CN117396333A

CN117396333A - Roofing membrane with improved mechanical properties

Info

Publication number: CN117396333A
Application number: CN202280038685.1A
Authority: CN
Inventors: 崔慧; 魏益哲; 魏勤
Original assignee: Sika Technology AG
Current assignee: Sika Technology AG
Priority date: 2021-07-30
Filing date: 2022-07-28
Publication date: 2024-01-12
Also published as: WO2023006911A1; EP4377082A1

Abstract

The invention relates to a membrane (1) comprising: i. a top film layer (2), ii a reinforcing scrim (3) having a first major surface and a second major surface, and iii optionally a back film layer (4), characterized in that at least a portion of the first major surface of the reinforcing scrim (3) is covered with an adhesive coating material (5), the adhesive coating material (5) comprising: a) a polyvinyl chloride resin, B) at least one polyvinyl chloride resin cross-linking agent, C) optionally at least one plasticizer, and D) optionally at least one inorganic filler. The invention also relates to a method for producing a membrane and to a roofing system comprising a roofing underlayment (5) and a membrane (1) attached to a surface of the roofing underlayment (5) by means of a connection using a mechanical or adhesive.

Description

Roofing membrane with improved mechanical properties

Technical Field

The present invention relates to the field of waterproofing above ground building structures by using waterproofing membranes. In particular, the present invention relates to roofing membranes having improved mechanical properties, flexibility at low temperatures, and hail impact resistance.

Background

In the construction field, polymeric sheets, commonly referred to as films, plates or sheets, are used to protect underground and above-ground constructions (e.g., basements, tunnels, and flat and low-sloping roofs) from penetrating water. Waterproof membranes are used, for example, to prevent water from entering through cracks in concrete structures due to building settlement, load deflection or shrinkage of the concrete. Waterproof roofing membranes for flat and low-pitch roof structures are typically provided as single-layer or multi-layer membrane systems. In a single layer system, a roofing membrane composed of a single polymeric water barrier layer is used to cover a roofing substrate. Single layer roofing membranes typically contain one or more reinforcing layers to increase the mechanical stability of the membrane. The multilayer film is composed of a plurality of polymeric water barrier layers having similar or different compositions. Single layer films have the advantage of lower production costs compared to multilayer films, but they also have lower resistance to mechanical damage caused by perforation of sharp objects.

Materials commonly used in roofing membranes include plastics, particularly thermoplastics such as plasticized polyvinyl chloride (p-PVC), thermoplastic olefins (TPE-O, TPO), and elastomers such as ethylene-propylene diene monomer (EPDM). The roofing membrane is typically delivered to the job site in roll form, transferred to the installation site, unrolled and adhered to the substrate to be waterproofed. The substrate to which the roofing membrane is adhered may be composed of a variety of materials. The substrate may be, for example, concrete, metal or wood deck, or it may comprise insulation panels or cover sheets and/or existing membranes.

The roofing membrane must be securely fastened to the roofing substrate to provide sufficient mechanical strength to resist shear forces imposed thereon due to high wind loads. Roofing systems generally fall into two categories depending on the manner in which the roofing membrane is secured to the roofing substrate. In mechanically attached roofing systems, the roofing membrane is secured to the roofing substrate using screws and/or barb plates. Mechanical fastening enables a high strength connection, but it provides a direct attachment to the roof substrate only where the mechanical fastener secures the membrane to the surface, which makes the mechanically attached membrane prone to flutter. In fully adhered roofing systems, the membrane is typically indirectly adhered to the roofing substrate by use of an adhesive composition.

The roofing membrane is exposed to various stresses during its lifetime, including thermal stress, prolonged exposure to ozone and ultraviolet radiation, and mechanical stress. Mechanically fastened PVC films are known to be more susceptible to weathering-induced aging than fully adhered systems. In addition, the aged roofing membranes exhibit a particularly poor resistance to mechanical impacts, such as the impact of hailstone. The mechanical properties of the roofing membrane may be improved, for example, by using a nonwoven reinforcement layer, such as a polyester fabric or laid scrim (scrim), which are integrated into the structure of the membrane. However, the use of such a reinforcing layer can also negatively impact the flexibility of the film. Due to the high stiffness of the yarns of the reinforcing layer, bending of the reinforced multilayer film at low temperatures will cause the scrim to exert a pushing force that ultimately results in delamination of the film layers, especially if a relatively thin top film layer is used.

Thus, there remains a need for a new reinforced roofing membrane that has excellent physical properties including tensile strength, tear and puncture resistance, flexibility at low temperatures, and hail resistance, and that can be used to provide increased life and improved safety for roofing systems.

