WO2023178190A1 - Composite précurseur de bande d'étanchéité et ses procédés d'utilisation - Google Patents

Composite précurseur de bande d'étanchéité et ses procédés d'utilisation Download PDF

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Publication number
WO2023178190A1
WO2023178190A1 PCT/US2023/064457 US2023064457W WO2023178190A1 WO 2023178190 A1 WO2023178190 A1 WO 2023178190A1 US 2023064457 W US2023064457 W US 2023064457W WO 2023178190 A1 WO2023178190 A1 WO 2023178190A1
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WIPO (PCT)
Prior art keywords
cured body
cured
flashing
precursor
composite
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PCT/US2023/064457
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English (en)
Inventor
Rodrigo MURILLO MAESE
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Holcim Technology Ltd.
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Publication of WO2023178190A1 publication Critical patent/WO2023178190A1/fr

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    • 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
    • E04D13/14—Junctions of roof sheathings to chimneys or other parts extending above the roof
    • E04D13/1407—Junctions of roof sheathings to chimneys or other parts extending above the roof for flat roofs
    • E04D13/1415—Junctions to walls extending above the perimeter of the roof
    • 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
    • E04D13/14—Junctions of roof sheathings to chimneys or other parts extending above the roof
    • E04D13/1407—Junctions of roof sheathings to chimneys or other parts extending above the roof for flat roofs
    • E—FIXED CONSTRUCTIONS
    • E04—BUILDING
    • E04D—ROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D7/00—Roof covering exclusively consisting of sealing masses applied in situ; Gravelling of flat roofs

Definitions

  • Embodiments of the present invention are directed toward precursor flashing composites prepared by employing liquid flashing compositions and fabric components, as well as methods for installing precursor flashing composites using liquid flashing compositions.
  • Typical membrane systems include asphaltbased systems, such as those that employ modified asphalt membranes, as well as polymeric systems that employ EPDM or thermoplastic olefin (TPO) membranes.
  • asphaltbased systems such as those that employ modified asphalt membranes
  • polymeric systems that employ EPDM or thermoplastic olefin (TPO) membranes.
  • the membranes can be secured to the roof surface by employing ballasting, mechanical fastening, or adhesives.
  • adjacent membranes are bonded to each other to form a water-tight seal between membranes. Flashing systems or assemblies are employed to create a water-tight seal between the membrane system and any vertical structural elements on the roof including, but not limited to, parapet walls, gutter edges, and various protrusions such as pipes that penetrate the roof surface.
  • liquid flashing compositions In the construction of modified asphalt membrane systems, it is common to employ liquid flashing compositions to create a seal with vertical surfaces. These liquid flashing compositions often include asphaltic-based compositions that include polyurethane or polymethyl methacrylate (PMMA) modification or reinforcement. The liquids can be used in conjunction with a fabric reinforcement, which can be mated to the vertical surface in conjunction with the liquid composition to ultimately form, upon drying or curing or the liquid composition, a flashing assembly.
  • PMMA polymethyl methacrylate
  • the liquids can be used in conjunction with a fabric reinforcement, which can be mated to the vertical surface in conjunction with the liquid composition to ultimately form, upon drying or curing or the liquid composition, a flashing assembly.
  • the flashing assemblies are typically prepared using flashing membranes, which may also be referred to as membrane flashings.
  • plastic flashings can be welded or adhered to the membrane system while being adhesively secured to the non-membrane vertical surfaces.
  • rubber membranes it is common to employ flashing membranes that include uncured rubber, which can be adhesively mated to the rubber membrane and adhesively mated to the vertical nonmembrane surfaces.
  • Embodiments of the present invention provide a precursor flashing composite comprising (i) a fabric component having a first planar surface and a second planar surface; (ii) a first pre-cured body disposed on a first portion of the first planar surface of the fabric component, wherein the first pre-cured body has a first geometric shape; (hi) a second precured body disposed on a second portion of the first planar surface of the fabric component, wherein the second pre-cured body has a second geometric shape; and (iv) wherein said first pre-cured body is positioned relative to the second pre-cured body to provide a hinge region between the first pre-cured body and the second pre-cured body.
