COMPOSITE CONSTRUCTION MATERIAL

Abstract

A multifunctional composition uses a unique back surfacing that is a parting agent for improved protection during storage and transportation, that protects the exposed surface from asphaltic staining and transfer of the back surfacing to the exposed or top surface of the material, that can be used on all types of asphaltic compounds including plastic and rubber modified bitumen and that can be applied using convention application techniques like heat welding, hot mopping molten asphalt or the like and cold applied mastics and cements or the like.

Claims

1. A process for creating and applying a material composition on a roof comprising: selecting a material composition comprising: an upper asphaltic layer; a lower asphaltic layer; a carrier mat located in between the upper layer and lower layer; a bottom surface comprised of at least one fabric which is composed of at least one of the following: polypropylene, polyethylene; the lower asphaltic layer is partially embedded into the fabric; and wherein at least a portion of the fabric remains on an outermost surface on the bottom surface of the material composition; and bonding the portion of the fabric on an outermost surface on the bottom surface of the material composition to a roof.

2. The process according to claim 1 wherein the portion of the fabric on the outermost surface on the bottom surface of the material composition is bonded to the roof using heat welding.

3. The process according to claim 1 wherein the portion of the fabric on the outermost surface on the bottom surface of the material composition is bonded to the roof using hot mopping.

4. The process according to claim 1 wherein the portion of the fabric on the outermost surface on the bottom surface of the material composition is bonded to the roof using molten asphalt.

5. The process according to claim 1 wherein the portion of the fabric on the outermost surface on the bottom surface of the material composition is bonded to the roof using cold applied mastics and cements.

6. The process according to claim 1 wherein the fabric has a basis weight between 5 and 20 g/m.sup.2, the fabric has a thickness between 0.1 and 0.5 mm, and the fabric has a tensile strength of at least 20 N/5 mm.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0039] For a more complete understanding of the present invention, reference is made to the following detailed description of exemplary embodiments considered in conjunction with the accompanying drawings.

[0040] FIG. 1 shows a roofing membrane 10 in accordance with an embodiment of the present disclosure.

[0041] FIG. 2 is a perspective, partially exploded cross view of a modified bituminous, laminated roofing membrane 10 in accordance with an exemplary embodiment of the present disclosure. For ease of visualization, the layers 12, 14, 20 are shown spaced apart.

[0042] FIG. 3 is a partially exploded cross view of a modified bituminous, laminated roofing membrane in accordance with another exemplary embodiment of the present disclosure with bottom compound layer 14 and light weight fabric layer 20 laminated together. Layer 20 is shown to be embedded about half way into bottom compound layer 14.

[0043] FIG. 4 is a perspective, partially exploded cross view of a modified bituminous, laminated roofing membrane 10 in accordance with an exemplary embodiment of the present disclosure. This embodiment of the roofing membrane 10 does not include an inner substrate or carrier mat 12.

[0044] FIG. 5 is a perspective, partially exploded cross view of a modified bituminous, laminated roofing membrane 10 in accordance with an exemplary embodiment of the present disclosure. This embodiment of the roofing membrane 10 does not include an inner substrate or carrier mat 12. This embodiment does include a highly reflective optional layer 34.

[0045] FIG. 6 is a perspective, partially exploded cross view of a modified bituminous, laminated roofing membrane 10 in accordance with an exemplary embodiment of the present disclosure. This embodiment of the roofing membrane 10 does not include an inner substrate or carrier mat 12. In this embodiment the top compound layer 16 shows a surfacing that can be made of a film, cross laminated film, aluminum, tri-coated aluminum film, PVDF film or the like or another surfacing such as acrylic, silicone or urethane coating.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

[0046] Surprisingly a simple solution to the problems has been found in using a light basis weight fabric (20) that can replace the sand, mica, talc or the like and the plastic film or the like. This light weight basis fabric prevents staining of asphalt from the back of the material to the upper or exposed layer of the material and that fabric can prevent sticking of the material to the rollers during manufacturing, can remain in place during storage and transportation and during the application of the material. The material with the light basis weight fabric can be applied using conventional techniques like heat welding, hot mopping or molten asphalt application or the like and be adhered using cold applied mastics and cements or the like on all types of asphaltic materials and all types of modified bitumen membranes including plastic and rubber modified membranes and combinations thereof of asphaltic and modified bitumen materials or the like.

