EP1243716A1 - Membran, insbesondere wasserdichte Membran und Verfahren zu ihrer Herstellung - Google Patents

Membran, insbesondere wasserdichte Membran und Verfahren zu ihrer Herstellung Download PDF

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Publication number
EP1243716A1
EP1243716A1 EP01610029A EP01610029A EP1243716A1 EP 1243716 A1 EP1243716 A1 EP 1243716A1 EP 01610029 A EP01610029 A EP 01610029A EP 01610029 A EP01610029 A EP 01610029A EP 1243716 A1 EP1243716 A1 EP 1243716A1
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EP
European Patent Office
Prior art keywords
foils
foil
membrane
mesh
woven
Prior art date
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Granted
Application number
EP01610029A
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English (en)
French (fr)
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EP1243716B1 (de
Inventor
Jan Johan Kühl
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Icopal Plastic Membranes AS
Original Assignee
Monarflex AS
Icopal Plastic Membranes AS
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Filing date
Publication date
Application filed by Monarflex AS, Icopal Plastic Membranes AS filed Critical Monarflex AS
Priority to DK01610029T priority Critical patent/DK1243716T3/da
Priority to AT01610029T priority patent/ATE408737T1/de
Priority to EP01610029A priority patent/EP1243716B1/de
Priority to DE60135824T priority patent/DE60135824D1/de
Priority to PCT/DK2002/000187 priority patent/WO2002075071A1/en
Publication of EP1243716A1 publication Critical patent/EP1243716A1/de
Application granted granted Critical
Publication of EP1243716B1 publication Critical patent/EP1243716B1/de
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    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D5/00—Roof covering by making use of flexible material, e.g. supplied in roll form
    • E04D5/10—Roof covering by making use of flexible material, e.g. supplied in roll form by making use of compounded or laminated materials, e.g. metal foils or plastic films coated with bitumen
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D5/00—Roof covering by making use of flexible material, e.g. supplied in roll form
    • E04D5/02—Roof covering by making use of flexible material, e.g. supplied in roll form of materials impregnated with sealing substances, e.g. roofing felt

