GB2560576A - Waterproof membrane - Google Patents

Waterproof membrane Download PDF

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Publication number
GB2560576A
GB2560576A GB1704270.6A GB201704270A GB2560576A GB 2560576 A GB2560576 A GB 2560576A GB 201704270 A GB201704270 A GB 201704270A GB 2560576 A GB2560576 A GB 2560576A
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GB
United Kingdom
Prior art keywords
layer
roofing membrane
bitumen
membrane according
waterproof roofing
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.)
Granted
Application number
GB1704270.6A
Other versions
GB201704270D0 (en
GB2560576B (en
Inventor
Izquierdo Rodriguez Maria
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.)
Chesterfelt Ltd
Original Assignee
Chesterfelt Ltd
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Filing date
Publication date
Application filed by Chesterfelt Ltd filed Critical Chesterfelt Ltd
Priority to GB1704270.6A priority Critical patent/GB2560576B/en
Publication of GB201704270D0 publication Critical patent/GB201704270D0/en
Publication of GB2560576A publication Critical patent/GB2560576A/en
Application granted granted Critical
Publication of GB2560576B publication Critical patent/GB2560576B/en
Active legal-status Critical Current
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Classifications

    • 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
    • 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
    • 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
    • B32B19/00—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica
    • B32B19/04—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica next to another layer of the same or of a different material
    • B32B19/041—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica next to another layer of the same or of a different material of metal
    • 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
    • B32B19/00—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica
    • B32B19/04—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica next to another layer of the same or of a different material
    • B32B19/045—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica next to another layer of the same or of a different material of synthetic resin
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B19/00—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica
    • B32B19/04—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica next to another layer of the same or of a different material
    • B32B19/046—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica next to another layer of the same or of a different material of paper or cardboard
    • 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
    • B32B19/00—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica
    • B32B19/06—Layered products comprising a layer of natural mineral fibres or particles, e.g. asbestos, mica next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/08—Layered products comprising a layer of synthetic resin 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
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/06—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B32B27/10—Layered products comprising a layer of synthetic resin as the main or only constituent of a layer, which is next to another layer of the same or of a different material of paper or cardboard
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    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/12—Layered products comprising a layer of synthetic resin next to a fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/32—Layered products comprising a layer of synthetic resin comprising polyolefins
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    • B32B27/00—Layered products comprising a layer of synthetic resin
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    • B32B29/00—Layered products comprising a layer of paper or cardboard
    • B32B29/002—Layered products comprising a layer of paper or cardboard as the main or only constituent of a layer, which is next to another layer of the same or of a different material
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B29/00—Layered products comprising a layer of paper or cardboard
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    • B32B3/00—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form
    • B32B3/26—Layered products comprising a layer with external or internal discontinuities or unevennesses, or a layer of non-planar form; Layered products having particular features of form characterised by a particular shape of the outline of the cross-section of a continuous layer; characterised by a layer with cavities or internal voids ; characterised by an apertured layer
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    • 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
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    • 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
    • B32B5/024—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
    • 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
    • B32B5/10—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 characterised by a fibrous or filamentary layer reinforced with filaments
    • 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
    • B32B7/04—Interconnection of layers
    • B32B7/12—Interconnection of layers using interposed adhesives or interposed materials with bonding properties
    • D—TEXTILES; PAPER
    • D06—TREATMENT OF TEXTILES OR THE LIKE; LAUNDERING; FLEXIBLE MATERIALS NOT OTHERWISE PROVIDED FOR
    • D06N—WALL, FLOOR, OR LIKE COVERING MATERIALS, e.g. LINOLEUM, OILCLOTH, ARTIFICIAL LEATHER, ROOFING FELT, CONSISTING OF A FIBROUS WEB COATED WITH A LAYER OF MACROMOLECULAR MATERIAL; FLEXIBLE SHEET MATERIAL NOT OTHERWISE PROVIDED FOR
    • D06N5/00—Roofing materials comprising a fibrous web coated with bitumen or another polymer, e.g. pitch
    • D06N5/003—Roofing materials comprising a fibrous web coated with bitumen or another polymer, e.g. pitch 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
