US20090056261A1 - Roofing membrane comprising microspheres - Google Patents

Roofing membrane comprising microspheres Download PDF

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Publication number
US20090056261A1
US20090056261A1 US11/718,902 US71890205A US2009056261A1 US 20090056261 A1 US20090056261 A1 US 20090056261A1 US 71890205 A US71890205 A US 71890205A US 2009056261 A1 US2009056261 A1 US 2009056261A1
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US
United States
Prior art keywords
bitumen
membrane
meth
roofing
acrylate
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.)
Abandoned
Application number
US11/718,902
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English (en)
Inventor
Jan Damgaard
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Icopal AS
Original Assignee
Icopal AS
Priority date (The priority date 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 date listed.)
Filing date
Publication date
Application filed by Icopal AS filed Critical Icopal AS
Priority to US11/718,902 priority Critical patent/US20090056261A1/en
Assigned to ICOPAL A/S reassignment ICOPAL A/S ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: DAMGAARD, JAN
Publication of US20090056261A1 publication Critical patent/US20090056261A1/en
Abandoned 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
    • 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
    • E04D5/12—Roof covering by making use of flexible material, e.g. supplied in roll form specially modified, e.g. perforated, with granulated surface, with attached pads

Definitions

  • the present invention relates to a foam in roofing systems for achieving superior flowing properties at high temperatures without sacrificing low temperature performance. More particularly, the present invention is in the field of roofing membranes and shingles, having a modified bituminous compound on the top surface, wherein microspheres are employed in the bituminous compound in order to achieve superior flowing properties.
  • bitumen-SBS bituminous sheet materials used for roofing applications
  • bitumen-APP materials bitumen-SBS products are more elastic, with greater flexibility at low temperatures.
  • bituminous membrane The waterproofing properties of a bituminous membrane depend upon the existence of continuous films of bitumen. To prevent rupture or flow of the bitumen a sheet material (felt) is normally incorporated. Felts add strength and spanning ability to the membrane but may, in turn, be responsible for membrane failures.
  • a bituminous membrane acts as a single composite structure, but its behaviour is influenced by the properties of the materials from which it is made, the surface to which it adheres, and the environment in which it must serve.
  • Bitumen a material that behaves as a viscous fluid at some temperatures and as an elastic solid at lower ones, has been employed for centuries in construction because of its waterproofing and adhesive properties. Through long experience many of its limitations have been recognized, but improved understanding of the factors affecting its performance has been gained through scientific research.
  • bitumen The waterproofing capability of bitumen is primarily a result of its nonporous characteristic. Although absorption of water by bitumens does occur, it is generally very limited and of little significance. For bitumen to perform as a water barrier there must be a continuous film free of any voids, pin holes or cracks. Provided this continuity is achieved the film can be as little as 0.005 inch thick, but deterioration of bitumen and other practical considerations usually dictate the use of a much thicker film.
  • bitumen behaves in a viscoelastic manner, and under the influence of an applied strain its deformation will depend upon the rate of strain and the temperature at which it occurs. At a warm temperature bitumen behaves as a liquid; at lower temperatures it behaves as an elastic solid. As the behaviour of both solid and liquid materials is involved, any mechanical properties such as load-strain must be related to the rate of deformation and temperature.
  • Deterioration or loss of the desirable properties of bitumen, normally takes the form of hardening.
  • the net result is a decrease in adhesive and flow properties and an increase in the softening point temperature and coefficient of thermal expansion.
  • Hardening of a bitumen results in a reduction in its ability to accommodate deformations without splitting.
  • the actual mechanisms of deterioration are not fully understood, but it is known that photo-oxidation is a major factor and that it is most active at high temperatures under solar radiation. Water, dissolved compounds from atmospheric pollution, attack by microbiological organisms, and changes in its internal structure are other factors contributing to hardening of bitumens.
  • Reinforcement is employed in a bituminous membrane to stabilize the bitumen film, to provide the strength required to span irregularities in its supporting surface, and to distribute local strains over a greater dimension. Adhesion between the bitumen films and reinforcement is essential, and it is normal to factory prime these materials by saturating them with hot bitumen. Bitumen saturation also minimizes the water absorption of felts, but since saturation is not complete they do absorb moisture and are not vapor impermeable. Bitumen coating of saturated felts further reduces the vapor permeance and increases the resistance to moisture penetration.
