WO2022178838A1

WO2022178838A1 - Thermoplastic sealing device with improved barrier properties

Info

Publication number: WO2022178838A1
Application number: PCT/CN2021/078172
Authority: WO
Inventors: Lanwei WANG; Yizhe Wei; Qin WEI
Original assignee: Sika Technology Ag
Priority date: 2021-02-26
Filing date: 2021-02-26
Publication date: 2022-09-01
Also published as: CN116887978A

Abstract

The invention is directed to a sealing device (1) comprising a polymeric waterproofing layer (2) and a barrier composite layer (3) comprising a polymeric connecting layer (4), a metallic or polymeric barrier layer (5), and a polymeric protective layer (6). The invention is also directed to a method for producing a sealing device and to a roof system comprising a roof underlayment (10) and a sealing device (1) adhered to a surface of the roof underlayment (10).

Description

Thermoplastic sealing device with improved barrier properties

Technical field

The invention relates to the field of waterproofing of above and below ground building constructions by using water impermeable thermoplastic sealing devices. In particular, the invention relates to thermoplastic waterproofing and roofing membranes, which are used for sealing of building substrates against leakage of water.

Background of the invention

In the field of construction polymeric sheets, which are often referred to as membranes, are used to protect underground and above ground constructions, such as basements, tunnels, and flat and low-sloped roofs, against penetration water. Membranes are applied, for example, to prevent ingress of water through cracks that develop in the concrete structure due to building settlement, load deflection or concrete shrinkage. Roofing membranes used for waterproofing of flat and low-sloped roof structures can be provided as single-ply or multi-ply membrane systems. In a single-ply system, the roof substrate is covered using a roofing membrane composed of a single waterproofing layer, which can be reinforced with a reinforcement layer, such as a layer of fiber material. In multi-ply systems, a roofing membrane composed of multiple waterproofing layers of different or similar materials are used. Single-ply membranes have the advantage of lower production costs compared to the multi-ply membranes, but they are also less resistant to mechanical damages cause by punctures of sharp objects.

Commonly used materials for waterproofing and roofing membranes include plastics, particularly thermoplastics such as plasticized polyvinylchloride (p-PVC) , thermoplastic olefins (TPE-O, TPO) , and elastomers such as ethylene- propylene diene monomer (EPDM) rubber. Bituminous materials are also used for providing membranes since they provide good resistance against environmental factors combined with relatively low costs compared to thermoplastic polymer materials. Bitumen compositions are typically modified with synthetic polymers to increase resistance to UV-radiation, toughness, and flexibility at low temperatures. The membranes are typically delivered to a construction site in form of rolls, unrolled, and cut into suitable pieces to be adhered on the surface of the substrate to be waterproofed. The substrate on which the membrane is adhered may be comprised of variety of materials depending on the installation site. The substrate may be, for example, a concrete, metal, or wood deck, or it may include a cover board and/or an insulation board and/or an existing waterproofing or roofing membrane.

Waterproofing and roofing membranes can be adhered to substrates by using several techniques such as by contact bonding or by using self-adhering membranes. In contact bonding both the membrane and the surface of the substrate are first coated with a solvent or water-based contact adhesive followed by joining the adhesive films with each other. The volatile components of the contact adhesive are “flashed off” to provide a partially dried adhesive film prior to contacting the membrane with the surface of the substrate. The main disadvantages of contact bonding relate to slowness of the installation process compared to self-adhering membranes, significant emissions of volatile compounds in case of solvent-based adhesives and limited application at cold temperatures in case of water-based contact adhesives.

Self-adhering membranes comprise a pre-applied layer of adhesive composition coated on the surface of the membrane. Typically, the pre-applied adhesive layer is also covered with a release liner to prevent premature unwanted adhesion and to protect the adhesive layer from moisture, fouling, and other environmental factors. At the time of use the release liner is removed and the membrane is secured to the substrate without using additional adhesives. Self-adhering membranes having a pre-applied adhesive layer covered by a release liner are also known as “peel and stick membranes” .

Migration of chemical substances from the adhesive layer into the membrane may in some cases be a significant problem, especially for TPO-based roofing membranes. For example, in case of contact bonding, a solvent-based adhesive is applied directly onto the back layer of the membrane and the volatile compounds may migrate from the adhesive composition into the polymer matrix of the membrane resulting the reduced service life of the membrane. The non-woven layer of a fleece/felt-backed roofing membrane can be used as a barrier layer against the migration of chemical compounds but due to the porous structure of the non-woven, the protective capability is only partial. Another disadvantage of the fleece-and felt-backed membranes include the higher production costs compared to bare-backed membranes. Self-adhering membranes contain a factory-applied adhesive layer on the lower surface of the membrane. The adhesive layer can be a butyl rubber-based adhesive or a bitumen-based adhesive, which may contain a variety of chemical compounds that can migrate from the adhesive layer into the membrane. Accelerated aging tests conducted using a QUVB tester have revealed that the adhesive layers of some commercially available TPO-based self-adhering membranes comprise components that will migrate into the membrane increasing the speed of aging of the membrane.

There thus remains a need for new type of a TPO-based membrane having improved barrier properties against the migration of chemical substances from the environment into the membrane material.

Summary of the invention

The object of the present invention is to provide a sealing device having improved barrier properties against migration of chemical compounds, which sealing device is suitable for waterproofing of substrates against the penetration of water.

The subject of the present invention is a sealing device as defined in claim 1.

It was surprisingly found out that a sealing device comprising a polymeric waterproofing layer and a barrier composite layer comprising a polymeric connecting layer, barrier layer, and a polymeric protective layer, wherein the barrier composite layer covers the bottom surface of the polymeric waterproofing layer, is able to solve or at least mitigate the problems related to prior art sealing devices used for waterproofing of substrates.

One of the advantages of the sealing device of the present invention is that the improvements in resistance against migration of chemical compounds can be achieved without significant increase in production and raw material costs of the sealing device, particularly compared to the State-of-the-Art waterproofing and roofing membranes. Another advantage of the present invention is that the sealing device can be manufactured by thermally laminating the components of the sealing device to each other instead of using adhesives, which enables using a simplified production process with increased production efficiency.

Other subjects of the present invention are presented in other independent claims. Preferred aspects of the invention are presented in the dependent claims.

Brief description of the Drawings

Fig. 1 shows a cross-section of a sealing device (1) comprising a polymeric waterproofing layer (2) and a barrier composite layer (3) covering the lower major surface of the polymeric waterproofing layer, the barrier composite layer comprising a polymeric connecting layer (4) , a barrier layer (5) , and a polymeric protective layer (6) , wherein the polymeric connecting layer (4) is arranged between the polymeric waterproofing layer (2) and the barrier layer (5) .

Fig. 2 shows a cross-section of a sealing device (1) of Fig. 1 further comprising a tie layer (7) arranged between the barrier layer (5) and the polymeric connecting layer (4) .

Fig. 3 shows a cross-section of a sealing device (1) of Fig. 1 further comprising a layer of fiber material (8) fully embedded into the polymeric waterproofing layer (2) and an adhesive layer (9) covering the lower major surface of the polymeric protective layer (6) .

Fig. 4 shows a cross-section of a roof system comprising a roof underlayment (10) and a sealing device (1) of Fig. 1 adhered to a surface of the roof underlayment (10) via an adhesive layer (9) .

