at the beginning of said laminating step is in the range of 250 to 350 degrees F.
A method as set forth in claim 1, wherein said laminating step comprises:
tensing the bonding sheet laterally before pressing the same against the one side of the waterproof isolating sheet.
A method as set forth in claim 1, wherein said laminating step comprises:
providing nip rollers between which the waterproof bonding membrane is passed; and adjusting the nip rollers to press the bonding sheet into the waterproof isolating sheet an amount in the range of .002 to .004 inches.
A method as set forth in claim 24, wherein:
said nip roller adjusting step comprises adjusting the nip rollers to reduce the overall thickness of the waterproof bonding membrane to an amount equal to 79% to 87% of the original thickness of the waterproof bonding membrane.
A method as set forth in claim 1, including:
providing a second waterproof bonding membrane shaped to cover that protion of the building substrate that is not covered by the first named waterproof bonding membrane; and joining adjacent side edges of the first and second named waterproof bonding membranes before adhering the same to the building substrate.
A method as set forth in claim 2, wherein:
said waterproof isolating sheet has a predetermined width, and includes first and second side edges;
said first and second bonding sheets each have a predetermined width that is narrower than the width of the waterproof isolating sheet, and includes first and second side edges.
A method as set forth in claim 27, wherein said sheet positioning step comprises:
aligning the first side edge of the first bonding sheet with the first side edge of the waterproof isolating sheet, thereby forming a first open strip of waterproof isolating sheet on one side thereof between the second side edge of the first bonding sheet and the second side edge of the waterproof isolating sheet; and aligning the second side edge of the second bonding sheet with the second side edge of the waterproof isolating sheet, thereby forming a second open strip of waterproof isolating sheet on the other side thereof between the first side edge of the second bonding sheet and the first side edge of the waterproof isolating sheet.
A method as set forth in claim 28 wherein said sheet joining step comprises:
positioning the first open strip of the first named waterproof bonding membrane over the second open strip of the second named waterproof bonding membrane and adhering the same together.
A method as set forth in claim 29, wherein said open strip adhering step comprises:
cleaning the first open strip of the first named waterproof bonding membrane and the second open strip of the second named waterproof bonding membrane;
roughening the first open strip of the first named waterproof bonding membrane and the second open strip of the second named waterproof bonding membrane;
applying a waterproof isolating sheet solvent to the first open strip of the first named waterproof bonding membrane and the second open strip of the second named waterproof bonding membrane; and pressing the first open strip of the first named waterproof bonding membrane and the second open strip of the second named waterproof bonding membrane together.
A method as set forth in claim 1, wherein:
said facing comprises a plurality of individual articles, such as the tiles, bricks, stones, slate pieces and the like; and said facing bonding step comprises positioning the individual facing articles on the building substrate and individually bonding the same thereto.
A method as set forth in claim 1, wherein said membrane bonding step comprises:
smoothing the surface of the building substrate to which the facing is to be mounted;
cleaning the surface of the building substrate to which the facing is to be mounted;
applying a layer of membrane bonding agent to the building substrate surface;
pressing the waterproof bonding membrane into the layer of membrane bonding agent; and curing the membrane bonding agent.
A method as set forth in claim 1, wherein said facing bonding step comprises:
applying a layer of facing bonding agent to the exposed side of the bonding sheet;
pressing the facing into the layer of facing bonding agent; and curing the facing bonding agent.
A method as set forth in claim 33, wherein:
said facing bonding agent comprises a mixture having a trowelable consistence, and includes Portland cement mortar; and said facing bonding agent applying step comprises manually trowelling a thin bed set layer of the facing bonding agent onto the other side of the waterproof bonding membrane.
A waterproof facing construction for building surfaces and the like, comprising:
a waterproof isolating sheet, constructed of an imperforate, substantially waterproof material, and shaped to cover a predetermined building surface;
a bonding sheet, constructed of a randomly distibuted continuous filament material, and having first and second sides, and a size and shape substantially commensurate with said waterproof isolating sheet; said bonding sheet first side being positioned overlying and laminated to one side of said waterproof isolating sheet in a predetermined orientation therewith to form a waterproof bonding membrane;
a facing shaped to cover the predetermined building surface;
a first layer of bonding agent positioned between and bonding the other side of said waterproof isolating sheet to the predetermined building surface; and a second layer of bonding agent positioned between and bonding said facing to the second side of said bonding sheet, whereby said waterproof bonding membrane securely isolates and mounts said facing on the predetermined building surface, and forms a waterproof membrane therebetween.
