US20160303825A1 - Peel and stick waterproofing material - Google Patents
Peel and stick waterproofing material Download PDFInfo
- Publication number
- US20160303825A1 US20160303825A1 US15/194,798 US201615194798A US2016303825A1 US 20160303825 A1 US20160303825 A1 US 20160303825A1 US 201615194798 A US201615194798 A US 201615194798A US 2016303825 A1 US2016303825 A1 US 2016303825A1
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- US
- United States
- Prior art keywords
- asphalt
- sheet
- layer
- polyester
- asphalt layer
- 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
Links
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- 239000000463 material Substances 0.000 title description 8
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- 239000010426 asphalt Substances 0.000 claims description 136
- 239000007788 liquid Substances 0.000 claims description 36
- 229920000139 polyethylene terephthalate Polymers 0.000 claims description 31
- 239000005020 polyethylene terephthalate Substances 0.000 claims description 31
- 239000011152 fibreglass Substances 0.000 claims description 30
- 230000001681 protective effect Effects 0.000 claims description 13
- 239000000853 adhesive Substances 0.000 claims description 12
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- 238000000034 method Methods 0.000 claims description 12
- 238000004519 manufacturing process Methods 0.000 claims description 7
- -1 polyethylene terephthalate Polymers 0.000 claims description 6
- 229920000642 polymer Polymers 0.000 claims description 6
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- FACXGONDLDSNOE-UHFFFAOYSA-N buta-1,3-diene;styrene Chemical compound C=CC=C.C=CC1=CC=CC=C1.C=CC1=CC=CC=C1 FACXGONDLDSNOE-UHFFFAOYSA-N 0.000 description 2
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- 229920000468 styrene butadiene styrene block copolymer Polymers 0.000 description 2
- 229920001935 styrene-ethylene-butadiene-styrene Polymers 0.000 description 2
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- 238000005299 abrasion Methods 0.000 description 1
- 239000003082 abrasive agent Substances 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 239000011248 coating agent Substances 0.000 description 1
- 230000008030 elimination Effects 0.000 description 1
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- 230000035515 penetration Effects 0.000 description 1
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Images
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Definitions
- Peel and stick waterproofing sheets and mats have been used for various purposes in construction.
- peel and stick sheets have been used on roofs and on foundations to protect against the seepage of water into houses and buildings.
- the peel and stick waterproof sheets are laid out on roofs and stick directly to the plywood, or other material, that forms the structural portion of the roof.
- Waterproofing sheets can also be applied directly to a foundation, such as a poured-in-place wall, or other foundation material, to protect against seepage of water into a basement or other area.
- waterproofing sheets which have a peel away layer that can be stuck directly to various surfaces that require waterproofing or for other purposes, such as structural stability, such as an underlayment for tile.
- An embodiment of the present invention may therefore comprise a self-adhesive protective sheet for attachment to a protected surface comprising: a polyester layer constructed from polyethylene terephthalate (PET) fibers that are bonded together to form a non-woven, liquid permeable PET sheet; an asphalt layer that is partially absorbed by the non-woven, liquid permeable PET sheet when asphalt, that forms the asphalt layer, is applied to the non-woven, liquid permeable PET sheet in a liquid state, so that a first side of the asphalt layer is bonded to the non-woven, liquid permeable PET sheet when the asphalt layer is in a solid state, the asphalt layer having a second side that has a tacky surface; a release film disposed on the second side of the asphalt layer that is secured to the tacky surface and can be peeled from the tacky surface so that the tacky surface can be attached to the protected surface.
- PET polyethylene terephthalate
- An embodiment of the present invention may further comprise a method of making a self-adhesive protective sheet comprising: providing a polyester sheet that is constructed from polyethylene terephthalate (PET) fibers that are bonded together to form a non-woven, liquid permeable PET protective sheet; placing liquid asphalt on the non-woven, liquid permeable PET sheet that is partially absorbed by the non-woven, liquid permeable PET sheet; allowing the liquid asphalt to cool to form an asphalt layer that is bonded, on a first side of the asphalt layer, to the non-woven, liquid permeable PET sheet as a result of absorption of a portion of the liquid asphalt by the non-woven, liquid permeable PET sheet on the first side of the asphalt layer; placing a release film on a tacky second surface of the asphalt layer that can be peeled from the second tacky surface so that the second tacky surface can be applied to a surface to be protected.
- PET polyethylene terephthalate
- An embodiment of the present invention may further comprise a self-adhesive protective sheet for attachment to a protected surface comprising: a polyester sheet constructed from polyethylene terephthalate fibers that are bonded together to form a non-woven, liquid permeable polyester sheet; a fiberglass layer; a first asphalt layer that is bonded, on a second side, to the fiberglass layer, and partially absorbed by the polyester sheet on a first side of the first asphalt layer, so that the first side of the asphalt layer is bonded to the polyester sheet; a second asphalt layer having a first side that is disposed on, and bonded to, the fiberglass layer, and a second side having a tacky surface; a release film disposed on a second side of the second asphalt layer that is secured to the tacky surface and that can be peeled from the tacky surface, so that the tacky surface can be attached to the protected surface.
