WO2007144612A2 - Improved sealing system for guttering and methods of manufacturing and using the same - Google Patents
Improved sealing system for guttering and methods of manufacturing and using the same Download PDFInfo
- Publication number
- WO2007144612A2 WO2007144612A2 PCT/GB2007/002196 GB2007002196W WO2007144612A2 WO 2007144612 A2 WO2007144612 A2 WO 2007144612A2 GB 2007002196 W GB2007002196 W GB 2007002196W WO 2007144612 A2 WO2007144612 A2 WO 2007144612A2
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- gutter
- section
- thermoplastic
- coated
- coating
- Prior art date
Links
Classifications
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D13/00—Special arrangements or devices in connection with roof coverings; Protection against birds; Roof drainage; Sky-lights
- E04D13/04—Roof drainage; Drainage fittings in flat roofs, balconies or the like
- E04D13/064—Gutters
- E04D13/068—Means for fastening gutter parts together
-
- E—FIXED CONSTRUCTIONS
- E04—BUILDING
- E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
- E04D13/00—Special arrangements or devices in connection with roof coverings; Protection against birds; Roof drainage; Sky-lights
- E04D13/04—Roof drainage; Drainage fittings in flat roofs, balconies or the like
- E04D13/064—Gutters
-
- C—CHEMISTRY; METALLURGY
- C08—ORGANIC MACROMOLECULAR COMPOUNDS; THEIR PREPARATION OR CHEMICAL WORKING-UP; COMPOSITIONS BASED THEREON
- C08L—COMPOSITIONS OF MACROMOLECULAR COMPOUNDS
- C08L23/00—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers
- C08L23/02—Compositions of homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Compositions of derivatives of such polymers not modified by chemical after-treatment
- C08L23/10—Homopolymers or copolymers of propene
Abstract
The present invention relates to a system for sealing joints between two guttering sections which have been pre-coated with a thermoplastic polymer and/ or a guttering section and a roof . In particular, it relates to a method for sealing the joints between sections of guttering where the gutter sections have been pre-coated with a protective, corrosion resistant polypropylene based material coating.
Description
Improved sealing system for guttering and methods of manufacturing and using the same
The present invention relates to a system for sealing joints between two guttering sections which have been pre-coated with a thermoplastic polymer and/or a guttering section and a roof. In particular, it relates to a method for sealing the joints between sections of guttering where the gutter sections have been pre-coated with a protective, corrosion resistant polyolefin coating.
It is known that metallic building materials such as guttering can be provided with a protective coating to improve their resistance to corrosion and to protect them from the elements to extend their useful lifespan. Originally, coatings such as enamel, polyester and acrylic were utilised to provide this corrosion resistance, however more recently thermoplastic polymers have been used as they are both strong and hardwearing and can be applied to surfaces often without the need for a primer or further adhesives .
Typically, gutter sections are pre-coated in a factory setting and can then be transported and connected together on-site. Applying the coatings in advance of the guttering being used on a building is desirable as it
CONFIRMATION COPY
is typically a safer, more accurate and easier job than applying a coating on-site. The coating material for the gutter sections is in the form of a finely divided powder which is then applied as an electrostatic spray onto the surface of the gutter sections after any gross surface soiling has been removed. The powder spray is usually applied using a corona gun at a high temperature
(typically 1502C - 2202C) to a section of gutter to ensure optimum adhesion and to provide a uniform layer of thermoplastic coating which does not require further curing. The coated metal can then be moved to the site of use and incorporated into a gutter system on a building.
Although the abovementioned method ensures that the pre- coated sections are themselves protected, the gutter system as a whole is made up from a number of conjoined sections, and these joint sections are still prone to leaks. This inherent weakness in the system commonly means that gutter systems cannot be provided with guarantees as to the integrity of the system for any significant period of time, despite the fact that individual coated sections my have a lifespan of well over 20 years. The currently accepted manner of sealing the joints is to use an adhesive sealing tape; however the adhesives used typically have a much shorter life than the thermoplastic coatings and it is often difficult to find an adhesive that adheres sufficiently well to the thermoplastic coating. Again, this results in a gutter system where the joints are likely to leak well before the remaining gutter elements are worn and in need of repair. An alternative option to the use of adhesive tape is to use a small amount of the finely divided thermoplastic powder which has been used to make the protective coating and apply over the gutter joints when the gutter is in place then melt with a heat gun. Although this option theoretically provides a
significantly better seal to the joint than an adhesive strip, the use of a thermoplastic powder on a gutter system in situ is extremely difficult, particularly in adverse weather conditions due to the powder being swept away before it is melted onto the joint or being unevenly distributed along the joint.