Definitions

  • the present invention relates generally to the technical field of membranes, in particular water proofing membranes and further to composite grid or mesh reinforced composite membranes.
  • the present invention relates in particular to membranes for use in the field of house building or construction, such as membranes for use as an underroof membrane, scaffold sheeting, tarpaulins, geo membranes, vapour barriers, wind barriers, damp proof membranes, world aid shelters, military shelters etc.
  • the present invention also relates to a method of producing a membrane, in particular a waterproofing membrane.
  • membranes for use in house building or construction
  • a number of membrane structures are known and described in the litterature, such as in US5229197, EP0491454, DE29805622, EP0177364, US5422179, US5860225, EP0855479, JP2162037, EP0708212, WO97/00362.
  • certain techniques include methods of producing and machines for the production of membranes are known, e.g. from DK 105423, DK 136082, DE OS 1635579 and DE OS 2030203. Reference is made to the above patent applications and patents and the above US patents are further hereby incorporated in the present specification by reference.
  • mesh or grid reinforced membranes allows for the utilisation of fairly thin foils constituting part of the grid or mesh reinforced composite membrane, still providing membranes exhibiting excellent properties as to mechanical strength, in particular tensile strength. It has commonly been known that in the composite membrane structures, in which two foil layers sandwich a reinforcing mesh or grid, the mechanical strength as expressed in tensile strength is predominantly determined by the strength of the reinforcing mesh or grid.
  • the composite membrane has, for most applications, been made from individual foil layers together providing a composite membrane structure of a foil layer thickness of 250 ⁇ m or even more.
  • LDPE low density polyethylene
  • PP polypropylene
  • the prior art LDPE based composite mesh or grid reinforced membranes have proven to be acceptable and proven to provide long term stable weather resistant and UV resistant membrane structures, provided the foil materials used for the composite material have been of a fairly large thickness for providing the properties required, such as the required surface properties and also providing a fairly stable and tough foil structure.
  • the membranes In the use of membranes, such as waterproofing membranes for house buildings, the membranes have to fulfil further requirements in relation to the intentional use of the membranes and also the application of the membranes at the building sites such as requirements in relation to puncture proof resistance of the membrane structure which characteristic may be measured according to specific requirements or standards.
  • the membranes have to comply with certain requirements as to tear strength, as defined in relevant ISO, BS, EN or DIN standards and have additionally to fulfil certain additional characteristics, which are often difficult to measure or specifically determine, which characteristics are, however, within the industry, often referred to as toughness, crack resistance, abrasive resistance, draping and noise characteristics.
  • the membranes to be used in the house construction industry have, apart from the above properties, also to be easily folded and comply with certain physical configurations and therefore, the membranes have to fulfil certain standards, as to draping, known from the clothing industry as a term, and further, the membranes to be used in housings, need to be extremely flexible and lightweight for allowing the workers to handle the membranes at the building site without damaging by puncturing, distorting, ripping the membranes and still further, should be of a type preventing the membranes from generating noise provided the membranes be exposed to wind pressure, fluctuation from ventilation air, impact or other mechanical influence, even below roofing materials such as tiles. Further, the membranes should, for obvious reasons, exhibit characteristics preventing the membranes from cracking or being torn apart through abrasive impact and still further should be resistant to delamination. In most applications, the relevant building membranes are further to constitute waterproof structures.
  • the presence of the reinforcing grid within a membrane structure reinforced by means of the mesh or grid may, under certain circumstances concentrate a force impact to specific minor areas of the foil materials and in doing so, provided the foil materials are extremely thin, even tear apart the foil materials, as the foil materials, due to their extreme small thickness exhibit a high degree of flexibility and bendability allowing the foil materials themselves to substantially accommodate any specific geometric configuration.
  • the present invention allows for the provision of composite membranes, i.e. membranes including two foil layers sandwiching a reinforcing mesh or grid structure which composite membranes provide the same properties and characteristics or even improved properties or characteristics as compared to the prior art composite membranes, still providing a lower weight and also improved properties as expressed in better draping, higher toughness and reduced noise.
  • the invention makes it possible to provide high strength, highly bendable and low noise composite membranes, including a reinforcing mesh or grid, which mesh or grid, as is well-known in the art, provides the overall tensile strength of the composite membrane and includes foils constituting a reduced percentage of the overall weight of the composite membrane as compared to the percentage by weight of foil materials of comparable prior art membranes, i.e. membranes exhibiting properties as to mechanical strength etc. comparable to the properties of the novel membranes according to the present invention.
  • a membrane for use in the field of house building or construction, in particular for use as an underroof membrane, scaffold sheeting, tarpaulins, geo textiles, vapour barriers, wind barriers, damp proof membranes, world aid shelters, military shelters etc. comprising:
  • the reinforcing mesh is, as distinct from the prior art reinforced membranes, allowed to be moved within the composite structure relative to the sandwiching foils through the provision of the lubricating material, and in doing so, allows the overall composite membrane to accommodate to a higher degree to the mechanical influences, for preventing the reinforcing mesh from exposing minor areas or points of the sandwiching foils to excessive forces which might else tear apart the foils in localised places.
  • the moveability of the polymer fiber, filament or wire material of the reinforcing mesh is established as the individual fibers, filaments etc. of the reinforcing mesh be allowed to move in the longitudinal direction of the fibers, filaments etc. in relation to the sandwiching foils of the composite membrane structure.
  • the membranes are typically of a large size or a large overall transversal dimension necessitating or allowing that the membranes be rolled or folded together for allowing the membranes to be shipped or transported.
  • the transportation of the membranes include transportation from the factory to the construction site and further moving or shifting the membranes around on the construction site, e.g. from a position on ground to a position on a roof structure.
  • the membranes need to be mechanically tough and flexible for allowing handling or transportation under these circumstances.
  • grid or mesh foil and membrane
  • grid or mesh is to be construed comprising any fiber, filament or wire structure of plastics material or any other relevant material, such as e.g. carbon reinforced plastic material etc. which exhibits an overall geometrical configuration resembling a mesh or any other structure differing from a conventional grid or mesh, still fulfilling the same purpose as a reinforcing grid or mesh.
