GB2372756A - Membrane lined gutters - Google Patents
Membrane lined gutters Download PDFInfo
- Publication number
- GB2372756A GB2372756A GB0104920A GB0104920A GB2372756A GB 2372756 A GB2372756 A GB 2372756A GB 0104920 A GB0104920 A GB 0104920A GB 0104920 A GB0104920 A GB 0104920A GB 2372756 A GB2372756 A GB 2372756A
- Authority
- GB
- United Kingdom
- Prior art keywords
- composite material
- membrane
- gutter
- material according
- adhesive
- 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- Withdrawn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
- 239000012528 membrane Substances 0.000 title claims abstract description 51
- 239000002131 composite material Substances 0.000 claims abstract description 39
- 239000000853 adhesive Substances 0.000 claims abstract description 27
- 230000001070 adhesive effect Effects 0.000 claims abstract description 27
- 239000000463 material Substances 0.000 claims abstract description 23
- 239000000956 alloy Substances 0.000 claims abstract description 12
- 229910045601 alloy Inorganic materials 0.000 claims abstract description 12
- 239000000758 substrate Substances 0.000 claims abstract description 9
- -1 polypropylene Polymers 0.000 claims abstract description 8
- 229920002943 EPDM rubber Polymers 0.000 claims abstract description 5
- 239000004743 Polypropylene Substances 0.000 claims abstract description 5
- 229910052751 metal Inorganic materials 0.000 claims abstract description 5
- 239000002184 metal Substances 0.000 claims abstract description 5
- 229920001155 polypropylene Polymers 0.000 claims abstract description 5
- 239000004698 Polyethylene Substances 0.000 claims abstract description 3
- 229920000573 polyethylene Polymers 0.000 claims abstract description 3
- 229910000831 Steel Inorganic materials 0.000 claims description 27
- 239000010959 steel Substances 0.000 claims description 27
- 238000004519 manufacturing process Methods 0.000 claims description 11
- 239000002904 solvent Substances 0.000 claims description 7
- 239000004645 polyester resin Substances 0.000 claims description 5
- 229920001225 polyester resin Polymers 0.000 claims description 5
- 239000000203 mixture Substances 0.000 claims description 4
- 239000004821 Contact adhesive Substances 0.000 claims description 3
- 238000009472 formulation Methods 0.000 claims description 3
- 229920002635 polyurethane Polymers 0.000 claims description 3
- 239000004814 polyurethane Substances 0.000 claims description 3
- 229920005989 resin Polymers 0.000 claims description 3
- 239000011347 resin Substances 0.000 claims description 3
- 229920002367 Polyisobutene Polymers 0.000 abstract description 4
- 238000000034 method Methods 0.000 description 15
- 238000005260 corrosion Methods 0.000 description 4
- 230000007797 corrosion Effects 0.000 description 4
- 239000011248 coating agent Substances 0.000 description 3
- 238000000576 coating method Methods 0.000 description 3
- 238000003466 welding Methods 0.000 description 3
- 230000003628 erosive effect Effects 0.000 description 2
- 238000005304 joining Methods 0.000 description 2
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 2
- 238000004078 waterproofing Methods 0.000 description 2
- 239000004411 aluminium Substances 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 238000011437 continuous method Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000011152 fibreglass Substances 0.000 description 1
- 238000009413 insulation Methods 0.000 description 1
- 230000007774 longterm Effects 0.000 description 1
- 239000013521 mastic Substances 0.000 description 1
- 239000003973 paint Substances 0.000 description 1
- 239000004033 plastic Substances 0.000 description 1
- 229920003023 plastic Polymers 0.000 description 1
- 229920000728 polyester Polymers 0.000 description 1
- 230000001681 protective effect Effects 0.000 description 1
- 238000005096 rolling process Methods 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
- 229920003051 synthetic elastomer Polymers 0.000 description 1
- 239000005061 synthetic rubber Substances 0.000 description 1
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D13/00—Special arrangements or devices in connection with roof coverings; Protection against birds; Roof drainage ; Sky-lights
- E04D13/04—Roof drainage; Drainage fittings in flat roofs, balconies or the like
- E04D13/064—Gutters
- E04D13/0648—Gutters comprising provisions for heat insulation, e.g. an insulation layer
-
- 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
- B32B15/00—Layered products comprising a layer of metal
- B32B15/04—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material
- B32B15/08—Layered products comprising a layer of metal comprising metal as the main or only constituent of a layer, which is next to another layer of the same or of a different material of synthetic resin