[0047] The preferred fabric (20) is a light weight fabric made of polypropylene, polyethylene or combination thereof. The more preferred fabric is a combination of polypropylene and polyethylene and an even more preferred fabric is made of polypropylene. The fabric is applied during the manufacturing process when the asphaltic or bitumen material is still hot so that the fabric can be partially embedded into the back of the material for good bond strength before and after application.

[0048] The fabric is usually purchased in roll form but this is optional. During manufacturing the fabric is usually adhered to the back of the material while it is still hot. It can be applied right after the molten compound is applied to the material or in a secondary step by reheating the back of the material and applying it then. An alternate way of adhering the fabric can be used, such as an adhesive to bond it to the back of the material for example. Any method of adhering the fabric to the material will be considered part of this patent.

[0049] The fabric is usually applied with an optional bow roller or similar device to help smooth out wrinkles in the fabric and make it a smooth layer on the back of the material. Making the fabric completely smooth is not necessary for the invention to work. Sometimes an optional pressure point is used like a nip roll or squeegee or the like or an S-wrap or the like that can help embed the fabric into the hot material but this is optional as other means can be employ or adhere the fabric during the manufacturing process.

[0050] The fabric usually does not melt during the manufacturing process but it can if desired. If desired, the fabric can be melted completely or partially during the manufacturing process as long as when the fabric is cooled a portion of the fabric remains on the outermost surface of the material so that it can act as a parting agent.

[0051] If melting or partially melting the fabric is desired one can envision multiple ways of melting the fabric like applying it to very hot compound or adding torches or the like or infrared heaters or the like or similar means of heating so that the bond strength between the fabric and the material can be improved. Melting or partially melting the fabric is not necessary for the invention to work.

[0052] The basis weight and thickness of the disclosed fabric is very important. If the fabric is too thin, asphaltic compound will bleed through during the manufacturing process and staining can occur or be transferred to the top or exposed surface of the material during storage or transportation. If the fabric is too thick it cannot be embedded to the proper depth in the compound and the fabric can debond after application or it will not melt readily when heat welding techniques are used.

[0053] If the fabric is too thick the bond strength is reduced if the molten asphalt or cold applied cements and mastics used may not penetrate the fabric to the back of the material. This penetration is needed so that a good bond is achieved. If the fabric is not penetrated by the molten asphalt or cold applied mastics the fabric could tear or delaminate after application and the roofing or siding material may not stay adhered.

[0054] There is a fine line as to the thickness of the fabric and the basis weight of the fabric so that it can protect the top surface of the material and still be applied by the three conventional application methods mentioned previously.

[0055] The preferred basis weight of this fabric is 5-40 g/m.sup.2, more preferred 10-30 g/m2, and even more preferred is a 15-20 g/m.sup.2 polypropylene fabric that has been treated to be hydrophobic. The polypropylene, polyethylene or combination thereof fabric has a preferred thickness of 0.1-0.5 mm thick, more preferred 0.15-0.30 mm thick, and even more preferred 0.17-0.20 mm thick.

[0056] The fabric must also be strong to work as an interface during application. The tensile strength of the disclosed fabric is important during manufacturing the material as it is applied when the asphaltic compound is hot so that it can embed into the material about half way, not break during manufacturing, and provide good bond strength for the field applied materials to withstand building movement, weather conditions and the like. The fabric has a preferred tensile strength of 20-80 N/50 mm in the machine direction (MD), more preferred 25-60 N/50 mm, and most preferred 30-50 N/50 mm.