  • the grid or mesh may have any appropriate configuration and also have varying dimensions and all embodiments complying with the above definition are consequently to be considered covered by the term grid or mesh.
  • a relevant lifetime for membranes to be used in the construction industry in general is often of the order of a few months to several years for the intentional application, being a temporary application and a so called permanent application, respectively, e.g. including 10 - 30 years, 30 - 50 years or even 50 - 100 years.
  • the term weather resistance is, in accordance with the above statements, to be considered in the context of the intentional use of the membrane or the membranes in question.
  • the weather resistance is to be considered in conjunction with the relevant lifetime of the membrane or the membranes in question, which lifetime is typically of the order of a maximum of 1-2 years.
  • the expression weather resistance means that within the relevant lifetime, the membrane is resistant to the weather conditions including the wind, any rain or snow and also the exposure to the sun as the UV radiation from the sun deteriorates the membrane materials.
  • an underroof membrane which is not exposed to the sunlight may, for the relevant lifetime of the order of 30-50 years or even more, be resistant to the exposure of wind and also water due to rain and snow and even the temperature variation from e.g. - 40°C to + 40°C or even larger temperature variations.
  • foil and membrane which in some aspects may be considered synonymous, are distinctly used for separate intentional purposes.
  • the term foil is used as the term defining an element or rather two elements of an overall foil or sheet configuration, which elements are together with the grid or mesh, composed into a composite structure constituting the membrane. It is to be understood that the foils which are combined with the reinforcing mesh or grid for establishing the membrane may themselves constitute membranes and be composed of individual foils, sheets, reinforcing fibers or mesh or grids without deviating from the meaning of the term foil as used in the present context.
  • the membrane according to the present invention may for other applications be considered constituting a foil or alternatively a sheet and the interpretation of the membrane as a foil or a sheet is not to be construed limiting in the present context.
  • lubricating materials such as lubricating oils have been well-known for decades.
  • the lubricating oils have been used for specific properties, in particular for providing improved water repellent characteristics of the plastic membranes and also for reducing the surface adhesive contact and the surface frictional characteristics of the plastic membranes.
  • lubricating oils are normally avoided in the foils for laminated membranes, since they often reduce lamination strength between the individual layers of foils.
  • plastic membranes, or alternatively plastic fibers or filaments which may also be provided with a lubricating surface coating for improving the ability of handling of the fibers or filaments be used in a lamination process in which one or more foils and/or plastic filaments or fibers or alternatively multilayer membranes or reinforced membranes be laminated to another plastics materials, precautions have been made for rinsing off any residual lubricating material or materials or precautions have been taken for eliminating any inadvertent degrading influence or impact from the residual lubricating materials in the final laminated product.
  • the content of the foil materials within the membrane structure may be reduced for reducing the overall weight of the membrane structure. Consequently, according to the teachings of the present invention, the first and second polymer materials may together constitute less than 90%, such as 80% or 50 - 80%, e.g. 60 - 80% or 70 - 80%, or alternatively 50 - 60%, 60 - 70%, 70 - 80% or 80 - 90% of the total weight of said membrane.
  • the provision of the lubricating material characteristic of the present invention allows, through the possible reduction of the overall weight of the membrane as compared to the prior art reinforced membranes through the reduction of the weight of the polymer material foils that the ratios as expressed in terms of mechanical strength in relation to the thickness or alternatively the weight per unit area of the membrane be increased as compared to the prior art membranes.
  • the membrane preferably exhibits a tear strength of the order of more than 800 N/mm thickness, preferably more than 1000 N/mm thickness, such as more than 1200 N/mm or even more than 1500 N/mm (measured according to ASTM D 1117-80 at a speed of 100mm/min., or ISO 6381/1 or prEN 12112-2:1995) also preferably exhibits a puncture resistance pr.
  • the membrane according to the present invention preferably exhibits a ratio as expected in tear strength to weight of higher than 1,0 N/(g/m 2 ), preferably higher than 1,4 N/(g/m 2 ).
  • the ratios expressing dependency of thickness or thicknesses are to be construed in terms of the foil or foils rather than the composite membrane or membranes.
  • the mesh or grid of the composite membrane according to the present invention may be made from any appropriate polymer fiber, filament or wire material, e.g. the materials polypropylene, preferably isotactic polypropylene, polyethylene, preferably high density polyethylene, polyester or polyesters, preferably polyethylene terephtalene (PET), polyamide or polyamides, polyacrylonitrile or polyurethane or polyurethanes or a combination of the above materials. Additionally, fibers of carbon fiber, aramide fibers (Kevlar ®), glass fibers etc. commonly used for reinforcing purposes within the plastics industry may be alternatively be used for the mesh or grid of the composite membrane according to the present invention.
  • polypropylene preferably isotactic polypropylene
  • polyethylene preferably high density polyethylene
  • polyester or polyesters preferably polyethylene terephtalene (PET)
  • PET polyethylene terephtalene
  • polyamide or polyamides polyacrylonitrile or polyurethan
  • the reinforcing mesh has to exhibit specific properties as to strength, which properties are predominantly determined by the material of the reinforcing mesh in question and the dimensions and size of the mesh material.
  • the reinforcing mesh may be made from a polymer fiber, filament or wire material of a thickness of 0.1 - 1 mm, preferably 0.1 - 0.4 mm or of a thickness of 0.1 - 0.15 mm, 0.15 - 0.2 mm, 0.2 - 0.25 mm, 0.25 - 0.3 mm, 0.3 - 0.35 mm, 0.35 - 0.4 mm, 0.4 - 0.45 mm, 0.45 - 0.5 mm, 0.5 - 0.55 mm, 0.55 - 0.6 mm, 0.6 - 0.65 mm, 0.65 - 0.7 mm (if circular), and/or said reinforcing mesh being made of polymer fiber, filament or wire material of a thickness of 300 - 4000 dtex
  • 1000 - 2000 dtex preferably 1000 - 1500 dtex, or of a thickness of 300 - 400 dtex, 400 - 500 dtex, 500 - 600 dtex, 600 - 700 dtex, 700 - 800 dtex, 800 - 900 dtex, 900 - 1000 dtex, 1000 - 1250 dtex, 1250 - 1500 dtex, 1500- 1750 dtex, 1750 - 2000 dtex, 2000 - 2500 dtex, 2500 - 3000 dtex, 3000 -3500 dtex or 3500 - 4000 dtex.
  • the mesh itself has to define a mesh structure of an appropriate configuration and size and according to presently preferred and advantageous embodiments of the membrane according to the present invention
  • the mesh preferably and advantageously defines a mesh size of the order of 5 - 40 mm, such as 5 - 20 mm, preferably 5 - 15 mm, such as approximately 10 mm, or a mesh size of the order of 5 - 7 mm, 7 - 9 mm, 9 - 11 mm, 11 - 13 mm, 13 - 15 mm, 15 - 20 mm, 20 - 25 mm, 25 -30 mm, 30 - 35 mm or 35 - 40 mm.