The proportion of thicknesses of the individual layers in Figures 1 to 4 is not true to scale. In particular, the ratio of the thickness of the polymeric waterproofing layer (2) to the thickness of the individual layers of the barrier composite layer (3) is in reality far higher than that shown in Figures 1-4.

Detailed description of the invention

The subject of the present invention a sealing device (1) comprising:

i. A polymeric waterproofing layer (2) comprising at least one polymer P1 and having an upper and lower major surfaces,

ii. A barrier composite layer (3) covering at least a portion of the lower major surface of the polymeric waterproofing layer, wherein the barrier composite layer comprises:

a) A polymeric connecting layer (4) comprising at least one polymer P2,

b) A barrier layer (5) , and

c) A polymeric protective layer (6) , wherein

the polymeric connecting layer (4) is arranged between the polymeric waterproofing layer (2) and the barrier layer (5) and wherein the barrier layer (5) is a metallic barrier layer or a polymeric barrier layer comprising at least one polymer P3 selected from the group consisting of ethylene vinyl alcohol and polyamide and the polymeric protective layer (6) comprises at least one polymer P4 selected from the group consisting of polyester, polyamide, and polycarbonate.

Substance names beginning with "poly" designate substances which formally contain, per molecule, two or more of the functional groups occurring in their names. For instance, a polyol refers to a compound having at least two hydroxyl groups. A polyether refers to a compound having at least two ether groups.

The term “polymer” designates a collective of chemically uniform macromolecules produced by a polyreaction (polymerization, polyaddition, polycondensation) where the macromolecules differ with respect to their degree of polymerization, molecular weight and chain length. The term also comprises derivatives of said collective of macromolecules resulting from polyreactions, that is, compounds which are obtained by reactions such as, for example, additions or substitutions, of functional groups in predetermined macromolecules and which may be chemically uniform or chemically non-uniform.

The term “melting temperature” refers to a temperature at which a material undergoes transition from the solid to the liquid state. The melting temperature (T _m) is preferably determined by differential scanning calorimetry (DSC) according to ISO 11357-3 standard using a heating rate of 2 ℃/min. The measurements can be performed with a Mettler Toledo DSC 3+ device and the T _m values can be determined from the measured DSC-curve with the help of the DSC-software. In case the measured DSC-curve shows several peak temperatures, the first peak temperature coming from the lower temperature side in the thermogram is taken as the melting temperature (T _m) .

The term “glass transition temperature” (T _g) designates the temperature above which temperature a polymer component becomes soft and pliable, and below which it becomes hard and glassy. The glass transition temperature is preferably determined by dynamical mechanical analysis (DMA) as the peak of the measured loss modulus (G” ) curve using an applied frequency of 1 Hz and a strain level of 0.1 %.

The “amount or content of at least one component X” in a composition, for example “the amount of the at least one polymer P1” refers to the sum of the individual amounts of all polymers P1 contained in the composition. Furthermore, in case the composition comprises 20 wt. -%of at least one polymer P1, the sum of the amounts of all polymers P1 contained in the composition equals 20 wt. -%.

The term “room temperature” designates a temperature of 23 ℃.

The sealing device of the present invention comprises a polymeric waterproofing layer and a barrier composite layer comprising a polymeric connecting layer, a barrier layer, and a polymeric protective layer. The term “layer” refers in the present disclosure to a sheet-like element having upper and lower major surfaces, a width defined between longitudinally extending edges, and a thickness defined between the upper and lower major surfaces. Preferably, a layer has a length and width at least 5 times, more preferably at least 15 times, even more preferably at least 25 times greater than the thickness of the layer. The term “polymeric layer” refers to a layer comprising a continuous phase composed of one or more polymers.

Preferably, the barrier composite layer covers at least 50 %, more preferably at least 65 %, even more preferably at least 75 %, still more preferably at least 85 wt. -%, of the area of the lower major surface of the polymeric waterproofing membrane. It may be preferable that narrow segments, also known as selvedges, on the lower major surface of the polymeric waterproofing layer near the longitudinal edges are left free of the barrier composite layer. Such selvedges having a width of 25 –150 mm, preferably 35 –100 mm, may be present on the surface of the polymeric waterproofing layer to enable overlapping and bonding the overlapped portions of sealing devices by means of heat-welding.

Preferably, the polymeric waterproofing layer and the polymeric connecting layer are both polyolefin-based layers. Term "polyolefin" refers in the present disclosure to homopolymers and copolymers obtained by polymerization of olefins optionally with other types of comonomers.

According to one or more embodiments, the at least one polymer P1 and P2 are selected from the group consisting of ethylene copolymers, polyethylene, propylene copolymers, and polypropylene.

Suitable polyethylenes to be used as the at least one polymer P1 and P2 include very-low-density polyethylene, low-density polyethylene, linear low-density polyethylene, medium-density polyethylene, high-density polyethylene, and ultra-high-molecular-weight polyethylene, particularly low-density polyethylene, linear low-density polyethylene, medium-density polyethylene, high-density polyethylene.

Suitable ethylene copolymers include random and block copolymers of ethylene and one or more C ₃-C ₂₀ α-olefin monomers, particularly one or more of propylene, 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-decene, 1-dodecene, and 1-hexadodecene, preferably comprising at least 60 wt. -%, more preferably at least 65 wt. -%of ethylene-derived units, based on the weight of the copolymer.

Suitable ethylene random copolymers include, for example, ethylene-based plastomers, which are commercially available, for example, under the trade name of

such as

EG 8100G,

EG 8200G,

SL 8110G,

KC 8852G,

VP 8770G, and

PF 1140G (all from Dow Chemical Company) ; under the trade name of

such as

3024,

3027,

3128,

3131,

4049,

4053,

5371, and

8203 (all from Exxon Mobil) ; and under the trade name of

(from Borealis AG) as well as ethylene-based polyolefin elastomers (POE) , which are commercially available, for example, under the trade name of

such as

7256,

7467,

7447,

8003,

8100,

8480,

8540,

8440,

8450,

8452,

8200, and

8414 (all from Dow Chemical Company) .

Suitable ethylene-α-olefin block copolymers include ethylene-based olefin block copolymers (OBC) , which are commercially available, for example, under the trade name of

such as

9100,

9107,

9500,

9507, and

9530 (all from Dow Chemical Company) .

Further suitable ethylene copolymers include copolymers of ethylene and vinyl acetate. Suitable copolymers of ethylene and vinyl acetate include those having a content of a structural unit derived from vinyl acetate in the range of 4 –90 wt. -%, preferably 6 –80 wt. -%, more preferably 8 –70 wt. -%, based on the weight of the copolymer. Suitable copolymers of ethylene and vinyl acetate are commercially available, for example, under the trade name of

(from Exxon Mobil) , under the trade name of

(from Repsol Quimica S.A. ) , under the trade name of

(from Arkema Functional Polyolefins) , under the trade name of

(from Eni versalis S.p.A. ) , and under the trade name of

(from Arlanxeo GmbH) .

Suitable polypropylenes include, for example, isotactic polypropylene (iPP) , syndiotactic polypropylene (sPP) , and homopolymer polypropylene (hPP) .

Suitable propylene copolymers include propylene-ethylene random and block copolymers and random and block copolymers of propylene and one or more C ₄-C ₂₀ α-olefin monomers, in particular one or more of 1-butene, 1-pentene, 1-hexene, 1-heptene, 1-octene, 1-decene, 1-dodecene, and 1-hexadodecene, preferably comprising at least 60 wt. -%, more preferably at least 65 wt. -%of propylene-derived units, based on the weight of the copolymer.

