GB2281051A - Liquid impermeable and vapour permeable laminate structure - Google Patents
Liquid impermeable and vapour permeable laminate structure Download PDFInfo
- Publication number
- GB2281051A GB2281051A GB9316967A GB9316967A GB2281051A GB 2281051 A GB2281051 A GB 2281051A GB 9316967 A GB9316967 A GB 9316967A GB 9316967 A GB9316967 A GB 9316967A GB 2281051 A GB2281051 A GB 2281051A
- Authority
- GB
- United Kingdom
- Prior art keywords
- laminate
- liquid impermeable
- vapour permeable
- layer
- vapour
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Withdrawn
Links
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
- B32B5/022—Non-woven fabric
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B7/00—Layered products characterised by the relation between layers; Layered products characterised by the relative orientation of features between layers, or by the relative values of a measurable parameter between layers, i.e. products comprising layers having different physical, chemical or physicochemical properties; Layered products characterised by the interconnection of layers
- B32B7/02—Physical, chemical or physicochemical properties
-
- 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
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/724—Permeability to gases, adsorption
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/724—Permeability to gases, adsorption
- B32B2307/7242—Non-permeable
- B32B2307/7246—Water vapor barrier
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/726—Permeability to liquids, absorption
- B32B2307/7265—Non-permeable
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2419/00—Buildings or parts thereof
- B32B2419/06—Roofs, roof membranes
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Textile Engineering (AREA)
- Laminated Bodies (AREA)
Abstract
A liquid impermeable and vapour permeable laminate structure (10) comprises a plurality of sheets (12), each sheet including a liquid impermeable layer (16). The sheets (12) are arranged with their edge portions in overlapping relation, and a vapour permeable layer (14) is provided between the overlapping edge portions. The structure is suited for use in forming roof coverings. The vapour permeable layer (14) may be in the form of a support substrate such as a spunbonded polymeric nonwoven material and the liquid impermeable layer (16) may be in the form of a membrane. <IMAGE>
Description
LIQUID IMPERMEABLE AND VAPOUR
PERMEABLE LAMINATE STRUCTURE
This invention relates to a liquid impermeable and vapour permeable laminate structure, and a method of forming such a laminate structure. In particular, but not exclusively, the invention relates to a waterproof and water vapour permeable laminate structure which is especially suited for use in the construction industry.
Various products are available which are waterproof and yet which afford a measure of water vapour permeability. Such water vapour permeability may be valuable in situations where the ambient conditions are such that unwanted condensation might occur where the membrane forms the interface between a relatively humid, warm air layer and a relatively cold outer layer. Such membranes may be manufactured in a variety of ways but typically fall into two main categories. Firstly, a liquid permeable support substrate may be coated such that the coating confers waterproof properties whilst allowing a measure of water vapour permeability, for example, by molecular diffusion of water vapour through the coating.
A typical example of a coating of this type is a monolithic coating of a polyurethane or polyurethane copolymer which may be formulated to obtain the required balance of waterproof and water vapour permeability properties.
The second main route to the manufacture of such membranes is by securing a pre-formed membrane to a supporting substrate. The membrane may, for example, be a polyurethane film or a microporous film of monolithic or coextruded construction having the property of being waterproof while being permeable to water vapour. Such a membrane may be attached to the support membrane by, for example, thermal bonding but, more usually, by adhesive bonding.
In the examples given above, the manufacturer of the finished product is limited within narrow ranges of water vapour permeability by the materials chosen as the barrier membrane. For a given thickness of coating or pre-formed membrane, the moisture vapour permeability will be governed by, for example, the chemical composition of the coating or membrane or by the size and frequency of the micropores in a microporous film. The manufacturer of the finished waterproof barrier will thus have little or no control over the water vapour permeability other than devising a method of bonding to the support substrate which minimises the adverse effects of such bonding upon the water vapour permeability.
Other methods of achieving water vapour permeability are known such as the use of microperforated films or closely woven or microfibre substrates which may be treated with water repellent agents. Such materials will also either be subject to the same restrictions as outlined above or may obtain their water barrier properties by surface tension and contact angle effects and may, therefore, be classed as water resistant only, and not as waterproof.
It is an object of the present invention to provide a laminate structure which obviates or mitigates these difficulties.