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D13/00—Special arrangements or devices in connection with roof coverings; Protection against birds; Roof drainage ; Sky-lights
- E04D13/04—Roof drainage; Drainage fittings in flat roofs, balconies or the like
- E04D13/064—Gutters
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D13/00—Special arrangements or devices in connection with roof coverings; Protection against birds; Roof drainage ; Sky-lights
- E04D13/04—Roof drainage; Drainage fittings in flat roofs, balconies or the like
- E04D13/064—Gutters
- E04D13/068—Means for fastening gutter parts together
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D3/00—Roof covering by making use of flat or curved slabs or stiff sheets
- E04D3/35—Roofing slabs or stiff sheets comprising two or more layers, e.g. for insulation
-
- 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
- B32B2311/00—Metals, their alloys or their compounds
- B32B2311/30—Iron, e.g. steel
-
- 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
- B32B2323/00—Polyalkenes
- B32B2323/10—Polypropylene
-
- 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
- B32B2367/00—Polyesters, e.g. PET, i.e. polyethylene terephthalate
-
- 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
- B32B37/00—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding
- B32B37/12—Methods or apparatus for laminating, e.g. by curing or by ultrasonic bonding characterised by using adhesives
Landscapes
- Engineering & Computer Science (AREA)
- Architecture (AREA)
- Civil Engineering (AREA)
- Structural Engineering (AREA)
- Laminated Bodies (AREA)
Abstract
A composite material (1) including a membrane (2) secured to a substrate (3) comprising a rigidised material wherein the membrane (2) is a waterproof membrane such as a polypropylene alloy, a flexible PVC alloy, a polyethylene alloy, EPDM or polyisobutylene and the substrate (3) is a rigidised metal. The substrate (3) and membrane (2) are bonded together using an appropriate adhesive. A fleece may be secured to the membrane. The composite material (1) can be formed into gutter sections and accessories for gutter systems.
Description
IMPROVEMENTS TO MEMBRANE LINED GUTTERS
The present invention relates to an improved membrane lined gutter. The primary purpose of a gutter is to collect and contain water running off an adjoining roof-slope and to direct it to disposal points.
Lightweight and flexible materials are used in gutter manufacture but these materials can have associated problems of leakage, instability and corrosion. Most commonly used, metal based, lightweight gutter systems are subject to one or more of these problems.
Although gutters can be manufactured from aluminium, glass reinforced plastics (G. R. P) materials and other suitable materials, the most preferred material is a 2mm-3mm thickness steel substrate with a pre or post galvanised coating. Steel is the most preferred material owing to
, -, availability, speed of manufacture and cost and 2mm thickness steel is the most predominant thickness.
Although steel has excellent strength to weight characteristics and 2mmthickness steel will support loads, for example from foot traffic, without undue deflection, it has an unreliable life span owing to the erosion of its galvanised coating and the subsequent corrosion of the steel substrate.
This erosion and corrosion process can take from as little as 12 months to 15 years to occur depending on a large variety of circumstances.
Measures have been taken to slow or prevent this process by the application of protective paints and to a certain extent these have been successful. However there is a significant price increase for a suitable coating.
In use sections of gutter must be joined together and the most common joint comprises the use of Polyisobutylene synthetic rubber mastic (P. I. B) in strip form within a bolted joggle and spigot joint. Although
Polyisobutylene can provide an effective seal for a considerable length of time it is fairly common for the joint to fail.
The above problems have been addressed to some extent by the provision of membrane lined gutters wherein roofing membranes are applied to gutters as the waterproofing medium. The membrane is applied to a suitable substrate, for example steel, and gutter sections are joined using existing membrane joint technology to form a homogenous lining. The resultant product is long term, leak free and able to withstand structural movement and corrosion.
The problem with membrane lined gutters is that they are inherently expensive and because of the increased costs are rarely used for"single skin"gutters but are more often used in insulated gutter systems.
