KR850001344B1 - Water-proof treated laminate product - Google Patents

Abstract

A waterproofed construction comprises a substrate having a continuous adherent waterproofing layer, which consists of a plurality of pre- formed, flexible, pressure-sensitive, adhesive waterproofing laminates. The pre-formed laminates are comprised of an upper support layer (a) laminated to a lower layer (6) of a waterproofing, pressure-sensitive, thermoplastic, bituminous adhesive compsn. (a) comprises the first and second layers of flexible sheet material laminated together, of which the first layer has a higher coeff. of linear thermal expansion than the second layer. Thus, the edges of the laminates curl downward towards the said substrate when exposed to an elevated temp.

Description

Waterproof structure

1 is a cross-sectional perspective view of a roofing laminate according to the present invention.

2 is a cross-sectional view of a preferred laminate structure of the present invention showing internal tip seal.

3 is a cross sectional view of two overlapping laminates showing the inner tip sealing force.

4 is a cross-sectional perspective view of a roof waterproofed in accordance with the present invention.

The present invention relates to a waterproof structure consisting of a substrate and a continuous waterproof layer attached thereto. In more detail, the present invention is waterproofed with a plurality of adhesive laminates, prepared by laminating an upper support layer consisting of first and second layers having different coefficients of linear thermal expansion to a lower layer made of a thermoplastic bituminous adhesive composition. It is about a structure.

The present invention provides a bituminous waterproofing layer-containing laminate suitable for waterproofing and sealing structures. The improved preformed flexible sheet laminate of the present invention is a pressure-sensitive type or a self-adhesive type used for roofing applications such as waterproof membranes, and is made of a laminated sheet material having a different coefficient of thermal expansion. A layer of bituminous waterproofing composition combined with a support layer is used.

The factory-formed adhesive bituminous waterproofing layer and the flexible sheet-like laminate of the support film are made of a conventional waterproof membrane which is applied in situ by laminating one or more layers of bitumen-impregnated paper or felt and bituminous adhesive. It has been widely used as a counterpart. Preformed tacky laminate membranes are consistently manufactured at the factory, eliminating the need for handling hot materials or using heating devices in the workplace, and are excellent in performance.

Flexible laminates of the type described above and their use as waterproofing membranes in various structures are described in John Hurst, US Pat. Nos. 3,741,856, 3,853,683 and 3,900,102. These patents describe methods of making flexible laminates that contain a backing, such as a layer of polymeric film or metal film, and a tacky bitumen-elastic waterproof composition. In particular, the laminate described in U.S. Patent No. 3,900,102 is manufactured in a factory in the form of a roll having a protective sheet such as silicone paper used for a sticky bituminous waterproofing layer, which is transported to a work place so that the adhesive surface is directed downward. It is possible to provide a continuous watertight seal by constructing and constructing each successive laminate strip so as to overlap the tip of the laminate strip that has been constructed first.

Ivette R. Canadian Patent No. 1.008,738 to Everett R. Davis describes an improved waterproof laminate of the same type as described in the above United States patents, wherein cross-laminated or biaxially cultured polymer films are described on the mentioned laminates. Use as a support material. As described in the Canadian patent above, the support film reduces the wrinkling of the laminate that is accompanied when the laminate is adhered to the substrate and subsequently exposed to heat (eg, sun exposure). Recently, preformed soluble laminates using cross-laminated high-density polyethylene film as a backing layer for the adhesive waterproof layer of asphalt-rubber compositions have been applied to roofs of various types of buildings in the form of overlapping strips, preventing long-term penetration of water and moisture. The method of forming the protective film which has been used widely. Protective coatings containing inert aggregates, pigments, metal flakes and the like were applied to the exposed surfaces of the laminated laminates to significantly extend the life of the waterproof laminate film. However, there is still a need in the art for a more advanced flexible laminate that can be used as a waterproof roof for building roofs.