  • the foils constituting the sandwiching structure in which the reinforcing mesh is interlayered have to establish a fairly large area of contact, as compared to the overall surface area of the membrane. Provided the area of contact between the two foils is extremely low, the foils will themselves be exposed to forces attempting to tear apart the two foils from one another causing a delamination of the membrane structure or alternatively the integrity and stability of the membrane structure is reduced or deteriorated.
  • the first and second foils in the sandwich structure should preferably provide an area of contact therebetween constituting more than 50%, such as 50 - 60%, preferably 60 - 70% or 70 - 80% or even more, preferably 80 - 90% of the overall surface area of said membrane.
  • the reinforcing mesh interlayered between the two foils of the membrane structure may define any appropriate mesh or grid configuration or grid structure, preferably a square or rectangular configuration or any other polygonal or similar configuration.
  • the reinforcing mesh may alternatively define a rhombing configuration or a grid of any other geometrical configuration including triangular, elliptical, circular or any other geometrical configuration including linear or curved boundary lines including convex or concave configurations or any combination of the above geometrical configurations.
  • the mesh itself may be woven or simply composed of laid strands of polymer fiber, filament or wire material.
  • the lubricant material providing the feature characteristic of the present invention of allowing the reinforcing mesh to be moveable relative to the first and second sandwiching foils may be a lubricant oil or wax, a mineral lubricant oil or wax or a synthetic lubricant oil or wax, such as an oil or wax having a melting point above approximately 30° - 50°C, or an oil or wax originally dispersed in water or another solvent which is evaporated in the process of producing the membrane.
  • the lubricant material may be present in the integral sandwich structure as the surface coating of the fiber or wire material of the reinforcing mesh.
  • the lubricant material being a wax or oil material, e.g. as described above, is present in the integral structure, the lubricant material may only be defined in terms of the amount present within the integral structure rather than as a dimensional surface coating thicknesses.
  • the lubricant material is present in amount of 10-40% by weight of the weight of the reinforcing mesh, such as 15-30% by weight, preferably 20-25% by weight, or alternatively 10-20%, 20-30% or 30-40% by weight.
  • the reinforcing mesh is made from e.g. multifilament fibers
  • the amount of lubricant material present within the integral membrane structure is somewhat higher than the amount present within a comparable membrane structure in which solid monofilament fibers be used for the reinforcing mesh, as the multifilament structure exhibits an increased total surface area as compared to the surface area of the monofilament structure.
  • the mesh be made from woven or non-woven laid materials, the amount of lubricant material is of course higher than the amount of lubricant used for a monofilament fiber mesh structure.
  • the foil materials of the two foils of the membrane according to the present invention may be selected from any appropriate polymer or other relevant foil material being a compound material normally and preferably including specific additions for the provision of specific properties, such as UV stabilisers, antioxidants, anti ozonants, light stabilisers, pigments, nucleants, impact modifiers, plastizicers, heat stabilisers providing the relevant and adequate characteristics and features complying with the characteristics and features in questions.
  • the membrane is a water and gas impermeable membrane, the materials chosen for the two foil materials of course have to comply with this requirement.
  • the membrane has e.g. to provide gas permeability and water impermeability, the materials selected for the two foils have correspondingly to comply with these requirements.
  • polymer materials such as flexible thermoplastics, i.e. polymers with low or medium crystallinity, and glass transition temperature below the lowest relevant application temperature are relevant.
  • copolymers both random polymers and block copolymers, and blends of polymers can be applied.
  • Crosslinkable polymers which are crosslinked after manufacturing of the foils, can also be used. Generally, polyolefins are preferred.
  • Particularly preferred materials include, polyethylene (PE), especially low-density polyethylene (LDPE), medium density polyethylene (MDPE, up to about 0,945 g/cm3 density); random copolymers of ethylene and an alpha-olefine (known as linear low density polyethylenes, LLDPE; or very low density polyethylenes, VLDPE's, alternatively termed plastomers; ethylene and vinylacetate (EVA); ethylene and butylacrylate (EBA); ethylene and methylacrylate (EMA); ethylene and acrylic acid (EAA); polypropylene (PP) material, especially isotactic polypropylene homopolymer, random copolymers of propylene and ethylene (alternatively termed raco-PP); copolymers of propylene, ethylene and optionally higher alpha-olefins such as heterophasic block polymers, thermoplastic polyolefins (TPO's) and polyolefine plastomers (POP's); Polybutylene
  • the polymers applicable for use in the foil material within the scope of the present invention may in general be subdivided into 2 types: A) flexible thermoplastics, capable of large plastic deformations, such as PE, and B) elastomers or rubbers.
  • Flexible plastics made up of polymers like polyethylene and polypropylene are different from rigid plastics in that they don't resist deformation as well, but they tend not to break when deformed. Instead they make plastic deformation, making yielding. This deformation can be of several hundred percent, the major part being irreversible. Accordingly, flexible plastics are not as strong as rigid ones, but they have a higher toughness.
  • Elastomers like polyisoprene, polybutadiene, polyisobutylene and thermoplastic polyurethanes have completely different mechanical behaviour from the other types of polymer-based materials mentioned above, since they are not just highly stretchable, but highly reversibly stretchable.
  • PVC poly(vinyl chloride)
  • PVC poly(vinyl chloride)
  • Foil materials may include flexible thermoplastics, i.e. polymers with low or medium crystallinity, and glass transition temperature below the relevant application temperature. Also, copolymers, both random polymers and block copolymers, and blends of polymers can be applied. Crosslinked polymers can also be used. Generally, polyolefins are preferred.
  • foil materials examples include:
  • the polymers can be prepared by various well-known catalyst technologies like Ziegler-Natta catalysts, metallocene based or single-site catalysts.
  • the polymerisation conditions may also favourably be set as to provide for bimodal molecular weight distribution, block copolymers or combinations of block and copolymers. All of these techniques and possibility of combinations are well-known to persons skilled in the art.
  • foil-polymers can optionally be cross-linked following the extrusion process, e.g. cross-linking of LDPE to form XLPE using gamma radiation or crosslinking of vinyl silane containing ethylene copolymers using water.
  • the materials for use in the foils of the membrane according to the present invention may be selected from any of the polymers, copolymers, elastomers, immiscible blends, composite materials or combinations thereof mentioned above.
  • the polymer material of the first foil may be identical to the polymer material of the second foil, however, according to an alternative embodiment, the polymer materials of the first and the second foils are different from one another.