Furthermore the membrane is usually bonded to steel approximately 0. 7mm thick to keep costs to a minimum and is then fabricated into a composite unit, which includes a rigid insulation board and a decorative steel lining tray, again of 0. 7mm thickness. The component parts are usually bonded together and make a rigid assembly when complete.
To date no steel having a thickness of less than 2mm has been deemed to have the required structural integrity to support the imposed loading for single skin gutters. Therefore the 0. 7mm thickness steel used in membrane lined gutters would be inadequate for single skin gutters other than for the smallest of gutters which would not be required to support foot traffic of any kind.
The aim of the present invention is therefore to develop a composite material comprising a membrane and a"thin gauge"material that has good inherent waterproofing qualities and the structural capabilities similar to 2mm thickness galvanised steel while keeping the costs to a minimum.
Accordingly the present invention provides a composite material including a membrane secured to a substrate comprising a rigidised material.
The membrane is preferably a waterproof membrane and may, for example be a polypropylene alloy, a flexible PVC alloy, a polyethylene alloy, EPDM (ethylene propylene diene monomer) or polyisobutylene (P. I. B.).
The rigidised material is preferably a rigidised metal, most preferably steel. The steel preferably has a thickness of less than or equal to 1.4mm
The membrane and rigidised materials are preferably bonded together using an adhesive. Suitable adhesives include moisture cured or solvent/moisture-cured polyurethanes or contact adhesives. The adhesive may alternatively be a polyester resin based adhesive, preferably the resin based adhesive is a solvent borne formulation. The resin based adhesive is preferably heat cured. The type of adhesive used depends on the bonding process that may, for example be continuous or blank bonding.
The membrane preferably includes a fleece secured to its underside. The fleece is preferably synthetic and may be secured to the membrane during membrane manufacture by means of a permanent adhesive. The fleece provides a suitable medium to aid secure bonding of the membrane to the rigidised material and allows a large variety of adhesives to be used.
The present invention also provides a gutter section formed from the composite material of the present invention.
Gutter sections formed from the composite material of the present invention are lightweight owing to the reduction in the amount of substrate by the use of a rigidised material. The reduction in weight allows longer gutter sections to be supplied thus reducing the number of joints needed.
The gutter section of the present invention has a strength and rigidity comparable to gutter sections made from 2mm thickness steel and can therefore be used in"single skin"gutters where membrane lined gutter sections were not previously acceptable.
The gutter sections of the present invention may be joined together to form a gutter system. The use of butt straps and rivets may join the sections, alternatively male-female clips may be used.
The joints are then sealed, preferably using a patch of the membrane that is heat-sealed over the joint to make it waterproof.
The composite material of the present invention can also be used to manufacture accessories for gutter systems, for example, outlet pipes.
The present invention will now be described in more detail with reference to the figures in which:
Figure 1 shows a first embodiment of the composite material of the present invention ; and
Figure 2 shows a second embodiment of the composite material of the present invention ; and Figure 3 shows a rigidising pattern applied to the composite material of the present invention.
The composite material 1 of Figure 1 is manufactured from a flexible polypropylene alloy membrane 2 securely bonded to galvanised steel 3 with a gauge thickness no greater than 1. 4mm.
The adhesive used to bond the membrane 2 to the steel 3 is a single component, solvent borne formulation based on a polyester resin. The adhesive is applied to the steel 3 by means of a roller. The steel 3 is then passed, by a conveyor, through an oven and heated to 1600. The solvent is flashed off by this heat and on emergence from the oven the membrane 2 is applied in continuous form to the steel 3 and then passed through "pinch"rollers to consolidate the bond. At the same time the composite material 1 is cooled by air or water or a combination of both.
The bonding process can be carried out in a number of ways with the most appropriate being :a) Continuous method (as described in relation to Figure 1)-the materials are bonded continuously from separate rolls with adhesive being introduced prior to application of pressure to form the bond. The resultant material may be either blanked into sheets or re-coiled for further processing ; or b) Blank method-the composite material is formed from individual sheets of membrane and galvanised steel. Adhesive is applied to either
the steel or the membrane or to both and a stack formed from several sheets, which is then be pressed to form the bond.
The resultant composite material does not have sufficient strength and rigidity to approach that of 2mm thickness galvanised steel so a rigidising process is applied to the composite material.