A facing construction as set forth in claim 35, wherein:
said bonding sheet material comprises spunbonded polyester.
A facing construction as set forth in claim 36, wherein:
said waterproof isolating sheet material comprises chlorinated polyethylene.
A facing construction as set forth in claim 37, wherein:
said waterproof isolating sheet is extruded from a die, whereby said waterproof isolating sheet exits the die at a temperature substantially above ambient temperature; and said bonding sheet is pressed against the one side of said waterproof isolating sheet immediately after the same exits the die, while said waterproof isolating sheet is still at a temperature substantially above ambient temperature to form a heat laminated construction.
A facing construction as set forth in claim 38, wherein:
said waterproof isolating sheet has a predetermined width, and includes first and second side edges;
said bonding sheet has a predetermined width that is narrower than the width of said waterproof isolating sheet, and includes first and second side edges;
said first side edge of said bonding sheet is aligned with the first side edge of said waterproof isolating sheet, thereby forming a first open strip of waterproof isolating sheet on one side thereof between the second side edge of said bonding sheet and the second side edge of said waterproof isolating sheet.
A waterproof facing construction for building surfaces and the like; comprising:
a waterproof isolating sheet, constructed of an imperforate, substantially waterproof material, and shaped to cover a predetermined building surface;
first and second bonding sheets, constructed of a randomly distibuted continuous filament material, and having first and second sides, and a size and shape substantially commensurate with said waterproof isolating sheet; said first and second bonding sheets being positioned overlying and laminated to the opposite sides of said waterproof isolating sheet in a predetermined orientation therewith to form a waterproof bonding membrane;
a facing shaped to cover the predetermined building surface;
a first layer of bonding agent positioned between and bonding one side of said waterproof bonding membrane to the predetermined building surface; and a second layer of bonding agent positioned between and bonding said facing to the other side of said waterproof bonding membrane, whereby said waterproof bonding membrane isolates and securely mounts said facing on the predetermined building surface, and forms a waterproof membrane therebetween.
A facing construction as set forth in claim 40, wherein:
said bonding sheet material comprises spunbonded polyester.
A facing construction as set forth in claim 41, wherein:
said waterproof isolating sheet material comprises chlorinated polyethylene.
A construction as set forth in claim 42, wherein:
said waterproof isolating sheet is extruded from a die, whereby said waterproof isolating sheet exits the die at a temperature substantially above ambient temperature; and said first and second bonding sheets are pressed against the sides of said waterproof isolating sheet immediately after the same exits the die, while said waterproof isolating sheet is still at a temperature substantially above ambient temperature to form a heat laminated construction.
A construction as set forth in claim 43, wherein:
said waterproof isolating sheet has a predetermined width and includes first and second side edges;
said first and second bonding sheets each have a predetermined width that is narrower than the width of the waterproof isolating sheet, and include first and second side edges;
said first side edge of said first bonding sheet is aligned with the first side edge of said waterproof isolating sheet, thereby forming a first open strip of waterproof isolating sheet on one side thereof between the second side edge of said first bonding sheet and the second side edge of said waterproof isolating sheet; and said second side edge of said second bonding sheet is aligned with the second side edge of said waterproof isolating sheet, thereby forming a second open strip of waterproof isolating sheet on the other side thereof between the first side edge of said second bonding sheet and the first side edge of said waterproof isolating sheet.
A waterproof bonding membrane for mounting facing on a building substrate, comprising:
a waterproofing sheet, constructed of an imperforate, substantially waterproof material, and shaped to cover that portion of the building substrate on which the facing is to be mounted;
a bonding sheet, constructed of a randomly distributed continuous filament material, and having a size and shape substantially commensurate with the waterproofing sheet; said bonding sheet being positioned overlying and laminated to one side of the waterproofing sheet, whereby the other side of said waterproofing sheet is bonded to the building substrate, and the facing is bonded to the exposed side of the bonding sheet to securely mount the facing to the building substrate and form a waterproof membrane therebetween.
A waterproof bonding membrane as set forth in claim 45, wherein:
said bonding sheet compises a first bonding sheet; and including a second bonding sheet, constructed of a randomly distributed continuous filament material, and having a size and shape substantially commensurate with the waterproofing sheet; said second bonding sheet being positioned overlying and laminated to the other side of the waterproofing sheet, whereby said second bonding sheet is bonded to the building substrate.
A waterproof bonding membrane as set forth in claim 46, wherein:
said bonding sheet material comprises spunbonded polyester.