Suitable propylene random and block copolymers are commercially available, for example, under the trade names of

and Versify (from Dow Chemical Company) and under the trade name of

(from Exxon Mobil) .

Further suitable propylene copolymers include heterophasic propylene copolymers. These are heterophasic polymer systems comprising a high crystallinity base polyolefin and a low-crystallinity or amorphous polyolefin modifier. The heterophasic phase morphology consists of a matrix phase composed primarily of the base polyolefin and a dispersed phase composed primarily of the polyolefin modifier. Suitable commercially available heterophasic propylene copolymers include reactor blends of the base polyolefin and the polyolefin modifier, also known as “in-situ TPOs” or “reactor TPOs or “impact copolymers (ICP) ” . These are typically produced in a sequential polymerization process, wherein the components of the matrix phase are produced in a first reactor and transferred to a second reactor, where the components of the dispersed phase are produced and incorporated as domains in the matrix phase. Heterophasic propylene copolymers comprising polypropylene homopolymer as the base polymer are often referred to as “heterophasic propylene copolymers (HECO) ” whereas heterophasic propylene copolymers comprising polypropylene random copolymer as the base polymer are often referred to as “heterophasic propylene random copolymers (RAHECO) ” . The term “heterophasic propylene copolymer” encompasses in the present disclosure both the HECO and RAHECO types of the heterophasic propylene copolymers.

Suitable heterophasic propylene copolymers include reactor TPOs and soft TPOs produced with LyondellBasell`s Catalloy process technology, which are commercially available under the trade names of

and

such as

CA 10A,

CA 12A, and

CA 60 A, and Hifax CA 212 A. Further suitable heterophasic propylene copolymers are commercially available under the trade name of

(from Borealis Polymers) , such as

SD233 CF.

Preferably, the at least one polymer P1 comprises at least 25 wt. -%, preferably at least 35 wt. -%, more preferably at least 45 wt. -%, even more preferably at least 55 wt. -%, of the total weight of the polymeric waterproofing layer.

According to one or more embodiments, the polymeric waterproofing layer further comprises at least one flame retardant FR.

The at least one flame retardant FR is preferably selected from the group consisting of magnesium hydroxide, aluminum trihydroxide, antimony trioxide, ammonium polyphosphate, and melamine-, melamine resin-, melamine derivative-, melamine-formaldehyde-, silane-, siloxane-, and polystyrene-coated ammonium polyphosphates.

Other suitable flame retardants for use as the at least one flame retardant FR include, for example, 1, 3, 5-triazine compounds, such as melamine, melam, melem, melon, ammeline, ammelide, 2-ureidomelamine, acetoguanamine, benzoguanamine, diaminophenyltriazine, melamine salts and adducts, melamine cyanurate, melamine borate, melamine orthophosphate, melamine pyrophosphate, dimelamine pyrophosphate and melamine polyphosphate, oligomeric and

polymeric

1, 3, 5-triazine compounds and polyphosphates of 1, 3, 5-triazine compounds, guanine, piperazine phosphate, piperazine polyphosphate, ethylene diamine phosphate, pentaerythritol, borophosphate, 1, 3, 5-trihydroxyethylisocyanaurate, 1, 3, 5-triglycidylisocyanaurate, triallylisocyanurate and derivatives of the aforementioned compounds.

Suitable flame retardants are commercially available, for example, under the trade names of

and

(both from Albemarle) and under the trade names of

(from Clariant) ,

(from Phos-Check) and FR

(from Budenheim) .

According to one or more embodiments, the at least one flame retardant FR comprises 2.5 –60 wt. -%, preferably 5 –55 wt. -%, more preferably 10 –50 wt. -%, of the total weight of the polymeric waterproofing layer.

The polymeric waterproofing layer can comprise, in addition to the at least one polymer P1 and the at least one flame retardant FR, auxiliary components, for example, UV-and heat stabilizers, antioxidants, plasticizers, fillers, dyes, pigments such as titanium dioxide and carbon black, matting agents, antistatic agents, impact modifiers, biocides, and processing aids such as lubricants, slip agents, antiblock agents, and denest aids. The total amount of these auxiliary components is preferably not more than 55 wt. -%, more preferably not more than 45 wt. -%, even more preferably not more than 35 wt. -%, based on the total weight of the polymeric waterproofing layer.

The thickness of the polymeric waterproofing layer is preferably not more than 5 mm, more preferably not more than 3.5 mm, even more preferably not more than 3 mm. According to one or more embodiments the polymeric waterproofing layer has a thickness in the range of 0.25 –5 mm, preferably 0.5 –3.5 mm, more preferably 0.75 –3 mm, even more preferably 0.85 –2.5 mm, still more preferably 1 –2.5 μm. The thickness of polymeric layers of the sealing device can be determined by using the measurement method as defined in DIN EN 1849-2 standard.

There are no strict limitations for the width and length of the polymeric waterproofing layer, and these depend on the intended use of the sealing device. The term “width” and “length” refer to the two perpendicular dimensions measured in the horizontal plane of the first and second major surfaces of a sheet-like element. Generally, the “width” of a sheet like element is the smaller of the horizontal dimensions of the sheet-like element. Consequently, the “width” of the polymeric waterproofing layer refers to the minor dimension measured in the horizontal plane of the polymeric waterproofing layer in a direction perpendicular to the length of the polymeric waterproofing layer.

For example, the sealing device can be provided in form of a narrow strip, wherein the polymeric waterproofing layer has a width, for example, in the range of 10 –500 mm, such as 50 –350 mm, particularly 75 –250 mm. The sealing device can also be provided in form of a broad sheet, wherein the polymeric waterproofing layer has a width of, for example, in the range of 0.75 –5 m, such as 1 –3.5 m, particularly 1 –2.5 m.

The sealing device of the present invention is typically provided in form of a prefabricated article, which is delivered to the construction site in form of rolls, which are then unwounded and cut to provide sheet-like articles having length of several times the width.

According to one or more embodiment, the sealing device is a waterproofing or roofing membrane, preferably a roofing membrane, wherein the polymeric waterproofing layer has a width in the range of 0.5 –5 m, more preferably 0.75 –3.5 m, even more preferably 1 –3 m, still more preferably 1.5 –2.5 m.

Preferably, the at least one polymer P2 comprises at least 35 wt. -%, preferably at least 50 wt. -%, more preferably at least 65 wt. -%, even more preferably at least 75 wt. -%, still more preferably at least 85 wt. -%, of the total weight of the polymeric connecting layer. According to one or more embodiments, the at least one polymer P2 comprises 50 –95 wt. -%, preferably 65 –95 wt. -%, more preferably 75 –95 wt. -%, of the total weight of the polymeric connecting layer.

The at least one polymer P1 and P2 are preferably compatible with each other.

By the polymers being “compatible” is understood to mean that the properties of a blend composed of the at least one polymer P1 and P2 are not inferior to those of the individual polymer components. It may also be preferable that the at least one polymer P1 and P2 are at least partially miscible with each other. By the polymer components being “miscible” is understood to mean that a polymer blend composed of the at least one polymer P1 and P2 has a negative Gibbs free energy and heat of mixing. The polymer blends composed of entirely miscible polymers tend to have one single glass transition point, which can be measured using dynamic mechanical thermal analysis (DMTA) . The glass transition point can be determined, for example, as the peak of the measured tan delta curve (ratio of storage and loss moduli) .