- An embodiment of the present invention may further comprise a method of making a self-adhesive protective sheet comprising: providing a first polyester sheet that is constructed from polyester fibers that are thermally bonded together to form a non-woven, liquid permeable layer of the self-adhesive protective sheet; providing a second polyester sheet that is constructed from polyester fibers that are thermally bonded together to form a non-woven, liquid permeable layer of the self-adhesive protective sheet; thermally bonding the first polyester sheet and the second polyester sheet to provide a polyester layer that is liquid permeable; placing asphalt on a fiberglass mesh that is partially absorbed by the fiberglass mesh; allowing the asphalt to cool to form a first asphalt layer that is bonded, on a second side of the first asphalt layer, to the fiberglass mesh as a result of absorption of a portion of the asphalt by the fiberglass mesh on the second side of the first asphalt layer; placing additional asphalt on the fiberglass mesh to form a second asphalt layer having a first side that is bonded to the fiberglass mesh and a second side
- FIG. 1 is a side cutaway view of an embodiment of a peel and stick waterproofing sheet.
- FIG. 2 is a side cutaway view of another embodiment of a peel and stick waterproofing sheet.
- FIG. 3 is a side view illustrating the manner in which waterproofing sheets of the embodiment of FIG. 1 are overlapped.
- FIG. 4 is a side view illustrating the manner in which the waterproofing sheets of the embodiment of FIG. 2 are overlapped.
- FIG. 5 is a side view of an embodiment of a device for assembling the waterproofing sheet of the embodiment of FIG. 1 .
- FIG. 6 is a side view of an embodiment of the device for assembling the waterproofing sheet of the embodiment of FIG. 2 .
- FIG. 1 is a cross-sectional side view of an embodiment of a peel and stick waterproofing sheet 100 .
- the waterproofing sheet 100 includes a polyester layer 102 , which is attached to an asphalt layer 104 .
- a release film 106 is connected to the exposed side of the asphalt layer 104 .
- the polyester layer 102 provides a structural support for the asphalt layer 104 .
- the polyester layer 102 has high tensile strength and lateral structural stability that maintains the asphalt layer 104 as a substantially uniform layer of asphalt across the surface of the polyester layer 102 .
- the polyester layer 102 is semi-porous.
- asphalt is applied or pooled, on the polyester layer 102 at a sufficiently high temperature, so that the asphalt of the asphalt layer 104 is in a liquid state. A portion of the asphalt is absorbed by the polyester layer 102 , so that a solid bond is formed between the asphalt layer 104 and the polyester layer 102 . Additionally, the asphalt layer 104 is modified by the addition of certain polymers, so that the asphalt layer 104 maintains a tactile surface, which holds the release film 106 in place on the exposed surface of the asphalt layer 104 . Release film 106 comprises a thin plastic sheet that adheres to the sticky surface of the exposed asphalt layer 104 .
- the release film has a spray silicon or other release agent on its surface, in one embodiment, to help the release film in the process of being peeled from the asphalt layer.
- the release film 106 can be peeled away from the asphalt layer 104 to expose the surface of the asphalt layer 104 . Once the release film 106 is removed, the asphalt layer 104 is sufficiently tacky to stick directly to the surface to be protected from water penetration or a surface to which tile is applied, or other surface.
- the polyester layer 102 is formed from polyethylene terephthalate (PET).
- PET polyethylene terephthalate
- the PET is provided in chips that are compressed and heated to form a PET liquid.
- the PET liquid is forced through a die that has a large number of small openings so that the liquid is extruded into fine threads.
- the threads are pulled and stretched to a proper diameter with an air venturi suction device.
- the threads are then laid out on a mesh to form a mat or sheet. Two of these mats or sheets are then joined together by heat fixing and, in some embodiments, the use of a binder.
- Some binding material may be a waterproof material. Otherwise, the asphalt layer 102 provides the waterproofing qualities of the waterproof sheet.
- the end result, of at least one embodiment, is a non-woven PET sheet that is liquid pervious and has high tensile strength resulting from the bonded polyester fibers.
- the polyester sheet is resistant to puncture, tearing and ripping.
- the polyester layer 102 is similar to a thick cloth that is pervious to liquids.
- the polyester layer has a thickness of about 20 to 40 mils, although those thicknesses can be varied to obtain desired results.
- the exposed asphalt layer i.e., the side of the asphalt layer that is not attached to a surface
- Granular aggregate may comprise coal slag, silica sand, or other granular materials.
- the use of the granular materials prevents the asphalt layer in the prior art devices, from sticking to machinery during the manufacturing/assembly process.
- the granular materials that are coated on the exposed surface of the asphalt cause problems during the manufacturing process. For example, excessive wear can occur in the machinery that is used to assemble the waterproof sheet. Assembly machines must be constantly adjusted and repaired as a result of the use of abrasive materials as a granular material to mask the exposed layer of the asphalt so that the exposed layer is not sticky.
- coal slag, silica sand, or other granular materials may generate dust that creates an environmental hazard and possible health problems. Consequently, the elimination of the granular materials is beneficial to the overall manufacturing process and the health and safety of workers.
- the release film 106 may have a coating of silicon or other release agent to assist in the process of peeling away the release film 106 from the asphalt layer 104 .