As well as joining gutter sections to each other it is also desirable to seal between a gutter section and the roof which it is being placed along side. Currently, many roofs are provided with thermoplastic olefin or polyolefin (TPO) membranes. TPO membranes are single-ply roof membranes constructed from ethylene propylene rubber. They have been tested as having excellent resistance to ozone, are algae-resistant, environmentally friendly and safe to install. TPO is highly resistant to tears, impacts, and punctures with good flexibility to. allow for building movement. TPO membranes are usually installed fully-adhered which means that the roof is "glued" to the substrate using a special adhesive. It is however difficult to then seal between the TPO membrane and a gutter without gluing the TPO membrane to the gutter, which does not form a particularly strong or watertight seal .
It is an object of the present invention to obviate or mitigate some of the problems associated with the prior art, particularly in relation to the sealing of joints between pre-coated gutter systems or between a pre-coated gutter section and a coated roof.
The present invention provides systems and methods for very easily and efficiently sealing the joint between a section of guttering and a nearby section of guttering or
roof, each of which are already coated with a thermoplastic material. Rather than using a glue to seal the joints as in the prior art, or a finely divided powder of thermoplastic material, the joints are sealed using either a patch or paste comprising thermoplastic material which is melted such that it fuses with the coating on the surrounding gutter sections .
According to a first aspect of the present invention there is provided a product for sealing a joint between two thermoplastic coated sections, comprising; a patch of thermoplastic material shaped such that it covers the joint between the two thermoplastic coated sections and extends, at least partially, onto each of the thermoplastic coated sections.
Providing the patch as a piece of preformed thermoplastic material rather than the powder of the prior art allows easy application to a joint and provides the means for sealing the joint in a form that is significantly easier to use in the field.
Preferably the patch of thermoplastic material has been formed from the same thermoplastic material which has been used to coat the thermoplastic coated sections.
Preferably the thermoplastic material is a polyolefin material .
Most preferably the thermoplastic material is a polypropylene material .
Most preferably the polypropylene material is an approximately 90% derivative of polypropylene.
Most preferably the polypropylene material further comprises one or more selected from the list of;
Flexicisers ; Stabilisers ; UV stabilisers; Colour pigments/dyes; Adhesives.
Most preferably the thermoplastic material is a blend of functionalized polyolefins.
Examples of a suitable polyolefin blend is PLASCOAT™ PPA571ES (Plascoat™ systems Ltd, Farnham, Surrey) or, even more preferably, TALISMAN 30™ (Plascoat™ systems Ltd, Farnham, Surrey) .
Most preferably the thermoplastic material has a melting point of approximately 154°C.
According to a second aspect of the present invention there is provided a method for sealing a joint between a section of gutter and an abutting area, comprising the steps;
- providing a gutter section which is coated on at least one surface with a polypropylene material; providing a patch of thermoplastic material which extends, at least partially between the section of gutter and an abutting area;
- applying heat to the patch at least at the interface where it extends onto the section of gutter and the abutting area to melt the patch such that it will fuse to the section of gutter and the abutting area
Preferably the thermoplastic coated sections are sections of guttering.
The Application of heat to the interface between the patch and the already coated surrounding area results in the patch and surrounding coating fusing together. As
the patch is shaped to overlap with the in situ sections heat can then be applied to re-melt both the patch and coating on the section such that when they cool a contiguous seal is formed across the joint.
Preferably the method further comprises the step;
- allowing the patch of thermoplastic material to cool.
According to a third aspect of the present invention there is provided a product for sealing a joint between two thermoplastic coated sections, comprising; a thermoplastic material; and a solvent suitable for solvating said thermoplastic material; which have been combined to form a paste.
Preferably the paste is provided in an airtight dispenser.
Providing the paste in an airtight container ensures that the solvent does not evaporate prior to use.
According to a fourth aspect of the present invention there is provided a method for sealing a joint between two thermoplastic coated sections, the method comprising the steps; applying a paste comprising a thermoplastic material and a solvent suitable for solvating said thermoplastic material such that the paste covers the joint between the two thermoplastic coated sections and extends, at least partially, onto each of the thermoplastic coated sections applying heat to the paste of thermoplastic material until the solvent is at least partially evaporated and the thermoplastic material at least partially melts; and allowing the thermoplastic material to cool to form a solid section which fuses with the thermoplastic coated sections.