  • Bituminous roofing materials are used in e.g. steep slope roofing applications and, therefore, must provide good traction for the safety of the roofer installing the material.
  • a typical installation involves mechanically fastening the material to a substrate. Alternatively torching may be applied to the roofing material. Less commonly the roofing material is adhered to the substrate using an adhesive compound.
  • roofing membranes typically comprise multiple layers of various materials configured to protect and optionally to insulate a roof deck or upper surface of a structure or building.
  • the roofing system protects the deck and the interior of the structure from the weather, including wind, rain, and other precipitation.
  • the roofing membrane is a sheet or mat of a solid, elastomeric substance, which protects the deck from the aforementioned weather elements.
  • Conventional membranes include those of EPDM (ethylene-propylenediene elastomer), modified bitumen, and plasticized polyvinylchloride.
  • a paving layer may be placed or laid on top of the membrane.
  • the paving layer typically comprises materials such as gravel or stone ballast, shingles, brick, or concrete.
  • the paving layer functions to physically protect the membrane from foot traffic and direct exposure to sunlight and the weather.
  • a problem commonly encountered with roofing systems is rupture of the membrane due to distortion or deterioration of the protective layer underneath the membrane.
  • the distortion and deterioration problems arise from the exposure of the protective layer to extreme heat from direct sunlight or moisture buildup due to weather exposure.
  • the membrane which is typically dark and elastomeric, absorbs significant heat from the sunlight, and further does not allow for timely escape of moisture trapped underneath it.
  • the membrane and the protective layer may separate to form void pockets, which leave the membrane with diminished mechanical support on its undersurface. The diminished support renders the membrane more subject to rupture.
  • the source of distortion and deterioration problems of the material in the protective layer varies according to the nature of the material. Some materials are susceptible to heat, some are susceptible to moisture, and some have inherently low mechanical strength.
  • Extruded, closed-cell polystyrene foams offer excellent mechanical strength and water resistance, but can become distorted at high service temperatures due to their relatively low heat distortion temperature. Such high service temperatures are typically encountered under a dark membrane in direct sunlight.
  • Expanded polystyrene bead foams typically better maintain their shape in a high temperature environment than extruded, closed-cell polystyrene foams because they typically have better bowing characteristics. Their bowing characteristics are better because the coalesced expanded bead structure allows for greater mechanical relaxation compared to the solid, cellular form of extruded, closed-cell foams. However, the coalesced expanded bead structure also results in lower mechanical strength and lower resistance to water transmission.
  • Closed-cell polyisocyanate foams have high heat distortion temperatures but have poor moisture resistance. Moisture weakens the cellular structure of such foams, and renders them subject to physical deterioration over time. Moisture also diminishes the insulation value of the foam. They are also relatively friable, which affects their handling characteristics.
  • Closed-cell polyurethane foams like closed-cell polyisocyanate foams, have high heat distortion temperatures and poor moisture resistance. They are also relatively friable, which affects their handling characteristics.
  • Expandable thermoplastic polymer beads are microspheres each comprising a thermoplastic polymer shell and a blowing agent as entrapped therein. When such expandable beads are heated at a temperature high enough to induce a sufficient degree of expansion for a certain length of time, expanded thermoplastic polymer beads are obtained. For example, when expandable micro sphere beads measuring about 15 ⁇ m in diameter and having a true specific weight of about 1.3 Kg/l are expanded by heating, expanded micro spheres measuring about 60 ⁇ m and having a true specific weight of about 0.03 kg/l may be obtained.
  • the expanded micro sphere can be obtained by heating the expandable micro sphere at a predetermined temperature.
  • the expanded micro sphere is a balloon-like artefact which can be imaged as a small rubber ball.
  • the expandable micro sphere is a thermally expandable micro sphere comprising a thermoplastic polymer shell and a blowing agent as entrapped therein.
  • thermoplastic polymer which can be used in the present invention includes polymers obtainable by polymerizing various monomers such as (meth)acrylonitrile, (meth)acrylates, styrenic monomers, vinyl halides, vinylidene halides, vinyl acetate, butadiene, vinylpyridine, chloroprene, etc; all of which may contain other comonomeric substances and crosslinking agents, such as divinylbenzene, ethylene glycol di(meth)acrylate, triethylene glycol di(meth)acrylate, trimethylolpropane tri(meth)acrylate, 1,3-butylene glycol di(meth)acrylate, allyl (meth)acrylate, triacrylformal, triallyl isocyanurate, etc.