The rigidising process forms ribs 4 along the length of the material 1, which form the pattern shown in Figure 3 and provide structural strength and improved rigidity.
Where the composite material is in sheet form the sheet is passed through a set of powered rolls. One roll is directly above the other (pinch roll format) and they are of sufficient width to allow the complete width of a sheet to pass through. The rolls are machined in rib format around the diameter and the ribs are formed so that the ribs of the top roll mate with the ribs of the bottom roll. The spacing between the rolls is adjustable to allow sufficient spacing between them such that when the sheet is passed through the ribbed form from the rolls is transferred to the entire length of the sheet to the required depth of profile.
Where the composite material is in a coil the coil is loaded onto a decoiling mandrell located behind the powered rolls and as the composite material is de-coiled it is passed through the rolls and the either cut into sheets or re-coiled.
The composite material 10 of Figure 2 is manufactured from a flexible polypropylene alloy membrane 11 with a synthetic polyester fleece 12 applied to the underside at the initial membrane manufacturing stage.
The fleece 12 is permanently bonded to the underside of the membrane 11 by an adhesive.
The fleece 12 provides a medium for securely bonding the alloy membrane 11 to galvanised steel 13 with a gauge thickness no greater than 1.2mm.
Due to the versatility of both the fleece 12 and galvanised steel 13 surfaces the two materials may be bonded together using a variety of adhesives, the nature of the adhesive being dependant on the bonding process used. Appropriate adhesives include moisture cured or solvent/moisture cured polyurethanes or alternatively contact adhesives may be employed.
The composite material 10 is subjected to a rigidising process as described above in relation to Figure 1.
Forming and fabrication method
The resultant material may be press formed into any gutter using traditional metalwork techniques, membrane fabrication methods or plastics welding technique or a combination of all three.
Typical fabrication methods employed for the manufacture of accessories would be press joining, flanging, rolling (e. g. into cylinders for outlets etc. ).
Typical membrane techniques employed would be hot air welding and forming to weather and seal corners and fabrication joints using strip membrane or formed membrane accessories. Hot air welding can be used to melt"rods"of material identical to the membrane composition to fill areas that are difficult to seal by the other methods.
Site Application The composite material gutters of the present invention are fitted in similar ways to existing gutters, for example they are supported by brackets or wrapped over and attached to the eaves purlins.
The composite gutters are easier and faster to fit than traditional systems as they are approximately 30% lighter in weight. This decrease in weight, together with processing from coiled materials provides the opportunity to offer far longer length gutters than can normally be provided and the further opportunity of site forming which would eliminate the maximum number of joints.
Joining
Gutters are joined together, for example, by means of butt straps or rivets. No seal is applied at this stage.
Sealing
The gutters are sealed using a patch of membrane that is heat sealed (hot air welded) over the mechanical join area.
Claims (21)
1. A composite material including a membrane secured to a substrate comprising a rigidised material.
2. A composite material according to Claim 1 wherein the membrane is a waterproof membrane.
3. A composite material according to Claim 1 or Claim 2 wherein the membrane is a polypropylene alloy, a flexible PVC alloy, a polyethylene alloy, EPDM (ethylene propylene diene monomer) or polyisobutylen (P. I. B.).
4. A composite material according to any preceding claim wherein the rigidised material is a rigidised metal.
5. A composite material according to Claim 4 wherein the metal is steel.
6. A composite material according to Claim 5 wherein the steel has a thickness of less than or equal to 1. 4mm.
7. A composite material according to any preceding claim wherein the membrane and rigidised materials are bonded together using an adhesive.
8. A composite membrane according to Claim 7 wherein suitable adhesives include moisture cured or solvent/moisture-cured polyurethanes, contact adhesives or polyester resin based adhesives.
9. A composite material according to Claim 8 wherein the adhesive is a polyester resin based adhesive and the resin based adhesive is a solvent borne formulation.
10. A composite material according to Claim 8 wherein the adhesive is a polyester resin based adhesive and is heat cured.
11. A composite material according to any preceding claim wherein the membrane includes a fleece secured to its underside.
