CA2429298C - Self adhering membrane for roofing applications - Google Patents

Self adhering membrane for roofing applications Download PDF

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Publication number
CA2429298C
CA2429298C CA002429298A CA2429298A CA2429298C CA 2429298 C CA2429298 C CA 2429298C CA 002429298 A CA002429298 A CA 002429298A CA 2429298 A CA2429298 A CA 2429298A CA 2429298 C CA2429298 C CA 2429298C
Authority
CA
Canada
Prior art keywords
membrane
adhesive
water impermeable
product
membrane product
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
CA002429298A
Other languages
French (fr)
Other versions
CA2429298A1 (en
Inventor
Michael J. Hubbard
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Holcim Solutions and Products US LLC
Original Assignee
Omnova Solutions Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Omnova Solutions Inc filed Critical Omnova Solutions Inc
Publication of CA2429298A1 publication Critical patent/CA2429298A1/en
Application granted granted Critical
Publication of CA2429298C publication Critical patent/CA2429298C/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

Links

Classifications

    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04DROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D5/00Roof covering by making use of flexible material, e.g. supplied in roll form
    • E04D5/14Fastening means therefor
    • E04D5/148Fastening means therefor fastening by gluing
    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09JADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J109/00Adhesives based on homopolymers or copolymers of conjugated diene hydrocarbons
    • C09J109/06Copolymers with styrene
    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09JADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J123/00Adhesives based on homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Adhesives based on derivatives of such polymers
    • C09J123/02Adhesives based on homopolymers or copolymers of unsaturated aliphatic hydrocarbons having only one carbon-to-carbon double bond; Adhesives based on derivatives of such polymers not modified by chemical after-treatment
    • C09J123/10Homopolymers or copolymers of propene
    • C09J123/14Copolymers of propene
    • C09J123/142Copolymers of propene at least partially crystalline copolymers of propene with other olefins
    • CCHEMISTRY; METALLURGY
    • C09DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
    • C09JADHESIVES; NON-MECHANICAL ASPECTS OF ADHESIVE PROCESSES IN GENERAL; ADHESIVE PROCESSES NOT PROVIDED FOR ELSEWHERE; USE OF MATERIALS AS ADHESIVES
    • C09J125/00Adhesives based on homopolymers or copolymers of compounds having one or more unsaturated aliphatic radicals, each having only one carbon-to-carbon double bond, and at least one being terminated by an aromatic carbocyclic ring; Adhesives based on derivatives of such polymers
    • C09J125/02Homopolymers or copolymers of hydrocarbons
    • C09J125/04Homopolymers or copolymers of styrene
    • C09J125/08Copolymers of styrene
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04DROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D11/00Roof covering, as far as not restricted to features covered by only one of groups E04D1/00 - E04D9/00; Roof covering in ways not provided for by groups E04D1/00 - E04D9/00, e.g. built-up roofs, elevated load-supporting roof coverings
    • E04D11/02Build-up roofs, i.e. consisting of two or more layers bonded together in situ, at least one of the layers being of watertight composition
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04DROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D13/00Special arrangements or devices in connection with roof coverings; Protection against birds; Roof drainage; Sky-lights
    • E04D13/16Insulating devices or arrangements in so far as the roof covering is concerned, e.g. characterised by the material or composition of the roof insulating material or its integration in the roof structure
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04DROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D5/00Roof covering by making use of flexible material, e.g. supplied in roll form
    • E04D5/02Roof covering by making use of flexible material, e.g. supplied in roll form of materials impregnated with sealing substances, e.g. roofing felt
    • EFIXED CONSTRUCTIONS
    • E04BUILDING
    • E04DROOF COVERINGS; SKY-LIGHTS; GUTTERS; ROOF-WORKING TOOLS
    • E04D5/00Roof covering by making use of flexible material, e.g. supplied in roll form
    • E04D5/10Roof covering by making use of flexible material, e.g. supplied in roll form by making use of compounded or laminated materials, e.g. metal foils or plastic films coated with bitumen
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/14Layer or component removable to expose adhesive
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/14Layer or component removable to expose adhesive
    • Y10T428/1476Release layer
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/24Structurally defined web or sheet [e.g., overall dimension, etc.]
    • Y10T428/24355Continuous and nonuniform or irregular surface on layer or component [e.g., roofing, etc.]
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/26Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10TTECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00Stock material or miscellaneous articles
    • Y10T428/26Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension
    • Y10T428/269Web or sheet containing structurally defined element or component, the element or component having a specified physical dimension including synthetic resin or polymer layer or component

Abstract

A preformed, single ply roofing membrane including a water impermeable layer; a hot melt pressure sensitive adhesive adhered to one side of the water impermeable layer, and a release liner covering the hot melt pressure sensitive adhesive.