The present invention relates to a laminate having a layer of a waterproof pressure sensitive or tacky bituminous composition that is completely attached to a layer of top and preferably a flexible support foil, the support having a different coefficient of thermal expansion, arranged to provide the laminate with the desired self-sealing force. To a waterproof structure. The laminate of the present invention preferably further has a layer of protective material adjacent to the adhesive layer, which can be removed from the adhesive layer without damage before adhering onto the substrate to be waterproofed. The laminate mentioned may further have a protective coating and / or film applied to the top layer before and after construction on the substrate to be waterproofed.

1 shows adhesion to a relatively thin support layer 7 made by laminating separate flexible sheets 2 and 3, such as a sheet of metal foil 2 and polymer film 3 or a sheet of two different synthetic polymer films. A roofing laminate of the present invention is shown consisting of a relatively thin layer 1 of bituminous waterproofing composition. Since the illustrated layers 1, 2 and 3 adhere well to each other, they do not separate from each other until the physical damage is such that they are separated into one or more layers. Although not shown, layers 2 and 3 are bonded to each other by a thin layer of adhesive, and the mentioned thin layers serve only to bond the two layers. The adhesive bituminous waterproofing layer 1 has sufficient adhesive properties such that no additional adhesive is required to completely adhere to the supporting layer 7. In order to protect the surface of the bituminous adhesive layer located away from layer 7, a removable protective sheet 4 such as silicone paper is attached to the surface of the adhesive layer mentioned. The protective sheet 4 mentioned does not fall off during handling of the laminate and is attached to the bituminous adhesive layer so that it is still attached, but it should be able to be easily separated and removed without physically damaging the layer 1.

The roofing laminate shown in FIG. 2 has a width ("W") of 91.44 cm (36 inches) and a length ("ι") of less than 60 feet (1828.8 cm). It is desirable to package this in the form of a roll, the substrate being unrolled in the workplace, the protective sheet 4 removed, and the substrate to be waterproofed of the exposed surface of the bituminous adhesive layer 1 (FIGS. 2, 3 and To 5 in Figure 4). Then another identical waterproof laminate strip is bonded in a position adjacent to the first bonded laminate. Care should be taken to ensure that the ends of each laminate slightly overlap, as in the method in Hurst, US Pat. Nos. 3,900,102 (eg, FIGS. 3 and 4). Additional continuous protective coating 6 can then be applied to the exposed surfaces of the laminated laminates as in FIG.

It is preferable that the sticky or pressure-sensitive bituminous waterproofing layer 1 useful in the present invention is of the type described in the aforementioned patent. Such a tacky composition consists of a mixture of a bituminous material with a natural or synthetic polymer, preferably a rubber or other elastomer. The amount of polymer used in the mentioned compositions is usually from about 1 to 100%, preferably from about 20 to 50% by weight of the bituminous material. As used herein, the term "bituminous material" includes compositions containing asphalt, tar (eg coal tar) or pitch. The bituminous adhesive compositions mentioned can be reinforced with fibers and / or atomizing fillers. Such an adhesive composition may contain a conventional weight component such as inorganic oil. Preferred polymers include thermoplastic polymers such as polyethylene and the like. As mentioned above, the preferred polymer component may be either fresh or reclaimed rubber, which is converted to a soft mixture by mixing with bitumen and preferably a heavy oil component at elevated temperatures. Typically preferred adhesive compositions have a softening point (measured by the Ring and Ball method) of 70 ° to 120 ° C., preferably 75 ° to 100 ° C. and a transmission of 50 to 400, preferably 50 to 100 dmm at 25 ° C., Has thermoplastic properties.

As mentioned in the above patents, in order to provide optimum sealing and waterproofing performance, the thickness of the adhesive layer mentioned is at least 0.025 cm (0.010 inch), preferably about 0.064 cm (0.025 inch) to about 0.508 cm (0.200). Inches). Such adhesive layers need not all be of the same composition, but may consist entirely of one or more of the aforementioned bituminous adhesive layers that can provide a thickness in the range described above. Furthermore, the adhesive layer may contain reinforcing materials that provide strength, such as opening fabrics, gauze or scrims, and the like. The adhesive layer 1 mentioned should be pressure sensitive and tacky at ambient temperature so that at least only the surface portion located away from the support sheet 3 can be adhered to the substrate. The bituminous adhesive layer forms a continuous waterproof coating and serves to elastically seal the holes at high and low temperatures.