    • B32B2250/00—Layers arrangement
    • B32B2250/04—4 layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2250/00—Layers arrangement
    • B32B2250/05—5 or more layers
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2255/00—Coating on the layer surface
    • B32B2255/02—Coating on the layer surface on fibrous or filamentary layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2255/00—Coating on the layer surface
    • B32B2255/06—Coating on the layer surface on metal layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2255/00—Coating on the layer surface
    • B32B2255/10—Coating on the layer surface on synthetic resin layer or on natural or synthetic rubber layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2255/00—Coating on the layer surface
    • B32B2255/12—Coating on the layer surface on paper layer
    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2255/00—Coating on the layer surface
    • B32B2255/24—Organic non-macromolecular coating
    • 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
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    • B32B2260/00—Layered product comprising an impregnated, embedded, or bonded layer wherein the layer comprises an impregnation, embedding, or binder material
    • B32B2260/02—Composition of the impregnated, bonded or embedded layer
    • B32B2260/021—Fibrous or filamentary layer
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    • B32B2260/04—Impregnation, embedding, or binder material
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    • B—PERFORMING OPERATIONS; TRANSPORTING
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    • B32B2419/00—Buildings or parts thereof
    • B32B2419/06—Roofs, roof membranes
    • C—CHEMISTRY; METALLURGY
    • C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
    • C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
    • C08L95/00—Compositions of bituminous materials, e.g. asphalt, tar, pitch

Abstract

The membrane 1 comprises a reinforcing layer 2 having a first and second surface, wherein at least a portion of the first and second surfaces is coated with a modified bitumen composition to provide first 3 and second 4 bitumen layers, the modified bitumen composition comprises bitumen, synthetic rubber and crumb rubber. The membrane may comprise a further layer comprising sand, mineral or plastic film provided on one of the first and second bitumen layers and may be provided on the other of the first and second bitumen layers. The entirety of one or both surfaces may be coated with the modified bitumen composition. The reinforcing layer may be in the form of a sheet. Also disclosed is a method of producing said multi-layer waterproof membrane and the use of the above multi-layer waterproof roofing membrane.

Description

(71) Applicant(s):
Chesterfelt Limited (Incorporated in the United Kingdom) Foxwood Way, Sheepbridge, CHESTERFIELD, Derbyshire, S41 9RX, United Kingdom (72) Inventor(s):
Maria Izquierdo Rodriguez (56) Documents Cited:
GB 2146270 A CN 202866009 U CN 105275156 A US 20160354993 A1 (58) Field of Search:
INT CL E04D Other: EPODOC, WPI
WO 2011/025554 A1 CN 202139765 U US 8298661 B2 (74) Agent and/or Address for Service:
Marks & Clerk LLP
New York Street, MANCHESTER, M1 4HD, United Kingdom (54) Title of the Invention: Waterproof membrane Abstract Title: Multi-layer roofing membrane (57) The membrane 1 comprises a reinforcing layer 2 having a first and second surface, wherein at least a portion of the first and second surfaces is coated with a modified bitumen composition to provide first 3 and second 4 bitumen layers, the modified bitumen composition comprises bitumen, synthetic rubber and crumb rubber. The membrane may comprise a further layer comprising sand, mineral or plastic film provided on one of the first and second bitumen layers and may be provided on the other of the first and second bitumen layers. The entirety of one or both surfaces may be coated with the modified bitumen composition. The reinforcing layer may be in the form of a sheet. Also disclosed is a method of producing said multi-layer waterproof membrane and the use of the above multi-layer waterproof roofing membrane.
Figure GB2560576A_D0001
FIGURE 1
Figure GB2560576A_D0002
FIGURE 2
Figure GB2560576A_D0003
1/1
WATERPROOF MEMBRANE
The present invention relates to a multi-layer waterproof membrane and a method of producing a multi-layer waterproof membrane. More particularly, the present invention relates to multi-layer waterproof roofing membranes comprising modified bitumen compositions and a method of making the same.
Waterproof membranes are typically used as roofing materials and are primarily used as roofing materials for non-residential properties, residential, and commercial properties. The membranes generally comprise a base sheet onto which a layer of bitumen is applied. The bitumen renders the membrane impermeable to water and the base sheet provides a medium onto which the bitumen can be applied.
However, known waterproof membranes suffer from a number of drawbacks. Firstly, bitumens are complex hydrocarbon products composed of very different categories of chemicals, namely asphaltenes and maltenes. The mechanical properties of bitumen are highly dependent on temperature. For example, at temperatures below about 0°C, bitumen is rigid and fragile, whereas at temperatures above about 38°C, bitumen is plastic, soft, and very adhesive. As such, at low temperatures and medium temperatures (around 25°C), bitumen is not sufficiently adhesive to be attached to a surface or substrate, such as a roof, through pressure alone. Since bituminous membranes are often intended to be used as roofing, they are exposed to extremes of temperature. Due to the changes in physical properties of bitumen at different temperatures, this may result in a reduction in performance of the membrane over time and possibly failure. If the waterproof membrane fails, this will generally only be noticed when the roof starts to allow water ingress into the building and this may result in damage to the roof, the building structure itself or the contents of the building.