  • FIG. 1 For embodiments of the present invention, Other embodiments of the present invention provide a method for creating a water-proof seal between a roofing membrane and a vertical structure extending from a roof surface to which the roofing membrane is secured, the method comprising (i) providing a precursor flashing composite including a fabric component having a first planar surface and a second planar surface, a first pre-cured body disposed on a first portion of the first planar surface of the fabric component, wherein the first pre-cured body has a first geometric shape, a second pre-cured body disposed on a second portion of the first planar surface of the fabric component, wherein the second pre-cured body has a second geometric shape; and wherein said first pre-cured body is positioned relative to the second pre-cured body to provide a hinge region between the first pre-cured body and the second pre-cured body; (ii) positioning the precursor flashing composite on a surface of a vertical structure and a surface of the roofing membrane; and (hi) applying a liquid flashing composition to the precursor flash
  • Yet other embodiments of the present invention provide a method of forming a precursor flashing composite, the method comprising (i) providing a fabric component with a first major planar surface and a second major planar surface; [ii] disposing a first liquid coating layer on the first major planar surface of the fabric component; [iii] disposing a second liquid coating layer on the first major planar surface of the fabric component; and (i v J curing the first liquid coating layer and the second liquid coating layer to thereby form a first body and a second body, respectively, wherein the first body has a first geometric shape, and wherein the second body has a second geometric shape.
  • a roofing system comprising (i) a roof deck; (ii) optionally, one or more roofing boards; [iii] a roofing membrane; [iv] a vertical structure extending from a roof surface to which the roofing membrane is secured; and (v) a flashing forming a water-proof seal between the roofing membrane and the vertical structure; wherein the flashing includes a composite flashing structure adhered into place with a flashing composition, where the composite flashing structure includes a fabric component having a first planar surface and a second planar surface, a first pre-cured body disposed on a first portion of the first planar surface of the fabric component, wherein the first pre-cured body has a first geometric shape, a second precured body disposed on a second portion of the first planar surface of the fabric component, wherein the second pre-cured body has a second geometric shape; and wherein said first pre-cured body is positioned relative to the second pre-cured body to provide a hinge region between the first
  • a precursor flashing composite to create a water-proof seal between a roofing membrane and a vertical structure extending from a roof surface, where including a fabric component having a first planar surface and a second planar surface, a first pre-cured body disposed on a first portion of the first planar surface of the fabric component, wherein the first pre-cured body has a first geometric shape, a second pre-cured body disposed on a second portion of the first planar surface of the fabric component, wherein the second pre-cured body has a second geometric shape; and wherein said first pre-cured body is positioned relative to the second pre-cured body to provide a hinge region between the first pre-cured body and the second pre-cured body.
  • FIG. 1 is a top-elevational view of a precursor flashing composite according to one or more embodiments of the present invention.
  • FIG. 2 is a cross-sectional side-view of a precursor flashing composite according to one or more embodiments of the present invention.
  • FIG. 3 is a top-elevational view of a precursor flashing composite according to one or more embodiments of the present invention.
  • FIG. 4 is a top-elevational of a precursor flashing composite according to one or more embodiments of the present invention.
  • FIG. 5 is a top-elevational of a precursor flashing composite according to one or more embodiments of the present invention.
  • FIG. 6 is a cross-sectional side-view of a precursor flashing composite according to one or more embodiments of the present invention.
  • Embodiments of the present invention are based, at least in part, on the discovery of a precursor flashing composite wherein a fabric component includes at least a first precured portion and a second pre-cured portion, each of which may include the cured residue of a liquid flashing composition.
  • the precursor flashing composites of the present invention advantageously provide ease of installation by reducing the amount of liquid flashing composition necessary to form a water-proof seal during field application. As a result, less uncured material is necessary during installation, which also provides environmental benefits.
  • the precursor flashing composites are therefore advantageously useful in preparing water-proof seals along vertical structures adjacent to a roofing membrane.
  • the precursor flashing composite includes a fabric and first and second pre-cured portions, which may also be referred to as pre-cured bodies, or simply bodies, disposed on the fabric.
  • pre-cured bodies or simply bodies
  • at least two or more bodies are disposed on the fabric component such that a hinge, which may also be referred to as a hinge region, a gap, or a flexible joint, is formed between the edges of at least two or more of the bodies.
  • the hinges are regions of the fabric component between the at least two or more bodies that allow for flexing, folding, articulation, and other manipulation of the composite along the hinge.
  • FIG. 1 shows a precursor flashing composite 100 including a fabric component 101, a first body 111 (i.e. pre-cured body 111], and a second body 112 (i.e. pre-cured body 112]. Further, the placement of body 111 and body 112 on fabric component 101 forms a hinge region 121 along the gap between the two bodies in the portion of fabric component 101 between first body 111 and second body 121.