The support layer 7 consists of a laminate bonded to the adhesive layer 1. This support layer 7 serves as a strength imparting and supporting film in the laminate, and also serves as a barrier to prevent water vapor from permeating the laminate. The support layer 7 thus has a thickness less than the thickness of the bituminous waterproofing layer 1, but should be of sufficient thickness to give the laminate, for example, tear and puncture resistance. The mentioned support layer 7 has a thickness of about 0.005 cm (0.002 inches) to about 0.064 cm (0.025 inches), preferably about 0.010 cm (0.004 inches) to about 0.025 cm (0.010 inches).

Preferred sheet materials which can be used for layer 7 are synthetic organics such as polyethylene, polypropylene or other polyolefins, polyamide polyesters such as polyethylene, terephthalate, polyurethane, polyvinylchloride, copolymers of vinyl chloride and vinylidene chloride. Films of polymers; Films of synthetic rubber such as polychloroprene or butyl rubber; And a film of metal or gold foil such as aluminum, copper or zinc. The upper sheet 3 of the film preferably has optimal weatherability. The polymer film can thus be made opaque, for example by adding a material such as carbon black. Protective coatings and films, such as colored laminates and films colored at the time of manufacture at the factory, may be applied to the surface of sheet 3 which is exposed to the climate.

Cross-laminated polymer films and bi-oriented polymer films are preferred synthetic polymer films that can be used in the layer 7 mentioned. As mentioned in the aforementioned Canadian patent, the above-mentioned film is further dimensionally stabilized when laminated on a bituminous adhesive layer of the type used in the present invention, adhered to a roof substrate and exposed to solar heat. Any film-forming polymer or copolymer capable of biaxial orientation or cross lamination can be used. Biaxially oriented films of polyolefin polymers such as high- and low-density polyethylene, vinylidene chloride, polystyrene, polyvinylchloride, rubber hydrochloride, polyethylene terephthalate and the like are commercially available. Particularly useful films are biaxially oriented polyolefins and cross-laminated polyolefins. Preferred polymer films that can be used for the support layer 7 are cross-laminated high-density polyethylene films such as polyethylene terephthalate and fillers such as carbon black, which make the film opaque, and biaxially cultured polyesters. Metal films or foils of about 0.00064 (0.00025 inches) to about 0.010 cm (0.004 inches) may be used as the sheet material for the mentioned support layer 7.

Layer 2 of the sheet material located directly below layer 3 is selected to have a coefficient of linear thermal expansion smaller than that of upper sheet 3 so that the tacky waterproof laminate exhibits an inner tip sealing force. After adhering such a laminate to the roofing organ, the tip of the laminate is bent downward toward the substrate by self-sealing and dried after a certain period of time. In practice, this occurs because the bonded laminate is exposed to repeated cycles of heating and cooling resulting from changes in ambient temperature. Since the upper flexible sheet layer 3 in the support layer has a larger coefficient of thermal expansion than the lower sheet layer 2 in the support, these two layers are closely bonded to each other, and the front end of the laminate has the property of drying downwardly, The tip of the laminate is preferably waterproof sealed. Such downward curling becomes irreversible because the thermoplastic bituminous adhesive layer fixes the laminate in a downwardly dried position. Sheets 2 and 3 having different coefficients of thermal expansion used in the support layer of the present invention should be of a material having a relatively good thermal dimensional stability and a near flat plate. The term " almost flat appearance " means a state where the upper and lower surfaces of the sheet material are substantially parallel to the horizontal plane and hardly curled upward or downward when unfolded without being adhered onto the flat plate. By "good thermal dimensional stability" is meant that the sheet-like material hardly shrinks when exposed to elevated temperatures, or shrinks to such an extent that at least impairs the desired self-sealing effect of the laminate. If one or both of the sheets 2 or 3 used in the support layer 7 is curled to a significant extent, for example, before adhering the adhesive layer 1 or considerably shrinks upon heating, the inherent shrinkage or curl of the materials mentioned is different. The use of layers with a coefficient of thermal expansion can reduce the self-sealing force of the given laminate. In the support layer 7, the lower layer 2 of the sheet material is preferably thinner than the upper layer of the sheet material.