Summary of The Invention

It is an object of the present invention to provide a novel and improved roofing membrane having improved physical properties, especially in terms of tensile strength, tear resistance, puncture resistance and hail impact resistance, as well as flexibility at low temperatures.

The subject of the invention is a membrane as defined in claim 1.

It has surprisingly been found that a film comprising a top layer and a reinforcing scrim, wherein at least a portion of the first main surface of the reinforcing scrim is covered with an adhesive coating material, can solve or at least alleviate the problems of the prior art reinforcing films.

One of the advantages of the films of the present invention is that improvements in mechanical properties and ageing resistance can be achieved without significantly increasing the production costs of the films.

Other aspects of the invention are given in the other independent claims. Preferred aspects of the invention are given in the dependent claims.

Drawings

Fig. 1 shows a cross section of a film (1) comprising a top layer of film (2), a reinforcing scrim (3) and an adhesive coating material (5) covering a first major surface of the reinforcing scrim (3).

Fig. 2 shows a cross section of a film (1) comprising a film top layer (2), a reinforcing scrim (3), a film backing layer (4) and an adhesive coating material (5) covering a first main surface of the reinforcing scrim (4), wherein the reinforcing scrim (3) is arranged between the film top layer and the film backing layer (2, 4).

Fig. 3 shows a cross section of a roof system comprising a roof lining (6) and the membrane (1) of fig. 2 adhered to the surface of the roof lining (6).

Detailed Description

The subject of the invention is a film (1) comprising:

i. a top film layer (2),

a reinforcing scrim (3), the reinforcing scrim (3) having a first major surface and a second major surface, and

optionally a film backing layer (4),

characterized in that at least a portion of the first main surface of the reinforcing scrim (3) is covered with an adhesive coating material (5) comprising:

a) A polyvinyl chloride resin,

b) At least one cross-linking agent for polyvinyl chloride resin,

c) Optionally at least one plasticizer, and

d) Optionally at least one inorganic filler.

The prefix "poly" in a substance name such as "polyol" or "polyisocyanate" refers to a substance that formally contains two or more functional groups per molecule that appear in its name. For example, the polyol is a compound having two or more hydroxyl groups, and the polyisocyanate is a compound having two or more isocyanate groups.

The term "polymer" refers to a collection of chemically homogeneous macromolecules produced by polymerization (polyaddition, polycondensation), wherein the macromolecules differ in their degree of polymerization, molecular weight and chain length. The term also includes derivatives of the set of macromolecules resulting from the polymerization reaction, i.e. compounds obtained by reaction of e.g. addition or substitution of functional groups in the predetermined macromolecules, which may be chemically homogeneous or chemically heterogeneous.

The term "glass transition temperature" (T) _g ) The temperature is shown as follows: above this temperature, the polymer component becomes soft and pliable, while below this temperature it becomes hard and glassy. The glass transition temperature is preferably determined by Dynamic Mechanical Analysis (DMA) using an application frequency of 1Hz and a strain level of 0.1% as the peak of the measured loss modulus (G ") curve.

The "amount or content of the at least one component X" in the composition, for example the "amount of the at least one plasticizer" refers to the sum of the individual amounts of all plasticizers contained in the composition. Furthermore, in the case where the composition comprises 20% by weight of at least one plasticizer, the sum of the amounts of all plasticizers contained in the composition is equal to 20% by weight.

The term "room temperature" means a temperature of 23 ℃.

The film of the present invention comprises a film top layer, a reinforcing scrim, and optionally a film backing layer, wherein at least a portion of the first major surface of the reinforcing scrim is covered with an adhesive coating material. The term "layer" refers in this disclosure to a sheet-like element having first and second major surfaces (i.e., top and bottom surfaces), a width defined between longitudinally extending edges, and a thickness defined between the first and second major surfaces. Preferably, the layer has a length and width that is at least 5 times, more preferably at least 15 times, even more preferably at least 25 times greater than the thickness of the layer.

Preferably, at least one of the film top layer and the backing layer is a polymer layer. The term "polymer layer" in this disclosure refers to a film comprising a continuous phase composed of one or more polymers. According to one or more embodiments, both the film backing layer and the top layer are polymeric layers. Preferably, the film of the present invention is a roofing film.

The reinforcing scrim is preferably a nonwoven scrim. The term "nonwoven scrim" in this disclosure refers to a nonwoven product comprised of at least two sets of parallel yarns (warp and weft) that are stacked on top of each other and chemically bonded to each other using one or more binders. Such nonwoven scrims are also referred to as "lay scrims". The yarns of the nonwoven scrim are typically arranged at an angle of 60-120 °, particularly 90±5°, towards each other, thereby forming interstices, wherein the interstices typically occupy more than 50% of the entire surface area of the nonwoven scrim.