According to the present invention there is provided a liquid impermeable and vapour permeable laminate structure comprising a plurality of sheets, each sheet including a liquid impermeable layer, the sheets being arranged with at least their edge portions in overlapping relation, and a vapour permeable layer being provided between said overlapping edge portions.
According to a further aspect of the present invention there is provided a method of forming a liquid impermeable and vapour permeable laminate structure comprising:
providing a plurality of sheets, each sheet including a liquid impermeable layer;
arranging the sheets with at least their edge portions in overlapping relation; and
providing a vapour permeable layer between said overlapping edge portions.
In use, the presence of the water vapour permeable layer between the overlapping edge portions provides a path through which moisture vapour may pass. Thus, the vapour permeability of the laminate structure may be controlled by varying the permeability of the vapour permeable layer, varying the thickness of the vapour permeable layer, or varying the extent of the overlap and thus the length of the vapour permeable path through the laminate.
The structure of the present invention is ideally suited for use in forming roof coverings, as the laminate provides a waterproof barrier which allows the passage of moisture, thus reducing the risk of condensation on the inside of the roof surface. For use on a sloping roof the overlapping sheets may be arranged in a similar manner to roof tiles and the like, with the lower edge of an upper sheet extending over an upper edge of a lower sheet.
Preferably, each sheet includes a support substrate, which may be vapour permeable or include a vapour permeable layer. Most preferably, the support substrate provides said vapour permeable layer between the overlapping edge portions.
The liquid impermeable layer of each sheet may also be vapour permeable, to provide a further route for vapour to permeate through the laminate structure. Also, the additional vapour path through the overlap may compensate for any adverse effect on the vapour permeability properties of the liquid impermeable layer caused by bonding the layer to a support substrate. Alternatively, the liquid impermeable layer may be water vapour impermeable.
According to another aspect of the present invention there is provided a laminate comprising a liquid impermeable layer and a vapour permeable layer, the arrangement being such that, in use, the laminate may form part of a liquid impermeable and vapour permeable laminate structure in which the vapour permeable layer provides a vapour transmission path through the structure.
According to a still further aspect of the present invention there is provided a method of forming a liquid impermeable and vapour permeable laminate structure comprising:
providing one or more sheets of laminate comprising a liquid impermeable layer and a vapour permeable layer; and
arranging said one or more sheets of laminate to form a liquid impermeable and vapour permeable laminate structure in which the vapour permeable layers of said one or more sheets of laminate provide a vapour transmission path through the structure.
Conveniently, the sheets of laminate are arranged with their edges overlapping to form said structure.
Alternatively, folds may be formed in a single sheet and the liquid impermeable layer pierced or cut in such a manner to retain the liquid impermeable quality of the structure, while providing a vapour transmission path through the liquid impermeable layer.
Preferably, the liquid impermeable layer is in the form of a membrane and the vapour permeable layer is in the form of a support substrate. Most preferably, the membrane is intermittently bonded to the substrate.
The liquid impermeable membrane may be vapour permeable or may be vapour impermeable.
Preferably the support substrate is a spunbonded polymeric nonwoven material. Methods of producing such materials are described, for example, in UK Patent Nos.
203,763, 203,764, 203,765 and 204,071. The substrate may be formed as a web and may be formed over a wide range of weights typically, but not exclusively, from 10 g/m2 to 200 g/m2. Preferably the webs are of weights from 50 g/m2 to 100 g/m2. For certain applications it may be desirable to impart particular characteristics, such as flame retardancy or ultra-violet radiation stability, to the spunbonded nonwoven web for example, by addition to the polymer melt from which the web is formed.
The preferred form of substrate provides a significant contribution to the desired strength and stability properties of the laminate as well as providing the water vapour permeation means and a controlling factor in water vapour permeation rate.
The laminate may be formed by bonding a permeable support substrate and a waterproof membrane by any means known in the art, for example by adhesive lamination, provided such bonding does not destroy and permeability of the support substrate. Such adhesive bonding is particularly useful when bonding sheets of chemically and physically dissimilar materials.