According to a fifth aspect of the present invention there is provided a method of coating a gutter section with polypropylene material, comprising the steps; - heating a section of metal to a temperature higher than that of the melting point of the polypropylene based material;
- spray coating the heated metal with a polypropylene based material; - reheating the spray coated metal to a temperature higher than that of the melting point of the polypropylene based material;
- allowing the spray coated metal to cool.
Preferably, the section of metal is heated to a temperature of >154°C.
Preferably the polypropylene material further comprises one or more selected from the list of; Flexicisers;
Stabilisers;
UV stabilisers;
Colour pigments/dyes ;
Adhesives .
Preferably an electrostatic spraying device is used to spray coat the heated metal .
Optionally the section of metal is shaped into the form of a gutter prior to being coated.
Alternatively the section of metal is shaped into the form of a gutter after being coated.
In order to provide a better understanding of the present invention, embodiments will be described by way of
example only and with reference to the following drawings in which;
Figure 1 is a diagram showing a perspective view of a patch according to one embodiment of the present invention prior to being applied to a joint between two coated sections of guttering; and
Figure 2 is a diagram showing a perspective view of a patch according to one embodiment of the present invention during application to a joint between two coated sections of guttering; and
Figure 3 is a diagram showing a perspective view of another embodiment of the present invention where a paste is being applied to a joint between two coated sections of guttering.
Figure 4 is a diagram showing a perspective view of the present invention after the patch or paste has been applied.
In a first embodiment of the present invention, as shown in figures 1 and 2) there is provided a pre-formed patch of thermoplastic material (1) which is used to seal a joint (2) between two sections of pre-coated guttering (3a and 3b) . In this embodiment the patch of thermoplastic material (1) is a flexible solid piece of polypropylene material comprising a 90% derivative of polypropylene along with flexicisers, stabilisers, UV stabilisers, colour pigments and adhesives which can be obtained from Plascoat Systems Limited, Farnham, Surrey under the trade name TALISMAN 30™. The pre-coated guttering (3a and 3b) shown in figures 1 and 2 has itself a coating of the same material (4) .
The inventors have also found that the guttering itself can be pre-coated without the need for adhesives to form a coating which is essentially fused to the gutter. In the preferred method, a section of gutter is heated to approximately 2000C (it is suggested that 200°C-220°C is the preferred range for heating, however >160°C would typically suffice with the proviso that >240°C can be problematic when using galvanised substrate as it starts to degrade) . An electrostatic gun is then used to apply the powdered polypropylene based thermoplastic material (TALISMAN 30™) to the heated surface and, as the surface is hot this causes the material to melt onto the guttering on contact. The coated gutter is then placed in an oven and reheated to approximately 2000C for 2-3 minutes. Beneficially, applying the coating to a preheated gutter section allows for a thicker coating (approximately 300 microns) than would be obtained if the gutter was spray coated cold or at room temperature and then placed in the oven where usual thicknesses of 1-200 microns would be obtained. To allow for future welding the thicker coat gives a substantial benefit.
There is a suggestion that a fluidised bed could also be used to coat the guttering. However, although this is theoretically possible the size of standard fluidised beds is such that it is not commercially feasible for large sections of guttering.
When preparing the guttering, the coating may be applied to pre-shaped gutters, or to flat metal section which can be formed into gutter section after coating. Advantageously, all sides of the gutter can be easily coated.
The patch of thermoplastic material (1) can be manufactured in a similar manner to the coated guttering by placing the powdered form of the TALISMAN 30™ onto a
"non-stick" plate. The powdered polypropylene based material is then exposed to heat such that it melts to form a smooth coating. The plate and molten polypropylene based material are then allowed to cool and the molten polypropylene based material then forms a solid sheet (although still flexible in this case) . The plate is made from a material which is selected because neither the molten polypropylene based material nor the cooled solid sheet of polypropylene based material will adhere to it strongly. The cooled solid sheet of thermoplastic polypropylene based material is then removed from the plate and is now in the form of a thermoplastic patch (1) . The patch (1) is approximately 5mm thick. The patch (1) can be made to different thicknesses, however the preference is that is not so thick that it loses malleability. The thickness is therefore selected to allow easy coverage of uneven joint (2) sections.
Figure 1 shows a perspective view of the thermoplastic patch (1) prior to it being applied to a joint (2). The thermoplastic patch (1) is shaped such that it covers the joint (2) but also extends beyond the joint (2) to overlap with the pre-coated gutter sections (3a and 3b) at either side.