Common materials for nonwoven scrims include metal fibers, inorganic fibers, such as glass fibers, aramid fibers, wollastonite fibers, and carbon fibers, and synthetic organic fibers, such as polyester fibers, polypropylene fibers, polyethylene fibers, polyamide fibers, and polyethylene terephthalate (PET).

Suitable binders for chemically bonding the yarns to each other include, for example, polyvinyl alcohol (PVA), polyvinyl acetate (PVAc), polyvinyl chloride (PVC), polyacrylates, acrylates, ethylene-vinyl acetate copolymers (EVA), polyurethanes (PUR), styrene butadiene copolymers (SB), and mixtures thereof. Chemical bonding is typically accomplished by impregnating the warp and weft yarns with an adhesive and then contacting each other.

According to one or more embodiments, the reinforcing scrim has a single warp or double warp construction, preferably a single warp construction. In a single warp structure, the first warp yarn (machine direction yarn) below the weft yarn (cross-machine direction yarn) is followed by the warp yarn above the weft yarn. The pattern repeats across the width of the scrim. The spacing between yarns may be regular across the width of the scrim. At the intersection point, the two yarns will always meet each other. In the double warp structure, the upper and lower warp yarns are always laid one on the other so that the weft yarns are always fixed between the upper and lower warp yarns. At the crossing point, the three yarns will always meet each other.

According to one or more embodiments, the reinforcing scrim has at least 4, preferably at least 5, more preferably at least 5.5, even more preferably at least 6, even more preferably at least 7 warp yarns per cm (in the machine direction of the scrim) and/or at least 4, preferably at least 5, more preferably at least 5.5, even more preferably at least 6, even more preferably at least 7 weft yarns per cm (in the cross direction of the scrim).

According to one or more preferred embodiments, the reinforcing scrim has 4-15, preferably 5-12, more preferably 5.5-12, even more preferably 6-10, still more preferably 7-10 warp yarns per cm (in the machine direction of the scrim) and/or 4-15, preferably 5-12, more preferably 5.5-12, even more preferably 6-10, still more preferably 7-10 weft yarns per cm (in the cross direction of the scrim).

The thickness of the yarns of the reinforcing scrim is not particularly limited, and the preferred thickness depends on the material of the scrim, and further depends on the density of the warp and weft yarns. Preferably, the yarns of the reinforcing scrim have a thickness of no more than 750 μm, more preferably no more than 500 μm, even more preferably no more than 350 μm. According to one or more embodiments, the thickness of the yarns of the reinforcing scrim is 100-750 μm, preferably 150-500 μm, more preferably 200-350 μm.

The mass per unit area of the reinforcing scrim preferably does not exceed 500g/m ² More preferably not more than 350g/m ² . According to one or more embodiments, the reinforcing scrim has a mass per unit area of 25 to 250g/m ² Preferably 50-200g/m ² Even more preferably 100-200g/m ² . The mass per unit area can be determined by measuring the mass of the scrim sample and dividing the mass by the area of the sample. Preferably, the mass per unit area of the reinforcing scrim is determined according to the definition of the ISO 9073-18:2007 standard。

Preferably, the thickness of the scrim is no greater than 1.0mm, preferably no greater than 0.75mm. According to one or more embodiments, the reinforcing scrim has a thickness of 0.10 to 1.0mm, preferably 0.15 to 0.75mm, more preferably 0.2 to 0.5mm, even more preferably 0.25 to 0.5mm.

According to one or more embodiments, the reinforcing scrim has an elongation at break of 2-35%, preferably 4-25%, more preferably 6-20%, as determined according to ISO 20932-1:2018 standard.

According to one or more preferred embodiments, the yarns of the reinforcing scrim comprise or consist of a synthetic organic polymer, preferably selected from the group consisting of polyester, polypropylene, polyethylene, polyamide and polyethylene terephthalate, more preferably from the group consisting of polyester, polypropylene and polyethylene, even more preferably polyester.

According to one or more embodiments, the film comprises a film backing layer, and the reinforcing scrim is disposed between the film top layer and the backing layer. Such films are particularly suitable for use as multilayer roofing membranes.

In accordance with one or more embodiments, the second major surface of the reinforcing scrim is directly attached to the film backing layer. The expression "directly connected" is understood to mean in the context of the present invention that no further layers or substances are present between the layers and that the opposite surfaces of the layers are directly bonded to each other or adhere to each other. The materials of the layers may also be mixed with each other at the transition region between the two layers.