It is known to modify bitumen to improve its mechanical properties. For example, US8298661 discloses a vapour barrier in which the barrier comprises a carrier support layer and an adhesive bitumen layer. The adhesive layer comprises a bitumen composition comprising bitumen, synthetic rubber, high density polyethylene, ground vulcanised crumb rubber and a plasticiser. The vapour barrier includes a removable release sheet on the adhesive layer. The release sheet stops the barrier from adhering to itself when it is rolled up. The bitumen is modified such that it has adhesive properties at low temperatures. The adhesive layer comprises a pressure sensitive bitumen composition which is attached to surfaces simply by the application of pressure and without requiring external heating. This type of barrier is known in the art as a 'peel and stick' product as the release sheet can be removed to reveal a bituminous layer which can be applied directly to a surface without the need for heating. The HDPE is intended to provide the modified bitumen with good high temperature flow resistance. 'Peel and stick' vapour barriers are not resilient enough to serve as roofing membranes. In addition, since the vapour barrier needs to be applied by pressing the vapour barrier to a substrate, it may be difficult to ensure adhesion between the vapour barrier and the substrate across the entire area of the barrier. Further, since the bituminous layer is required to have a degree of adhesiveness to allow it to be applied to a substrate, it may be unsuitable to be applied using heat as the heat may damage the thin membrane or cause the bituminous layer to become too fluid and result in an inconsistent thickness of the bitumen across the barrier. In addition, since the vapour barrier is applied using pressure only, this requires the bitumen layer to have a degree of adhesiveness. The degree of adhesiveness must be sufficient at ambient temperatures to allow the vapour barrier to be attached to the substrate. Therefore, at low temperatures, for example of less than 10°C, the bitumen may lose its adhesiveness thereby making it unable to be affixed to a substrate.
Blown bitumens, which are dark petroleum residues modified by oxidation, are known in the art and have been used in the production of roofing felts or membranes for many years and generally provide satisfactory performance. However, the requirements of the industry now often mean that high performance roofing felts or membranes are needed. Such high performance membranes require a high degree of elasticity and improved durability.
There are two main groups of compounds which can be used to modify the waterproof coating in roofing felts to achieve improved performance, both of which can be processed on roofing product manufacturing machines. One type is the thermoplastic polyolefin group, the plastomers, and the other is the thermoplastic rubber group, the elastomers. The most prominent plastomer in the field of roofing products is atactic polypropylene (APP), whilst the most commonly used of the thermoplastic rubbers are styrenic block copolymers.
Elastomers such as SBS (styrene-butadiene-styrene), SBR (styrene-butadiene-rubber), SIS (styreneisoprene-styrene) and SEBS (styrene-ethylene-butylene-styrene) are typically blended with bitumen to produce modified bitumen with improved flexibility, fatigue resistance, strength, resistance to permanent deformation and elasticity. Inherent rheological properties of bitumen are changed from predominantly visco-elastic to elastic. Thermoplastic block copolymers SBS are the best performing copolymers in bitumen modification. These provide the desired characteristics of high temperature softening, penetration at ambient temperatures and low temperature flexibility.
Thermoplastics such as ethylene vinyl acetate (EVA), APP, and polypropylene have also been used for bitumen modification. Modification with APP produces a heavy coating of high melting point bitumen particularly suitable for the torch welding method of bonding. In this method, a torch is used to apply heat to bitumen to make it more adhesive and thereby provide a better bond once the bitumen has cooled. Once the bitumen has been heated, it may be applied to a roof and allowed to cool. Once the bitumen has cooled, it provides a strong bond to the substrate on which it has been applied.
Further, bitumen blended with crumb rubber, e.g. ground rubber, ground recycled rubber, ground tyre rubber or recycled tyre rubber, has been used extensively. Crumb rubber is obtained by grinding used tyres or any other appropriate source. Bituminous compositions comprising crumb rubber increase fatigue life and elasticity, reduce reflective cracking and low-temperature cracking whilst improving tensile strength. Furthermore, since the crumb rubber is made from used tyres, there are also environmental advantages.