- the asphalt layer 104 may be modified by mixing certain polymers with the asphalt layer 104 , so that the asphalt layer 104 remains tacky after it cools. These polymers may comprise styrene-butadiene-styrene (SBS), styrene-isoprene-styrene (SIS), styrene-ethylene-butadiene-styrene (SEBS), or atactic-polypropylene (APP). Of course, other polymers may be used and other processes may be employed to maintain the tackiness of the asphalt layer 104 when the release film 106 is removed.
- SBS styrene-butadiene-styrene
- SIS styrene-isoprene-styrene
- SEBS styrene-ethylene-butad
- the polyester layer 102 Because of the manner in which the polyester layer 102 is constructed from extruded threads of PET and other polyesters, the polyester layer 102 has high tensile strength and lateral stability, as well as a high degree of puncture resistance.
- the polyester layer 102 acts as a structural support for maintaining the asphalt layer 104 and prevents the asphalt layer 104 from being penetrated, ripped or pulled apart.
- the peel and stick waterproofing sheet may be used as a roof underlayment, a floor underlayment, a tile underlayment and any application where strength and protection is needed, as well as waterproofing.
- the thickness of the peel and stick waterproofing sheet 100 may range from approximately 30-60 mils, although that thickness may be varied for various applications.
- the waterproofing sheet 100 can be applied to a roof deck and roofing foam can be applied directly to the polyester layer 102 . Because the polyester layer 102 is permeable, the roofing foam easily bonds to the polyester layer 102 . roofing tiles can then be placed on the roofing foam and secured in place by the foam. The roofing foam then holds the roofing tiles in place and the waterproofing sheet 100 provides a secure waterproof underlayment that has high strength and provides a high degree of protection. Good attachment is achieved between the foam and the polyester layer because some of the foam is absorbed in the very top portion of the polyester layer, which provides a strong attachment between the foam and the polyester layer 102 .
- the peel and stick waterproofing sheet 100 can be used below grade.
- waterproofing sheet 100 can be attached directly to the foundation of a building, so that the asphalt layer 104 sticks directly on the foundation of the building with the polyester layer 102 providing puncture resistance, thereby eliminating and/or minimizing the need for additional protection materials to protect the waterproofing layer from puncture by rocks or other physical abrasion.
- the width of the waterproofing sheet 100 may be any desired width.
- the waterproofing sheet 100 is two meters wide and can be constructed in any desired length.
- multiple sheets can be used, such as an underlayment on a roof and overlapped, so that multiple courses of the waterproofing sheet 100 can be used to cover the entire deck of a roof.
- FIG. 2 illustrates another embodiment of a peel and stick waterproofing sheet 200 .
- a polyester layer 202 is disposed on a first surface of an asphalt layer 204 .
- a fiberglass mesh 206 is disposed on a second surface of the first asphalt layer 204 .
- a second asphalt layer 208 has a first side that is disposed on the fiberglass mesh 206 .
- a second side of the asphalt layer 208 is covered by release film 210 in the same manner as disclosed above with respect to FIG. 1 .
- the fiberglass mesh 206 provides additional structural stability for the asphalt layers 204 , 208 .
- the additional structural stability provided by the fiberglass mesh 206 supports the asphalt layers 204 , 208 in areas where the asphalt layers 204 , 208 are not connected to the polyester layer 202 , as explained in more detail below with respect to FIGS. 3 and 4 .
- FIG. 3 is a cross-sectional view of two peel and stick waterproof layers that are overlapped and provide a waterproof seal.
- the first sheet 314 may comprise a lower layer of a course laid across a roof or a foundation, while the second sheet 316 is laid in a course across the roof above, or higher than, the first sheet 314 .
- Sheet 314 includes a polyester layer 302 and an asphalt layer 304 .
- the release layer has been removed and the asphalt layer 304 is adhered directly to the protected surface 318 .
- the protected surface 318 may comprise a roof deck with lower portions of the roof on the left side of FIG. 3 and higher portions on the right side of FIG. 3 .
- the seam between the first sheet 314 and the second sheet 316 would run approximately horizontally across the roof deck.
- the polyester layer 302 is either removed or not formed on a portion of the asphalt layer 304 .
- This portion of the exposed asphalt layer 304 is referred to as the selvage edge.
- a waterproof film 310 is laid across the exposed portion on top of the first side of the asphalt layer 304 , which creates a waterproof barrier.
- the bottom, or second side, of the asphalt layer 308 of the second sheet 316 is placed over the waterproof film 310 to create a waterproof barrier between asphalt layer 308 and asphalt layer 304 .
- the polyester layer 306 is raised above the level of the polyester layer 302 . Water running down a roof, or down the side of a foundation, flows in the direction of arrow 320 , from right to left, as illustrated in FIG. 3 . In this manner, water is not pooled but flows over the overlapping layers.
- FIG. 4 is a cross-sectional view of another embodiment of peel and stick waterproof sheets 422 , 424 that are overlapped.
- the first sheet 422 includes a polyester layer 402 that is bonded to asphalt layer 404 .
- Fiberglass layer 406 is bonded to both the asphalt layer 404 and asphalt layer 408 .
- the fiberglass mesh layer 406 provides stability for the asphalt layers 404 , 408 in the section where the polyester layer 402 is not connected to the asphalt layers 404 , 408 .
- This open portion referred to as the selvage edge, includes a waterproof film 410 disposed on the top, or first surface, of the asphalt layer 404 .