  • the process of contacting and laminating the two foils together is of course easily established, due to the compatibility of the two foils being of the same material, whereas provided different materials be chosen for the two foils, certain precautions may necessitate that one or both foils be primed or otherwise treated for allowing the two foils to be contacted and sealed together.
  • the sealing or lamination should be effective, to form a durable or long term stable structure, not only under static conditions; but also dynamic conditions, such as conditions prevailing in a roof structure under various wind loading.
  • multilayer foil materials may be used for one or both foils of the membrane according to the present invention, or alternatively, for making a special surface layer, such as highly UV-stabilised or flame retardant layer, which may be utilised in connection with the membrane according to the present invention.
  • one or both foils of the reinforced membrane according to the present invention may be provided with a coating of a metallic or alternatively a non-metallic compound providing a specific radiation opaqueness or radio transmission characteristic, such as a specific IR transmission/reflection spectrum, e.g. an IR reflection spectrum corresponding to the IR reflection spectrum of soil.
  • first and/or second foils may be light reflecting or alternatively light transmitting or at least partly translucent or alternatively pigmented for providing a specific light transmission colouring or transparency.
  • the polymer material of the first foil and or the second foil may advantageously be provided through extrusion of the polymer material in question at a specific extrusion temperature, such as an extrusion temperature within the range 150°C -270°C, such as 220°C - 230°C, and be applied in the lamination process to the other foil for providing the sandwich structure in which the reinforcing mesh or grid is embedded in accordance with the teachings of the present invention.
  • a specific extrusion temperature such as an extrusion temperature within the range 150°C -270°C, such as 220°C - 230°C
  • the polymer material of the first and/or the second foil may be made through curing the polymer material or materials in question, as the curing may be carried out at a curing temperature providing a softening point above 100°C and preferably a melting point above 100°C.
  • the two foils of the composite membrane according to the present invention may be produced through any appropriate per se well-known techniques, such as extrusion coating, hot melt application, hot melt powder application etc.
  • the membrane has to fulfil certain requirements as discussed above as to tensile strength and the membrane preferably provides a tensile strength of the order of no less than 6 kN/m width or equivalently 300N/5 cm width, such as 6 - 20 kN/m width.
  • the membrane including the features characteristic of the membrane according to the present invention may constitute a microporous or microperforated foil as the first and second foils may be laminated together and may constitute a microporous film produced from the laminated original first and second foils which are exposed after lamination to a uni- or bi-directional stretching process for causing microparticulate generators included in the original foil materials to create micropores of the laminated and unidirectional or bidirectional stretched laminated foils, and the polymer fiber or monofilament material of the reinforcing mesh further being constituted by fiber or monofilament material converted from unstretched fiber or monofilament material into stretched fiber or monofilament material in a stretching process carried out in conjunction with the unidirectional or bidirectional stretching of the laminated original first and second foils.
  • the unidirectional or bidirectional elongation of the original first and second foils being an elongation of the order of 10 - 1000%, such as 50 - 500%, e.g. 100- 400%, and the stretching of the fiber or wire material of the mesh structure being of the same order as the uni- or bidirectional elongation of the original first and second foil materials.
  • a membrane in particular a waterproofing membrane for use in the field of house building or construction, in particular for use as an underroof membrane, scaffold sheeting, tarpaulins, geo membranes, vapour barriers, wind barriers, damp proof membranes, world aid shelters, military shelters etc., comprising:
  • the membrane according to the second aspect of the present invention may, according to the teachings of the present invention, be implemented in accordance with the above-described preferred and advantageous embodiments of the membrane according to the first aspect of the present invention.
  • a membrane in particular a waterproofing membrane for use in the field of house building or construction, in particular for use as an underroof membrane, scaffold sheeting, tarpaulins, geo membranes, vapour barriers, wind barriers, damp proof membranes, world aid shelters, military shelters etc., the method comprising:
  • the sandwich structure establishing the enclosure for the reinforcing mesh in the membrane according to the present invention may be established in accordance with two alternative techniques, as in the first place, the first and second foils may be produced separately and prefabricated prior to the laminating of the foils together in the sandwich structure or alternatively, the first foil may be extruded prior to, and the second foil in conjunction with the step of laminating the first and the second foil together in the sandwich structure.
  • Fig. 1 is an overall perspective and schematic view illustrating a first embodiment of a method of producing, in accordance with the teachings of the present invention, a membrane including a reinforcing grid or mesh
  • Fig. 2a is similar to Fig. 1 an overall perspective and schematic view illustrating an alternative and presently preferred embodiment of a method according to the present invention of producing a grid or mesh reinforced membrane according to the present invention
  • Fig. 2b is, similar to Figs. 1 and 2a, an overall perspective and schematic view illustrating a further alternative embodiment of the method according to the present invention of producing a grid or mesh reinforced membrane according to the present invention.
  • Fig. 1 is an overall perspective and schematic view illustrating a first embodiment of a method of producing, in accordance with the teachings of the present invention, a membrane including a reinforcing grid or mesh
  • Fig. 2a is similar to Fig. 1 an overall perspective and schematic view illustrating an alternative and presently preferred embodiment of a method according to the present invention of producing a grid or mesh reinforced
  • FIG. 3 is a perspective and schematic view illustrating a further or third embodiment of the method of producing a grid or mesh reinforced membrane according to the present invention
  • Fig. 4 is a perspective, schematic and partly sectional view of a membrane according to the present invention including a reinforcing grid or mesh
  • Figs. 5 and 6 are perspective, schematic and partly sectional views similar to the view of Fig. 4, illustrating a particular aspect of the present invention of producing a unidirectional or alternatively a bidirectional stretched foil for generating a microporous membrane
  • Figs. 7 and 8 are perspective and schematic views illustrating the advantages accomplished through the grid or mesh reinforcing technique characteristic of the present invention as to mechanical tear resistance as compared to a prior art grid or mesh reinforced membrane.
  • a process line is shown designated the reference numeral 10 in its entirety for carrying out a method of producing a composite grid or mesh reinforced membrane composed of two laminated plastic foils between which a reinforcing mesh or grid is interlayered.
  • the reference numerals 12 and 20 designate two plastic foils from which the composite or reinforced membrane is produced.