[0057] FIG. 1 shows a roofing membrane 10 in accordance with an embodiment of the present disclosure. The roofing membrane 10 has an inner substrate or carrier mat 12 composed of polyester or fiberglass or other similar material from which a roofing substrate or carrier mat 12 may be made. Bottom compound and top compound layers 14, 16, respectively, are made of compounds such as asphaltic or modified bitumen compound, or combinations thereof, are laminated or coated to opposing sides of the substrate or carrier mat 12 in one or more steps. Layer 12 can be impregnated with the asphaltic or modified bitumen compound or the like or combinations thereof in one or more steps. Top compound layer 16 has a plurality of optional granules (18) disposed over the upper surface thereof forming an optional granular surface. Optionally, peripheral edges 22, 24 may be left smooth (without granules) to form a bonding or overlap area where optional beads of adhesive 26, 28 may be applied. Optional layers 30, 32 are release films for optional Layers 26, 28. As noted above, while the membrane 10 is described as a roofing membrane, it could also be used for other applications, such as siding. The asphalt or asphaltic compound can be applied and or impregnate the mat in one, two or even more steps during production.

[0058] Bottom layer 20 is a light basis weight fabric made of polypropylene, polyethylene, or combination thereof. The light basis weight fabric should be made from hydrophobic fibers or treated to be hydrophobic to prevent absorption, wicking, or sucking up of liquids or moisture from the air, environment or atmospheres but this is not mandatory for the invention to work. As noted above, while the membrane 10 is described as a roofing membrane, it could also be used for other applications, such as siding.

[0059] FIG. 2 shows a roofing membrane 10 in accordance with an embodiment of the present disclosure with the layers 12, 14 and 20 are shown spaced apart. The roofing membrane 10 has an inner sheet or carrier mat 12 composed of polyester or fiberglass or other similar material from which a fabric may be made. Bottom compound and top compound layers 14, 16, respectively, are made of compounds such as asphaltic or modified bitumen compound, or combinations thereof, are laminated to opposing sides of the substrate or carrier mat 12 in one or more steps. Layer 12 can be impregnated with compounds such as asphaltic or modified bitumen compound, or combinations thereof in one or more steps. Bottom layer 20 is a fabric made of polypropylene, polyethylene or combination thereof and acts as the back surface and or parting agent layer. Top layer 16 has a plurality of optional granules 18 disposed over the upper surface thereof forming a granular surface 19. Optional granules 18 can be seen to be partially embedded in top compound Layer 16 that is made of an asphaltic or modified bitumen compound or the like or combinations thereof. As noted above, while the membrane 10 is described as a roofing membrane, it could also be used for other applications, such as siding.

[0060] Bottom layer 20 is a light basis weight fabric made of polypropylene, polyethylene or combination thereof is shown to be partially embedded in the asphaltic and or bottom asphaltic compound layer 14.

[0061] FIG. 3 shows membrane 10, with bottom compound layer 14 and light weight fabric layer 20 laminated together. Layer 20 is shown to be embedded about half way into bottom compound layer 14. Bottom compound and top compound layers 14, 16, respectively, are made of compounds such as asphaltic or modified bitumen compound, or combinations thereof are laminated to opposing sides of the substrate or carrier mat 12 in one or more steps. The roofing membrane 10 has an inner substrate or carrier mat 12 composed of polyester or fiberglass or other similar material from which a roofing substrate or carrier mat may be made. Layer 12 is shown separate for ease of viewing. Layer 12 can be impregnated with compounds such as the asphaltic or modified bitumen compound, or combinations thereof, in one or more steps. Top layer 16 has a plurality of optional granules 18 disposed over the upper surface thereof forming an optional granular surface 19. Optional granules 18 are shown covered with a white acrylic or similar coating forming a highly reflective optional layer 22. As noted above, while the membrane 10 is described as a roofing membrane, it could also be used for other applications, such as siding, walk way pads or a protection course for below grade construction.