Most preferably, the component layers of the laminate are thermally bonded. Thermal bonding may be achieved using a combination of heat and pressure and an intermittent bond pattern to maintain the permeability of the support substrate. The bonded area is preferably 5% to 50% of the surface area of the laminated layers, and most preferably 14% to 20% of the surface area. The temperature and pressures selected for the bonding process are chosen to ensure an adequate thermal bond between the different sheet materials whilst minimising any adverse physical effects to the components. This is particularly important with respect to the film membrane component where inappropriate lamination conditions may result in an unacceptable amount of "pin-holing" with a consequent reduction in barrier properties.
With thermal bonding, the achievement of adequate and permanent bonding between the different layers requires that the materials are compatible, that is the materials should have broadly similar softening temperatures and be sufficiently chemically compatible such that autogenous bonding occurs under conditions of appropriate heat and pressure.
These and other aspects of the present invention will now be described, by way of example, with reference to the accompanying drawings, in which:
Figure 1 is a schematic cross-section of a laminate structure in accordance with one embodiment of the present invention;
Figure 2 is a schematic cross-section showing the laminate structure of Fig. 1 being utilised as a sloping roof underlay; and
Figures 3 and 4 are schematic cross-sections of laminate structures in accordance with further embodiments of the present invention.
Reference is first made to Figure 1 of the drawings which shows a schematic cross-section of a laminate structure 10 in accordance with one embodiment of the present invention. The structure 10 comprises a plurality of sheets of laminate 12, each comprising a vapour permeable support substrate 14 to which a water impermeable membrane 16 is intermittently bonded. The water vapour permeable laminate structure 10 is formed by overlapping the sheets of laminate 12 such that the sheets 12 are offset from one another with the permeable support substrate 14 forming an intermediate layer between the layers of water impermeable membrane 16, in the overlapped areas 18. The water vapour permeability of the resulting laminate structure may be controlled by varying the permeability of the support substrate 14 for example by varying the basis weight and hence the thickness of the substrate.The water vapour permeability of the overlapped laminate structure 10 may be further controlled by adjusting the extent of overlap.
Where a laminate structure 10 of the type illustrated in Figure 1 is to be used to provide an inclined coating it is preferred that the length of the overlaps 18 is oriented approximately horizontal. If the overlapped sheets of laminate are used, for example, as a sloping roof underlay with the support membrane to the outside, as illustrated in schematic cross-section in Figure 2 of the drawings, the sheets are positioned such that the membrane 16 of each sheet and the side of the laminate A is downmost in order to provide a totally waterproof barrier. Excess moisture within the building is then free to permeate by route B through the overlapped area 18.
The laminate structure 10 may be similarly used with the impermeable membrane 16 outermost.
The individual sheets of laminate 12 are bonded together in their overlapped arrangement to form the finished moisture vapour permeable laminate structure 10.
As with the formation of the sheets of laminate, this may be achieved by any means known in the art, for example by adhesive lamination provided such bonding does not destroy the permeability of the overlapped laminate 12 in the overlap area 18. In this preferred embodiment the overlapped sheets 12 are thermally bonded using a combination of heat and pressure in an intermittent bond pattern as heretofore described.
A structure 20 in accordance with a further embodiment of the present invention is illustrated in
Figure 3 of the drawings in which the overlapped sheets of laminate 12 are combined with a second permeable support substrate 22 which is bonded as a single, continuous sheet to the membrane side of the overlapped laminate sheets.
The second permeable substrate 22, in addition to providing additional support and dimensional stability, provides a protective layer for the membrane surface. In a further refinement of this embodiment the second support substrate 22 may be made hydrophilic by, for example, the addition of hydrophilic agents to the polymer melt. In extreme conditions where the temperature of the enclosed air falls below the dew point, the hydrophilic layer, positioned towards the inside of the roof space, will absorb the excess moisture and help prevent the formation of condensation droplets.
A further waterproof and water vapour permeable structure 30 incorporating the principle of the present invention will now be described with reference to Figure 4 of the drawings in which two overlapping laminate structures 10a, 10b, as heretofore described, are combined in such a manner that the laminate structure 30 affords a waterproof barrier whether side A is attached uppermost or downmost when used, for example, as a sloping roof underlay. In this example, the overlapped areas may be in line with each other or may, as illustrated in Figure 4, be offset from each other in which case the extent of offset would also be influential upon the water vapour permeability of the total laminate structure.