According to one or more embodiments, the at least one polymer P1 comprises at least 25 wt. -%, preferably at least 50 wt. -%, more preferably at least 75 wt. -%, based on the total weight of the at least one polymer P1, of at least one ethylene-based polymer P11 and the at least one polymer P2 comprises at least 25 wt. -%, preferably at least 50 wt. -%, more preferably at least 75 wt. -%, based on the total weight of the at least one polymer P2, of at least one ethylene-based polymer P21. Generally, the expression “the at least one component X comprises at least one component XN” , such as “the at least one polymer P1 comprises at least one ethylene-based polymer P11” is understood to mean in the context of the present disclosure that the respective layer comprises one or more ethylene-based polymers P11 as representatives of the at least one polymer P1.

According to one or more further embodiments, the at least one polymer P1 comprises at least 25 wt. -%, preferably at least 50 wt. -%, more preferably at least 75 wt. -%, based on the total weight of the at least one polymer P1, of at least one propylene-based polymer P12 and the at least one polymer P2 comprises at least 25 wt. -%, preferably at least 50 wt. -%, more preferably at least 75 wt. -%, based on the total weight of the at least one polymer P2, of at least one propylene-based polymer P22.

The terms “ethylene-based polymer” and “propylene-based polymer” refer in the present disclosure to polymers comprising more than 50 wt. -%, preferably more than 55 wt. -%, of ethylene or propylene derived units, respectively.

The thickness of the polymeric connecting layer is preferably not more than 500 μm, more preferably not more than 400 μm, even more preferably not more than 300 μm. According to one or more embodiments the polymeric connecting layer has a thickness in the range of 5 –450 μm, preferably 15 –350 μm, more preferably 25 –300 μm, even more preferably 35 –250 μm, still more preferably 50 –200 μm.

According to one or more embodiments, at least a portion of the lower major surface of the polymeric waterproofing layer is directly connected to a surface of the polymeric connecting layer.

The expression “directly connected” is understood to mean in the context of the present disclosure that no further layer or substance is present between the two layers and that the opposing surfaces of the two layers are directly bonded to each other or adhere to each other. At the transition area between the two layers, the materials forming the layers can also be present mixed with each other.

According to one or more embodiments, the polymeric connecting layer has been thermally laminated to at least portion of the lower major surface of the polymeric waterproofing layer in a manner that gives direct bonding between the polymeric connecting layer and the polymeric waterproofing layer. The term “thermal-lamination” or “thermo-lamination” refers in the present disclosure to a process in which the respective layers are bonded to each other by the application of heat and pressure and without using an adhesive, such that the layers remain adhered to each other when the pressure is removed.

The barrier composite layer further comprises a barrier layer, which can be a metallic barrier layer or a polymeric barrier layer comprising at least one polymer P3, and a polymeric protective layer comprising at least one polymer P4.

According to a first preferred embodiment, the barrier layer is a metallic barrier layer and the at least one polymer P4 is selected from the group consisting of polyester, polyamide, and polycarbonate.

The metallic barrier layer is preferably a metallized plastic film or a metal film, more preferably an aluminum or aluminum alloy film, even more preferably an aluminum film. The thickness of the metallic barrier layer is preferably not more than 100 μm, more preferably not more than 50 μm, even more preferably not more than 25 μm. According to one or more embodiments, the metallic barrier layer has a thickness of 1 –50 μm, preferably 1.5 –35 μm, more preferably 2.5 –25 μm, even more preferably 2.5 –15 μm.

The polymeric connecting layer and the metallic barrier layer can be directly or indirectly connected to each other over at least a portion of their opposing major surfaces and the polymeric protective layer and the metallic barrier layer can be directly or indirectly connected to each other over at least a portion of their opposing major surfaces. The expression “indirectly connected” is understood to mean in the context of the present disclosure that the layers are connected to each other via a connecting layer, such an adhesive layer.

According to one or more embodiments, the polymeric connecting layer and the metallic barrier layer are indirectly connected to each other over at least a portion of their opposing major surfaces and/or the polymeric protective layer and the metallic barrier layer are indirectly connected to each other over at least a portion of their opposing major surfaces.

According to one or more embodiments, the metallic barrier layer has been adhesively laminated to at least portion of a lower major surface of the polymeric connecting layer and/or the polymeric protective layer has been adhesively laminated to at least portion of a lower major surface of the metallic barrier layer.

The term “adhesive lamination” refers to a process in which the respective layers are bonded to each by using an adhesive composition. Suitable adhesives for use in bonding of the layers of the barrier composite layer to each other include, for example, one-component and two-component polyurethane and epoxide adhesives, non-reactive and reactive hot-melt adhesives, and acrylic adhesives.

The polymeric protective layer comprises at least one polymer P4 selected from the group consisting of polyester, polyamide, and polycarbonate. The protective layer is used to improve the resistance of the barrier layer against environmental factors, such as prolonged exposure to UV-irradiation, temperature fluctuations, fouling, and mechanical impacts.

Suitable polyesters for use as the at least one polymer P4 include poly (ethylene terephthalate) (PET) and poly (butylene terephthalate) (PBT) .

Especially suitable poly (ethylene terephthalate) sto be used as the at least one polymer P4 have:

- a high content of ethylene terephthalate units, such as at least 90 wt. -%, preferably at least 95 wt. -%, more preferably at least 97.5 wt. -%, based on the weight of the poly (ethylene terephthalate) and/or

- a low content of dioxyethylene terephthalate units, such as not more than 10 wt. -%, preferably not more than 5 wt. -%, more preferably not more than 2.5 wt. -%, based on the weight of the poly (ethylene terephthalate) and/or

- a melting temperature (T _m) determined by differential scanning calorimetry (DSC) according to ISO 11357-3 standard using a heating rate of 2 ℃/min of at or above 200 ℃, preferably at or above 225 ℃, more preferably at or above 250 ℃.

Suitable poly (ethylene terephthalate) sare commercially available, for example, under the trade name of

(from Goodyear Chemical Company) ; under the trade name of

(from Celanese) , and under the trade name of

(from Dupont) .

Suitable polyamides to be used as the at least one polymer P4 include aromatic and aliphatic crystalline and semi-crystalline polyamides. Amorphous polyamides are in generally not preferred. The term “amorphous polyamide” refers here to polyamides that lack a crystalline melting point (T _m) as determined by differential scanning calorimetric (DSC) or an equivalent technique. Amorphous polyamides are distinct from the crystalline or semi-crystalline polyamides, such as Nylon 6 and Nylon 12.

Suitable polyamides include, for example, Nylon 6 (PA6) , which is synthetized by ring-opening polymerization of caprolactam; Nylon 6-6 (PA66) , which is synthesized by polycondensation of hexamethylenediamine and adipic acid; and Nylon 12 (PA12) , which can be synthetized either by polycondensation of ω-aminolauric acid or by ring-opening polymerization of laurolactam. Bioplastic polyamides, such as Nylon 11, which is synthetized by polymerization of 11-aminoundecanoic acid, are also suitable.

Suitable polyamides are commercially available, for example, under the trade name of

(from EMS Chemie) , such as

G16 and G21, which are copolyamides having both linear aliphatic units and ring-like aromatic components; under the trade name of

(from Gabriel Performance Products) , such as

100, which is an aliphatic polyamide; under the trade name of Rilsan (from Arkema) , such as

TMNO TLD,

BMNO TLD, and

AMNO TLD; and under the trade name of

(from Evonik) .