According to the invention, at least a portion of the first major surface of the reinforcing scrim is covered with an adhesive coating material.

In order to provide a sufficient bond between the reinforcing scrim and the top film layer, it is preferred that at least 50%, more preferably at least 75%, even more preferably at least 85%, still more preferably at least 95% of the first major surface of the reinforcing scrim is covered by the adhesive coating material. According to one or more embodiments, the first major surface of the reinforcing scrim is substantially completely covered by the adhesive coating material. The expression "substantially complete" is understood to mean that at least 97.5%, preferably 98.5%, more preferably 99% of the first main surface of the reinforcing scrim is covered with adhesive coating material.

It is also preferred that the reinforcing scrim is at least partially impregnated with an adhesive coating material. The term "impregnating" is understood to mean that the substrate contains pores which have been filled to the saturation point with the corresponding composition, in this case with an adhesive coating material.

The adhesive coating material comprises:

a) A polyvinyl chloride resin,

b) At least one cross-linking agent for polyvinyl chloride resin,

c) Optionally at least one plasticizer, and

d) Optionally at least one inorganic filler.

According to one or more embodiments, the adhesive coating material comprises:

a) 25 to 75% by weight, preferably 35 to 65% by weight, more preferably 40 to 60% by weight of a polyvinyl chloride resin,

b) 0.1 to 15 wt.%, preferably 1 to 10 wt.%, more preferably 2.5 to 7.5 wt.% of the at least one polyvinyl chloride resin cross-linking agent,

c) 0-55wt. -%, preferably 5-50wt. -%, more preferably 15-45wt. -% of the at least one plasticizer, and

d) 0-35 wt.%, preferably 2.5-30 wt.%, more preferably 5-25 wt.% of the at least one inorganic filler.

Suitable polyvinyl chloride resins for the adhesive coating material include polyvinyl chloride resins having a K-value in the range of 50-85, more preferably 65-75, as determined by using the method described in the ISO 1628-2-1998 standard. The K-value is a measure of the polymerization grade of the polyvinyl chloride resin and is determined from the viscosity value of the polyvinyl chloride homopolymer as the original resin dissolved in cyclohexanone at 30 ℃.

According to one or more embodiments, the at least one polyvinyl chloride cross-linking agent is a polyisocyanate.

Suitable polyisocyanates for use as the at least one polyvinyl chloride crosslinking agent include, for example, aliphatic, cycloaliphatic and aromatic polyisocyanates, especially monomeric di-and tri-functional isocyanates. The term "monomer" in this disclosure means a molecule having at least one polymerizable group. In the context of polyisocyanates, monomeric polyisocyanates are particularly free of urethane groups. Non-monomeric polyisocyanates, such as oligomers, polymers and derivatives of monomeric polyisocyanates, such as adducts of monomeric diisocyanates, are also suitable.

According to one or more embodiments, the at least one polyvinyl chloride resin cross-linking agent is a monomeric diisocyanate, preferably selected from 4,4' -diphenylmethane diisocyanate, optionally with a proportion of 2,4' -and/or 2,2' -diphenylmethane diisocyanate (MDI), 2, 4-toluene diisocyanate or a mixture with 2, 6-Toluene Diisocyanate (TDI), 1, 6-Hexamethylene Diisocyanate (HDI) and 1-isocyanato-3, 5-trimethyl-5-isocyanatomethylcyclohexane (IPDI). Furthermore, it is known to the person skilled in the art that technical grade products of diisocyanates may often contain isomer mixtures or other isomers as impurities.

Suitable plasticizers for the adhesive coating material include, for example, linear or branched phthalates such as Diisononylphthalate (DINP), dinonylphthalate (L9P), diallyl phthalate (DAP), di-2-ethylhexyl phthalate (DEHP), dioctyl phthalate (DOP), diisodecyl phthalate (DIDP), and mixed linear phthalates (911P). Other suitable plasticizers include phthalate-free plasticizers, such as trimellitate plasticizers, adipic acid polyesters, and biochemical plasticizers. Examples of biochemical plasticizers include epoxidized vegetable oils, such as epoxidized soybean oil and epoxidized linseed oil, and acetylated waxes and oils derived from plants, such as acetylated castor wax and acetylated castor oil.