  • Body 111 and body 112 are the cured residue of a liquid flashing composition applied to on fabric component 101.
  • firstbody 111 and second body 112 are bonded or secured to fabric component 101 by virtue of being applied to the fabric as a liquid that is subsequently cured.
  • fabric component 101 extends beyond first body 111 and second body 112.
  • bodies 111, 112 may be formed such that none of the fabric component 101 is exposed along the outside perimeter of fabric 101 (i.e. outside relative to bodies 111, 112].
  • the skilled person will appreciate that the amount of fabric component 101 extending beyond body 111 and body 112 may be selected according to the type of installation for which precursor flashing composite 100 is adapted.
  • first body 111 includes a hinge edge 211, longitudinal edges 221, 231, and a lateral edge 241.
  • Second body 112 includes a hinge edge 212, longitudinal edges 222, 232, and a lateral edge 242.
  • longitudinal edges 221, 231 and 222, 232 are adjacent to lateral edges 241 and 242, respectively.
  • the distance between hinge edges 211 and 212 represents hinge region 121, which allows for the precursor flashing composite to be folded to match a desired configuration during installation (i.e. angle between the vertical structure and the roofing membrane].
  • fabric component 101 has thickness 272
  • bodies 111, 112 have thickness 271
  • precursor flashing composite has overall thickness 273.
  • Hinge region 121 is shown as fabric component 101 between bodies 111, 112.
  • hinge region 121 is adapted to allow for folding of fabric component 101 during installation to accommodate any number of installation geometries encountered in roofing environments.
  • hinge region 121 is adapted to be folded to generally form at a least a 90-degree angle.
  • FIG. 3 shows pre-cured bodies 311, 312, 313, and 314 disposed on fabric component 101.
  • a first hinge region 321 is formed between body 311 and 312.
  • a second hinge region 322 is formed between body 311 and 313.
  • a third hinge region 323 is formed between body 313 and 314.
  • perforation 331 may be formed in fabric component 101, which allows fabric component 101 to be separated along perforation 331, thereby allowing for hinge regions 321, 322, 323 to all be independently foldable.
  • perforation 331 may include an actual perforation formed during manufacturing of precursor flashing composite. Perforation 331 may also be a marked line indicating to an installer where to cut fabric component 101. Perforation 331 may be formed through machine manipulation such that an installer can tear fabric component 101 along perforation 331. Perforation 331 may also be a pre-cut portion of fabric component 101.
  • the present invention may encompass many variations of foldable precursor flashing composites.
  • perforations may be formed in the fabric component such that the fabric component may be separated from itself, or portions of the fabric component may be removed according to a pattern of perforations.
  • An object of the present invention is to create a water-proof seal between a vertical structure adjacent to a roofing surface.
  • the precursor flashing composite is advantageously adapted to lay flat against both the vertical structure and the roofing surface when installed. Accordingly, variations of foldable precursor flashing composites may be required to achieve this objective.
  • a vertical structure adjacent to a roofing surface may employ a precursor flashing composite including a single hinge region, which allows for an approximately 90-degree fold during installation of the precursor flashing composite.
  • the bodies may be shaped as rectangular, and the fabric component may be shaped as rectangular.
  • the hinge region may be formed into a pointed corner or have degree of curvature to accommodate the needs of the vertical structure.
  • precursor flashing composite 400 In other examples, such as where it is desired to install the composite at the corner of a roof where two parapet walls intersect, a different precursor flashing composite is required to allow for easy installation into the corner of the parapets.
  • An example of a suitable precursor flashing composite for this use is shown in FIG. 4, where pre-cured bodies 411, 412, 413, 414 are disposed on fabric component 101.
  • a perforation 431 is formed such that a portion 401 of fabric component 101 is removable from precursor flashing composite 400.
  • vertical structures such as circular vents, which may be found on a roofing structure, may demand another type of precursor flashing composite.
  • precursor flashing composites may have perforations such that when wrapped around the circular, vertical structure during installation, the perforations are broken allowing for the precursor flashing composite to lay flat against the roofing surface and the vertical structure.
  • FIG. 5 An example of a suitable precursor flashing composite for this use is shown in FIG. 5, where composite 500 includes a plurality of pre-cured bodies 511, each of which are disposed on fabric component 501. A plurality of perforations 531 are formed in fabric component 501 such that fabric component 501 can be separated along each of perforations 531 during installation.
  • precursor flashing composite 500 may be advantageously installed at a rounded vertical surface rising from a roofing surface.