The term “polycarbonate” refers in the present disclosure to a polymer comprising the same or different carbonate units, or a copolymer that comprises the same or different carbonate units, as well as one or more units other than carbonate, for example, homopolycarbonates, copolycarbonates and thermoplastic polyestercarbonates. Suitably polycarbonates may be obtained, for example, by reactions of bisphenol compounds with carbonic acid compounds, such as phosgene, or by a melt re-esterification process of diphenyl carbonate or dimethyl carbonate.

Suitable polycarbonates to be used as the at least one polymer P4 include linear and branched polycarbonates, preferably having a weight average molecular weight (M _w) in the range of 10000 –75000 g/mol, more preferably 10000 –50000 g/mol, even more preferably 15000 –40000 g/mol, wherein the M _w is preferably determined by measuring the relative solution viscosity in dichloromethane or in mixtures of equal amounts by weight phenol/o-dichlorobenzene calibrated by light scattering.

Suitable polycarbonates are commercially available, for example, under the trade names of

(from Sabic) ,

(from Covestro) , and

(from Plaskolite) .

According to a second preferred embodiment, the barrier layer is a polymeric barrier layer comprising ethylene vinyl alcohol as the at least one polymer P3, wherein the at least one polymer P4 selected from the group consisting of polyester and polyamide, and the barrier composite layer further comprises a tie layer arranged between the polymeric barrier layer and the polymeric connecting layer.

The term “ethylene vinyl alcohol (EVOH) ” refers in the present disclosure to copolymers of vinyl alcohol and ethylene. Suitable ethylene vinyl alcohols can be obtained, for example, by hydrolyzation of ethylene vinyl acetate copolymers or by chemical reaction of ethylene monomers with vinyl alcohol.

Suitable ethylene vinyl alcohols to be used as the at least one polymer P3 have:

- a molar content of ethylene comonomers in the range of 10 –75 mol. -%, preferably 15 –65 mol. -%and/or

- a hydrolyzation degree of at least 35 %, preferably at least 50 %, more preferably at least 75 %, in case the ethylene vinyl alcohol has been obtained by hydrolyzation of ethylene vinyl acetate copolymers.

Suitable ethylene vinyl alcohols are commercially available, for example, under the trade names of

(from Mitsubishi Chemicals) and

(from Kuraray) .

In embodiments where the barrier layer is a polymeric barrier layer comprising an ethylene vinyl alcohol as the at least one polymer P3, a tie layer is arranged between the polymeric barrier layer and the polymeric connecting layer to enable bonding of the polymeric barrier layer to the polymeric connecting layer by using thermal lamination means.

Suitable polymers for use in the tie layer include, for example, maleic anhydride functionalized polyolefins, such as maleic anhydride grafted homopolymers and copolymers of ethylene and propylene.

According to one or more embodiments, the tie layer comprises at least one maleic anhydride grafted polyolefin, preferably selected from the group consisting of maleic anhydride grafted polyethylene and maleic anhydride grafted polypropylene.

Preferably, the at least one maleic anhydride grafted polyolefin comprises at least 35 wt. -%, preferably at least 50 wt. -%, more preferably at least 75 wt. -%, even more preferably at least 85 wt. -%, of the total weight of the tie layer.

According to one or more embodiments, the thickness of the tie layer is 1 –15 %, preferably 1 –10 %, more preferably 1.5 –7.5 %, even more preferably 2 –5 %, of the total thickness of the barrier composite layer.

The thickness of the tie layer is preferably not more than 75 μm, more preferably not more than 50 μm, even more preferably not more than 35 μm. According to one or more embodiments, polymeric barrier layer has a thickness of 0.5 –65 μm, preferably 1 –50 μm, more preferably 1.5 –25 μm, even more preferably 1.5 –20 μm, still more preferably 2 –10 μm.

Preferred polyesters and polyamides for use as the at least one polymer P4 have already been discussed above.

According to a third preferred embodiment, the barrier layer is a polymeric barrier layer comprising polyamide as the at least one polymer P3, wherein the at least one polymer P4 is a polyester, and the barrier composite layer further comprises a tie layer arranged between the barrier layer and the polymeric connecting layer.

Preferred polyamides for use as the at least one polymer P3, preferred polyesters for use as the at least one polymer P4, and preferred embodiments of the tie layer have already been discussed above.

The thickness of the polymeric barrier layer is preferably not more than 350 μm, more preferably not more than 250 μm, even more preferably not more than 150 μm. According to one or more embodiments, polymeric barrier layer has a thickness in the range of 1 –300 μm, preferably 2.5 –200 μm, more preferably 5 –150 μm, even more preferably 10 –100 μm, still more preferably 10 –50 μm.

The thickness of the polymeric protective layer is preferably not more than 250 μm, more preferably not more than 150 μm, even more preferably not more than 100 μm. According to one or more embodiments, polymeric barrier layer has a thickness in the range of 1 –150 μm, preferably 2.5 –100 μm, more preferably 5 –100 μm, even more preferably 10 –50 μm.

The polymeric barrier layer and the polymeric protecting layer and can be directly or indirectly connected to each other over at least a portion of their opposing major surfaces.

According to one or more embodiments, the polymeric barrier layer and the polymeric protective layer are directly connected to each other over at least a portion of their opposing major surfaces.

According to one or more embodiments, the polymeric protective layer has been thermally laminated to at least portion of the lower major surface of the polymeric barrier layer in a manner that gives direct bonding between the polymeric protective layer and the polymeric barrier layer.

According to one or more embodiments, the sealing device further comprises a layer of fiber material fully embedded into the polymeric waterproofing layer and/or a second polymeric waterproofing layer covering at least a portion of the upper major surface of the polymeric waterproofing layer. By the expression “fully embedded” is meant that the layer of fiber material layer is fully covered by the matrix of the polymeric waterproofing layer.

The layer of fiber material may be used to ensure the mechanical stability when the sealing device is exposed to varying environmental conditions, in particular to large temperature fluctuations.

The term “fiber material” designates in the present document materials composed of fibers comprising or consisting of, for example, organic, inorganic or synthetic organic materials. Examples of organic fibers include, for example, cellulose fibers, cotton fibers, and protein fibers. Particularly suitable synthetic organic materials include, for example, polyester, homopolymers and copolymers of ethylene and/or propylene, viscose, nylon, and polyamides. Fiber materials composed of inorganic fibers are also suitable, in particular, those composed of metal fibers or mineral fibers, such as glass fibers, aramid fibers, wollastonite fibers, and carbon fibers. Inorganic fibers, which have been surface treated, for example, with silanes, may also be suitable. The fiber material can comprise short fibers, long fibers, spun fibers (yarns) , or filaments. The fibers can be aligned or drawn fibers. It may also be advantageous that the fiber material is composed of different types of fibers, both in terms of geometry and composition.

Preferably, the layer of fiber material is selected from the group consisting of non-woven fabrics, woven fabrics, and laid scrims.

The term “non-woven fabric” designates in the present document materials composed of fibers, which are bonded together by using chemical, mechanical, or thermal bonding means, and which are neither woven nor knitted. Non-woven fabrics can be produced, for example, by using a carding or needle punching process, in which the fibers are mechanically entangled to obtain the nonwoven fabric. In chemical bonding, chemical binders such as adhesive materials are used to hold the fibers together in a non-woven fabric.