  • the homopolymers, copolymers or terpolymer of at least one monomer selected from among methyl methacrylate, acrylonitrile and vinylidene chloride are especially useful.
  • the blowing agent (foaming agent) for causing thermal expansion of the micro spheres have a boiling point not higher than the softening temperature of the thermoplastic polymer shell and includes n-pentane, isopentane, neopentane, butane, isobutane, hexane, isohexane, neohexane, heptane, isoheptane, octane and isooctane, or mixtures thereof, to mention just a few preferred examples.
  • hydrocarbons such as petroleum ether, etc. and chlorinated hydrocarbons such as methyl chloride, methylene chloride, dichloroethane, dichloroethylene, trichloroethane, trichloroethylene, etc. can also be used.
  • the weight average particle diameter of expandable micro spheres is preferably about 1-100 ⁇ m.
  • the true specific weight of the expandable micro spheres is preferably about 1.1-1.5 kg/l.
  • Heating the expandable micro sphere at a predetermined temperature gives the expanded micro sphere.
  • the heating can be effected by various methods such as air heating, steam heating, microwave heating, infrared or far-infrared heating, etc.
  • expandable micro spheres mentioned above are commercially available and any of such commercial products can be utilized.
  • the gas is intimately mixed with a thermoplastic adhesive while the adhesive is in a molten state and then the mixture is pressurized to form a solution which, upon dispensing at a lower pressure, releases the gas and foamed adhesive results.
  • the techniques described in these applications result in very useful foamed adhesives and bonding techniques. However, such techniques are not entirely satisfactory in producing hot melt thermoplastic adhesives on a continuous, uniform quality basis. Such techniques have also been found to be limited in their applicability to hot melt thermoplastic materials and further improvements are needed.
  • bitumens can be modified by the addition of specially formulated compounds.
  • additives that improve adhesion properties, making it possible for bitumens to adhere to a wet surface and even retain their bond when later wetting of the bitumen-solid interface occurs.
  • Anti-oxidants retard the rate of hardening from chemical and internal structure changes resulting from oxidation.
  • problems with flowing bituminous roofing materials at higher temperatures still remains to be solved.
  • the major object of the present invention is to provide a high temperature resistant roofing membrane without sacrificing the low temperature performance of the membrane.
  • the density of the microsphere foamed membranes of the present invention is approx. 25% lower than membranes not employing a foam.
  • the present invention involves roof coverings in the form of roofing membranes and shingles having an upper layer of a modified bituminous compound, whose composition utilizes bitumen, plastomeric modifiers and fillers, a reinforcement layer, and optionally a lower layer of a self-adhesive compound, whose composition utilizes bitumen (asphalt), elastomeric modifiers, tackifying resins, and fillers.
  • the expanded microspheres may be distributed across the entire membrane, but is preferably only used in the top layer.
  • a roofing membrane comprising:
  • top-layers of membranes having no microspheres and membranes including commercially available expanded microspheres were made using the following blends:
  • the blends are made on the diaf mixer at a mixing temperature of 180° C., according to normal procedure.
  • Expancel is added after the filler.
  • the addition is timed in such a way that the Expancel is mixed for 15 minutes after the addition.
  • the cold bend temperature of the foamed blend is 4° C. higher than for the non-foamed blend, while the melting point R&B of the foamed blend is 6.8° C. higher.
  • the flow resistance is measured using only the weight of the membrane itself. The time to 50 mm flow is 48 hours for the non-foamed blend, while it is well in excess of two weeks for the foamed blend.
  • the density of the non-foamed blend is approx. 25% higher than for the foamed blend.
  • the resistance against footprints is at the same level for the foamed and the non-foamed product.
  • the size distribution of the air bubbles was found by taking microscope pictures and then counting the bubbles and measuring their sizes.
  • Expancel has provided a size distribution curve for Expancel 095D120 expanded in air for comparison.
  • the size distribution for a foamed sample that was kept at 180° C. for 24 hours is very close to the curve for the unaged sample; this indicates that the blend can be kept at elevated temperatures for some time without loosing the bubbles.
  • a second foamed sample was kept at 190° C. for one hour; it can be seen that the size distribution moves towards higher sizes. So it would seem that there is an upper limit for the temperature the blends can be kept at for a longer period, without changing the characteristics.