  • precursor flashing composites according to the present invention may be cut to size or in order to create overlap regions between a flashing composite and any other flashing components, including another precursor flashing composite. These modifications may be required according to roofing needs and may be made without impacting the integrity of the waterproof seal formed by using the precursor flashing composite.
  • Some embodiments can be described with respect to the percentage of the surface area of fabric component that the pre-cured body covers. For example, the pre-cured body may cover greater than 80%, in other embodiments greater than 85%, and in other embodiments greater than 90% of the surface area of the fabric. In one or more embodiments, the cured body covers from about 80 to about 99% of the fabric of the body. A greater percentage of the surface area of the fabric covered advantageously requires less liquid flashing composition during installation of the precursor flashing composite.
  • the hinge region may have a width, which is measured from precured body to pre-cured body, of from about 0.1 to about 2 inches, in other embodiments from about 0.2 to about 0.7 inches, or in other embodiments from about 0.25 to about 0.5 inches.
  • the pre-cured portions are the cured residue of a liquid flashing composition applied to a surface of a fabric.
  • These bodies are generally three-dimensional bodies that may have a substantially uniform thickness, although a non- uniform thickness may offer advantages in certain situations. While certain shapes may be advantageous for certain installations (as suggested above), the shape of the body may be regular or irregular polygonal shapes, curved shapes, and other two-dimensional shapes. Relative to plurality of bodies that may exist in a composite, the composites of one or more embodiments may have a substantially uniform thickness relative to each other.
  • the one or more pre-cured bodies of a given composite may have a thickness of greater than 0.2 mm, in other embodiments greater than 0.7 mm, and in other embodiments greater than 1.0 mm.
  • the pre-cured bodies may have a thickness of less than 25 mm, in other embodiments less than 20 mm, and in other embodiments less than 15 mm.
  • the precured bodies may have a thickness of from about 0.2 to about 25 mm, in other embodiments from about 0.7 to about 20 mm, and in other embodiments from about 1.0 to about 15 mm.
  • the composites of this invention may have more than one pre-cured body disposed on the fabric component.
  • the composite may have at least two or more pre-cured bodies formed on a fabric component, where the at least two or more pre-cured bodies are formed having the same planar shapes.
  • the at least two or more pre-cured bodies having the same planar shapes may have uniform thicknesses.
  • the at least two or more pre-cured bodies having the same planar shapes may have non-uniform thicknesses.
  • pre-cured bodies may be referenced according to their relative placement during installation of a precursor flashing composite.
  • pre-cured bodies placed upon a roofing surface may be referred to as roof-oriented bodies or roof bodies
  • pre-cured bodies placed upon a vertical surface adjacent to a roofing surface may be referred vertical surface-oriented bodies or vertical bodies.
  • vertical does not require vertical structures to be perpendicular to a roofing surface. Instead, vertical structures refer to any structure which extends upward from an adjacent roofing surface.
  • the pre-cured bodies may be the cured residue of a liquid flashing composition.
  • a liquid flashing composition may be employed in the installation of the flashing composites of this invention.
  • the liquid flashing compositions employed in the practice of this invention may include liquid flashing compositions that are generally known in the art. The skilled person understands that liquid flashing compositions are generally flowable compositions (at operating conditions) that can be applied to a substrate to form an uncured or partially cured coating that, upon curing, forms a cured residue of the composition.
  • the liquid flashing compositions have an appropriate viscosity to allow useful application methods such as brushing or rolling, while at the same time having sufficiently low viscosity to prevent deleterious sagging or running when applied to a vertical surface.
  • compositions may cure by different mechanisms depending on the nature of the compositions itself.
  • the composition can cure by evaporation of a solvent without any chemical reactions taking place with one or more of the constituents of the composition.
  • the compositions may cure by a reaction taking place wherein one of the ingredients acts a reactant (e.g. one-part curable composition) or where two or more of the ingredients react with each other (e.g. two-part curable composition).
  • a reactive cure may take place where one or more of the ingredients react with moisture (i.e. water in the environment), such as a one-part polyurethane or a moisture-curable alkoxysilane polymer.
  • compositions may include two-part reactive compositions where a first reactant is supplied by a first part of the composition [e.g. an A-side stream) and a second reactant is supplied by a second component (e.g. a B-side stream). Upon mixing or contact, two parts form a reactive mixture that cures to form a cured residue.
  • the constituents of the composition that react and form a cured component of the overall composition may form a continuous (e.g. matrix) or discontinuous phase of the overall cured composition.