- the fiberglass mesh layer 406 provides stability and strength to the exposed selvage edge.
- the second sheet 424 has a polyester layer 414 that is bonded to the asphalt layer 416 .
- Fiberglass mesh layer 418 is bonded to both the asphalt layer 416 and asphalt layer 420 .
- the second, or lower side, of the asphalt layer 420 attaches to the waterproof film 410 and the protected surface 426 , after removal of the releasable layer to provide a waterproof seal between the first sheet 422 and the second sheet 424 .
- the second or lower surface of the asphalt layer 408 is secured to the protected surface 426 , which may comprise a roof deck or a foundation surface.
- the second or lower side of asphalt layer 420 is attached directly to the protected surface 426 . Water runs over the sealed overlap area in the direction of arrow 428 .
- FIG. 5 is a side view of an assembler 500 for assembling the peel and stick waterproof sheet illustrated in FIG. 1 .
- a roll of polyester sheeting 502 is fed into a splicer 504 .
- Splicer 504 functions to splice or join the end of the roll of polyester sheeting 502 to an additional roll of polyester sheeting 504 when the roll 502 ends.
- the empty roller is then removed and the additional roll 504 slides to the position of roll 502 .
- Another additional roll can then be placed in the initial position of additional roll 504 , as shown in FIG. 5 .
- the polyester sheeting After the polyester sheeting leaves the splicer 504 , it enters a looper 506 , which allows the splicing operation to occur without stopping the assembler 500 .
- the polyester sheet then moves to coater 508 , which puddles asphalt on a top surface of the polyester sheeting in liquid form, so that the polyester sheeting is coated with an asphalt layer, such as asphalt layer 104 illustrated in FIG. 1 .
- a metering roll controls the thickness of asphalt layer 104 .
- the coated polyester sheet then moves over the cooling table 510 until the asphalt layer 104 is cooled to a solid state for application of a release film 106 . Release film roll 512 is located over the asphalt layer disposed on the polyester sheeting.
- the sheeting then moves over the cooling table 514 until it cools sufficiently to enter the looper 516 .
- the looper 516 provides sufficient time to allow the winder 518 to wind and cut the assembled waterproof sheeting.
- FIG. 6 is a side view of an assembler 600 for assembling the waterproof sheeting that is disclosed in FIG. 2 .
- a roll of fiberglass mesh 602 passes through the splicer 608 .
- An additional roll of fiberglass mesh 604 is fed through the splicer 608 to splice the end of the roll 602 to the beginning of roll 604 .
- Looper 610 provides sufficient time for the splicer 608 to form the splice without stopping the assembler 600 .
- the fiberglass mesh then passes to coater 612 .
- Coater 612 applies a first asphalt layer, such as asphalt layer 204 , to the top surface of the fiberglass mesh.
- the asphalt is pooled on a top portion of the fiberglass sheeting and metered by a metering roller to achieve a proper thickness.
- the bottom surface of the fiberglass mesh is coated with asphalt by a wicking roll (not shown) which is partially submerged in a reservoir of asphalt.
- a scraper is then used to remove extra asphalt and to achieve a desired thickness of the bottom layer 208 of asphalt.
- the fiberglass mesh that is coated with a top layer, such as top layer 204 , and a bottom layer, such as bottom layer 208 , of asphalt then passes to the applicator for the polyester sheeting 614 .
- the applicator 614 applies a polyester layer, such as polyester layer 202 , to the top or first surface of asphalt layer 204 .
- Applicator 616 applies the release film, such as release film 210 , to the second or bottom surface of the asphalt layer 208 .
- the assembled sheet then passes over a cooling section 616 , which sprays water and air on the combined layers to evaporatively cool the sheet to the looper 620 .
- the looper 620 provides sufficient time for the winder 622 to wind and cut the sheet into rolls.
- the present invention therefore provides waterproof sheeting that uses a polyester layer that provides high lateral stability and puncture resistance.
- the waterproof sheeting can be manufactured without the problems associated with granular coatings that create excessive wear to the assemblers and environmental hazards relating to dust created by the granular particles.
- the waterproof sheeting can be used in many applications, including waterproof roof underlayments, waterproof sheeting for foundations, underlayment for tile and flooring, and various other applications.
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Abstract
Description
- This application is a divisional application of U.S. application Ser. No. 14/645,497, filed Mar. 12, 2015, entitled “Peel and Stick Waterproofing Material,” which application is based upon and claims priority to U.S. provisional application Ser. No. 61/952,024, filed Mar. 12, 2014, entitled “Peel and Stick Waterproofing Material,” which applications are specifically incorporated herein by reference for all that they disclose and teach.
- Peel and stick waterproofing sheets and mats have been used for various purposes in construction. For example, peel and stick sheets have been used on roofs and on foundations to protect against the seepage of water into houses and buildings. The peel and stick waterproof sheets are laid out on roofs and stick directly to the plywood, or other material, that forms the structural portion of the roof. Waterproofing sheets can also be applied directly to a foundation, such as a poured-in-place wall, or other foundation material, to protect against seepage of water into a basement or other area. In fact, there are many uses for waterproofing sheets which have a peel away layer that can be stuck directly to various surfaces that require waterproofing or for other purposes, such as structural stability, such as an underlayment for tile.