  • the foils 12 and 20 constitute a bottom and top layer, respectively, of the final membrane and are delivered from two rolls 14 and 22, respectively.
  • the rolls 14 and 22 are journalled on axle 16 and 24, respectively.
  • the two foils 12 and 20 are joint together by means of two pressure rollers 18 and 26 for contacting the two foils 12 and 20 to one another. From a grid or mesh supply or roll 30, a mesh or grid 28 is delivered.
  • the roll 30 is journalled on an axle 32 and is passed round a supporting roller 34 for allowing a lubricating oil or wax to be sprayed on to the fibers of the grid or mesh 28.
  • the lubricating oil or wax is designated the reference numeral 40 and is delivered from dies 38 from a container 36, preferably a heated container, in which the lubricating oil or wax is contained.
  • the foils 12 and 20 may be constituted by any appropriate, preferably weather resistant plastics material, such as a PE, preferably LDPE or MDPE; LLDPE; VLDPE, alternatively termed plastomers; EVA; EBA; EMA; EAA; PP, preferably isotactic polypropylene homopolymer; random copolymers of propylene and ethylene, alternatively termed raco-PP; copolymers of propylene, ethylene and optionally higher alpha-olefins such as heterophasic block polymers, TPO; Polybutylene (Poly(1-butene)); block copolymers; crosslinked polymers such as EPDM, SBR, EPR, PIB, PEX, PIP, polyisobutylene and TPU; Plasticized PVC ; and blends or mixtures of any of the above, preferably having a bimodal molecular weight distribution, being block copolymers or combinations of block and copolymers.
  • a PE preferably
  • the fibers of the mesh or grid 28 may be constituted by any relevant fiber, filament or wire material which is compatible with the foil materials of the foils 12 and 20 and which are further compatible with the lubricating oil or wax 40.
  • relevant materials are polypropylene, preferably isotactic or syndiotactic polypropylene, polyethylene, preferably high density polyethylene polyester or polyesters, polyamide or polyamides, polyacrylonitrile or polyurethane or polyurethanes or a combination of the above materials.
  • the reinforcing grid or mesh may be made from polymer fiber, filament or wire material of a thickness of 0.1 - 1mm, preferably 0.1 - 0.4 mm or of a thickness of 0.1 - 0.15 mm, 0.15 - 0.2 mm, 0.2 - 0.25 mm, 0.25 - 0.3 mm, 0.3 - 0.35 mm, 0.35 - 0.4 mm, 0.4 - 0.45 mm, 0.45 - 0.5 mm, 0.5 - 0.55 mm, 0.55 - 0.6 mm, 0.6 - 0.65 mm, 0.65 - 0.7 mm, 0.7 - 0.75 mm, 0.75 - 0.8 mm, 0.8 - 0.85 mm, 0.85 - 0.9 mm, 0.9 - 0.95 mm, 0.95 - 1 mm, and/or said reinforcing mesh being made of polymer fiber, filament or wire material of a thickness of 300 - 4000 dtex (g/10.000m), e.g.,
  • 1000 - 2000 dtex preferably 1000 - 1500 dtex, or of a thickness of 300 - 600 dtex, 600 - 700 dtex, 700 - 800 dtex, 800 - 900 dtex, 900 - 1000 dtex, 1000 - 1250 dtex, 1250 - 1500 dtex, 1500 - 1750 dtex, 1750- 2000 dtex, 2000 - 2500 dtex, 2500 - 3000 dtex, 3000 -3500 dtex or 3500 - 4000 dtex.
  • the grid or mesh 28 may advantageously define a square or alternatively a rectangular mesh configuration defining a mesh size of the order of 5 - 40mm, such as 5 - 20 mm, preferably 5 - 15 mm, such as approximately 10 mm, or a mesh size of the order of 0 - 7 mm, 7 - 9 mm, 9 - 11 mm, 11 - 13 mm, 13 - 15 mm, 15 - 20 mm, 20 - 25 mm, 25 -30 mm, 30 - 35 mm or 35 - 40 mm.
  • a composite sandwich 42 is produced which is input to a heating oven 44 in which the plastic materials of the foils 12 and 40 are softened for causing the two foils 12 and 20 to adhere to one another.
  • the resulting or final product is output from an output aperture 46 of the oven 44 and is shown in the right hand part of Fig. 1 and is designated the reference numeral 50.
  • FIG. 2a an alternative embodiment of a plant for producing the composite grid or mesh reinforced membrane according to the present invention is shown designated the reference numeral 10' in its entirety.
  • components or elements which have been described previously and are designated in the previous description a specific reference numeral, are in the description designated the same reference numeral as previously used and are only discussed or described in the context necessitated by the description itself.
  • Components or elements differing from components or elements, respectively, described previously, still fulfilling the same purpose as a component or element previously described is designated the same reference integer, however added a marking for identifying the difference to the previously described component or element.
  • the process line outlined in Fig. 2a basically differs from the above-described plant 10 shown in Fig. 1 in that the softening oven 44 is omitted and the prefabricated foil 20 is substituted by a foil 25 which is readily extruded from an extruder 21 prior to the step of contacting the foil with the reinforcing grid or mesh 28 and the bottom foil 12 and may be considered constituting a molden foil.
  • an extruder 21 is shown including an extrusion die 23 from which the extruded foil 25 is delivered.
  • the foil 25 is, along with the reinforcing grid or mesh 28 and the bottom foil 12 input to a small gap between a pressure roller 17 which is pressed in the direction indicated by an arrow 19 into contact with a large diameter cooling roller 27 which is journalled on an axle 29.
  • the grid or mesh 28 is passed round an additional roller 35 prior to introducing the grid or mesh into the gap between the prefabricated bottom foil 12 and the readily extruded foil 25.
  • Fig. 2a the softening oven 44 is omitted and the final product delivered from the large diameter cooling roll 27 is passed round two rollers 31 and 33 before the finalised and cooled off membrane 50 is collected on a roll 52 which is journalled on an axle 54.
  • an additional supply 22' of an additional foil is shown in phantom lines indicating a technique of producing a multilayer membrane by the supply of an additional foil 20' similar to the previously described foil 20 shown in Fig. 1 to the gap between the rollers 17 and 27 as the additional foil 20' is positioned on top of the readily extruded foil 25.
  • a further alternative embodiment of a plant for producing the composite grid or mesh reinforced membrane according to the present invention is shown, designated the reference numeral 10" in its entirety.
  • the process line outlined in Fig. 2b basically differs from the process line or plant 10' shown in Fig. 2a in that the bottom foil 12 is produced online by means of a further extruder 21' including an extrusion die 23' from which the extruded foil 25' is delivered.
  • the extruded and softened foil 25' is passed round a cooling roller 27' which is journalled on an axle 29' from the cooling roller 27', a soft, yet partly solidified foil constituting the bottom foil 12 is delivered to the gap between the pressure roller 17 and the large diameter cooling roller 27, also shown in Fig. 2a.
  • each of the two laminating foils 12 and 14 may be composed of a plurality of individual foils or alternatively constitute co-extruded multilayer foils.
  • FIG. 3 an alternative or third method of producing the grid or mesh reinforced, composite membrane according to the present invention is shown.
  • the membrane is produced by sequentially laying the individual components of the membrane on top of one another. From the right hand side of Fig. 3, the bottom foil 12 is shown, on top of which transversal fibers 28a extend. Further, on top of the transversal fibers 28a, longitudinally extending fibers 28b are positioned extending longitudinally relative to the foil 12 and at the same time, the lubricating oil or wax 40 is discharged and applied to the mesh or grid 28 from the dies 38. Finally, on top of the grid or mesh 28 composed of the individual orthogonal fibers 28a and 28b, the top foil 20 is applied.
  • Fig. 4 a particular feature characteristic of the present invention is illustrated.