The term “laid scrim” refers in the present disclosure web-like non-woven products composed of at least two sets of parallel yarns (also designated as weft and warp yarns) , which lay on top of each other and are chemically bonded to each other. The yarns of a non-woven scrim are typically arranged with an angle of 60 –120°, such as 90 ± 5°, towards each other thereby forming interstices, wherein the interstices occupy more than 60%of the entire surface area of the laid scrim. Typical materials for laid scrims include metal fibers, inorganic fibers, in particular glass fibers, and synthetic organic fibers, in particular polyester, polypropylene, polyethylene, and polyethylene terephthalate (PET) .

According to one or more embodiments, the layer of fiber material is a non-woven fabric, preferably having a mass per unit weight of not more than 350 g/m ², preferably not more than 300 g/m ². According one or more embodiments, the layer of fiber material is a non-woven fabric having a mass per unit weight of 15 –300 g/m ², preferably 20 –250 g/m ², more preferably 25 –200 g/m ², even more preferably 30 –150 g/m ².

Preferably, the non-woven fabric comprises synthetic organic and/or inorganic fibers. Particularly suitable synthetic organic fibers for the non-woven fabric include, for example, polyester fibers, polypropylene fibers, polyethylene fibers, nylon fibers, and polyamide fibers. Particularly suitable inorganic fibers for the non-woven fabric include, for example, glass fibers, aramid fibers, wollastonite fibers, and carbon fibers.

According to one or more embodiments, the non-woven fabric of the layer of fiber material has as the main fiber component synthetic organic fibers, preferably selected from the group consisting of polyester fibers, polypropylene fibers, polyethylene fibers, nylon fibers, and polyamide fibers. According to one or more further embodiments, the non-woven fabric of the layer of fiber material has as the main fiber component inorganic fibers, preferably selected from the group consisting of glass fibers, aramid fibers, wollastonite fibers, and carbon fibers, more preferably glass fibers.

The second polymeric waterproofing layer may have the same or different composition than the polymeric waterproofing layer. According to one or more embodiments, the second polymeric waterproofing layer comprises at least 25 wt. -%, preferably at least 35 wt. -%, more preferably at least 45 wt. -%, even more preferably at least 55 wt. -%, based on the total weight of the second polymeric waterproofing layer, of the at least one polymer P1.

The polymeric waterproofing layer and the second polymeric waterproofing layer may be directly or indirectly connected to each other over at least a portion of their opposing major surfaces. According to one or more embodiments, the polymeric waterproofing layer and the second polymeric waterproofing layer are directly connected to each other over at least a portion of their opposing major surfaces.

It may furthermore be preferred that the sealing device shows an impact resistance measured according to EN 12691: 2005 standard in the range of 200 -1500 mm and/or a longitudinal and a transversal tensile strength measured at a temperature of 23 ℃ according to DIN ISO 527-3 standard of at least 5 MPa and/or a longitudinal and transversal elongation at break measured at a temperature of 23 ℃ according to DIN ISO 527-3 standard of at least 300 %and/or a water resistance measured according to EN 1928 B standard of 0.6 bar for 24 hours and/or a maximum tear strength measured according to EN 12310-2 standard of at least 100 N.

According to one or more embodiments, the sealing device further comprises a pressure sensitive adhesive covering at least a portion of the lower major surface of the polymeric protective layer.

The term “pressure sensitive adhesive” refers in the present disclosure to viscoelastic materials, which adhere immediately to almost any kind of substrates by application of light pressure and which are permanently tacky. The tackiness of an adhesive layer can be measured, for example, as a loop tack. Preferably, the pressure sensitive adhesive composition has a loop tack adhesion to a glass plate measured at a temperature of 23 ℃ of at least 2.5 N/25 mm, preferably at least 5 N/25 mm, more preferably at least 10 N/25 mm. The loop tack adhesion can be measured using a "FINAT test method no. 9 (FTM 9) as defined in FINAT Technical Handbook, 9th edition, published in 2014.

Suitable pressure sensitive adhesive layers include, for example, water-based, solvent-based, hot-melt, and crosslinked pressure sensitive adhesives, such as UV-cured pressure sensitive adhesives. The term “hot-melt pressure sensitive adhesive (HM-PSA) ” refers in the present disclosure to solvent-free pressure sensitive adhesives, which are applied as a melt.

Suitable pressure sensitive adhesives include adhesives based on acrylic polymers, styrene block copolymers, amorphous polyolefins (APO) , amorphous poly-alpha-olefins (APAO) , vinyl ether polymers, bitumen, and elastomers such as, for example, styrene-butadiene rubber (SBR) , ethylene propylene diene monomer (EPDM) rubber, butyl rubber, polyisoprene, polybutadiene, natural rubber, polychloroprene rubber, ethylene-propylene rubber (EPR) , nitrile rubber, acrylic rubber, ethylene vinyl acetate rubber, and silicone rubber. In addition to the above-mentioned polymers, suitable pressure sensitive adhesives typically comprise one or more additional components including, for example, tackifying resins, waxes, and additives, for example, UV-light absorption agents, UV-and heat stabilizers, optical brighteners, pigments, dyes, and desiccants.

According to one or more preferred embodiments, the pressure sensitive adhesive layer is composed of an acrylic pressure sensitive adhesive. The term “acrylic pressure sensitive adhesive” designates in the present disclosure pressure sensitive adhesive compositions containing one or more acrylic polymers as the main polymer component.

Suitable acrylic pressure sensitive adhesives include, for example, water-based acrylic pressure sensitive adhesives, solvent-based acrylic pressure sensitive adhesives, acrylic hot-melt pressure sensitive adhesives (HM-PSA) , and UV-cured acrylic pressure sensitive adhesives.

Preferably, the pressure sensitive adhesive layer covers at least 50 %, more preferably at least 75 %, even more preferably at least 85 %, still more preferably at least 95 wt. -%of the area of the lower major surface of the polymeric protective layer. According to one or more embodiments, the pressure sensitive adhesive layer covers essentially the whole area of the lower major surface of the polymeric protective layer, such as at least 97.5 %, preferably at least 99 %of the area of the lower major surface of the polymeric protective layer

The pressure sensitive adhesive layer can be present on the lower major surface of the polymeric protective layer in form of a continuous or a discontinuous adhesive layer. The term “continuous adhesive layer” refers in the present disclosure to layers consisting of one single area coated with an adhesive composition whereas the term “discontinuous adhesive layer” refers to layers consisting of two or more areas coated with an adhesive composition, which areas are not connected to each other to form a continuous layer. According to one or more embodiments, the pressure sensitive adhesive layer is a continuous adhesive layer.

Preferred thickness of the pressure sensitive adhesive layer depends on the detailed composition of the adhesive. According to one or more embodiments, the pressure sensitive adhesive layer has a thickness determined by using the measurement method as defined in EN 1849-2: 2019 standard of 25 –500 μm, preferably 50 –350 μm, more preferably 75 –300 μm, even more preferably 100 –250, in particular 100 –200 μm and/or a coating weight of at least 75 g/m ², preferably least 100 g/m ², more preferably at least 125 g/m ², such as 100 –1000 g/m ², preferably 125 –750 g/m ², more preferably 150 –500 g/m ², even more preferably 150 –350 g/m ².