- An embodiment of the present invention may therefore comprise a self-adhesive protective sheet for attachment to a protected surface comprising: a polyester layer constructed from polyethylene terephthalate (PET) fibers that are bonded together to form a non-woven, liquid permeable PET sheet; an asphalt layer that is partially absorbed by the non-woven, liquid permeable PET sheet when asphalt, that forms the asphalt layer, is applied to the non-woven, liquid permeable PET sheet in a liquid state, so that a first side of the asphalt layer is bonded to the non-woven, liquid permeable PET sheet when the asphalt layer is in a solid state, the asphalt layer having a second side that has a tacky surface; a release film disposed on the second side of the asphalt layer that is secured to the tacky surface and can be peeled from the tacky surface so that the tacky surface can be attached to the protected surface.
- An embodiment of the present invention may further comprise a method of making a self-adhesive protective sheet comprising: providing a polyester sheet that is constructed from polyethylene terephthalate (PET) fibers that are bonded together to form a non-woven, liquid permeable PET protective sheet; placing liquid asphalt on the non-woven, liquid permeable PET sheet that is partially absorbed by the non-woven, liquid permeable PET sheet; allowing the liquid asphalt to cool to form an asphalt layer that is bonded, on a first side of the asphalt layer, to the non-woven, liquid permeable PET sheet as a result of absorption of a portion of the liquid asphalt by the non-woven, liquid permeable PET sheet on the first side of the asphalt layer; placing a release film on a tacky second surface of the asphalt layer that can be peeled from the second tacky surface so that the second tacky surface can be applied to a surface to be protected.
- An embodiment of the present invention may further comprise a self-adhesive protective sheet for attachment to a protected surface comprising: a polyester sheet constructed from polyethylene terephthalate fibers that are bonded together to form a non-woven, liquid permeable polyester sheet; a fiberglass layer; a first asphalt layer that is bonded, on a second side, to the fiberglass layer, and partially absorbed by the polyester sheet on a first side of the first asphalt layer, so that the first side of the asphalt layer is bonded to the polyester sheet; a second asphalt layer having a first side that is disposed on, and bonded to, the fiberglass layer, and a second side having a tacky surface; a release film disposed on a second side of the second asphalt layer that is secured to the tacky surface and that can be peeled from the tacky surface, so that the tacky surface can be attached to the protected surface.
- An embodiment of the present invention may further comprise a method of making a self-adhesive protective sheet comprising: providing a first polyester sheet that is constructed from polyester fibers that are thermally bonded together to form a non-woven, liquid permeable layer of the self-adhesive protective sheet; providing a second polyester sheet that is constructed from polyester fibers that are thermally bonded together to form a non-woven, liquid permeable layer of the self-adhesive protective sheet; thermally bonding the first polyester sheet and the second polyester sheet to provide a polyester layer that is liquid permeable; placing asphalt on a fiberglass mesh that is partially absorbed by the fiberglass mesh; allowing the asphalt to cool to form a first asphalt layer that is bonded, on a second side of the first asphalt layer, to the fiberglass mesh as a result of absorption of a portion of the asphalt by the fiberglass mesh on the second side of the first asphalt layer; placing additional asphalt on the fiberglass mesh to form a second asphalt layer having a first side that is bonded to the fiberglass mesh and a second side having a tacky surface; placing the polyester layer on a first side of the first asphalt layer, so that the first side of the first asphalt layer is partially absorbed by the polyester layer to from a bond between the polyester layer and the first asphalt layer; placing a release film on the tacky surface of the second side of the second asphalt layer.
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FIG. 1 is a side cutaway view of an embodiment of a peel and stick waterproofing sheet. -
FIG. 2 is a side cutaway view of another embodiment of a peel and stick waterproofing sheet. -
FIG. 3 is a side view illustrating the manner in which waterproofing sheets of the embodiment ofFIG. 1 are overlapped. -
FIG. 4 is a side view illustrating the manner in which the waterproofing sheets of the embodiment ofFIG. 2 are overlapped. -
FIG. 5 is a side view of an embodiment of a device for assembling the waterproofing sheet of the embodiment ofFIG. 1 . -
FIG. 6 is a side view of an embodiment of the device for assembling the waterproofing sheet of the embodiment ofFIG. 2 . -
FIG. 1 is a cross-sectional side view of an embodiment of a peel andstick waterproofing sheet 100. As illustrated inFIG. 