Description

SELF ADHERING MEMBRANE FOR ROOFING APPLICATIONS
BACKGROUND INFORMATION
The present invention relates generally to a roofing membrane for roofing applications.
A roofing system generally includes a roof deck which is considered the structural supporting surface of a building extending between the surrounding exterior walls of the building. The roof deck may be constructed from plywood, metal decking or concrete or any other suitable material. Depending upon the construction, the roof deck may extend over the surrounding exterior walls or the roof deck may stop short of the exterior walls thereby forming a parapet wall, i.e., a low retaining wall at the edge of the roof deck. If desired, the roofing system may also include an insulation barrier formed from polyisocyanurate or any other suitable material applied over the roof deck.
To make the roof deck and building weather resistant a single-ply roofing membrane is installed over the deck. Such a single-ply roofing membrane is typically made from a shingle sheet of a water impermeable polymeric material.
Conventional roofing membranes have been installed on roof decks using a variety of different methods.
For example, the field or interior of the roofing membrane may be held to the roof deck by the use of ballast and/or penetrating fastener means for retaining the field of a roofing membrane installed to a roof deck is by utilizing a plurality of small, circular, metal plates having a hole in the center and a roofing screw or other suitable fastener. In order to anchor the roofing membrane, the small, circular, metal plates are spaced apart in rows on the roofing membrane and the fastener is driven through the hole in each plate, the roofing membrane, any insulation material and then into the roof deck. 'the metal plates are then covered by overlapping roofing membranes.
Roofing membranes have also been held to roofing decks using non-penetrating fastener means such as by adhering the field of the roofing membrane to the roof deck using an adhesive that is applied to the roofing membrane at the site of the roofing installation.
However, all of the known methods for installing roofing membranes are relatively time and labor intensive.
SUMMARY OF THE INVENTION
It is one object of the present invention to provide a self adhering membrane for roofing applications that may be installed quickly and easily.
It is a further object of the present invention to provide a roofing membrane including a hot melt pressure sensitive adhesive adhered to one side thereof to allow the roofing membrane to be bonded to a roofing deck and/or a parapet wall to form a water impermeable covering over the roofing deck and/or parapet wall.
In one broad aspect the present invention provides a preformed roofing membrane comprising a water impermeable layer, and a hot melt pressure sensitive adhesive adhered to one side of the water impermeable layer.
BRIEF DESCRIPTION OF THE DRAWINGS
FIG. 1 is a cross sectional view of a preformed roofing membrane in accordance with one aspect of the present invention;
FIG. 2 is a cross sectional view of a preformed roofing membrane in accordance with another aspect of the present invention; and FIG. 3 is a preformed roofing membrane in accordance with another aspect of the present invention.
DETAILED DESCRIPTION
Referring the figures, wherein like reference characters represent like elements, there is shown a preformed self adhering roofing membrane 10 in
-2-accordance with the present invention. As noted, the preformed self adhering roofing membrane 10 includes water impermeable layer 12, a hot melt pressure sensitive adhesive 14 adhered to one side of water impermeable layer 12, and a release liner 16 covering pressure sensitive adhesive 14.
The preformed self adhering roofing membrane is securely attached to a roof substrate comprising a roof deck or parapet wall or curb to form a water impervious structure. The roof deck and/or parapet wall and/or curb may be constructed from plywood, metal decking or concrete or any other suitable material.
On existing construction, the self adhering roofing membrane 10 may be applied to a smooth asphalt top surface. If desired, the roofing system, of which the roofing membrane is a part, may also include an insulation barrier formed from polyisocyanurate or any other suitable material applied over the roof deck. A
suitable primer may be used on the roof substrate surface to enhance the adhesion of the self adhering roofing membrane.
The water impermeable layer 12 of the preformed self adhering roofing membrane 10 may be formed of, for example, appropriate thermosetting materials and thermoplastic materials. Suitable thermoplastic materials include:
polyvinyl chloride, thermoplastic olefin, polyethylene and polypropylene, chlorinated polyethylene, chlorosulfonated polyethylene and polyisobutylene, etc and suitable thermosetting materials include EPDM, butyl rubber, neoprene, etc. The pre:~ormed self adhering single ply roofing membrane 10 may or may not include reinforcing meshes or scrims located between the water impermeable layer 12 and the pressure sensitive adhesive 14. 1'he water impermeable layer may range from about: 0.5 to 2.3 mm (.02 to .09 inches) thick, preferably about 1.1 to 2.3 mm (.045 to .09 inches) thick.
The water impermeable layer 12 may range from about 15 to 365 cm (0.5 to 12 feet) wide and of indeterminate length depending upon the intended application.