  • the fibers 28a and 28b of the grid or mesh 28 are provided with or coated with a lubricating wax or oil.
  • the reference numeral 40a designate microglobules or microdroplets of the lubricating wax or oil allowing the fibers 28a and 28b to move and shift relative to the sandwiching foils 12 and 20 and in doing so allowing the composite membrane structure to accommodate force impacts which might else cause the composite membrane structure to be torn apart, as is illustrated in Figs. 7 and 8.
  • the wax or oil is applied in and present as a thin surface coating rather than present in individual microglobules or microdroplets.
  • Figs. 5 and 6 a further feature of the present invention is illustrated.
  • microgenerators for the generation of microperforations of the sandwiching foils 12 and 40 are shown, which generators are designated the reference numeral 52.
  • the foils 12 and 20 are in the embodiment shown in Fig. 5 constituted by unidirectionally stretched foils and similarly, at least the fibers 28b are constituted by longitudinally extendable or stretchable fibers.
  • the foils 12 and 20 and also the fibers 28b have been stretched, as indicated by the arrow 57 and through the elongation of the foils 12 and 20, the microperforation generators 53 cause the foils 12 and 20 to be perforated, as is illustrated in the left hand part of Fig.
  • the reference numeral 55 designates a microperforation of the top foil 20.
  • the perforations, such as the perforation 55 of the foil 20 is generated by means of microperforation generators 53, originally present at the interface between the two foils 12 and 20, the generation of a microperforation in the one foil, such as the foil 20, most likely also causes the generation due to the same microperforation generator of the opposite foil, such as the foil 12. Consequently, the perforation generation technique illustrated in Figs. 5 and 6 results in the generation of a microperforated two-layer foil structure, which foil structure is also a grid or mesh reinforced membrane structure.
  • the foils 12 and 20 are bidirectionally stretchable foils and also the fibers 20a constitute stretchable fibers
  • the elongation step illustrated by the arrow 57 may be complemented by an additional elongation step for elongating the foils 12 and 20 and also the fibers 28a in a transversal direction relative to the direction indicated by the arrow 54 and consequently along the longitudinal direction of the fibers 28a. Consequently, a mesh reinforced bidirectionally stretched microperforated mesh or grid reinforced membrane structure is provided.
  • the toughness or mechanical strength improving aspect of the present invention is perceptually illustrated as in Fig. 7, the membrane according to the present invention is shown, which membrane is exposed to a force impact along the direction indicated by the arrow 58.
  • the foil is maintained in the specific position shown in Fig. 8 by means of an arresting post 56.
  • the force impact or the pull 58 will inevitably generate stresses in the foils 12 and 20 of the membrane structure 50.
  • the foils 12 and 20 are themselves of a strength far lower than the strength of the fibers 28a and 28b, the force impact to the membrane structure is transformed into a force impact to the foils 12 and 20 through the whole membrane structure.
  • the impact may cause local stress concentrations at certain areas or points of the foil and may tear apart the membrane structure.
  • a similar situation is shown in which a conventional grid or mesh reinforced membrane 60 is shown in which the sandwiching foils are designated the reference numerals 62 and 64 and the reinforcing grid or mesh is designated the reference numeral 66.
  • the reinforcing grid or mesh 66 of the membrane structure 60 shown in Fig. 8 is rigidly fixated within the foil sandwiching structure and cannot be shifted relative to the sandwiching foils 62 and 64.
  • the force impact along the direction indicated by the arrow 58 may consequently cause a local stress to the foils 62 and 64 causing a tearing apart of the foils from the reinforcing grid or mesh 66, as is indicated by the reference numeral 70 which reference numeral indicates certain tearing lines along which the foils 62 and 64 are torn apart.
  • a bimodal MWD LLDPE e.g. BorstarTM from Borealis, Grade FB 2230 was used to extrude the bottom foil 12 having a thickness corresponding to app. 60 g/m 2 .
  • the bottom foil 12 was fitted with the 12 x 12 mm reinforcing mesh 28 made from PP multifilament 1100 denier using a PE-paraffin wax, and a blend of 70/30 LDPE and DEX PLASTOMERS' Exact plastomer was used to readily extrude the top foil 20 in a thickness corresponding to app 90 g/m 2 . Black pigmentation (carbon black) and UV-stabiliser was added. Accordingly, the overall membrane was produced on a plant similar to the plant shown in Fig. 2, as the top foil was produced in an online extrusion process prior to the lamination process carried out by means of the large diameter cooling roller 27.
  • the lubricant material was present in an amount of approximately 20% by weight of the weight of the multifilament reinforcing mesh 28.
  • the mechanical properties, i.e. tensile strength, tearing strength and puncture proof resistance, of the resulting membrane are compared to the corresponding properties of a conventional LDPE-based membrane produced by the above described conventional methods in the tables below.
  • a blend of LDPE and the Exact plastomer from DEX PLASTOMERS i.e. a copolymer of ethylene and octene having a high comonomer-content, were mixed in a 70/30-ratio and used to extrude the bottom foil 12 having a thickness corresponding to app. 60 g/m 2 .
  • the bottom foil 12 was fitted with the 8 x 8 mm reinforcing mesh 28 made from PP multifilament 1100 denier using a PE-paraffin wax, and a blend of LDPE and the Exact plastomer from DEX PLASTOMERS in a 70/30 ratio was used to readily extrude the top foil 20 in a thickness corresponding to app 90 g/m 2 .
  • Black pigmentation (carbon black) and UV-stabiliser was added.
  • the lubricant material was present in an amount of approximately 20% by weight of the weight of the multifilament reinforcing mesh 28.
  • a polypropylene base copolymer comprising a minor amount of ethylene (2 - 4 %), i.e. a raco (random copolymer) PP, with a melting point of app. 148°C, is used to extrude the bottom foil 12 having a thickness corresponding to app. 40 g/m 2 .
  • the bottom foil is fitted with the 15 x 15 mm reinforcing mesh 28 made from PP multifilament 1100 denier using a PE-paraffin wax, and the same raco-PP is used to readily extrude the top foil 20 in a thickness corresponding to app 40 g/m 2 , resulting in a membrane having a thickness corresponding to app. 105 g/m 2 .
  • the resulting membrane has properties making it applicable for use as a vapour control layer in construction.
  • a heterophasic copolymer of propylene and ethylene (TPO, termoplastic polyolefin), e.g. Hifax or Astryn from Montell, including blue dye is used to extrude the top foil 12 having a thickness corresponding to app. 150 g/m 2 .
  • the top foil 12 is fitted with the 9 x 12 mm reinforcing mesh 28 made from 0,37 mm ⁇ monofilament PET 1500 denier, and the same heterophasic copolymer including white dye is used to readily extrude the top foil 20 in a thickness corresponding to app 200 g/m 2 , resulting in a membrane having a thickness corresponding to app. 390 g/m 2 .
  • the resulting membrane has properties making it applicable for uses necessitating heat welding, i.e. as humid or wet room membranes.
  • POY partly stretched fibers
  • the membrane is then stretched uni-axially or directionally or bib-axially or directionally, whereby the mesh-fibers are fully stretched (FOY, Fully oriented yarns), inducing high strength and low elongation.
  • FOY Fully oriented yarns
EP01610029A 2001-03-21 2001-03-21 Membran, insbesondere wasserdichte Membran und Verfahren zu ihrer Herstellung Expired - Lifetime EP1243716B1 (de)