A waterproof bonding membrane as set forth in claim 47, wherein:
said waterproofing sheet material comprises chlorinated polyethylene.
A waterproof bonding membrane as set forth in claim 48, wherein:
said waterproofing sheet is extruded from a die, whereby said waterproofing sheet exits the die at a temperature substantially above ambient temperature; and said first and second bonding sheets are pressed against the opposite sides of the waterproofing sheet immediately after the same exits the die, while said waterproofing sheet is still at a temperature substantially above ambient temperature to form a heat laminated construction.
A waterproof bonding membrane as set forth in claim 49, wherein:
said waterproofing sheet has a predetermined width and includes first and second side edges;
said first and second bonding sheets each have a predetermined width that is narrower than the width of the waterproofing sheet, and include first and second side edges;
said first side edge of said first bonding sheet is aligned with the first side edge of said waterproofing sheet, thereby forming a first open strip of waterproofing sheet on one side thereof between the second side edge of said first bonding sheet and the second side edge of said waterproofing sheet; and said second side edge of said second bonding sheet is aligned with the second side edge of said waterproofing sheet, thereby forming a second open strip of waterproofing sheet on the other side thereof between the first side edge of said second bonding sheet and the first side edge of said waterproofing sheet.
A waterproof bonding membrane as set forth in claim 5n, wherein:
said waterproof bonding membrane is flexible to conform to the shape of the building substrate.
A waterproof bonding membrane as set forth in claim 45, wherein:
said bonding sheet material comprises spunbonded polyester.
waterproof bonding membrane as set forth in claim 52, wherein:
said bonding sheet material comprises straight fibers.
A waterproof bonding membrane as set forth in claim 45, wherein:
said waterproofing sheet material comprises chlorinated polyethylene.
A waterproof bonding membrane as set forth in claim 45, wherein:
said waterproofing sheet is extruded from a die, whereby said waterproofing sheet exits the die at a temperature substantially above ambient temperature; and said bonding sheet is pressed against the one side of the waterproofing sheet immediately after the same exits the die, while said waterproofing sheet is still at a temperature substantially above ambient temperature to form a heat laminated construction.
A waterproof bonding membrane as set forth in claim 46, wherein:
said waterproofing sheet has a predetermined width and includes first and second side edges;
said first and second bonding sheets each have a predetermined width that is narrower than the width of the waterproofing sheet, and includes first and second side edges;
said first side edge of said first bonding sheet is aligned with the first side edge of said waterproofing sheet, thereby forming a first open strip of waterproofing sheet on one side thereof between the second side edge of said first bonding sheet and the second side edge of said waterproofing sheet; and said second side edge of said second bonding sheet is aligned with the second side edge of said waterproofing sheet, thereby forming a second open strip of waterproofing sheet on the other side thereof between the first side edge of said second bonding sheet and the first side edge of said waterproofing sheet.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US71921185A | 1985-04-02 | 1985-04-02 | |
| US719,211 | 1985-04-02 |
Publications (1)
| Publication Number | Publication Date |
|---|---|
| CA1252380A true CA1252380A (en) | 1989-04-11 |
Family
ID=24889199
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA000484213A Expired CA1252380A (en) | 1985-04-02 | 1985-06-17 | Waterproof bonding membrane and method |
Country Status (1)
| Country | Link |
|---|---|
| CA (1) | CA1252380A (en) |
Cited By (2)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5318832A (en) * | 1992-11-02 | 1994-06-07 | Gencorp Inc. | Anti-fracture, water-resistant, masonry-bondable membrane |
| US5860255A (en) * | 1996-05-09 | 1999-01-19 | Gencorp Inc. | Masonry-bondable, water-resistant flexible membrane |
-
1985
- 1985-06-17 CA CA000484213A patent/CA1252380A/en not_active Expired
Cited By (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US5318832A (en) * | 1992-11-02 | 1994-06-07 | Gencorp Inc. | Anti-fracture, water-resistant, masonry-bondable membrane |
| US5481838A (en) * | 1992-11-02 | 1996-01-09 | Gencorp Inc. | Anti-fracture, water-resistant, masonry-bondable membrane |
| US5595625A (en) * | 1992-11-02 | 1997-01-21 | Gencorp Inc. | Method of manufacturing an anti-fracture, water-resistant, masonry-bondable membrane |
| US5860255A (en) * | 1996-05-09 | 1999-01-19 | Gencorp Inc. | Masonry-bondable, water-resistant flexible membrane |
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