  • reactive curing may take place in conjunction with removal of any solvent or carrier that may be present within the composition.
  • the liquid flashing composition includes a one-part polyurethane composition.
  • these compositions typically include isocyanate prepolymers that are crosslinked upon exposure to water (e.g. moisture within the air).
  • the liquid flashing compositions include two-part polyurethane compositions that are formedby two distinct reactant streams.
  • useful two-part polyurethane compositions include an A-side stream, which includes an isocyanate or isocyanate prepolymer, and a B-side stream, which includes an isocyanate-reactive component, such as a polyol.
  • these compositions can include various other additives, which are typically supplied together with the polyol within the B-side stream, such as catalysts, plasticizers, and extenders.
  • the liquid flashing compositions include two-part acrylate resin compositions.
  • these compositions may include methyl methacrylate monomer compositions, which are typically supplied in a first stream.
  • These polymers either alone or in combination with other constituents, may crosslink upon exposure or contact to a catalyst or initiator, which is typically supplied by a second reactant stream.
  • a free radical initiator such as a peroxide, is supplied to the acrylate polymers.
  • the liquid flashing compositions include silicon adhesives, which may also be referred to as polysiloxane adhesives.
  • silicon- containing polymer adhesive systems also include polymer systems that include terminal siloxy or alkylsiloxy groups.
  • these polysiloxane adhesives can cure upon exposure to water (e.g. moisture within the air).
  • These compositions may include various complementary constituents such as tackifier resins, moisture scavengers, and silane adhesion promoters.
  • These adhesive systems are generally known in the art as disclosed in WO 2014/145482, WO 2014/095650, U.S. Patent Nos. 7,019,074, 6,183,551, and U.S. Publication No. 2007/0282080.
  • the reactive component e.g. moisture-curable isocyanate-containing constituent
  • flashing compositions may include asphalt or polymeric constituents that do not necessarily react with the reactive component.
  • the liquid flashing composition is an asphalt-based composition that is modified by one or more reactive polymer such as polyisocyanate prepolymers alkoxy-silane terminated prepolymers.
  • Useful flashing compositions are commercially available.
  • useful flashing compositions can be obtained under the tradenames Ultraflash one-part liquid flashing, Ultraflash two-part liquid flashing, Multi-purpose MB Flashing Cement, Firestone AC Fast FR, and Multi-Purpose MB Cold Adhesive.
  • the precursor flashing composite includes a flashing fabric component.
  • These fabrics may include those fabrics conventionally employed in constructing flashings for asphaltic roof systems as known in the prior art.
  • fabric is a synthetic fabric including glass or polymeric fibers or filaments.
  • the fabric is a woven fabric.
  • the fabric may be non-woven.
  • the fabric may include a non-woven fabric with woven reinforcement.
  • the fabric includes a continuous filament polyester, needle punched, nonwoven fabric.
  • the fabric is a scrim reinforced nonwoven polyester mat.
  • the fabric is a glass fiber mat.
  • the fabric is a polyolefin fabric, including nonwoven polypropylene or polyethylene mats.
  • flashing fabric is commonly sold as a rolled product.
  • Each roll includes a width of fabric corresponding with a width of the roll, while the length is the amount of fabric wound into the roll.
  • the width of the fabric component may be about 6 inches or greater, in other embodiments about 12 inches or greater, in other embodiments about 18 inches or greater, in other embodiments, about 24 inches or greater, in other embodiments about 30 inches or greater, and in other embodiments about 36 inches or greater.
  • the length of flashing fabric installed at any one time may be selected by the installer in accordance with how quickly the installer is able to apply the liquid flashing composition during its working window before curing.
  • an installer is able to install a precursor flashing composite of greater length during the working window of the liquid flashing composition relative to flashing fabric alone.
  • the length of the fabric component is about 4 feet or greater, in other embodiments 5 feet or greater, in other embodiments 6 feet or greater, in other embodiments 7 feet or greater, in other embodiments 8 feet or greater, other embodiments 9 feet or greater. in other embodiments 10 feet or greater, other embodiments 11 feet or greater, in other embodiments 12 feet or greater, in other embodiments 13 feet or greater. in other embodiments 14 feet or greater, in other embodiments 15 feet or greater, in other embodiments 16 feet or greater, in other embodiments 17 feet or greater, in other embodiments 18 feet or greater, in other embodiments 19 feet or greater, and in other embodiments 20 feet or greater.