Inert fillers include inorganic powders such as limestone, slate dust (slate flour), hydrated lime, cement, silica, and gypsum as well as fibres, such as cellulose. The addition of fillers generally makes the bitumen harder and stiffer. This results in the deformation or flow produced by a given load and is shown by an increase in softening point, a reduction in penetration and an increase in stiffness. The extent of the hardening or stiffening effect depends on the amount of filler added as well as the particle size, shape and grading.
The present invention has been made in consideration of the known problems with existing waterproof membranes.
According to a first aspect of the present invention, there is provided a multi-layer waterproof membrane comprising a reinforcing layer having a first surface and a second surface, wherein at least a portion of the first and second surfaces is coated with a modified bitumen composition to form first and second bitumen layers, the modified bitumen composition comprising bitumen, synthetic rubber, and crumb rubber.
The provision of a modified bitumen layer on both sides of the reinforcing layer provides for a robust and versatile waterproof membrane. In addition, the provision of a modified bitumen layer on both sides of the reinforcing layer also allows for the provision of further layers of materials on one or both sides of the reinforcing layer. As such, a weather-resistant layer of sand, mineral, or plastic may be provided on an upper surface of the multi-layer membrane to provide additional resistance to the weather or to protect the membrane from direct sunlight. Mineral may be slate. The slate may be granulated, crushed, or powdered. The upper surface is the surface that will face generally upwards when the membrane is affixed to a roof. Preferably, the weather-resistant layer is affixed to the membrane by the modified bitumen. In addition, by having both faces at least partially coated with the modified bitumen composition, the reinforcing layer is waterproofed on both sides by the modified bitumen layer, so materials which would normally be damaged or weakened by water, such as paper or organic fibres (natural fibres), can be used as the reinforcing layer. This also allows materials which could degrade over time due to exposure to air to be used. In addition, in cases where the reinforcing layer is able to retain water, by having both faces of the reinforcing layer at least partially covered by the modified bitumen composition means that the membrane does not absorb water. If water were to be absorbed this could result in the weight of the membrane increasing, causing increase strain on the membrane itself and any roof to which it is applied. In addition, this may result in water being held in close proximity to the substrate to which the membrane is applied. The substrate may be, for example, wooden joists or boards or metal sheets. The substrate may also be an underlayer of another roofing membrane or material. By retaining moisture in proximity to the substrate, this could lead to degradation of the substrate. As such, having at least a portion of both sides of the reinforcing layer at least partially coated with the modified bitumen composition results in cost savings and allows recycled materials to be used and is therefore more environmentally friendly. In addition, the multi-layer waterproof membrane according to the first aspect of the present invention may be mechanically fixed to a substrate, such as by way of nails, staples, tacks, or similar due to it having an extra layer of bitumen when compared to known membranes which provides additional strength.
As such, a further layer comprising sand, mineral or plastic film may be provided on at least one of the first and second bitumen layers.
Preferably, a layer comprising sand, mineral or plastic film is provided on the other of the first and second bitumen layers.
The sand, mineral, or plastic film serves to provide for a more robust multi-layer waterproof membrane that is resistant to the weather and direct sunlight. They also may obviate the need for a release sheet, which is used to stop pressure-applied membranes from adhering to themselves when they are rolled up. Removing the need for a release sheet reduces the waste produced and makes application of the membrane to a substrate easier. However, a release sheet may be used with the multi-layer membrane of the present invention, if required.
Any combination of sand, mineral or plastic film may be provided on the first and second bitumen layers. For example, both layers may be provided with sand, mineral or plastic film. In other examples, one layer may be provided with sand and the other layer may be provided with mineral or plastic film. The plastic film may be a high density polyethylene (HDPE) film or a low density polyethylene (LDPE) film. A mixture of sand, mineral and/or plastic film may be provided on the first and second bitumen layers.
Preferably, sand, mineral, and/or plastic film is provided on both the first and second bitumen layers.