For example, when the preformed self adhering membrane 10 is installed over the parapet wall or curb of a roofing installation the water impermeable layer ranges from 15 to 91 cm (6 to 36 inches) in width and indeterminate in length as desired.
-3-Adhered to one side of the water impermeable layer 12 is the hot melt pressure sensitive adhesive 14. The hot melt pressure sensitive adhesive 14 is applied directly to the water impermeable layer 12 using most any suitable method well known in the art. For example, the hot melt pressure sensitive adhesive may be applied directly to the water impermeable layer 12 using a hot melt spray method or by using a slot die method. It will be appreciated that by using a hot melt method to apply the pressure sensitive adhesive 14 directly to the water impermeable layer 12 better and more uniform bond strength may be achieved in contrast to the use of a transfer adhesive.
Hot melt pressure sensitive adhesives 14 in accordance with the present invention are solvent-free adhesives, that are characteristically solid at temperatures below about 82°C (180°F), are low viscosity fluids above about 82°C (180°F), and rapidly set upon cooling. Hot melt pressure sensitive adhesives may be applied to a water impermeable layer of a roofing membrane by a hot melt method or by other conventional methods. Exemplary hot melt pressure sensitive adhesives include ethylene vinyl acetate copolymers, compatible with paraffin; styrene-isoprene-styrene copolymers; styrene-butadiene-styrene copolymers; ethylene ethyl acrylate copolymers; and polyurethane reactive, butyl or halo-butyl rubbers, acrylic, ethylene propylene rubber, ethylene propylene dime terpolymer rubber or styrene/butadiene rubbers and styrene-ethylene-butene-styrene copolymers including a variety of tackifying resins, and optionally waxes, antioxidants, plasticizers, and other materials added to the adhesive formulation to enhance the polymer performance. To be considered useful for the preformed singly ply roofing membrane 10 in accordance with the present invention, the pressure sensitive, hot melt adhesive 14 preferably does not include a curing or crosslinking agent whereby the adhesive maintains the desired thermoplastic properties. The pressure sensitive hot melt pressure sensitive adhesive 14 preferably has a minimum peel strength of 3.4 kPa at 21°C (0.5 psi at 70°F) as determined in accordance with ASTM D 3330 for roofing applications.
By way of a representative example only, a particular preferred hot melt pressure sensitive adhesive 14 is ADCOT"' PSA-3 hot melt pressure sensitive -4_ adhesive commercially available from ADCO Products, Inc. (Michigan C',enter, Michigan).
The hot melt pressure sensitive adhesive 14 thickness may range from about 0.10 to 0.3 8 mrn (.004 to .015 inches).
A release liner 16 is applied against the pressure sensitive, hot melt adhesive 14 surface to prevent premature unwanted adhesion and, in the case of rolls, ease of unwind without sticking to the backing. The release liner 16 is applied after the application of the pressure sensitive adhesive 14 to water impermeable layer 12.
For ease of application, the release liner 16 may be sliced into multiple sections to allow for portioned release of the liner from the water impermeable layer during application of the preformed self adhering membrane 10. The release liner 16 may comprise paper, or polyethylene, polypropylene or polyester films of a type well known in the art.
As shown in FIG. l, the water impermeable layer 12; hot melt pressure 1 S sensitive adhesive 14 and release liner 16 may be co-extensive. During application, two self adhering roofing membranes 10 may be joined by positioning the roofing membranes in an overlapping relationship with each other and then heat welding or adhesively bonding the overlapping edges or if the membranes are butted together, a cover cap may be adhered or hot air welded over the seam between t:he two roofing membranes. In alternate embodiment, as shown in FIG. 2, the release liner 16 and hot melt pressure sensitive adhesive 14 may be coextensive and the combined release liner 16 and pressure sensitive adhesive 14 may be spaced from at least one marginal edge of the water impermeable layer 12 to provide a free edge of water impermeable layer. The free edge of water impermeable layer 12 may overlap an adjacent water impermeable layer and either be hot air welded or solvent based adhered or tape adhered to the overlapped membrane depending upon the type of water impermeable layer to be joined. In yet another embodiment as shown in FIG. 3, the hot melt pressure sensitive adhesive 14 and the release liner 16 may be coextensive and the combined release liner and pressure sensitive adhesive may be spaced from at least one marginal edge of the water impermeable layer. The free edge of water impermeable layer includes a cured, pressure sensitive adhesive composition 18 including a release liner as described in U.S. Patent No.
5,242.,727.
The preformed self adhering membranes 10 may be joined together by overlapping the cured pressure sensitive adhesive 18 and the water impermeable layer I2 and then removing the release liner 20 and pressing the adhesive against the membrane.
The preformed self adhering membrane 10 as shown in the figures is joined to the roof substrate by removing the release liner 16 and then pressing the hot melt pressure sensitive adhesive 14 directly to the roof substrate.