1 , thewaterproofing sheet 100 includes apolyester layer 102, which is attached to anasphalt layer 104. Arelease film 106 is connected to the exposed side of theasphalt layer 104. Thepolyester layer 102 provides a structural support for theasphalt layer 104. Thepolyester layer 102 has high tensile strength and lateral structural stability that maintains theasphalt layer 104 as a substantially uniform layer of asphalt across the surface of thepolyester layer 102. Thepolyester layer 102 is semi-porous. During construction of the peel and stickwaterproof sheet 100, asphalt is applied or pooled, on thepolyester layer 102 at a sufficiently high temperature, so that the asphalt of theasphalt layer 104 is in a liquid state. A portion of the asphalt is absorbed by thepolyester layer 102, so that a solid bond is formed between theasphalt layer 104 and thepolyester layer 102. Additionally, theasphalt layer 104 is modified by the addition of certain polymers, so that theasphalt layer 104 maintains a tactile surface, which holds therelease film 106 in place on the exposed surface of theasphalt layer 104.Release film 106 comprises a thin plastic sheet that adheres to the sticky surface of the exposedasphalt layer 104. The release film has a spray silicon or other release agent on its surface, in one embodiment, to help the release film in the process of being peeled from the asphalt layer. Therelease film 106 can be peeled away from theasphalt layer 104 to expose the surface of theasphalt layer 104. Once therelease film 106 is removed, theasphalt layer 104 is sufficiently tacky to stick directly to the surface to be protected from water penetration or a surface to which tile is applied, or other surface. - In one embodiment, the
polyester layer 102 is formed from polyethylene terephthalate (PET). The PET is provided in chips that are compressed and heated to form a PET liquid. The PET liquid is forced through a die that has a large number of small openings so that the liquid is extruded into fine threads. The threads are pulled and stretched to a proper diameter with an air venturi suction device. The threads are then laid out on a mesh to form a mat or sheet. Two of these mats or sheets are then joined together by heat fixing and, in some embodiments, the use of a binder. Some binding material may be a waterproof material. Otherwise, theasphalt layer 102 provides the waterproofing qualities of the waterproof sheet. The end result, of at least one embodiment, is a non-woven PET sheet that is liquid pervious and has high tensile strength resulting from the bonded polyester fibers. The polyester sheet is resistant to puncture, tearing and ripping. In addition, thepolyester layer 102 is similar to a thick cloth that is pervious to liquids. In general, the polyester layer has a thickness of about 20 to 40 mils, although those thicknesses can be varied to obtain desired results. - In other known waterproof sheets, the exposed asphalt layer, i.e., the side of the asphalt layer that is not attached to a surface, is normally coated with a granular aggregate. Granular aggregate may comprise coal slag, silica sand, or other granular materials. The use of the granular materials prevents the asphalt layer in the prior art devices, from sticking to machinery during the manufacturing/assembly process. The granular materials that are coated on the exposed surface of the asphalt cause problems during the manufacturing process. For example, excessive wear can occur in the machinery that is used to assemble the waterproof sheet. Assembly machines must be constantly adjusted and repaired as a result of the use of abrasive materials as a granular material to mask the exposed layer of the asphalt so that the exposed layer is not sticky. Further, the coal slag, silica sand, or other granular materials, may generate dust that creates an environmental hazard and possible health problems. Consequently, the elimination of the granular materials is beneficial to the overall manufacturing process and the health and safety of workers.
- The
release film 106 may have a coating of silicon or other release agent to assist in the process of peeling away therelease film 106 from theasphalt layer 104. As mentioned above, theasphalt layer 104 may be modified by mixing certain polymers with theasphalt layer 104, so that theasphalt layer 104 remains tacky after it cools. These polymers may comprise styrene-butadiene-styrene (SBS), styrene-isoprene-styrene (SIS), styrene-ethylene-butadiene-styrene (SEBS), or atactic-polypropylene (APP). Of course, other polymers may be used and other processes may be employed to maintain the tackiness of theasphalt layer 104 when therelease film 106 is removed. - Because of the manner in which the
polyester layer 102 is constructed from extruded threads of PET and other polyesters, thepolyester layer 102 has high tensile strength and lateral stability, as well as a high degree of puncture resistance. Thepolyester layer 102 acts as a structural support for maintaining theasphalt layer 104 and prevents theasphalt layer 104 from being penetrated, ripped or pulled apart. As such, the peel and stick waterproofing sheet may be used as a roof underlayment, a floor underlayment, a tile underlayment and any application where strength and protection is needed, as well as waterproofing. In general, the thickness of the peel andstick waterproofing sheet 100 may range from approximately 30-60 mils, although that thickness may be varied for various applications. In one application, thewaterproofing sheet 100 can be applied to a roof deck and roofing foam can be applied directly to thepolyester layer 102. Because thepolyester layer 102 is permeable, the roofing foam easily bonds to thepolyester layer 102. Roofing tiles can then be placed on the roofing foam and secured in place by the foam. The roofing foam then holds the roofing tiles in place and thewaterproofing sheet 100 provides a secure waterproof underlayment that has high strength and provides a high degree of protection. Good attachment is achieved between the foam and the polyester layer because some of the foam is absorbed in the very top portion of the polyester layer, which provides a strong attachment between the foam and thepolyester layer 102. - In another application, the peel and stick
waterproofing sheet 100 can be used below grade. For example, waterproofingsheet 100 can be attached directly to the foundation of a building, so that theasphalt layer 104 sticks directly on the foundation of the building with thepolyester layer 102 providing puncture resistance, thereby eliminating and/or minimizing the need for additional protection materials to protect the waterproofing layer from puncture by rocks or other physical abrasion. - The width of the