Landscapes

  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Compositions Of Macromolecular Compounds (AREA)
  • Adhesives Or Adhesive Processes (AREA)
  • Synthetic Leather, Interior Materials Or Flexible Sheet Materials (AREA)
  • Laminated Bodies (AREA)
  • Manufacture Of Porous Articles, And Recovery And Treatment Of Waste Products (AREA)
US11/718,902 2004-11-11 2005-11-09 Roofing membrane comprising microspheres Abandoned US20090056261A1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US11/718,902 US20090056261A1 (en) 2004-11-11 2005-11-09 Roofing membrane comprising microspheres

Applications Claiming Priority (5)

Application Number Priority Date Filing Date Title
EP04078109.8 2004-11-11
EP04078109A EP1657377A1 (en) 2004-11-11 2004-11-11 Roofing membrane comprising microspheres
US62757204P 2004-11-12 2004-11-12
US11/718,902 US20090056261A1 (en) 2004-11-11 2005-11-09 Roofing membrane comprising microspheres
PCT/IB2005/003350 WO2006051385A1 (en) 2004-11-11 2005-11-09 Roofing membrane comprising microspheres

Publications (1)

Publication Number Publication Date
US20090056261A1 true US20090056261A1 (en) 2009-03-05

Family

ID=34928656

Family Applications (1)

Application Number Title Priority Date Filing Date
US11/718,902 Abandoned US20090056261A1 (en) 2004-11-11 2005-11-09 Roofing membrane comprising microspheres

Country Status (5)

Country Link
US (1) US20090056261A1 (no)
EP (2) EP1657377A1 (no)
CA (1) CA2586257A1 (no)
NO (1) NO20072958L (no)
WO (1) WO2006051385A1 (no)

Cited By (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2010110661A2 (en) 2009-03-24 2010-09-30 De Veenvoort B.V. Covering material for water- or weather-proofing
US20130149035A1 (en) * 2011-05-19 2013-06-13 Timothy Geary Pot hole repair patch and method of installation
US8858115B2 (en) * 2011-05-19 2014-10-14 Geary Trust, The Pothole and utility cut repair overlay and method of installation
US9109108B1 (en) * 2013-08-13 2015-08-18 Pak-Lite, Inc. LVT flooring and underlayment including extruded sheet material with expanded microspheres
US20180051465A1 (en) * 2016-08-22 2018-02-22 Owens Corning Intellectual Capital, Llc Roofing shingles