Preferably, the membrane is a heat-applied membrane. The term heat-applied is a term of the art and the skilled person would understand that this defines a membrane which requires heating of the membrane itself and/or of bitumen applied to a substrate, such as a roof, in order to attach the membrane to the roof. The membrane may be described as a 'torch-on' membrane since a torch is used to heat the bitumen in the membrane and/or the bitumen applied to a substrate to assist in adhesion. Another method for applying the membrane of the present invention to a substrate is via the pour and roll method. In this method, a liquid or semi-liquid bitumen composition is applied to a substrate. Whilst the bitumen is still in a liquid or semi-liquid state, the membrane of the present invention is applied on top of the bitumen. Rollers are then used on the surface of the membrane away from the liquid or semi-liquid bitumen to push the membrane into the bitumen. The heat of the liquid or semi-liquid bitumen at least partially melts at least a portion of the modified bitumen composition applied to the membrane of the present invention. The membrane may also be heated by any suitable means, such as a torch, in order to assist the bonding process. When allowed to cool, this forms a strong bond between the membrane and the substrate.
Thus, heat applied membranes are very different to pressure applied membranes and pressure applied membranes may become damaged if they are applied using heat. The membrane of the first aspect of the present invention may be applied to a substrate by bonding with hot bitumen, fused by torch application, mechanical fixing, or by a cold applied method.
Preferably, the multi-layer waterproof membrane is a roofing membrane. Roofing membranes are required to be resistant to the weather and are therefore thicker than vapour membranes, which are used to simply exclude moisture and are not required to resist the weather. The provision of the modified bitumen layer on both sides of the reinforcing layer, with the option of additional layers of sand, mineral, or plastic film on one or both sides, allows the multi-layer waterproof membrane of the present invention to act as a roofing material, which is in contrast to prior art membranes which are not sufficiently robust to act as roofing materials by themselves, but only as underlays.
The reinforcing layer may be of any suitable construction. The reinforcing layer may be porous or non-porous. The reinforcing layer may be woven or non-woven. The reinforcing layer may be a porous, non-directional tissue. The reinforcing layer may be in the form of a sheet. The reinforcing layer may comprise plastic, metal, fibreglass, paper, hessian, polyester, or any other suitable material. The reinforcing layer may comprise resin-bonded fibreglass. The reinforcing layer may comprise a non-woven sheet of polyester staple fibres and/or polyester continuous filaments.
Preferably, the reinforcing layer comprises rag fibre paper and/or rope brown paper. Preferably, the paper weight is from about 120 g/m2 to about 600 g/m2, more preferably from about 250g/m2 to about 350g/m2. In another embodiment, the weight of the paper is from about 120g/m2 to about 350 g/m2, and preferably from about 135 g/m2 to about 170 g/m2. The weight of the paper may be from about 170g/m2 to about 350 g/m2.
In combination with the paper, hessian scrim may also be used. The weight of the hessian scrim may be about 90 g/m2 to about 110 g/m2, and preferably from about 92 g/m2 to about 105 g/m2.
The reinforcing layer may comprise a bitumen-saturated and coated paper sheet. The reinforcing layer may further comprise at least one hessian sheet. The at least one hessian sheet may be attached to at least one side of the paper sheet. The paper sheet and hessian sheet may be laminated together using the modified bitumen composition. As such, the reinforcing layer may itself by multi-layered. The paper sheet may comprise rag fibre paper and/or rope brown paper. The rag fibre paper or rope brown paper may be recycled from waste paper and textiles.
In another embodiment, the reinforcing layer may comprise a non-woven glass fibre carrier made of bonded chopped fibreglass strands formed into a porous non-directional tissue. The glass fibre carrier bound by a modified urea formaldehyde resin, which is a highly cross-linked thermoplastic. The weight of the fibreglass carrier is typically from about 60 g/m2 to about 120 g/m2, and preferably from about 65 g/m2 to about 100 g/m2.
In another embodiment, the reinforcing layer comprises a non-woven polyester fabric, which is optionally reinforced. The spun-bonded polyester non-woven layer is bonded mechanically, for example by a needle punching process, and then thermally bonded via a low melt polymer. The weight of the polyester fabric is typically from about 100 g/m2 to about 350 g/m2, and preferably from about 150 g/m2 to about 250 g/m2. The polyester fabric may be reinforced with glass filaments in the machine direction. The weight of the reinforced polyester fabric is typically from about 100 g/m2 to about 350 g/m2, and preferably about 150 g/m2 to about 250 g/m2.
It will be appreciated that the modified bitumen composition may be absorbed into the reinforcing layer and/or may form a continuous sheet of modified bitumen which permeates from one side of the reinforcing layer to the other. Thus, the first and second bitumen layers do not have to be entirely distinct or separate from one another and may be at least partially connected. However, at least a portion of both sides of the reinforcing layer is coated with the modified bitumen composition. Having both sides of the reinforcing layer being at least partially coated with the modified bitumen composition provides a membrane which has improved resistance to the weather and allows for long-term use as a roofing membrane. In addition, since the modified bitumen composition is applied to both sides of the reinforcing membrane, this makes the method of producing a multi-layer waterproof membrane more straightforward. If a different material were to be applied to both sides of the reinforcing layer, this would increase the complexity and cost of the manufacturing process.