One example of the laminate of the present invention, which exhibits the above-described inner tip sealing force after adhering to a roof substrate, is the laminate described in the presently pending US Patent Application No. 159,753, which is almost the upper layer 3 of the sheet material described above. A layer of high-density polyethylene having plate properties and good thermal stability is used, and aluminum foil having the same properties as the bottom layer 2 is used. Since the mentioned polyethylene film has a coefficient of thermal expansion about 5 times greater than the coefficient of thermal expansion of aluminum films (Table I), the tips of the bonded laminates are shown in FIGS. 2 and 3 after exposure to changes in ambient temperature. Self-sealing as shown and bent downwards or rolls towards the adhesive layer.

The self-sealing down-tip curling phenomenon shown in FIGS. 2 and 3 is a further flat sheet layer (not shown), for example a sheet having good dimensional stability and a coefficient of thermal expansion lower than sheet 3, as described above. A film thinner than 3 can be promoted by adhering to the surface of sheet material 2 located far from film 3. Likewise, the downward tip-curing shown in FIGS. 2 and 3 can be adjusted or offset to a desired degree by using a film having a coefficient of linear thermal expansion greater than sheet 2 as an additional sheet or film attached to metal surface 2. Can be.

The preferred self-sealing down-tip curling phenomenon shown in FIGS. 2 and 3 is achieved by using a flat polymeric film of good dimensional stability as the top layer 3 having a coefficient of thermal expansion that is at least two times greater than the linear-coefficient of thermal expansion of layer 2. Can be obtained. Suitable synthetic polymer films for obtaining the desired self-sealing properties of the laminates of the invention are polymer films having a coefficient of linear thermal expansion of at least 42.3 × 10 ⁻⁶ cm / ° C. (30 × 10 ⁻⁶ in / oF). Table 1 below lists the films and foils with the mentioned coefficient of thermal expansion.

TABLE 1

Film (Paper) Rough Line-Coefficient of Thermal Expansion cm / ℃ × 10 ^-6 (in / ⁰ F × 10 ^-6 )

Polyester 14.1 (10)

Aluminum 16.92 (12)

Polyvinylfluoride 39.48 (28)

Nylon (polyamide) 77.55 (55)

Polycarbonate 50.76 (36)

Polymethyl Methacrylate 54.99 (39)

Polyethylene 93.06 (66)

The lifespan of the waterproof membrane layer produced using the waterproof roofing laminate of the present invention can be extended by applying the protective coating 6 after applying the laminate of the present invention on the roof substrate in the workplace as shown in FIG. have. Such in-situ coatings are currently commonly used in waterproof laminates of the type described in the above-mentioned patents, and are known to significantly enhance the durability of the constructed laminate-membrane. The mentioned coating protects the exposed polymeric support film from harmful ultraviolet radiation and weather damage. Typical in-situ coatings for such applications are bitumen, eg asphalt-based compositions, containing plasticizers, fillers, antioxidants or pigments. If reflective particulates, such as particles or fragments of metals such as aluminum, are present in the mentioned coatings, the temperature of the laminate film layer is reduced. The protective coating mentioned is applied to the surface of the 7 laminated laminate film layer in a thickness of about 0.005 (0.002) to about 0.178 cm (0.079 inch). The invention will be explained in more detail in the following examples.

Example 1

Three laminate samples useful for waterproofing purposes are constructed and tested for their tendency to curl at their tips after exposure to high and low temperatures. The structure of each of the laminates is listed in Table II below.