According to one or more embodiments, the sealing device further comprises a release liner covering at least portion of the outer major surface of the pressure sensitive adhesive layer facing away from the lower major surface of the polymeric protective layer. Preferably, the pressure sensitive adhesive layer and the release liner are directly connected to each other over at least portion of their opposing major surfaces. The release liner may be used to prevent premature unwanted adhesion and to protect the pressure sensitive adhesive layer from moisture, fouling, and other environmental factors. In case the sealing device is provided in form of rolls, the release liner enables ease of unwind without sticking of the adhesive to the back side of the sealing device. The release liner may be sliced into multiple sections to allow portioned detachment of the liner from the adhesive layer.

Suitable materials for the release liner include Kraft paper, polyethylene coated paper, silicone coated paper as well as polymeric films, for example, polyethylene, polypropylene, and polyester films coated with polymeric release agents selected from silicone, silicone urea, urethanes, waxes, and long chain alkyl acrylate release agents.

The preferences given above for the polymeric waterproofing layer, the barrier composite layer, the layer of fiber material, and the pressure sensitive adhesive layer apply equally to all subjects of the present invention unless otherwise stated.

Another subject of the present invention is a method for producing a sealing device of the present invention, the method comprising steps of:

I) Providing a polymeric waterproofing layer (2) and a barrier composite layer (3) and

II) Laminating the barrier composite layer (3) to the lower major surface of the polymeric waterproofing layer (2) .

The step of providing the barrier composite layer may comprise providing the polymeric connecting layer, optionally the tie layer, the barrier layer, and the polymeric protective layer and coupling the layers to each other. The coupling of the individual layers of the barrier composite layer can be conducting using any conventional techniques known to a person skilled in the art, such as heat-melting, thermo-laminating, or adhesive lamination. The composite barrier layer is preferably bonded to the lower major surface of the polymeric waterproofing layer by using thermo-lamination means.

The further details of the method for producing the sealing device depend on the embodiment of the sealing device, particularly on the type of the individual layers of the barrier composite layer.

For example, in case the barrier layer is a metallic barrier layer, the step of providing the barrier composite layer may comprise bonding the polymeric connecting layer, the metallic barrier layer and the polymeric protective layer to each other using adhesive lamination means. Alternatively, the metallic barrier layer can first be bonded to the polymeric protective layer by using adhesive lamination means and the polymeric connecting layer can then be coated to an opposite surface of the metallic barrier layer by film casting.

In case of a polymeric barrier layer, the step of providing the barrier composite layer can comprise co-extruding the compositions of the polymeric connecting layer, the tie layer, the polymeric barrier layer, and the polymeric protective layer to obtain the composite barrier layer. The barrier composite layer is then laminated to the lower major surface of the polymeric waterproofing layer by using thermo-lamination means.

In case the sealing device comprises a pressure sensitive adhesive layer, the method for producing a sealing device contains a further step III) of applying a pressure sensitive adhesive composition on the lower major surface of the polymeric protective layer.

The pressure sensitive adhesive composition may be applied to the lower major surface of the polymeric protective layer by using any conventional techniques such as slot die coating, extrusion coating, roller coating, direct gravure coating, offset gravure coating, reverse gravure roll-coating, powder dispersion, or spray lamination techniques.

According to one or more embodiments, the method for producing a sealing device comprises a further step IV) of winding the composite element obtained in step II) or III) into a roll.

Another subject of the present invention is a roof system comprising a roof underlayment (10) and a sealing device (1) of the present invention adhered to a surface of the roof underlayment (10) by using mechanical or adhesive bonding means.

According to one or more embodiments, the roof underlayment comprises a cover board and/or an insulation board.

Preferably, the insulation board comprises at least one foam panel having a closed cell structure. Suitable foam panels having a closed cell structure include molded expanded polystyrene (EPS) foam panels, extruded expanded polystyrene (XPS) foam panels, polyurethane foam panels (PUR) , and polyisocyanurate (PIR) foam panels.

The thickness of the insulation board is not particularly restricted. It may be preferable that the insulation board has a thickness determined by using the measurement method as defined in DIN EN 1849-2 standard of 5 –500 mm, preferably 10 –350 mm, even more preferably 25 –150 mm.

According to one or more embodiments, the insulation board comprises at least one foam panel having a closed cell structure selected from the group consisting of molded expanded polystyrene (EPS) foam panel, extruded expanded polystyrene (XPS) foam panel, polyurethane foam panel (PUR) , and polyisocyanurate (PIR) foam panel, preferably having a density in the range of 10 –150 g/l, more preferably 15 –100 g/l, even more preferably 25 –75 g/l.

The insulation board can be secured to a roof substrate, such as a roof deck, by using any suitable fastening means, such as by using adhesive bonding or mechanical fastening means.

According to one or more embodiments, the roof underlayment comprises a cover board.

Suitable cover boards include, for example, gypsum boards, fiber-reinforce gypsum boards, wood fiber boards, cementitious boards, high-density (compressed) polyisocyanurate boards, perlite boards, asphaltic boards, mineral fiber boards, and plywood or oriented strand boards. The cover board may be used in addition of instead of the insulation board.

According to one or more embodiments, the roof underlayment comprises the insulation board and the cover board, wherein the cover board is positioned between the sealing device and the insulation board. The cover board can be secured to the insulation board by using any suitable fastening means, such as by using adhesive bonding or mechanical fastening means.

According to or more embodiments, the roof system further comprises a vapor control layer arranged on the bottom side of the roof underlayment opposite to the side of the sealing device.

The vapor control layer is liquid impermeable but at least partially permeable to moisture vapor. According to one or more embodiments, the vapor control layer has a water vapor diffusion equivalent air layer thickness value (Sd-value) measured according to the method as defined in ISO 1931 standard of not more than 100 m, preferably not more than 50 m.

According to one or more further embodiments, the vapor control layer has a moisture variable diffusion resistance. In these embodiments, the vapor control layer has a lower water vapor diffusion resistance at higher relative humidity of the surroundings and higher water vapor diffusion resistance at lower relative humidity of the surroundings. For example, the Sd-value of the vapor control layer can be in the range of 0.5 –20 m, preferably 1 –10 m at relative humidity of 80 %, and in the range of 25 –100 m, preferably 35 –65 m at relative humidity of 20 %.

The composition of the vapor control layer is not particularly restricted. Preferably, the vapor control layer comprises at least polymer selected from the group consisting of polyethylene (PE) , polypropylene (PP) , ethylene –vinyl acetate copolymers (EVA) , ethylene –α-olefin co-polymers, ethylene –propylene co-polymers, polyvinylchloride (PVC) , ethylene acrylic acid co-polymers, polyurethane, polyesters, co-polyesters, polyether-esters, polystyrene (PS) , polyethylene terephthalate (PET) , polyamides (PA) , co-polyamides, and ionomers. The term “ionomer” refers to a polymer that comprises ionic groups that are carboxylate salts, for example, ammonium carboxylates, alkali metal carboxylates, alkaline earth carboxylates, transition metal carboxylates and/or combinations of such carboxylates. Such polymers are generally produced by partially or fully neutralizing the carboxylic acid groups of precursor or parent polymers that are acid copolymers, for example, by reaction with a base.

Preferably, the vapor control layer has a thickness of 5 –500 μm, more preferably 25 –350 μm, even more preferably 50 –250 μm and/or a mass per unit are of 25 –500 g/m ², more preferably 50 –350 g/m ², even more preferably 75 –250 g/m ².