The modified bitumen composition preferably does not comprise or include high density polyethylene (HDPE). Since the membrane of the first aspect of the present invention is a heatapplied membrane, the inclusion of HDPE would have no benefit to the desired properties of the modified bitumen composition and may actually cause the membrane to be unsuitable for application using heat.
The modified bitumen composition preferably does not comprise a plasticiser. Preferably, the modified bitumen composition does not comprise a petroleum-based oil plasticiser. Examples of petroleum-based plasticisers include aromatic, naphthenic and paraffinic oil. Since the multi-layer waterproof membrane of the present invention is a heat-applied membrane, the modified bitumen composition is exposed to naked flames during normal application and the use of a petroleum-based oil plasticiser may present a fire hazard. In addition, once installed, the membrane of the present invention provides less of a fire risk. Further, the chance of volatile organic compounds being released is reduced in view of the absence of petroleum-based oil plasticisers. In addition, since the multi-layer waterproof membrane of the present invention is a roofing membrane, the membrane may be exposed to direct sunlight and therefore heat up. If the membrane comprises bitumen which softens or liquefies at temperatures below those observed when the membrane is exposed to direct sunlight, as would be the case with a bitumen comprising a plasticiser, this may result in the membrane becoming detached from the substrate to which it is attached over time.
The modified bitumen composition may comprise about 70 to 95% by weight bitumen. Preferably, the modified bitumen composition comprises about 80 to 93% by weight bitumen, and more preferably about 85 to 92% by weight bitumen.
The modified bitumen composition may comprise about 1 to 15% by weight synthetic rubber. Preferably, the modified bitumen composition comprises about 1 to 10% by weight synthetic rubber, and more preferably about 1 to 6% by weight synthetic rubber.
The modified bitumen composition may comprise about 1 to 25% by weight crumb rubber. Preferably, the modified bitumen composition comprises about 2 to 20% by weight crumb rubber, and more preferably about 4 to 16% by weight crumb rubber.
The modified bitumen composition may comprise inorganic filler. The amount of organic filler is independent of the levels of the bitumen, synthetic rubber, and crumb rubber, which will remain in the same ratios as outlined above. The inorganic filler may comprise from about 0% to about 50% by weight of the total composition of bitumen, synthetic rubber, crumb rubber and inorganic filler.
The inorganic filler may be one of, or a mixture of, limestone, slate dust (slate flour), hydrated lime, cement, silica, and gypsum, as well as fibres such as cellulose.
The bitumen may be of any suitable type. Preferably, the bitumen is of penetration grade bitumen used for roofing membrane production. Suitable bitumens have a penetration value, as measured according to Standard EN 1426, in the range of from about 20 to 350 dmm, preferably from about 40 to about 250 dmm, and most preferably from about 70 to about 200 dmm. Penetration grade is a term of the art and the skilled person would recognise the types of bitumen which are covered by this meaning. The penetration grade bitumen may be of any of the following grades 40-50, 60-70, 85-100, 120-150, and 200-300. Preferably, the bitumen used is 160/220. The bitumen may be combined or blended with other bitumens in order to accommodate different anticipated working conditions.
The synthetic rubber may be any suitable synthetic rubber used for bitumen modification. Particularly suitable rubbers include SIS, SEBS, styrene-butadiene (SB) block copolymers and SBR, as well as mixtures or blends of two or more synthetic rubbers. Preferably, the synthetic rubber comprises styrene-butadiene-styrene (SBS). Preferably, the synthetic rubber is radial SBS. Preferably, the SBS is in the form of a pellet, granule, flake or powder. The SBS may comprise radial or linear SBS, or a mixture of radial and linear SBS.
The crumb rubber may be from any suitable source. Preferably, the crumb rubber comprises recycled crumb rubber from vehicle tyres. The rubber may be vulcanised or devulcanised. The crumb rubber may be basic tyre tread rubber. The rubber may comprise a blend of natural rubber and styrene-butadiene rubber. The average particle size (weight average) of the crumb rubber is from about 0.15 mm to about 0.6 mm, preferably from about 0.3 mm to about 0.5 mm. Preferably, the average particle size (weight average) is around 0.4 mm.