waterproofing sheet 100 may be any desired width. In one embodiment, thewaterproofing sheet 100 is two meters wide and can be constructed in any desired length. As illustrated inFIGS. 3 and 4 , multiple sheets can be used, such as an underlayment on a roof and overlapped, so that multiple courses of thewaterproofing sheet 100 can be used to cover the entire deck of a roof. -
FIG. 2 illustrates another embodiment of a peel and stick waterproofing sheet 200. As illustrated inFIG. 2 , apolyester layer 202 is disposed on a first surface of anasphalt layer 204. Afiberglass mesh 206 is disposed on a second surface of thefirst asphalt layer 204. Asecond asphalt layer 208 has a first side that is disposed on thefiberglass mesh 206. A second side of theasphalt layer 208 is covered byrelease film 210 in the same manner as disclosed above with respect toFIG. 1 . Thefiberglass mesh 206 provides additional structural stability for the asphalt layers 204, 208. The additional structural stability provided by thefiberglass mesh 206 supports the asphalt layers 204, 208 in areas where the asphalt layers 204, 208 are not connected to thepolyester layer 202, as explained in more detail below with respect toFIGS. 3 and 4 . -
FIG. 3 is a cross-sectional view of two peel and stick waterproof layers that are overlapped and provide a waterproof seal. In the embodiment illustrated inFIG. 3 , thefirst sheet 314 may comprise a lower layer of a course laid across a roof or a foundation, while the second sheet 316 is laid in a course across the roof above, or higher than, thefirst sheet 314.Sheet 314 includes apolyester layer 302 and anasphalt layer 304. The release layer has been removed and theasphalt layer 304 is adhered directly to the protectedsurface 318. For example, the protectedsurface 318 may comprise a roof deck with lower portions of the roof on the left side ofFIG. 3 and higher portions on the right side ofFIG. 3 . The seam between thefirst sheet 314 and the second sheet 316 would run approximately horizontally across the roof deck. In the overlapping portions of thefirst sheet 314 and the second sheet 316, thepolyester layer 302 is either removed or not formed on a portion of theasphalt layer 304. This portion of the exposedasphalt layer 304 is referred to as the selvage edge. Awaterproof film 310 is laid across the exposed portion on top of the first side of theasphalt layer 304, which creates a waterproof barrier. The bottom, or second side, of theasphalt layer 308 of the second sheet 316, is placed over thewaterproof film 310 to create a waterproof barrier betweenasphalt layer 308 andasphalt layer 304. Thepolyester layer 306 is raised above the level of thepolyester layer 302. Water running down a roof, or down the side of a foundation, flows in the direction ofarrow 320, from right to left, as illustrated inFIG. 3 . In this manner, water is not pooled but flows over the overlapping layers. -
FIG. 4 is a cross-sectional view of another embodiment of peel and stickwaterproof sheets 422,424 that are overlapped. As illustrated inFIG. 4 , thefirst sheet 422 includes apolyester layer 402 that is bonded toasphalt layer 404.Fiberglass layer 406 is bonded to both theasphalt layer 404 andasphalt layer 408. Thefiberglass mesh layer 406 provides stability for the asphalt layers 404, 408 in the section where thepolyester layer 402 is not connected to the asphalt layers 404, 408. This open portion, referred to as the selvage edge, includes awaterproof film 410 disposed on the top, or first surface, of theasphalt layer 404. Thefiberglass mesh layer 406 provides stability and strength to the exposed selvage edge. The second sheet 424 has apolyester layer 414 that is bonded to theasphalt layer 416.Fiberglass mesh layer 418 is bonded to both theasphalt layer 416 andasphalt layer 420. The second, or lower side, of theasphalt layer 420, attaches to thewaterproof film 410 and the protectedsurface 426, after removal of the releasable layer to provide a waterproof seal between thefirst sheet 422 and the second sheet 424. After removal of the release layer onfirst sheet 422, the second or lower surface of theasphalt layer 408 is secured to the protectedsurface 426, which may comprise a roof deck or a foundation surface. Similarly, the second or lower side ofasphalt layer 420 is attached directly to the protectedsurface 426. Water runs over the sealed overlap area in the direction ofarrow 428. -
FIG. 5 is a side view of an assembler 500 for assembling the peel and stick waterproof sheet illustrated inFIG. 1 . As shown inFIG. 5 , a roll of polyester sheeting 502 is fed into asplicer 504.Splicer 504 functions to splice or join the end of the roll of polyester sheeting 502 to an additional roll ofpolyester sheeting 504 when the roll 502 ends. The empty roller is then removed and theadditional roll 504 slides to the position of roll 502. Another additional roll can then be placed in the initial position ofadditional roll 504, as shown inFIG. 5 . After the polyester sheeting leaves thesplicer 504, it enters alooper 506, which allows the splicing operation to occur without stopping the assembler 500. The polyester sheet then moves to coater 508, which puddles asphalt on a top surface of the polyester sheeting in liquid form, so that the polyester sheeting is coated with an asphalt layer, such asasphalt layer 104 illustrated inFIG. 1 . A metering roll controls the thickness ofasphalt layer 104. The coated polyester sheet then moves over the cooling table 510 until theasphalt layer 104 is cooled to a solid state for application of arelease film 106.Release film roll 512 is located over the asphalt layer disposed on the polyester sheeting. The sheeting then moves over the cooling table 514 until it cools sufficiently to enter thelooper 516. Thelooper 516 provides sufficient time to allow thewinder 518 to wind and cut the assembled waterproof sheeting. -