From the above described embodiments it will be evident that the present invention provides an effective liquid impermeable and vapour permeable barrier which avoids many of the disadvantages of existing laminates.
It will also be clear to those of skill in the art that the above described embodiments are merely exemplary of the present invention and that various improvements and modifications may be made thereto without departing from the scope of the invention.
Claims (25)
1. A liquid impermeable and vapour permeable laminate structure comprising a plurality of sheets, each sheet including a liquid impermeable layer, the sheets being arranged with at least their edge portions in overlapping relation, and a vapour permeable layer being provided between overlapping edge portions.
2. The laminate of claim 1 in the form of a roof covering.
3. The laminate of claim 2, for use as a covering on a sloping roof, wherein the lower edge of an upper sheet extends over an upper edge of a lower sheet.
4. The laminate of claim 1, 2 or 3 wherein each sheet includes a support substrate.
5. The laminate of claim 4 wherein the support substrate provides said vapour permeable layer between the overlapping edge portions.
6. The laminate of any of claims 1 to 5 wherein the liquid impermeable layer of each sheet is also vapour permeable.
7. The laminate of any of claims 1 to 5 wherein the liquid impermeable layer of each sheet is water vapour impermeable.
8. A method of forming a liquid impermeable and vapour permeable laminate structure comprising:
providing a plurality of sheets, each sheet including a liquid impermeable layer;
arranging the sheets with at least their edge portions in overlapping relation; and
providing a vapour permeable layer between said overlapping edge portions.
9. A laminate comprising a liquid impermeable layer and a vapour permeable layer, the arrangement being such that, in use, the laminate may form part of a liquid impermeable and vapour permeable laminate structure in which the vapour permeable layer provides a vapour transmission path through the structure.
10. The laminate of claim 9 wherein the liquid impermeable layer is in the form of a membrane and the vapour permeable layer is in the form of a support substrate.
11. The laminate of claim 9 or claim 10 wherein the liquid impermeable membrane is vapour permeable.
12. The laminate of any of claims 9 to 11 wherein the vapour permeable layer is a spun bonded polymeric non-woven material.
13. The laminate of any of claims 9 to 12 wherein the vapour permeable layer is in the form of a support substrate formed as a web.
14. The laminate of claim 13 wherein the web is of a weight from 10 g/m2 to 200 g/m2.
15. The laminate of claim 14 wherein the web is of a weight from 50 g/m2 to 100 g/m2.
16. The laminate of any of claims 9 to 15 wherein a liquid impermeable layer is in the form of a membrane and the vapour impermeable layer is in the form of a support substrate and the membrane is intermittently bonded to the substrate.
17. The laminate of claim 16 wherein the bonded area is preferably 5% to 50% of the surface area of the laminated layers.
18. The laminate of claim 17 wherein the bonded area is 14% to 20% of the surface area.
19. The laminate of any of claims 9 to 18 wherein the component layers of the laminate are thermally bonded.
20. The laminate of any of claims 9 to 18 wherein the component layers of the laminate are adhesively bonded.
21. A method of forming a liquid impermeable and vapour permeable laminate structure comprising:
providing one or more sheets of laminate comprising a liquid impermeable layer and a vapour permeable layer; and
arranging said one or more sheets of laminate to form a liquid impermeable and vapour permeable laminate structure in which the vapour permeable layers of said one or more sheets of laminate provide a vapour transmission path through the structure.
22. The method of claim 21 in which the sheets of laminate are arranged with their edges overlapping.
23. The method of claim 21 wherein folds are formed in a single sheet of laminate and the liquid impermeable layer pierced or cut in such a manner to retain the liquid impermeable quality of the structure, while providing a vapour transmission path through the liquid impermeable layer.
24. A laminate structure substantially as described herein and as illustrated in Figures 1 and 2, or Figure 3, or Figure 4 of the accompanying drawings.