The multi-layer waterproof membrane comprises the modified bitumen composition on both sides of the reinforcing layer. As such, the multi-layer waterproof membrane comprises at least three layers, namely a first modified bitumen layer, the reinforcing layer, and the second modified bitumen layer.
In other embodiments, the multi-layer waterproof membrane comprises at least four layers. In particular, the multi-layer waterproof membrane may comprise a layer comprising sand, mineral or plastic film, a second layer comprising a modified bitumen composition, a third layer comprising a reinforcing layer, and a fourth layer comprising a modified bitumen composition.
In another embodiment, the multi-layer waterproof membrane comprises at least five layers. In particular, the multi-layer waterproof membrane may comprise a layer comprising sand, mineral, or plastic film, a second layer comprising a modified bitumen composition, a third layer comprising a reinforcing layer, a fourth layer comprising a modified bitumen composition, and a fifth layer comprising sand, mineral, or plastic film.
The multi-layer waterproof roofing membrane of the first aspect of the present invention may comprise a removable release sheet. The removable release sheet may comprise a plastic film, sand, or mineral. As such, at least one of the layers in addition to the reinforcing layer and the first and second bitumen layers may be a release layer.
The multi-layer waterproof membrane of the first aspect of the present application may be provided in sheet-like laminates with a width in the range of from about 30 cm to about 130 cm, from about 45 cm to about 120 cm, and preferably from about 80 to 110 cm. The length of the membranes may be from about 5 to about 30 m, from about 5 to about 25 m. The membrane may be provided rolled up into a roll.
The multi-layer waterproof membrane of the first aspect of the present invention may have a thickness of from about 0.5 mm to 10 mm, from about 1 to about 5 mm, and preferably from about 1.5 to about 3.7 mm.
In a second aspect of the present invention, there is provided a method for producing a multi-layer waterproof roofing membrane comprising; providing a reinforcing layer having a first surface and a second surface; coating at least a portion of the first surface and the second surface with a modified bitumen composition comprising bitumen, synthetic rubber, and crumb rubber; and allowing the membrane to cool.
In one embodiment, a layer comprising sand, mineral or plastic film is applied to at least one of the first surface and the second surface. A layer comprising sand, mineral or plastic film may be applied to the other of the first surface and the second surface.
The multi-layer waterproof roofing membrane produced according to the method of the second aspect of the present invention may comprises any embodiment or combination of features as described in respect of the membrane of the first aspect of the present invention.
In a third aspect of the present invention, there is provided a use of a multilayer waterproof membrane according to the first aspect of the present invention or produced by a method according to the second aspect of the present invention.
The invention of the first and second aspects of the present invention will now be further described with reference to the following non-limiting figures in which:
Figure 1 is a cross-section through a multi-layer waterproof membrane according to the first aspect of the present invention; and
Figure 2 is a flowsheet of the method of producing a multi-layer waterproof membrane according to the first aspect of the present invention.
Figure 1 illustrates a cross-section through a multi-layer waterproof membrane 1. A reinforcing layer 2 is provided and has a first and a second surface. A modified bitumen composition comprising bitumen, synthetic rubber, and crumb rubber is provided on the first surface to provide a first bitumen layer 3 and is also provided on the second surface to provide a second bitumen layer 4. A layer 5 comprising sand, mineral, or a plastic film, such as HDPE or LDPE, is provided on the second bitumen layer 4. On the first bitumen layer 3, there is provided a layer 6 comprising sand, mineral, or a plastic film, such as HDPE or LDPE.
Figure 2 is a flowsheet of the method according to the second aspect of the present invention. A material to be used as the reinforcing layer is usually provided in a roll. The material is unrolled, where necessary, and then coated on both sides in a modified bitumen composition comprising bitumen, synthetic rubber, and crumb rubber. A layer of sand, mineral, or plastic film is then applied to at least one side of the coated reinforcing layer by conventional means. The membrane is allowed to cool and is then rolled up into a roll. The rolled-up membrane may then be packaged in any suitable manner. The skilled person will recognise that unrolling the material may not be required where the reinforcing material is provides in sheets, and that rolling up the finished material and packaging it may similarly not be required.
The multi-layer waterproof membrane of the present invention provides numerous advantages over known membranes. The membrane of the present invention has improved low-temperature flexibility and fatigue resistance and is easier to apply and has better adhesion than known membranes. In addition, due to the inclusion of recycled ground rubber, the present invention offers environmental benefits too.