Families Citing this family (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
DE102023000194A1 (de) * 2023-01-23 2024-07-25 Jv"Jfm Lega Group" Llc Modifikator für Bitumen, bitumenhaltiges Bindemittel und bitumenhaltige Stoffe und Materialien

Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2893889A (en) * 1956-04-02 1959-07-07 United States Gypsum Co Intumescent fire-retarding bituminous coating composition and roofing made therefrom
US4512806A (en) * 1979-07-23 1985-04-23 Minnesota Mining And Manufacturing Company Flame resistant ashaltic compositions
US4755409A (en) * 1986-01-24 1988-07-05 Hyload Corporation Waterproofing laminate
US4871605A (en) * 1983-08-05 1989-10-03 Genstar Building Materials Company Inorganic fiber mat based bituminous sheet materials
US4879163A (en) * 1987-09-24 1989-11-07 Bay Mills Limited Textiles containing interstices and processes for making such textiles
US20030101671A1 (en) * 2000-05-25 2003-06-05 Icopal Gmbh Roofing membrane

Family Cites Families (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US4195461A (en) * 1978-04-06 1980-04-01 Isola Fabrikker A/S Roofing shingle
US5314556A (en) * 1990-05-08 1994-05-24 Bay Mills Limited Process for manufacturing reinforced roofing membranes
JPH11166300A (ja) * 1997-12-04 1999-06-22 Showa Kogyo Kk 屋根下葺材
US6708456B2 (en) * 1999-11-30 2004-03-23 Elk Premium Building Products, Inc. Roofing composite
US20030091812A1 (en) * 2001-11-13 2003-05-15 Building Materials Investment Corporation Breathable, flexible wax release coating on a construction underlayment

Patent Citations (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2893889A (en) * 1956-04-02 1959-07-07 United States Gypsum Co Intumescent fire-retarding bituminous coating composition and roofing made therefrom
US4512806A (en) * 1979-07-23 1985-04-23 Minnesota Mining And Manufacturing Company Flame resistant ashaltic compositions
US4871605A (en) * 1983-08-05 1989-10-03 Genstar Building Materials Company Inorganic fiber mat based bituminous sheet materials
US4755409A (en) * 1986-01-24 1988-07-05 Hyload Corporation Waterproofing laminate
US4879163A (en) * 1987-09-24 1989-11-07 Bay Mills Limited Textiles containing interstices and processes for making such textiles
US20030101671A1 (en) * 2000-05-25 2003-06-05 Icopal Gmbh Roofing membrane

Cited By (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2010110661A2 (en) 2009-03-24 2010-09-30 De Veenvoort B.V. Covering material for water- or weather-proofing
US20130149035A1 (en) * 2011-05-19 2013-06-13 Timothy Geary Pot hole repair patch and method of installation
US8534954B2 (en) * 2011-05-19 2013-09-17 The Geary Trust Pot hole repair patch and method of installation
US8858115B2 (en) * 2011-05-19 2014-10-14 Geary Trust, The Pothole and utility cut repair overlay and method of installation
US9109108B1 (en) * 2013-08-13 2015-08-18 Pak-Lite, Inc. LVT flooring and underlayment including extruded sheet material with expanded microspheres
US20180051465A1 (en) * 2016-08-22 2018-02-22 Owens Corning Intellectual Capital, Llc Roofing shingles
US10458119B2 (en) * 2016-08-22 2019-10-29 Owens Corning Intellectual Capital, Llc Roofing shingles

Also Published As

Publication number Publication date
WO2006051385A1 (en) 2006-05-18
CA2586257A1 (en) 2006-05-18
EP1657377A1 (en) 2006-05-17
EP1812664A1 (en) 2007-08-01
NO20072958L (no) 2007-06-11

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AS Assignment

Owner name: ICOPAL A/S, DENMARK

Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:DAMGAARD, JAN;REEL/FRAME:020492/0969

Effective date: 20080124

STCB Information on status: application discontinuation

Free format text: ABANDONED -- FAILURE TO RESPOND TO AN OFFICE ACTION