Particularly suitable phthalate-free plasticizers for the adhesive coating material include alkyl esters of benzoic acid, dialkyl esters of aliphatic dicarboxylic acids, polyesters of aliphatic dicarboxylic acids or aliphatic diols, triols and tetrols whose end groups are unesterified or have been esterified with monofunctional agents, trialkyl esters of citric acid, acetylated trialkyl esters of citric acid, glycerol esters, mono-alkylene glycols, di-alkylene glycols, benzoic acid diesters of tri-or polyalkylene glycols, trimethylol propane esters, dialkyl esters of cyclohexane dicarboxylic acid, dialkyl esters of terephthalic acid, trialkyl esters of trimellitic acid, triaryl esters of phosphoric acid, diaryl alkyl esters of phosphoric acid, trialkyl esters of phosphoric acid and aryl esters of alkylsulfonic acid.

According to one or more embodiments, the at least one plasticizer is selected from phthalate, trimellitate plasticizers, adipic acid polyesters, and biochemical plasticizers.

Particularly suitable inorganic fillers for the binder coating material include inert mineral fillers, which, unlike mineral binders, do not react with water, i.e. do not undergo hydration reactions in the presence of water.

Suitable inert mineral fillers include, for example, sand, granite, calcium carbonate, clay, expanded clay, diatomaceous earth, pumice, mica, kaolin, talc, dolomite, xonotlite, perlite, vermiculite, wollastonite, barite, magnesium carbonate, calcium hydroxide, calcium aluminate, silica, fumed silica, fused silica, aerogel, glass beads, hollow glass spheres, ceramic spheres, bauxite, crushed concrete, and zeolite. The term "calcium carbonate" as inert mineral filler refers herein to calcite filler produced from chalk, limestone or marble by grinding and/or precipitation.

The thickness of the adhesive coating material is not particularly limited. According to one or more embodiments, the thickness of the adhesive coating material is 25-350 μm, preferably 50-300 μm, more preferably 75-200 μm.

According to one or more preferred embodiments, the film top layer and/or backing layer is a polyvinyl chloride based layer, preferably comprising:

a) 25 to 65% by weight, preferably 35 to 55% by weight, of a polyvinyl chloride resin,

b) 10 to 50% by weight, preferably 15 to 45% by weight, of at least one plasticizer, and

c) 0-30 wt%, preferably 1-30 wt%, of at least one inert mineral filler, all proportions being based on the total weight of the film backing layer or top layer.

Suitable polyvinyl chloride resins, plasticizers and inert mineral fillers include those described above as suitable for the adhesive coating material.

Preferably, the composition of the film top layer and/or backing layer has a glass transition temperature (T) below-20deg.C, more preferably below-25deg.C _g ) It was determined by Dynamic Mechanical Analysis (DMA) using an application frequency of 1Hz and a strain level of 0.1%.

According to one or more embodiments, the at least one inert mineral filler is present in the film backing layer and/or backing layer in an amount of 5 to 30 wt%, preferably 10 to 30 wt%, more preferably 15 to 30 wt%, based on the total weight of the film backing layer or backing layer.

According to one or more embodiments, the film top layer and/or backing layer further comprises:

d) From 0 to 15% by weight, preferably from 0.5 to 10% by weight, more preferably from 0.5 to 7.5% by weight, based on the total weight of the film top layer or backing layer, of at least one flame retardant.

The at least one flame retardant is preferably selected from magnesium hydroxide, aluminum trihydroxide, antimony trioxide, ammonium polyphosphate and melamine-, melamine resins-, melamine derivatives-, melamine-formaldehyde-, silanes-, siloxanes-and polystyrene-coated ammonium polyphosphates.

Other suitable flame retardants for use as the at least one flame retardant include, for example, 1,3, 5-triazine compounds such as melamine, melam, melem, cyanuramide, melamine-2-ureido melamine, acetoguanamine, benzoguanamine, diaminophenyl triazine, melamine salts and adducts, melamine cyanurate, melamine borate, melamine orthophosphate, melamine pyrophosphate, bis-melamine pyrophosphate and melamine polyphosphate, oligomeric and polymeric 1,3, 5-triazine compounds and polyphosphates of 1,3, 5-triazine compounds, guanine, piperazine phosphate, piperazine polyphosphate, ethylenediamine phosphate, pentaerythritol, borophosphate, 1,3, 5-trihydroxyethyl isocyanurate, 1,3, 5-triglycidyl isocyanurate, triallyl isocyanurate and derivatives of the foregoing.

Suitable flame retardants are available, for example, under the trade nameAnd->(all from Albemarle) and under the trade name +.>(from Clariant), a->(from Phos-Check) and FR->Commercially available (from Budensheim).

The film top and back layers may contain additional auxiliary components such as UV and heat stabilizers, antioxidants, dyes, pigments such as titanium dioxide and carbon black, matting agents, antistatic agents, impact modifiers, biocides and processing aids such as lubricants, slip agents, antiblocking agents and anti-blocking (denost) aids. The total amount of these auxiliary components is preferably not more than 45% by weight, more preferably not more than 35% by weight, even more preferably not more than 25% by weight, based on the total weight of the film top layer or backing layer.