  • the fabric may be characterized by a basis weight of greater than 50 g/m 2 , in other embodiments greater than 60 g/m 2 , and in other embodiments greater than 70 g/m 2 .
  • the glass fiber mat may be characterized by a basis weight of less than 150 g/m 2 , in other embodiments less than 130 g/m 2 , and in other embodiments less than 100 g/m 2 .
  • the glass fiber mat may be characterized by a basis weight of from about 50 to about 150 g/m 2 , in other embodiments from about 60 to about 130 g/m 2 , and in other embodiments from about 70 to about 110 g/m 2 .
  • the glass mat may be characterized by a thickness of greater than 0.5 mm, in other embodiments greater than 0.7 mm, and in other embodiments greater than 1.0 mm. In these or other embodiments, the glass mat may be characterizedby a thickness of less than 2.0 mm, in other embodiments less than 1.5 mm, and in other embodiments less than 1.2 mm. In one or more embodiments, the glass mat may be characterized by a thickness of from about 0.5 to about 2.0 mm, in other embodiments from about 0.7 to about 1.5 mm, and in other embodiments from about 1.0 to about 1.2 mm.
  • the fabric may be characterized by a basis weight of greater than 70 g/m 2 , in other embodiments greater than 85 g/m 2 , and in other embodiments greater than 100 g/m 2 .
  • the polyester fabric may be characterized by a basis weight of less than 400 g/m 2 , in other embodiments less than 300 g/m 2 , and in other embodiments less than 280 g/m 2 .
  • the polyester fabric may be characterized by a basis weight of from about 70 to about 400 g/m 2 , in other embodiments from about 85 to about 300 g/m 2 , and in other embodiments from about 100 to about 280 g/m 2 .
  • the glass mat may be characterized by a thickness of greater than 0.3 mm, in other embodiments greater than 0.7 mm, and in other embodiments greater than 1.0 mm.
  • the polyester fabric may be characterized by a thickness of less than 4.0 mm, in other embodiments less than 2.0 mm, and in other embodiments less than 1.5 mm.
  • the polyester fabric may be characterized by a thickness of from about 0.3 to about 4.0 mm, in other embodiments from about 0.7 to about 2.0 mm, and in other embodiments from about 1.0 to about 1.5 mm.
  • the fabric may be characterized by a basis weight of greater than 35 g/m 2 , in other embodiments greater than 42 g/m 2 , and in other embodiments greater than 50 g/m 2 .
  • the polyolefin mat may be characterized by a basis weight of less than 400 g/m 2 , in other embodiments less than 300 g/m 2 , and in other embodiments less than 280 g/m 2 .
  • the polyolefin mat may be characterized by a basis weight of from about 35 to about 400 g/m 2 , in other embodiments from about 42 to about 300 g/m 2 , and in other embodiments from about 50 to about 280 g/m 2 .
  • the glass mat may be characterized by a thickness of greater than 0.3 mm, in other embodiments greater than 0.7 mm, and in other embodiments greater than 1.0 mm.
  • the polyolefin mat may be characterized by a thickness of less than 4.0 mm, in other embodiments less than 2.0 mm, and in other embodiments less than 1.5 mm.
  • the polyolefin mat may be characterized by a thickness of from about 0.3 to about 4.0 mm, in other embodiments from about 0.7 to about 2.0 mm, and in other embodiments from about 1.0 to about 1.5 mm.
  • UltraFlashTM Fabric available from ELEVATE.
  • the composite of the present invention can be used to flash between a membrane on a longitudinal surface and a vertical surface of a roof to form a roof system.
  • Other components of the roof system may be conventional in nature.
  • FIG. 6, shows roof system 660 including roof deck 605, optional construction and/or insulation board layer 604, roofing membrane 603, and vertical structure 606.
  • installed precursor flashing composite 600 is shown having fabric component 601, first pre-cured body 611, second pre-cured body 612, and cured liquid flashing composition 602.
  • Installed precursor flashing composite 600 and cured liquid flashing composition 602 advantageously create a water-proof seal between roofing membrane 603 and vertical structure 606.
  • roofing systems of this invention can include a variety of roof decks such as concrete pads, steel decks, wood beams, and foamed concrete decks.
  • the membrane layer is an asphaltic membrane system.
  • these membrane systems can be formed from modified-bitumen rolled membrane product. These membranes are commonly modified with atactic polypropylene (e.g. APP 160 available from ELEVATE) and styrene-butadiene-styrene block copolymer (e.g. SBS FR Torch available from ELEVATE). These membranes may include a roof substrate contacting adhesive surface and an upper surface that may include a weather resistant film or granule surface.