In an alternative embodiment a number of thermoplastic patches (1) could be used to seal a joint (2) if a single patch was too small to span the full length.
Figure 2 shows a plan view of the thermoplastic patch (1) when placed in position on the joint (2) . In use, heat is applied using a heat gun/blow torch to the interface (5) formed by the overlap between the thermoplastic patch (1) and the coating (4) on the gutter sections (3a and 3b) . The application of heat causes both the thermoplastic patch (1) and the underlying section of
coating (4) on the gutter sections (3a and 3b) at the interface (5) to melt. The heat source is then removed and the molten section of thermoplastic patch (1) and coating (4) at the interface (5) is allowed to cool and re-solidify. As the thermoplastic patch (1) and gutter coating (4.) are both the same polypropylene based material they re-solidify as a single solid section resulting in a continuous thermoplastic layer extending across the joint (2) as can be seen in Figure 4.
In this embodiment it would also be possible to seal between the guttering and an abutting roof section which had been covered in a TPO membrane. A thermoplastic patch could be positioned to extend onto both the TPO membrane and the coating on a gutter section. Heat is applied using a heat gun/blow torch to the interface formed by the overlap between the thermoplastic patch and the coating on the gutter sections and also the interface formed by the overlap between the thermoplastic patch and the TPO membrane. Alternatively the TPO membranes could be extended onto the coated gutter section and heat applied to the overlap negating the need for a patch. This can work because the 90% derivative of polypropylene along with flexicisers, stabilisers, UV stabilisers, colour pigments and adhesives which can be obtained from
Plascoat Systems Limited, Farnham, Surrey under the trade name TALISMAN 30™ is surprisingly able to fuse with a TPO membrane .
It is clear from the above that the preference is to use the TALISMAN 30™ polypropylene based material for the thermoplastic material due to its ability to easily bind/fuse to metals commonly used to produce guttering without the need for adhesive, however theoretically any appropriate thermoplastic material could be used in its place, for example polyethylene, in order to provide a patch sealing system.
In a second embodiment of the present invention (as shown in Figure 3) there is provided a paste (6) containing both polyolefin thermoplastic material and a solvent. The paste (6) is used to seal a joint (12) between two sections of pre-coated guttering (13a and 13b) . In the preferred embodiment the solvent is an alcohol based solvent. In alternative embodiments, water or a water based solvent can be used. The paste (6) is held in the chamber of a dispensing gun (8) . The chamber is airtight when the dispensing gun (8) is not in the process of dispensing the paste (6) . When the paste (6) is dispensed from the dispensing gun (8) , the solvent element of the paste (6) will begin to evaporate. In use, the paste (6) is dispensed onto the joint (12) between two sections of pre-coated guttering (13a and 13b) such that it covers the joint (12) and extends onto each of the two sections of pre-coated guttering (13a and 13b) . A heat source is used to elevate the temperature of the paste (6) resulting in further evaporation of the solvent element of the paste (6) as well as the melting of the thermoplastic material present in both the paste (6) and on the surface of the sections of pre-coated guttering (13a and 13b) . When the melted thermoplastic is allowed to cool it fuses with the melted thermoplastic coating on the of pre-coated guttering (13a and 13b) forming a solid patch which is contiguous with the coating that was already present on the two sections of pre-coated guttering (13a and 13b) as shown in Figure 4.
The present invention has applicability in a wide range of building areas where sections of building materials which have been pre-coated with a corrosion resistant thermoplastic are combined leaving joint sections. It is particularly useful in guttering systems where exposed joints are undesirable and as the positioning of guttering often makes on-site working difficult.
Further modifications and improvements may be added without departing from the scope of the invention herein described. For example, where the thermoplastic material is described as being polyolefin, any appropriate alternative thermoplastic material can be used such as polyethylene. It is however desirable to select a thermoplastic material that, when melted, is able to fuse to metal .
Claims
1. A product for sealing a joint between two thermoplastic coated sections, comprising; a patch of thermoplastic material shaped such that it covers the joint between the two thermoplastic coated sections and extends, at least partially, onto each of the thermoplastic coated sections.
2. A product for sealing a joint between two thermoplastic coated sections, comprising; a thermoplastic material; and a solvent suitable for solvating said thermoplastic material; which have been combined to form a paste.
3. A product as in Claims 1 or 2 wherein the thermoplastic material is a polyolefin material.
4. A product as in Claims 1 or 2 wherein the thermoplastic material is a polypropylene material.
5. A product as in Claim 4 wherein the polypropylene material is an approximately 90% derivative of polypropylene .
6. A product as in Claim 4 or 5 wherein the polypropylene material further comprises one or more selected from the list of;
Flexicisers;
Stabilisers;
UV stabilisers;
Colour pigments/dyes; Adhesives.