12. A composite material according to Claim 11 wherein the fleece is synthetic.
13. A composite material according to Claim 12 wherein the fleece is secured to the membrane during membrane manufacture by means of a permanent adhesive.
14. A gutter section formed from the composite material of any of
Claims 1 to 13.
15. A gutter system comprising two or more gutter sections of
Claim 14 joined together.
16. A gutter system according to Claim 15 wherein the two or more gutter sections are joined together by the use of butt straps and rivets or male-female clips.
17. A gutter system according to Claims 15 or 16 wherein the joints between the two or more gutter sections are sealed using a patch of the membrane that is heat-sealed over the joint to make it waterproof.
18. Accessories for gutter systems made from a composite material of any of Claims 1 to 13.
19. A composite material substantially as described herein and with reference to the figures.
20. A gutter system substantially as described herein.
21. Accessories for gutter systems substantially as described herein.
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GB0104920A GB2372756A (en) | 2001-02-28 | 2001-02-28 | Membrane lined gutters |
Applications Claiming Priority (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GB0104920A GB2372756A (en) | 2001-02-28 | 2001-02-28 | Membrane lined gutters |
Publications (2)
Publication Number | Publication Date |
---|---|
GB0104920D0 GB0104920D0 (en) | 2001-04-18 |
GB2372756A true GB2372756A (en) | 2002-09-04 |
Family
ID=9909677
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
GB0104920A Withdrawn GB2372756A (en) | 2001-02-28 | 2001-02-28 | Membrane lined gutters |
Country Status (1)
Country | Link |
---|---|
GB (1) | GB2372756A (en) |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2007144612A2 (en) * | 2006-06-14 | 2007-12-21 | Specialist Coatings Limited | Improved sealing system for guttering and methods of manufacturing and using the same |
GB2441831A (en) * | 2006-09-18 | 2008-03-19 | David Wiltshire | Gutter with waterproof liner |
CN103615074A (en) * | 2013-11-29 | 2014-03-05 | 杭州丹尼建材有限公司 | Production technology of roof tiles |
Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB2081336A (en) * | 1980-08-08 | 1982-02-17 | Williams William & Sons Glassg | Insulated roof guttering and expansion joint |
GB2227762A (en) * | 1989-01-21 | 1990-08-08 | Steelpress | Metal gutter |
GB2238805A (en) * | 1989-12-06 | 1991-06-12 | Steelpress Ltd | Insulated roof gutter |
JPH0419132A (en) * | 1990-05-15 | 1992-01-23 | Matsushita Electric Works Ltd | Manufacture of eave gutter |
GB2347696A (en) * | 1999-02-19 | 2000-09-13 | Kingspan Res & Dev Ltd | Gutter formed from insulated panels |
-
2001
- 2001-02-28 GB GB0104920A patent/GB2372756A/en not_active Withdrawn
Patent Citations (5)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
GB2081336A (en) * | 1980-08-08 | 1982-02-17 | Williams William & Sons Glassg | Insulated roof guttering and expansion joint |
GB2227762A (en) * | 1989-01-21 | 1990-08-08 | Steelpress | Metal gutter |
GB2238805A (en) * | 1989-12-06 | 1991-06-12 | Steelpress Ltd | Insulated roof gutter |
JPH0419132A (en) * | 1990-05-15 | 1992-01-23 | Matsushita Electric Works Ltd | Manufacture of eave gutter |
GB2347696A (en) * | 1999-02-19 | 2000-09-13 | Kingspan Res & Dev Ltd | Gutter formed from insulated panels |
Cited By (4)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2007144612A2 (en) * | 2006-06-14 | 2007-12-21 | Specialist Coatings Limited | Improved sealing system for guttering and methods of manufacturing and using the same |
WO2007144612A3 (en) * | 2006-06-14 | 2008-05-08 | Specialist Coatings Ltd | Improved sealing system for guttering and methods of manufacturing and using the same |
GB2441831A (en) * | 2006-09-18 | 2008-03-19 | David Wiltshire | Gutter with waterproof liner |
CN103615074A (en) * | 2013-11-29 | 2014-03-05 | 杭州丹尼建材有限公司 | Production technology of roof tiles |
Also Published As
Publication number | Publication date |
---|---|
GB0104920D0 (en) | 2001-04-18 |
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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) |