  • polymeric membranes may be used.
  • Useful polymeric membranes include both thermoplastic and thermoset materials.
  • membrane prepared from poly(ethylene-co-propylene-co-diene) terpolymer rubber or poly(ethylene-co-propylene) copolymer rubber can be used.
  • roofing membranes made from these materials are well known in the art as described in U.S. Patent Nos. 6,632,509, 6,615,892, 5,700,538, 5703,154, 5,804,661, 5,854,327, 5,093,206, and 5,468,550, which are incorporated herein by reference.
  • Other useful polymeric membranes include those made from various thermoplastic polymers or polymer composites.
  • thermoplastic olefin i.e. TPO
  • thermoplastic vulcanizate i.e. TPV
  • polyvinylchloride PVC
  • ballast material is applied over the protective membrane. In many instances, this ballast material simply includes aggregate in the form of rock, stone, or gravel; U.S. Patent No. 6,487,830, is incorporated herein in this regard.
  • Practice of this invention is likewise not limited by the selection of any particular insulation board.
  • the insulation boards are optional.
  • Several insulation materials can be employed including polyurethane or polyisocyanurate cellular materials. These boards are known as described in U.S. Patent Nos. 6,117,375, 6,044,604, 5,891,563, 5,573,092, U.S. Publication Nos. 2004/0109983, 2003/0082365, 2003/0153656, 2003/0032351, and 2002/0013379, as well as U.S. Serial Nos. 10/640,895, 10/925,654, and 10/632,343, which are incorporated herein by reference.
  • cover boards may include high density polyurethane or polyisocyanurate board as disclosed in U.S. Publication Nos. 2006/0127664, 2013/0164524, 2014/0011008, 2013/0036694, and 2012/0167510, which are incorporated herein by reference.
  • the cover boards may include construction boards such as DensDeck.
  • insulation boards and cover boards may carry a variety of facer materials including, but not limited to, paper facers, fiberglass- reinforced paper facers, fiberglass facers, coated fiberglass facers, metal facers such as aluminum facers, and solid facers such as wood.
  • the construction boards of this invention can be secured to a building structure by using various known techniques.
  • the construction boards can be mechanically fastened to the building structure (e.g. the roof deck).
  • the construction boards can be adhesively secured to the building structure.
  • the present invention provides for installed flashings to form waterproof seals that exhibit excellent adhesion strength.
  • the installed flashing composites of the present invention provide an adhesion strength that can be determined according to the methods defined by ASTM D413. In one or more embodiments, the adhesion strength is comparable to that of traditional flashing arrangements.
  • a roof system advantageously employing the precursor flashing composites of the present invention can be prepared by a method that includes providing a precursor flashing composite as described herein, positioning the precursor flashing composite at a desired location, and then applying a liquid flashing composition to at least partially cover the exposed fabric of the precursor flashing composite.
  • the step of positioning the precursor flashing composite includes positioning composite to traverse a location at or near where a membrane ends at a vertical structure so that composite contacts both the membrane and the vertical surface. In this regard, reference can be made to FIG. 6.
  • composite 600 is positioned so that first pre-cured body 611 is positioned to contact vertical surface 606, second pre-cured body 612 is positioned to contact membrane 603, and hinge area 609 traverses the corner formed by vertical structure 606 and membrane 603.
  • the step of positioning may include one or more sub-steps. For example, it may be useful to secure the composite into position prior to applying the liquid flashing composite, particularly to the vertical surface. This may be accomplished with mechanical or adhesive fastening (e.g. a base coat of liquid flashing material can be applied to the surfaces upon which the composite is placed or the composite can be temporarily affixed with a mechanical fastener).
  • the step of positioning may include folding or otherwise manipulating the hinge area to facilitate shaping the composite to the corner in which it is installed.
  • the liquid flashing composition is applied.
  • the liquid flashing composition is applied in a manner such that the fabric of the composite is at least partially covered to thereby form a water-tight seal.
  • the liquid flashing composition can be applied to cover a portion of the pre-cured bodies.
  • liquid flashing composition can be applied by using brushing or rolling techniques. In other embodiments, especially where the liquid flashing composition has a higher viscosity, known tools such as knives and trowels can be employed. Also, the liquid flashing composition can be applied as one single layer or as multiple layers. In other embodiments, a first layer of liquid flashing composition can be applied to the vertical surface of the vertical structural element, and then the precursor flashing composite can be applied to the first layer of liquid flashing material, and then another layer of liquid flashing material may be applied to cover the fabric component.