Priority Applications (5)

Application Number Priority Date Filing Date Title
DK01610029T DK1243716T3 (da) 2001-03-21 2001-03-21 Membran, specielt en vandtæt membran, og en fremgangsmåde til fremstilling af en membran, specielt en vandtæt membran
AT01610029T ATE408737T1 (de) 2001-03-21 2001-03-21 Membran, insbesondere wasserdichte membran und verfahren zu ihrer herstellung
EP01610029A EP1243716B1 (de) 2001-03-21 2001-03-21 Membran, insbesondere wasserdichte Membran und Verfahren zu ihrer Herstellung
DE60135824T DE60135824D1 (de) 2001-03-21 2001-03-21 Membran, insbesondere wasserdichte Membran und Verfahren zu ihrer Herstellung
PCT/DK2002/000187 WO2002075071A1 (en) 2001-03-21 2002-03-20 A membrane, in particular a waterproofing membrane, and a method of producing a membrane, in particular a waterproofing membrane

Applications Claiming Priority (1)

Application Number Priority Date Filing Date Title
EP01610029A EP1243716B1 (de) 2001-03-21 2001-03-21 Membran, insbesondere wasserdichte Membran und Verfahren zu ihrer Herstellung

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EP1243716A1 true EP1243716A1 (de) 2002-09-25
EP1243716B1 EP1243716B1 (de) 2008-09-17

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EP (1) EP1243716B1 (de)
AT (1) ATE408737T1 (de)
DE (1) DE60135824D1 (de)
DK (1) DK1243716T3 (de)
WO (1) WO2002075071A1 (de)

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2007000646A1 (en) * 2005-06-27 2007-01-04 Bruce Simon Van Halderen Material and joint for a shelter
CN100449088C (zh) * 2006-10-24 2009-01-07 甘国工 房屋建筑顶层防漏止滑篷布
CN101255686B (zh) * 2008-02-29 2012-03-28 上海新纺织产业用品有限公司 一种高强度土工格栅网
WO2014088778A1 (en) * 2012-12-05 2014-06-12 Johns Manville White and black ply laminate and methods
EP2768665A4 (de) * 2011-10-17 2015-06-10 Berry Plastics Corp Flammwidrige verstärkte folie für explosionswiderstandsschutz
US9790406B2 (en) 2011-10-17 2017-10-17 Berry Plastics Corporation Impact-resistant film
GB2550371A (en) * 2016-05-17 2017-11-22 King Thomas Scaffold sheeting
EP3438379A1 (de) * 2017-08-03 2019-02-06 Procopi Beckenabdichtfolie, ihr verschweissungsverfahren, becken mit einer solchen folie
WO2021089420A1 (en) * 2019-11-04 2021-05-14 Valsem Industries Sas A novel, steel wire reinforced, anti-theft flexible cover and method

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EP1541337A1 (de) * 2003-12-01 2005-06-15 Icopal Plastic Membranes A/S Membran und Verfahren zu deren Herstellung
EP1541338B1 (de) * 2003-12-01 2007-05-09 Icopal Plastic Membranes A/S Membran und Verfahren zu deren Herstellung
WO2007027602A1 (en) 2005-08-29 2007-03-08 Bfs Diversified Products, Llc Thermoplastic roofing membranes
US7882671B2 (en) 2006-02-21 2011-02-08 Bfs Diversified Products, Llc Multi-layer co-extruded roofing membrane
JP6034635B2 (ja) * 2012-09-27 2016-11-30 旭化成株式会社 微多孔性フィルム及び電池用セパレータ
CN108795180A (zh) * 2018-06-29 2018-11-13 深圳市艾贝比品牌管理咨询有限公司 一种防水涂料
CN113403863B (zh) * 2021-07-13 2024-03-15 中纺新材料科技有限公司 一种防水阻燃高强户外包面料及其制备方法

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Cited By (11)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2007000646A1 (en) * 2005-06-27 2007-01-04 Bruce Simon Van Halderen Material and joint for a shelter
CN100449088C (zh) * 2006-10-24 2009-01-07 甘国工 房屋建筑顶层防漏止滑篷布
CN101255686B (zh) * 2008-02-29 2012-03-28 上海新纺织产业用品有限公司 一种高强度土工格栅网
EP2768665A4 (de) * 2011-10-17 2015-06-10 Berry Plastics Corp Flammwidrige verstärkte folie für explosionswiderstandsschutz
US9790406B2 (en) 2011-10-17 2017-10-17 Berry Plastics Corporation Impact-resistant film
WO2014088778A1 (en) * 2012-12-05 2014-06-12 Johns Manville White and black ply laminate and methods
US10081945B2 (en) 2012-12-05 2018-09-25 Johns Manville White and black ply laminate
GB2550371A (en) * 2016-05-17 2017-11-22 King Thomas Scaffold sheeting
EP3438379A1 (de) * 2017-08-03 2019-02-06 Procopi Beckenabdichtfolie, ihr verschweissungsverfahren, becken mit einer solchen folie
FR3069874A1 (fr) * 2017-08-03 2019-02-08 Procopi Membrane d'etancheite de bassin, son procede de soudage, bassin ayant celle-ci
WO2021089420A1 (en) * 2019-11-04 2021-05-14 Valsem Industries Sas A novel, steel wire reinforced, anti-theft flexible cover and method

Also Published As

Publication number Publication date
DE60135824D1 (de) 2008-10-30
EP1243716B1 (de) 2008-09-17
WO2002075071A1 (en) 2002-09-26
ATE408737T1 (de) 2008-10-15
DK1243716T3 (da) 2009-02-02

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