7. A product as in any of the previous Claims wherein the thermoplastic material is a blend of functionalised polyolefins.
8. A product as in any of the previous Claims wherein the thermoplastic material has a melting point of approximately 1540C.
9. A product according to Claim 2 wherein the paste is provided in an airtight dispenser.
10. A process for sealing a joint between a section of gutter and an abutting area, comprising the steps; - providing a gutter section which is coated on at least one surface with a polypropylene material; providing a patch of thermoplastic material according to any of Claims 1 or 3 to 8, which extends, at least partially between the section of gutter and an abutting area; applying heat to the patch at least at the interface where it extends onto the section of gutter and the abutting area to melt the patch such that it will fuse to the section of gutter and the abutting area.
11. A process as in Claim 8 wherein the method further comprises the step;
- allowing the patch of thermoplastic material to cool.
12. A method of coating a gutter section with polypropylene material for use in the process of Claims 10 or 11, comprising the steps; - heating a section of metal to a temperature higher than that of the melting point of the polypropylene based material; - spray coating the heated metal with a polypropylene based material;
- reheating the spray coated metal to a temperature higher than that of the melting point of the polypropylene based material;
- allowing the spray coated metal to cool .
13. A method of coating a gutter section as in Claim 12 wherein the section of metal is heated to a temperature of >154°C.
14. A method of coating a gutter section as in Claims 12 or 13 wherein the polypropylene material further comprises one or more selected from the list of;
Flexicisers;
Stabilisers;
UV stabilisers;
Colour pigments/dyes ; Adhesives .
15. A method of coating a gutter section as in Claims 12 to 14 wherein an electrostatic spraying device is used to spray coat the heated metal.
16. A method of coating a gutter section as in Claims 12 to 15 wherein the section of metal is shaped into the form of a gutter prior to being coated.
17. A method of coating a gutter section as in Claims 12 to 16 wherein the section of metal is shaped into the form of a gutter after being coated.
Applications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| GB0611765A GB0611765D0 (en) | 2006-06-14 | 2006-06-14 | Improved sealing system and method of using the same |
| GB0611765.9 | 2006-06-14 |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| WO2007144612A2 true WO2007144612A2 (en) | 2007-12-21 |
| WO2007144612A3 WO2007144612A3 (en) | 2008-05-08 |
Family
ID=36775625
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| PCT/GB2007/002196 WO2007144612A2 (en) | 2006-06-14 | 2007-06-13 | Improved sealing system for guttering and methods of manufacturing and using the same |
Country Status (2)
| Country | Link |
|---|---|
| GB (1) | GB0611765D0 (en) |
| WO (1) | WO2007144612A2 (en) |
Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3139412A (en) * | 1961-03-17 | 1964-06-30 | Dow Chemical Co | Calking and sealing composition containing polypropylene |
| US4306389A (en) * | 1978-08-14 | 1981-12-22 | Bucker Thomas W | Protective device |
| GB2372756A (en) * | 2001-02-28 | 2002-09-04 | Ash & Lacy Building Prod Ltd | Membrane lined gutters |
| WO2005066297A1 (en) * | 2004-01-05 | 2005-07-21 | Sika Technology Ag | Protective film consisting of a hot-melt adhesive and method and device for applying said film |
-
2006
- 2006-06-14 GB GB0611765A patent/GB0611765D0/en not_active Ceased
-
2007
- 2007-06-13 WO PCT/GB2007/002196 patent/WO2007144612A2/en active Application Filing
Patent Citations (4)
| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| US3139412A (en) * | 1961-03-17 | 1964-06-30 | Dow Chemical Co | Calking and sealing composition containing polypropylene |
| US4306389A (en) * | 1978-08-14 | 1981-12-22 | Bucker Thomas W | Protective device |
| GB2372756A (en) * | 2001-02-28 | 2002-09-04 | Ash & Lacy Building Prod Ltd | Membrane lined gutters |
| WO2005066297A1 (en) * | 2004-01-05 | 2005-07-21 | Sika Technology Ag | Protective film consisting of a hot-melt adhesive and method and device for applying said film |
Also Published As
| Publication number | Publication date |
|---|---|
| GB0611765D0 (en) | 2006-07-26 |
| WO2007144612A3 (en) | 2008-05-08 |
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