  • the precursor flashing composite can be applied to both the vertical surface and the horizontal (or a portion of the horizontal) surface such that the fabric component traverses the transition or corner between the vertical and horizontal surfaces.
  • the liquid flashing composition is applied to traverse the precursor flashing composite and the vertical surface of the vertical structural element. As shown in FIG. 6, application of the liquid flashing composition can extend from the surface of membrane 603 to a surface of vertical surface 606, or it may only traverse a portion of the precursor flashing composite.
  • the bodies formed on the fabric of the precursor flashing may serve as a guide or level during installation.
  • the thickness of a body provides for a visual indicator of the appropriate thickness of liquid flashing composition to be applied to obtain a waterproof barrier. Further, this feature provides for a way to prevent excess liquid flash composition from being applied in accordance with the desire to reduce the amount of liquid flashing composition required during installation of the flashing composite.
  • the precursor flashing composite can be formed through a variety of techniques that generally include applied a liquid flashing composition to a fabric.
  • the pre-cured bodies can first be formed (e.g. within a mold) and then secured to the fabric.
  • the fabric is placed into a contact with a template or form and then the liquid flashing composition is applied to the fabric in a manner that allows the form to dictate the shape of the cured body.
  • the form or template may be formed using masking techniques.
  • a mask is placed on a first major surface of the fabric component (or otherwise some means of allowing the liquid flashing to be applied in a pattern).
  • the liquid flashing composition is applied to the fabric, sufficient time is provided to allow the composition to cure.
  • the pre-cured composite may be heated or placed into an environment to facilitate curing.
  • the formed precursor flashing composite may be further processed to optionally attach adhesives with release liners used during installation of the precursor flashing composite. Additionally, the formed precursor flashing composite may be packed as a flat pack or rolled according to storage needs. [0078] Various modifications and alterations that do not depart from the scope and spirit of this invention will become apparent to those skilled in the art. This invention is not to be duly limited to the illustrative embodiments set forth herein.

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  • Engineering & Computer Science (AREA)
  • Architecture (AREA)
  • Civil Engineering (AREA)
  • Structural Engineering (AREA)
  • Laminated Bodies (AREA)

Abstract

L'invention concerne un composite précurseur d'une bande d'étanchéité comprenant (i) un composant de tissu ayant une première surface plane et une seconde surface plane ; (ii) un premier corps pré-durci disposé sur une première partie de la première surface plane du composant de tissu, le premier corps pré-durci ayant une première forme géométrique ; (iii) un second corps pré-durci disposé sur une seconde partie de la première surface plane du composant de tissu, le second corps pré-durci ayant une seconde forme géométrique ; et (iv) ledit premier corps pré-durci étant positionné par rapport au second corps pré-durci pour obtenir une région charnière entre le premier corps pré-durci et le second corps pré-durci.
PCT/US2023/064457 2022-03-15 2023-03-15 Composite précurseur de bande d'étanchéité et ses procédés d'utilisation WO2023178190A1 (fr)

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US63/319,819 2022-03-15

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US5512118A (en) 1991-04-24 1996-04-30 Bridgestone/Firestone, Inc. Method of covering roofs with rooftop curable heat seamable roof sheeting
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US5468550A (en) 1994-06-06 1995-11-21 Bridgestone/Firestone, Inc. EPDM roofing membrane with improved burn resistivity
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US7019074B2 (en) 2003-04-23 2006-03-28 Kaneka Corporation Curable composition
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US20070282080A1 (en) 2006-06-02 2007-12-06 Kaneka Corporation Curable composition
US20140011008A1 (en) 2007-01-30 2014-01-09 Firestone Building Products Co., LLC High density polyurethane and polyisocyanurate construction boards and composite boards
US20130164524A1 (en) 2010-04-14 2013-06-27 John B. Letts Construction boards with coated facers
WO2014095650A2 (fr) 2012-12-17 2014-06-26 Henkel Ag & Co. Kgaa Polyuréthanes à terminaisons silane et faible module
WO2014145482A2 (fr) 2013-03-15 2014-09-18 Firestone Building Products Co., LLC Adhésif de liaison et systèmes de couverture collés préparés à l'aide de celui-ci
US20210254343A1 (en) * 2020-02-18 2021-08-19 Building Materials Investment Corporation Matrix assisted two component roof coating system and method

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