FIG. 6 is a side view of anassembler 600 for assembling the waterproof sheeting that is disclosed inFIG. 2 . As illustrated inFIG. 6 , a roll of fiberglass mesh 602 passes through thesplicer 608. An additional roll of fiberglass mesh 604 is fed through thesplicer 608 to splice the end of the roll 602 to the beginning of roll 604.Looper 610 provides sufficient time for thesplicer 608 to form the splice without stopping theassembler 600. The fiberglass mesh then passes tocoater 612.Coater 612 applies a first asphalt layer, such asasphalt layer 204, to the top surface of the fiberglass mesh. The asphalt is pooled on a top portion of the fiberglass sheeting and metered by a metering roller to achieve a proper thickness. The bottom surface of the fiberglass mesh is coated with asphalt by a wicking roll (not shown) which is partially submerged in a reservoir of asphalt. A scraper is then used to remove extra asphalt and to achieve a desired thickness of thebottom layer 208 of asphalt. The fiberglass mesh that is coated with a top layer, such astop layer 204, and a bottom layer, such asbottom layer 208, of asphalt then passes to the applicator for the polyester sheeting 614. The applicator 614 applies a polyester layer, such aspolyester layer 202, to the top or first surface ofasphalt layer 204.Applicator 616 applies the release film, such asrelease film 210, to the second or bottom surface of theasphalt layer 208. The assembled sheet then passes over acooling section 616, which sprays water and air on the combined layers to evaporatively cool the sheet to thelooper 620. Thelooper 620 provides sufficient time for thewinder 622 to wind and cut the sheet into rolls. - The present invention therefore provides waterproof sheeting that uses a polyester layer that provides high lateral stability and puncture resistance. The waterproof sheeting can be manufactured without the problems associated with granular coatings that create excessive wear to the assemblers and environmental hazards relating to dust created by the granular particles. The waterproof sheeting can be used in many applications, including waterproof roof underlayments, waterproof sheeting for foundations, underlayment for tile and flooring, and various other applications.
- The foregoing description of the invention has been presented for purposes of illustration and description. It is not intended to be exhaustive or to limit the invention to the precise form disclosed, and other modifications and variations may be possible in light of the above teachings. The embodiment was chosen and described in order to best explain the principles of the invention and its practical application to thereby enable others skilled in the art to best utilize the invention in various embodiments and various modifications as are suited to the particular use contemplated. It is intended that the appended claims be construed to include other alternative embodiments of the invention except insofar as limited by the prior art.
Claims (8)
Priority Applications (3)
Application Number | Priority Date | Filing Date | Title |
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US15/194,798 US20160303825A1 (en) | 2014-03-12 | 2016-06-28 | Peel and stick waterproofing material |
US15/359,819 US9821532B2 (en) | 2014-03-12 | 2016-11-23 | Peel and stick waterproofing material |
US16/008,181 US10857759B2 (en) | 2014-03-12 | 2018-06-14 | Peel and stick waterproofing material |
Applications Claiming Priority (3)
Application Number | Priority Date | Filing Date | Title |
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US201461952024P | 2014-03-12 | 2014-03-12 | |
US14/645,497 US9534378B2 (en) | 2014-03-12 | 2015-03-12 | Peel and stick waterproofing material |
US15/194,798 US20160303825A1 (en) | 2014-03-12 | 2016-06-28 | Peel and stick waterproofing material |
Related Parent Applications (1)
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US16/008,181 Continuation-In-Part US10857759B2 (en) | 2014-03-12 | 2018-06-14 | Peel and stick waterproofing material |
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US15/359,819 Active US9821532B2 (en) | 2014-03-12 | 2016-11-23 | Peel and stick waterproofing material |
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Cited By (7)
Publication number | Priority date | Publication date | Assignee | Title |
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US9821532B2 (en) | 2014-03-12 | 2017-11-21 | Tamko Building Products, Inc. | Peel and stick waterproofing material |
US10857759B2 (en) | 2014-03-12 | 2020-12-08 | Tamko Building Products, Llc | Peel and stick waterproofing material |
US10709642B2 (en) | 2016-06-18 | 2020-07-14 | Totusrx Inc. | Smart pack system for medicines |
CN109777312A (en) * | 2018-12-31 | 2019-05-21 | 苏州腾茂电子科技有限公司 | A kind of preparation process of high temperature heat conductivity electrical apparatus insulation foam tape |
US20200240101A1 (en) * | 2019-01-29 | 2020-07-30 | Amir Rudyan | Below grade, blind side, dual waterproofing membrane assembly incorporating a sheet membrane with adhesive to fully bond to concrete/shotcrete, and a method of making, and using same |
US10968596B2 (en) * | 2019-01-29 | 2021-04-06 | Amir Rudyan | Below grade, blind side, dual waterproofing membrane assembly incorporating a sheet membrane with adhesive to fully bond to concrete/shotcrete, and a method of making, and using same |
US11427983B2 (en) | 2019-01-29 | 2022-08-30 | Amir Rudyan | Below grade, blind side, improved dual waterproofing membrane assembly incorporating a sheet membrane with adhesive to fully bond to concrete/shotcrete, and a method of making, and using same |
Also Published As
Publication number | Publication date |
---|---|
US9821532B2 (en) | 2017-11-21 |
CA2885144A1 (en) | 2015-09-12 |
US9534378B2 (en) | 2017-01-03 |
US20150259900A1 (en) | 2015-09-17 |
US20170072660A1 (en) | 2017-03-16 |
CA2885144C (en) | 2022-06-21 |
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