According to one or more embodiments, the film has a thickness of 0.5-5.0mm, preferably 0.75-3.5mm, more preferably 0.85-3.0mm, as determined by using the measurement method as defined in the EN 1849-2:2019 standard.

The films of the present invention are typically provided in the form of prefabricated film articles which are delivered to the job site and unwound from rolls to provide sheets having a width of 1-5m and a length of several times the width. However, the films may also be used in the form of strips of width, typically 1-35cm, preferably 5-25cm, for example for sealing joints between two adjacent films. In addition, the membrane may also be provided in the form of a planar body for repairing damaged locations in existing bonded roof systems.

The preferences given above for the film top and back layers, reinforcing scrim, and adhesive coating materials apply equally to all aspects of the present invention, unless otherwise indicated.

Another subject of the invention is a process for producing a film according to the invention, comprising the steps of:

i) Providing a film top layer (2) and a reinforcing scrim (3), the reinforcing scrim (3) having an adhesive coating material (5) covering at least a portion of the first major surface of the reinforcing scrim (3), and

II) laminating the reinforcing scrim (3) to the second main surface of the film top layer (2).

According to one or more embodiments, the method further comprises the steps of:

III) providing a film backing layer (4)

IV) laminating the film backing layer (4) to the film top layer (2) such that the reinforcing scrim (3) is sandwiched between the film top layer and the film backing layer (2, 4).

Lamination of the layers to each other may be performed using any conventional technique known to those skilled in the art, such as thermal (caloric) lamination, thermal lamination, and adhesive lamination. The choice of suitable lamination technique depends on the film embodiment.

According to one or more embodiments, the reinforcing layer has been thermally laminated to at least a portion of the second major surface of the film top layer in a manner that provides a direct connection between the adhesive coating material and the film top layer, and/or the film backing layer has been thermally laminated to at least a portion of the second major surface of the reinforcing scrim in a manner that provides a direct connection between the film backing layer and the reinforcing scrim.

Another subject of the invention is a roofing system comprising a roofing underlayment (6) and a membrane (1) according to the invention, said membrane being attached to the surface of the roofing underlayment (6) by using mechanical fastening or adhesive connection means, preferably by using mechanical fastening means.

According to one or more embodiments, the roof lining comprises a cover sheet and/or a heat shield.

Preferably, the insulating panel comprises at least one foam panel having a closed cell structure. Suitable foam boards having a closed cell structure include molded Expanded Polystyrene (EPS) foam boards, extruded expanded polystyrene (XPS) foam boards, polyurethane foam boards (PUR) and Polyisocyanurate (PIR) foam boards.

The thickness of the heat insulating plate is not particularly limited. It may be preferred that the insulation panel has a thickness of 5-500mm, preferably 10-350mm, even more preferably 25-150mm, as determined by using the measurement method defined in DIN EN 1849-2 standard.

According to one or more embodiments, the heat shield comprises at least one foam panel having a closed cell structure, said foam panel being selected from the group consisting of molded Expanded Polystyrene (EPS) foam panels, extruded expanded polystyrene (XPS) foam panels, polyurethane foam Panels (PUR) and Polyisocyanurate (PIR) foam panels, preferably having a density in the range of 10-150g/l, more preferably 15-100g/l, even more preferably 25-75 g/l.

The heat shield may be secured to the roof substrate, e.g. roof deck, by using any suitable fastening means, e.g. by using an adhesive connection or mechanical fastening means, preferably by mechanical fastening means.

According to one or more embodiments, the roof lining comprises a cover sheet.

Suitable cover sheets include, for example, gypsum board, fiber reinforced gypsum board, wood fiber board, cement board, high density (compressed) polyisocyanurate board, perlite board, asphalt board, mineral fiber board, and plywood or oriented strand board. A cover plate may be used instead of or in addition to the heat shield.

According to one or more embodiments, the roof underlayment comprises a heat shield and a cover sheet, wherein the cover sheet is preferably located between the membrane and the heat shield. The cover plate may be secured to the heat shield by using any suitable fastening means, such as by using an adhesive connection or mechanical fastening means.

According to one or more embodiments, the roofing system further comprises a vapor control layer disposed on a bottom side of the roofing underlayment opposite the membrane side.

The vapor control layer is liquid impermeable but at least partially permeable to water vapor. According to one or more embodiments, the vapor control layer has a water vapor diffusion equivalent air layer thickness value (Sd value) of not more than 100m, preferably not more than 50m, measured according to the method defined in the ISO 1931 standard.