25. A method of forming a laminate structure substantially as described herein.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB9316967A GB2281051A (en) | 1993-08-14 | 1993-08-14 | Liquid impermeable and vapour permeable laminate structure |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB9316967A GB2281051A (en) | 1993-08-14 | 1993-08-14 | Liquid impermeable and vapour permeable laminate structure |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| GB9316967D0 GB9316967D0 (en) | 1993-09-29 |
| GB2281051A true GB2281051A (en) | 1995-02-22 |
Family
ID=10740532
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| GB9316967A Withdrawn GB2281051A (en) | 1993-08-14 | 1993-08-14 | Liquid impermeable and vapour permeable laminate structure |
Country Status (1)
| Country | Link |
|---|---|
| GB (1) | GB2281051A (en) |
Cited By (3)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE29511308U1 (en) * | 1995-07-13 | 1995-10-26 | Christian Heinrich Sandler GmbH & Co. KG, 95126 Schwarzenbach a d Saale | Breathable roof membrane |
| EP0923982A2 (en) * | 1997-12-19 | 1999-06-23 | Coronor Composites GmbH | Web-shaped membrane for positioning between chambers having a humidity and pressure gradient |
| EP1316600A2 (en) * | 2001-11-30 | 2003-06-04 | Icopal A/S | A fire resistant, flexible laminate |
Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO1986004106A1 (en) * | 1984-12-28 | 1986-07-17 | Decade Waterproofing And Products Pty. Ltd. | Waterproof membrane |
| EP0288257A2 (en) * | 1987-04-21 | 1988-10-26 | British Sisalkraft Limited | Flexible membranes |
| US4803111A (en) * | 1985-08-27 | 1989-02-07 | Chadwick Industries Pty. Limited | Membrane roofing system |
| US4828635A (en) * | 1988-04-13 | 1989-05-09 | Les Produits Isolofoam Inc. | Laminated, thermal insulation panel |
| US5208098A (en) * | 1990-10-23 | 1993-05-04 | Amoco Corporation | Self-bonded nonwoven web and porous film composites |
| EP0570215A2 (en) * | 1992-05-13 | 1993-11-18 | DON & LOW (HOLDINGS) LIMITED | Improvements in and relating to liquid impermeable and liquid vapour permeable laminates |
-
1993
- 1993-08-14 GB GB9316967A patent/GB2281051A/en not_active Withdrawn
Patent Citations (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| WO1986004106A1 (en) * | 1984-12-28 | 1986-07-17 | Decade Waterproofing And Products Pty. Ltd. | Waterproof membrane |
| US4803111A (en) * | 1985-08-27 | 1989-02-07 | Chadwick Industries Pty. Limited | Membrane roofing system |
| EP0288257A2 (en) * | 1987-04-21 | 1988-10-26 | British Sisalkraft Limited | Flexible membranes |
| US4828635A (en) * | 1988-04-13 | 1989-05-09 | Les Produits Isolofoam Inc. | Laminated, thermal insulation panel |
| US5208098A (en) * | 1990-10-23 | 1993-05-04 | Amoco Corporation | Self-bonded nonwoven web and porous film composites |
| EP0570215A2 (en) * | 1992-05-13 | 1993-11-18 | DON & LOW (HOLDINGS) LIMITED | Improvements in and relating to liquid impermeable and liquid vapour permeable laminates |
Cited By (6)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE29511308U1 (en) * | 1995-07-13 | 1995-10-26 | Christian Heinrich Sandler GmbH & Co. KG, 95126 Schwarzenbach a d Saale | Breathable roof membrane |
| EP0923982A2 (en) * | 1997-12-19 | 1999-06-23 | Coronor Composites GmbH | Web-shaped membrane for positioning between chambers having a humidity and pressure gradient |
| DE19756787A1 (en) * | 1997-12-19 | 1999-07-01 | Coronor Composites Gmbh | Membrane-like membrane for arrangement between rooms with a difference in air humidity and air pressure |
| EP0923982A3 (en) * | 1997-12-19 | 2002-07-03 | Coronor Composites GmbH | Web-shaped membrane for positioning between chambers having a humidity and pressure gradient |
| EP1316600A2 (en) * | 2001-11-30 | 2003-06-04 | Icopal A/S | A fire resistant, flexible laminate |
| EP1316600A3 (en) * | 2001-11-30 | 2003-08-20 | Icopal A/S | A fire resistant, flexible laminate |
Also Published As
| Publication number | Publication date |
|---|---|
| GB9316967D0 (en) | 1993-09-29 |
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Legal Events
| Date | Code | Title | Description |
|---|---|---|---|
| WAP | Application withdrawn, taken to be withdrawn or refused ** after publication under section 16(1) |