Claims (21)

CLAIMS:
1. A membrane product comprising:
a water impermeable membrane; and a pressure sensitive, hot melt first adhesive adhered to one side of the water impermeable membrane, wherein the first adhesive is in direct contact with at least a portion of the water impermeable membrane, wherein the first adhesive is free of a curing additive, wherein the first adhesive has a thickness of 0.004 to 0.015 inches, wherein the membrane product is adhered to a portion of a building by the first adhesive, wherein the membrane product is self adhering, and wherein the water impermeable membrane is the outermost layer of the membrane product relative to the building.
2. The membrane product of Claim 1, wherein the membrane is formed of a thermoplastic material.
3. The membrane product of Claim 1, wherein the membrane is formed of a thermosetting material.
4. The membrane product of Claim 3, wherein the thermosetting material is selected from EPDM, butyl rubber, and neoprene.
5. The membrane product of Claim 1, wherein the water impermeable membrane ranges from 6 inches - 12 feet wide.
6. The membrane product of Claim 1, wherein the water impermeable membrane ranges from 6 inches - 3 feet wide.
7. The membrane product of Claim 1, wherein the first adhesive is a solvent-free adhesive.
8. The membrane product of Claim 1, wherein the first adhesive is selected from ethylene vinyl acetate copolymers, compatible with paraffin;

styrene-isoprene-styrene copolymers; styrene-butadiene-styrene co-polymers; ethylene ethyl acrylate copolymers; and polyurethane reactive, butyl or halo-butyl rubbers, acrylic, ethylene propylene rubber (EPR), ethylene propylene diene terpolymer rubber (EPDM) or styrene/butadiene rubbers (SBR) and styrene-ethylene-butene-styrene copolymers.
9. The membrane product of Claim 1, wherein the water impermeable membrane is single ply.
10. The membrane product of Claim 1, wherein the membrane product is adhered to a roof deck.
11. The membrane product of Claim 1, wherein the water impermeable membrane includes a reinforcing mesh located intermediate the adhesive and the water impermeable membrane, and wherein the adhesive is in direct contact with the water impermeable membrane at openings in the reinforcing mesh.
12. A membrane product consisting essentially of:
a water impermeable membrane; and a pressure sensitive, hot melt first adhesive adhered to one side of the water impermeable membrane, wherein the first adhesive is in direct contact with at least a portion of the water impermeable membrane, wherein the first adhesive is free of a curing additive, wherein the first adhesive has a thickness of 0.004 to 0.015 inches, wherein the membrane product is adhered to a portion of a building by the first adhesive, and wherein the membrane product is self adhering.
13. The membrane product of Claim 12, wherein the water impermeable membrane is the outermost layer of the membrane product relative to the building.
14. The membrane product of Claim 12, wherein the membrane is formed of a thermoplastic material.
15. The membrane product of Claim 12, wherein the membrane is formed of a thermosetting material.
16. The membrane product of Claim 15, wherein the thermosetting material is selected from EPDM, butyl rubber, and neoprene.
17. The membrane product of Claim 12, wherein the first adhesive is a solvent-free adhesive.
18. The membrane product of Claim 12, wherein the first adhesive is selected from ethylene vinyl acetate copolymers, compatible with paraffin;
styrene-isoprene-styrene copolymers; styrene-butadiene-styrene co-polymers; ethylene ethyl acrylate copolymers; and polyurethane reactive, butyl or halo-butyl rubbers, acrylic, ethylene propylene rubber (EPR), ethylene propylene diene terpolymer rubber (EPDM) or styrene/butadiene rubbers (SBR) and styrene-ethylene-butene-styrene copolymers.
19. The membrane product of Claim 12, wherein the water impermeable membrane is single ply.
20. The membrane product of Claim 12, wherein the membrane product is adhered to a roof deck.
21. The membrane product of Claim 12, wherein the water impermeable membrane includes a reinforcing mesh located intermediate the adhesive and the water impermeable membrane, and wherein the adhesive is in direct contact with the water impermeable membrane at openings in the reinforcing mesh.
CA002429298A 2002-05-22 2003-05-21 Self adhering membrane for roofing applications Expired - Lifetime CA2429298C (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US10/153,132 US7101598B2 (en) 2002-05-22 2002-05-22 Self adhering membrane for roofing applications
US10/153,132 2002-05-22

Publications (2)

Publication Number Publication Date
CA2429298A1 CA2429298A1 (en) 2003-11-22
CA2429298C true CA2429298C (en) 2007-04-10

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US (5) US7101598B2 (en)
CA (1) CA2429298C (en)

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CA2429298A1 (en) 2003-11-22
US9528268B2 (en) 2016-12-27
US10167637B2 (en) 2019-01-01
US20100279049A1 (en) 2010-11-04
US20170298630A1 (en) 2017-10-19
US20030219564A1 (en) 2003-11-27
US8852701B2 (en) 2014-10-07
US7101598B2 (en) 2006-09-05
US20070026183A1 (en) 2007-02-01
US20150267410A1 (en) 2015-09-24

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