According to one or more embodiments, the sealing device adhered to a surface of the roof underlayment via an adhesive layer.

According to one or more embodiments at least 50 %, preferably at least 75 %, most preferably at least 85 %of the area of the lower major surface of the polymeric protective layer is adhered to the surface of the roof underlayment via the adhesive layer. According to one or more embodiments, the entire area of the lower major surface of the polymeric protective layer is adhered to the surface of the roof underlayment via the adhesive layer.

Examples

Preparation of test specimens

First exemplary sealing device had the following buildup:

i. A polymeric waterproofing layer reinforced with a polyester scrim, the waterproofing layer having a thickness of 1.2 mm (

TM-12) and

ii. A barrier composite layer comprising:

a) A polyethylene layer having a thickness of 100 μm,

b) An aluminum foil having a thickness of 7 μm, and

c) A poly (ethylene terephthalate) layer having a thickness of 12 μm.

The first exemplary sealing device was prepared by bonding the layers a) to c) to each other using adhesive lamination means followed by bonding of the thus obtained barrier composite layer via the polyethylene layer to the lower major surface of the polymeric waterproofing layer by using thermo-lamination means.

Second exemplary sealing device had the following buildup:

TM-12) and

ii. A barrier composite layer comprising:

a) A polyethylene layer having a thickness of 85 μm,

b) An EVOH layer having a thickness of 12 μm, and

c) A poly (ethylene terephthalate) layer having a thickness of 50 μm.

A tie layer having a thickness of 3 μm was arranged between the polyethylene layer a) and the EVOH layer b) .

The second exemplary sealing device was prepared by co-extruding the layers a) to c) and the tie layer followed by bonding the thus obtained barrier composite layer via the polyethylene layer to the lower major surface of the polymeric waterproofing layer by using thermo-lamination means.

A layer of butyl adhesive was then coated on the lower major surface of the polymeric protective layers using a coating weight of 400 g/m ². The butyl adhesive contained butyl resin, tackifying resin, process oil, liquid rubber, and fillers. The thus obtained sealing devices were then tested for its adhesive and mechanical properties.

A sealing device having of the polymeric waterproofing layer without the barrier composite layer was used in a reference example.

The values for adhesive peel resistance from a TPO-membrane and the low temperature flexibility are shown in Table 1.

Shear and peel strength 180°

Samples having dimensions of 50 x 250 mm were cut from the tested sealing device and bonded via the butyl adhesive layer to a TPO membrane sheet followed by measurement of the peel resistances. All the tests were conducted at a temperature of 23 ±2 ℃ and using a peeling angle of 180 °. The measurements for peel resistance were conducted according to EN 12316 standard.

Low temperature flexibility

The measurements for the low temperature flexibility were conducted according to EN 495-5 standard. In the measurement, a sample of the tested sealing device was bended at a temperature of -40 ℃ and then visually analyzed for the presence of cracks in the polymeric layers.

Claims

A sealing device (1) comprising:

i. A polymeric waterproofing layer (2) comprising at least one polymer P1 and having an upper and lower major surfaces,

ii. A barrier composite layer (3) covering at least a portion of the lower major surface of the polymeric waterproofing layer, wherein the barrier composite layer comprises:

a) A polymeric connecting layer (4) comprising at least one polymer P2,

b) A barrier layer (5) , and

c) A polymeric protective layer (6) , wherein

the polymeric connecting layer (4) is arranged between the polymeric waterproofing layer (2) and the barrier layer (5) and wherein the barrier layer (5) is a metallic barrier layer or a polymeric barrier layer comprising at least one polymer P3 selected from the group consisting of ethylene vinyl alcohol and polyamide and the polymeric protective layer (6) comprises at least one polymer P4 selected from the group consisting of polyester, polyamide, and polycarbonate.
The sealing device according to claim 1, wherein the polymeric waterproofing layer (2) and the polymeric connecting layer (4) are polyolefin-based layers.
The sealing device according to claim 1 or 2, wherein the at least one polymer P1 and P2 are selected from the group consisting of ethylene copolymers, polyethylene, propylene copolymers , and polypropylene.
The sealing device according to any one of previous claims, wherein the at least one polymer P1 comprises at least 35 wt. -%, preferably at least 45 wt. -%, of the total weight of the polymeric waterproofing layer (2) .
The sealing device according to any one of previous claim, wherein the polymeric waterproofing layer (2) has a thickness in the range of 0.25 –5.0 mm, preferably 0.5 –3.5 mm.
The sealing device according to any one of previous claims, wherein the at least one polymer P2 comprises at least 50 wt. -%, preferably at least 65 wt. -%, of the total weight of the polymeric connecting layer (4) .
The sealing device according to any one of previous claim, wherein the polymeric connecting layer (4) has a thickness in the range of 15 –350 μm, preferably 35 –250 μm.
The sealing device according to any one of previous claim, wherein the polymeric connecting layer (4) has been thermally laminated to at least portion of the lower major surface of the polymeric waterproofing layer (2) in a manner that gives direct bonding between the polymeric connecting layer (4) and the polymeric waterproofing layer (2) .
The sealing device according to any one of previous claims, wherein the barrier layer (5) is a metallic barrier layer, preferably an aluminum or aluminum alloy film or

wherein the barrier layer (5) is a polymeric barrier layer comprising ethylene vinyl alcohol as the at least one polymer P3, the at least one polymer P4 is selected from the group consisting of polyester and polyamide and the barrier composite layer (3) further comprises a tie layer (7) arranged between the barrier layer (5) and the polymeric connecting layer (4) or

wherein the barrier layer (5) is a polymeric barrier layer comprising polyamide as the at least one polymer P3, the at least one polymer P4 is a polyester and the barrier composite layer (3) further comprises a tie layer (7) arranged between the barrier layer (5) and the polymeric connecting layer (4) .
The sealing device according to claim 9, wherein the tie layer (7) comprises at least one maleic anhydride grafted polyolefin, preferably selected from the group consisting of maleic anhydride grafted polyethylene and maleic anhydride grafted polypropylene.
The sealing device according to claim 9 or 10, wherein the metallic barrier layer has a thickness in the range of 1 –50 μm, preferably 1.5 –35 μm.
The sealing device according to any one of claims 9-11, wherein the polymeric barrier layer has layer has a thickness in the range of 1 –300 μm, preferably 2.5 –200 μm.
The sealing device according to any one of claims 9-12, wherein the polymeric protective layer (6) has a thickness in the range of 1 –150 μm, preferably 2.5 –100 μm.
The sealing device according to any one of previous claims further comprising a layer of fiber material (8) fully embedded into the polymeric waterproofing layer (2) and/or a second polymeric waterproofing layer (2’) covering at least a portion of the upper major surface of the polymeric waterproofing layer (2) .
The sealing device according to claim 14, wherein the non-woven fabric comprises inorganic and/or organic fibers.
The sealing device according to any one of previous claims further comprising a pressure sensitive adhesive layer (9) covering at least a portion of the lower major surface of the polymeric protective layer (6) .
A method for producing a sealing device (1) according to any one of previous claims, the method comprising steps of:

I) Providing a polymeric waterproofing layer (2) and a barrier composite layer (3) and

II) Laminating the barrier composite layer (3) to the lower major surface of the polymeric waterproofing layer (2) .
A roof system comprising a roof underlayment (10) and a sealing device (1) according to any of claims 1-16 adhered to a surface of the roof underlayment (10) by using mechanical or adhesive bonding means.