Claims (25)

1. A multi-layer waterproof roofing membrane comprising a reinforcing layer having a first surface and a second surface, wherein at least a portion the first and second surfaces is coated with a modified bitumen composition to provide first and second bitumen layers, the modified bitumen composition comprising bitumen, synthetic rubber, and crumb rubber.
2. A multi-layer waterproof roofing membrane according to Claim 1, wherein a further layer comprising sand, mineral or plastic film is provided on at least one of the first and second bitumen layers.
3. A multi-layer waterproof roofing membrane according to Claim 2 wherein a layer comprising sand, mineral or plastic film is provided on the other of the first and second bitumen layers.
4. A multi-layer waterproof roofing membrane according to any preceding claim, wherein the entirety of the first or second surface is coated with the modified bitumen composition.
5. A multi-layer waterproof roofing membrane according to Claim 4, wherein the entirety of both surfaces are coated with the modified bitumen composition.
6. A multi-layer waterproof roofing membrane according to any preceding claim, wherein the membrane is a heat-applied or torch-on membrane.
8. A multi-layer waterproof roofing membrane according to any preceding claim, wherein the reinforcing layer is in the form of a sheet.
9. A multi-layer waterproof roofing membrane according to any preceding claim, wherein the reinforcing layer is porous.
10. A multi-layer waterproof roofing membrane according to any of Claims 1 to 8, wherein the reinforcing layer is non-porous.
11. A multi-layer waterproof roofing membrane according to any preceding claim, wherein the reinforcing layer comprises plastic, metal, fibreglass, paper, hessian or polyester.
12. A multi-layer waterproof roofing membrane according to any preceding claim, wherein the reinforcing layer is a porous, non-directional tissue, or resin-bonded fibreglass, or a non-woven sheet of polyester staple fibres and/or continuous polyester filaments.
13. A multi-layer waterproof roofing membrane according to any of Claims 1 to 11, wherein the reinforcing layer comprises a bitumen-saturated and coated paper sheet.
14. A multi-layer waterproof roofing membrane according to Claim 13, wherein the reinforcing layer further comprises at least one hessian sheet
15. A multi-layer waterproof roofing membrane according to Claim 14, wherein the at least one hessian sheet is applied on at least one side of the paper sheet.
16. A multi-layer waterproof roofing membrane according to any one of Claims 11 to 15, wherein the paper sheet comprises rag fibre paper and/or rope brown paper.
17. A multi-layered waterproof roofing membrane according to Claim 16, wherein the rag fibre and/or rope brown paper is recycled from waste paper and textiles.
18. A multi-layer waterproof roofing membrane according to any preceding claim, wherein the modified bitumen composition does not comprise HDPE.
19. A multi-layer waterproof roofing membrane according to any preceding claim, wherein the modified bitumen composition does not comprise a petroleum-based oil plasticiser.
20. A multi-layer waterproof roofing membrane according to any preceding claim, wherein the modified bitumen composition comprises from about 70 to about 95% by weight bitumen, preferably from about 80 to about 93% by weight bitumen, and more preferably about 85 to about 92% by weight bitumen.
21. A multi-layer waterproof roofing membrane according to any preceding claim, wherein the modified bitumen composition comprises from about 1 to about 15% by weight synthetic rubber, preferably about 1 to about 10% by weight synthetic rubber, and more preferably about 1 to about 6% by weight synthetic rubber.
22. A multilayer waterproof roofing membrane according to any preceding claim, wherein the modified bitumen composition comprises about 1 to about 25% by weight crumb rubber, preferably about 2 to about 20% by weight crumb rubber, and more preferably about 4% to about 16% by weight crumb rubber.
23. A multi-layer waterproof roofing membrane according to any preceding claim, wherein the membrane comprises at least four layers.
24. A multi-layer waterproof roofing membrane according to Claim 23, wherein the membrane comprises at least five layers.
25. A method for producing a multi-layer waterproof roofing membrane comprising: providing a reinforcing layer having a first surface and a second surface; coating at least a portion of the first surface and the second surface with a modified bitumen composition comprising bitumen, synthetic rubber, and crumb rubber; and allowing the membrane to cool.
26. Use of a multi-layer waterproof roofing membrane according to any of Claims 1 to 24 or as produced by a method according to Claim 25 as a roofing membrane.
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Application No: GB1704270.6 Examiner: Miss Erin Bunton
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WO2023237609A1 (en) * 2022-06-07 2023-12-14 Sika Technology Ag A method for sealing a substate

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