[0062] Bottom layer 20 is a light basis weight fabric made of polypropylene, polyethylene or combination thereof is shown to be partially embedded in the asphaltic and or bottom asphaltic compound layer 14.

[0063] The embodiment shown on FIG. 4 does not include an inner substrate or carrier mat 12. The asphalt or modified asphalt can be coated directly to light weight fabric 20 in one or more steps to form layer 16. Layer 16 is often called the top compound and is made from asphalt and or modified bitumen compound that is laminated or coated to one side of fabric 20. The top compound layer 16 shows a plurality of granules disposed over the upper surface thereof forming an optional granular surface 19. Bottom layer 20 is a light basis weight fabric made of polypropylene, polyethylene or combination thereof is shown to be partially embedded in the asphaltic and or modified bitumen compound layer 16.

[0064] The embodiment shown on FIG. 5 does not include an inner substrate or carrier mat 12. The asphalt or modified asphalt can be coated directly to light weight fabric 20 in one or more steps to form layer 16. Layer 16 is often called the top compound and is made from asphalt and or modified bitumen compound that is laminated or coated to one side of fabric 20. The top compound layer 16 shows a plurality of granules 18 disposed over the upper surface thereof forming an optional granular surface 19 that has been coated with a highly reflective optional layer 34 to make a membrane with a highly reflective top surface. Bottom layer 20 is a light basis weight fabric made of polypropylene, polyethylene or combination thereof is shown to be partially embedded in the asphaltic and or modified bitumen compound layer 16.

[0065] The embodiment shown on FIG. 6 does not include an inner substrate or carrier mat 12. The asphalt or modified asphalt can be coated directly to light weight fabric 20 in one or more steps to form layer 16. Layer 16 the top compound is made from asphalt and or modified bitumen compound that is laminated or coated to one side of fabric 20. The top compound layer 16 shows a surfacing that can be made of a film, cross laminated film, aluminum, tri-coated aluminum film, PVDF or similar film, or another surfacing such as acrylic, silicone or urethane coating. Alternately if layer 36 is a film it can be coated or laminated directly with asphaltic or modified bitumen compound to form layer 16 and bottom layer 20 is then laminated to the asphaltic or modified bitumen compound layer 16. Bottom layer 20 is a light basis weight fabric made of polypropylene, polyethylene or combination thereof is shown to be partially embedded in the asphaltic and or modified bitumen compound layer 16.

In one embodiment the material composition comprises: [0066] an upper asphaltic layer; [0067] a lower asphaltic layer; [0068] a carrier mat located in between the upper layer and lower layer; [0069] a bottom surface comprised of at least one fabric which is composed of at least one of the following: polypropylene, polyethylene; [0070] the lower asphaltic layer is partially embedded into the fabric; and [0071] wherein at least a portion of the fabric remains on an outermost surface on the bottom surface of the material composition.
A process for creating and applying a material composition on a roof comprising: [0072] selecting a material composition comprising: [0073] an upper asphaltic layer; [0074] a lower asphaltic layer; [0075] a carrier mat located in between the upper layer and lower layer; [0076] a bottom surface comprised of at least one fabric which is composed of at least one of the following: polypropylene, polyethylene; [0077] the lower asphaltic layer is partially embedded into the fabric; and [0078] wherein at least a portion of the fabric remains on an outermost surface on the bottom surface of the construction material; and [0079] bonding the portion of the fabric on an outermost surface on the bottom surface of the material composition to a roof.

[0080] The above is a detailed description of particular embodiments of the invention. It is recognized that departures from the disclosed embodiments may be made within the scope of the invention and that obvious modifications will occur to a person skilled in the art. Those of skill in the art should, in light of the present disclosure, appreciate that many changes can be made in the specific embodiments which are disclosed herein and still obtain a like or similar result without departing from the spirit and scope of the invention. All of the embodiments disclosed and claimed herein can be made and executed without undue experimentation in light of the present disclosure.