TABLE 2

The polymer film "A" used in the laminates of Table II was fabricated by stacking four laminated, high density polyethylene composite films (0.005 cm (2 mil) thick) with a total thickness of 0.020 cm (0.008 in. (8 mil)). Film] The thickness of the aluminum foil layer used is 0.0009 cm (0.35 mil) The thickness of the waterproof adhesive layer mentioned is 0.152 cm (60 mil) and is sticky, usually the stickiness of asphalt, styrene-butadiene rubber and inorganic oil. This waterproof adhesive layer is finally attached to the laminate The polymer film "B" is a layer of ionomer resin film of 0.003 cm (1 mil) thick .. Protection applied to the top surface of each laminate. The coating consists of a 0.018 cm (7 mil) thick film of a unique in-situ coating composition containing an asphalt, plasticizer and hot-reflective aluminum debris.

Each of the laminate samples 1 to 3 cut to a size of 3 '' x 6 '' (7.62 cm x 15.24 cm) was adhered onto the substrate with the adhesive side facing downward. After exposure to a temperature cycle of 65.6 ° C. (150 ° F.) to -26.1 ° C. (-15 ° F.), the substrate is dried upwardly at 21.1 ° C. (70 ° F.) and laminated sample 3, as shown in FIG. Likewise, it is rolled downward toward the substrate to exhibit a desirable inner tip sealing force.

Example II

Several rolls of 91.44 cm (3 feet) wide and 1828.8 cm (60 feet) long adhesive waterproof laminate strip with a 0.015 cm (6 mil) thick waterproof bituminous adhesive layer, as shown in Table II laminate, It was installed in a branch of a department store in Wall Long Island. The rolls mentioned were sold to professional roofing contractors and were constructed as part of the roof cladding. The constructed laminate had a structure similar to laminate sample 2 in Table II using metal foil on polymer film “A”, but instead of the 0.018 cm (7 mil) thick protective coating used in Table II, “Surlyn A thin protective coating made of ionomer resins (available from DuPont) was attached to the surface of aluminum foil away from Polymer A to provide weather resistance. After about one month, it was visually observed that the tip of the constructed laminate strips tended to be spaced upwards away from the substrate.

Roofing laminates of the present invention have been described as having a width of at least about 91.44 cm (36 inches) in relation to their use to form a continuous waterproofing film on the roof, but laminate strips of narrower dimensions than those mentioned may be used. For example, a laminate strip of the present invention about 10.16 cm (4 inches) wide can be used for the seams between the insulation plates of the roof. In addition, laminate strips for use in uncoated strips in roof construction may have a width of, for example, 30.48 cm (12 inches).

Claims (1)

In a waterproof structure consisting of a substrate and a continuous waterproof layer attached thereto, a plurality of preformed flexible pressure-sensitive adhesive waterproof laminates are used as the waterproof layer; The preformed laminate has an upper support layer 7 laminated to the lower layer I of the waterproof pressure-sensitive thermoplastic bituminous adhesive composition before application to the mentioned substrate; The adhesive layer in the mentioned laminate is located adjacent to the mentioned substrate; The mentioned support layer 7 consists of the second layer 2 and the first layer 3 of the flexible sheet material laminated together; Sheet materials of the first layer 3 and the second layer 2 are each independently polyolefin, polyamide, polyester, polyurethane, polyvinyl chloride, copolymer of vinyl chloride and vinylidene chloride, synthetic rubber, metal film And a sheet of metal foil; The second layer 2 of the sheet material is located between the first layer 3 of the sheet material and the lower layer 1 of the adhesive composition; The first layer 3 of the flexible sheet material has a larger coefficient of linear thermal expansion than the second layer 2 of the sheet material; The upper support layer 7 has a relatively good thermal dimensional stability, and exhibits almost a flat appearance before laminating it on the adhesive layer 1, and because of this feature, the mentioned laminate is applied to the mentioned substrate to expose to elevated temperatures. Afterwards the end of the mentioned laminate is pushed downwards towards the mentioned substrate due to the difference in the coefficient of thermal expansion mentioned.

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