According to one or more further embodiments, the vapor control layer has a moisture variable diffusion resistance. In these embodiments, the vapor control layer has a lower resistance to water vapor diffusion at a higher ambient relative humidity and a higher resistance to water vapor diffusion at a lower ambient relative humidity. For example, the Sd value of the vapor control layer may be in the range of 0.5-20m, preferably 1-10m, at 80% relative humidity, and may be in the range of 25-100m, preferably 35-65m, at 20% relative humidity.

The composition of the vapor control layer is not particularly limited. Preferably, the vapor control layer comprises at least a polymer selected from the group consisting of Polyethylene (PE), polypropylene (PP), ethylene-vinyl acetate copolymer (EVA), ethylene-alpha-olefin copolymer, ethylene-propylene copolymer, polyvinyl chloride (PVC), ethylene acrylic copolymer, polyurethane, polyester, copolyester, polyetherester, polystyrene (PS), polyethylene terephthalate (PET), polyamide (PA), copolyamide, and ionomer. The term "ionomer" refers to a polymer comprising ionic groups that is a carboxylate salt, such as an ammonium carboxylate, an alkali metal carboxylate, an alkaline earth metal carboxylate, a transition metal carboxylate, and/or a combination of these carboxylate salts. These polymers are typically prepared by partially or fully neutralizing carboxylic acid groups of a precursor or parent polymer that is an acid copolymer, for example by reaction with a base.

Preferably, the vapor control layer has a thickness of 5-500 μm, more preferably 25-350 μm, even more preferably 50-250 μm and/or 25-500g/m ² More preferably 50-350g/m ² Even more preferably 75-250g/m ² Is a mass per unit area.

Examples

Preparation of the film

An exemplary film consists of a PVC-based film top layer and a backing layer, and a polyester-based reinforcing scrim of the present invention having an adhesive coating material sandwiched between the film top layer and the backing layer covering the top surface of the scrim. The film was prepared by coextruding the film top layer and backing layer on opposite surfaces of the reinforcing scrim using a laboratory-sized coextrusion apparatus. The polyester-based reinforcing scrim of the present invention had 7.2 warp yarns per cm of scrim (warp density) and 7.2 weft yarns per cm of scrim (weft density). The linear density of the warp and weft yarns was 840 denier.

The film top layer and backing layer had a thickness of 1.7mm, the reinforcing scrim had a thickness of 0.3mm, and the adhesive coating material covering the top surface of the reinforcing scrim had a thickness of 0.1 mm.

The reference film consisted of the film backing and top layers of the exemplary film, with a common polyester reinforcing scrim of 0.25mm thickness sandwiched between the film backing and top layers.

The films were then tested for tensile strength, elongation at break, lamination force, tear resistance, static puncture resistance, and flexibility at low temperatures. The results of these measurements are listed in table 1.

Tensile Strength and elongation at break

The tensile strength and elongation at break of the samples cut from the test films were measured in the Machine Direction (MD) and the cross direction (CMD). The measurements were carried out at a temperature of 23℃according to the GB 12952-2011 standard.

Lamination force

The lamination force of a sample of 50X 200mm in size cut from the test film in the machine direction was measured. The measurement was performed by peeling the top layer of film from the reinforcing scrim at a constant speed of 100mm/min using a tensile tester.

Tear resistance

The tear resistance of samples cut from the test films in the machine and transverse directions was measured. Measurements were performed at a temperature of 23℃according to EN 12310-2 standard.

Static puncture resistance

The static puncture resistance of the samples cut from the test film in the machine direction was measured. The measurements were carried out at a temperature of 23℃according to EN ISO 12236 standard.

Low temperature flexibility

The low temperature flexibility was measured according to the GB 12952-2011 standard. Sample strips of dimensions 100X 25mm were first cut from the test film in the machine direction.

The strips were then stored at the measured temperature for 1 hour, then bent and visually analyzed for the presence of cracks in the polymer layer. In the absence of signs of cracking, the measurement is repeated at a lower temperature until the first crack can be detected.

Hail impact resistance

Hail impact resistance was tested according to the following procedure.

Round ice balls having different diameters, velocities and impact energies were directed to the sides of test sample films consisting of test films adhered to a separator. The isolation board is polyisocyanurate isolation board with the thickness of 38mmAvailable from Hunter Panels). The membrane is mechanically adhered to the separator plate by the outer surface of the membrane backing layer using an aluminum bar frame.

The test sample is placed in a climatic chamber (refrigerator) to simulate conditions during hail. The temperature of the climatic chamber is reduced until the surface of the film reaches a value of 4.4 ℃ or less. The puck is then impacted against the outer surface of the roofing membrane.

If the film survived the impact of the puck without showing any loss of material integrity, the "damage to the film" was evaluated as "pass". Tables 2 and 3 show the results obtained with the films of the invention (Ex-1, ex-2) and with the reference films (Ref-1, ref-2).

TABLE 1

^a The top layer of the film, ^b film backing layer

TABLE 2

TABLE 3 Table 3

Ref-1	Ice hockey diameter [ mm ]]	Impact energy [ J]	Results
				Ref-1.1	50.8	41.6	By passing through
Ref-1.2	50.8	57.9	By passing through
				Ref-1.3	50.8	64	By passing through
Ref-1.4	50.8	64.1	Failed to pass
				Ref-1.5	50.8	66.6	Failed to pass
Ref-1.6	50.8	100.9	Failed to pass
				Ref-1.7	50.8	102.6	Failed to pass
Ref-1.8	50.8	132.2	Failed to pass
				Ref-2
Ref-2.1	60.5	130.2	By passing through
				Ref-2.2	60.5	141	Failed to pass
Ref-2.4	60.5	145.1	Failed to pass
				Ref-2.6	60.5	199.3	Failed to pass

Claims

1. A membrane (1) comprising:

i. a top film layer (2),

a reinforcing scrim (3) having a first major surface and a second major surface, and

optionally a mulching film backing layer (4),

a) A polyvinyl chloride resin,

b) At least one cross-linking agent for polyvinyl chloride resin,

c) Optionally at least one plasticizer, and

d) Optionally at least one inorganic filler.

2. The film of claim 1, wherein the film is a roofing film.

3. The film according to claim 1 or 2, characterized in that the density of warp and/or weft yarns of the reinforcing scrim (3) is at least 4 yarns/cm, preferably at least 5 yarns/cm, more preferably at least 6 yarns/cm, even more preferably at least 7 yarns/cm.

4. The film according to any of the preceding claims, characterized in that the thickness of the yarns of the reinforcing scrim (3) is 100-750 μm, preferably 150-500 μm, more preferably 250-450 μm.

5. The film according to any of the preceding claims, characterized in that the yarns of the reinforcing scrim (3) comprise or consist of synthetic organic polymers, preferably selected from the group consisting of polyesters, polypropylene, polyethylene, polyamides and polyethylene terephthalates.

6. The film according to any of the preceding claims, characterized in that the film comprises a film backing layer (4) and the reinforcing scrim (3) is arranged between the film top layer and film backing layer (2, 4).

7. The film according to any of the preceding claims, characterized in that the second main surface of the reinforcing scrim (3) is directly connected to the film backing layer (4).

8. The film according to any of the preceding claims, characterized in that the reinforcing scrim (3) is at least partially impregnated with the adhesive coating material (5).

9. The film according to any one of the preceding claims, characterized in that the adhesive coating material (5) comprises:

a) 25 to 75% by weight, preferably 35 to 65% by weight of said polyvinyl chloride resin,

b) 0.1 to 15 wt%, preferably 1 to 10 wt%, of said at least one polyvinyl chloride resin cross-linking agent,

c) 0 to 55 wt%, preferably 5 to 50 wt% of the at least one plasticizer, and

d) 0-35 wt%, preferably 2.5-30 wt% of said at least one inorganic filler.

10. The film according to any of the preceding claims, wherein the at least one polyvinyl chloride cross-linking agent is a polyisocyanate.

11. The film according to any of the preceding claims, characterized in that the thickness of the adhesive coating material (5) is 50-300 μm, preferably 75-200 μm.

12. The film according to any of the preceding claims, characterized in that the film top layer (2) and/or backing layer (4) comprises:

a) 25 to 65% by weight of a polyvinyl chloride resin,

b) 10-50% by weight of at least one plasticizer, and

c) 0-30% by weight of at least one inert mineral filler, all proportions being based on the total weight of the film top layer (2) or back layer (4).

13. A film according to any of the preceding claims, characterized in that the film has a thickness of 0.5-5.0mm, preferably 0.75-3.5mm, determined by using a measurement method as defined in the EN 1849-2:2019 standard.

14. A process for producing a film according to any one of the preceding claims, the process comprising the steps of:

15. Roof system comprising a roof mat (6) and a membrane (1) according to any one of claims 1-13, which membrane is attached to the surface of the roof mat (6) by means of a mechanical fastening or an adhesive connection, preferably by means of a mechanical fastening.

16. Roof system according to claim 15, wherein the roof underlayment (6) comprises a cover sheet and/or a heat insulation sheet.