Roofing membrane with integrated surface reinforcement

Abstract

A surface-reinforced bitumen roofing membrane includes at least two layers, namely 1) a bitumen compound layer, and 2) a fiber mat, and can optionally include a) an optional bleed blocker layer that is located between the bitumen compound layer and the fiber mat, b) an optional liquid applied coating that partially or fully encapsulates the fiber mat, c) an optional release liner that is releasably positioned on the bottom surface of the bitumen roofing membrane, and/or d) an optional release film that is releasably positioned on the fiber mat surface.

Claims

1. A surface-reinforced bitumen roofing membrane that includes a bitumen compound layer, a fiber mat that is position on or above at least a portion of a top surface of said bitumen compound layer, and one or more of a) a bleed blocker layer located between said bitumen compound layer and said fiber mat, b) a liquid applied coating that partially or fully encapsulates or impregnates said fiber mat, c) said fiber mat extending beyond a first side edge of said bitumen compound layer along a longitudinal length of said bitumen compound layer, d) said fiber mat extending beyond a first side edge and an opposite second side of said bitumen compound layer along a longitudinal length of said bitumen compound layer, e) said fiber mat spaced from said first side edge of said bitumen compound layer to form a lap line region along said longitudinal length of said of said bitumen compound layer, f) said fiber mat spaced from said first side edge and said opposite second side of said bitumen compound layer to form a lap line region along both sides of said bitumen compound layer along said longitudinal length of said of said bitumen compound layer, g) said fiber mat spaced from said first side edge of said bitumen compound layer to form a lap line region along said longitudinal length of said of said bitumen compound layer, and a release liner that is releasably positioned on a top surface of said lap line region, or h) said fiber mat spaced from said first side edge and said opposite second side of said bitumen compound layer to form a lap line region along both sides of said bitumen compound layer along said longitudinal length of said of said bitumen compound layer, and release liner that is releasably positioned on a top surface of both of said lap line regions.

2. The surface-reinforced bitumen roofing membrane as defined in claim 1, wherein said bitumen compound layer comprises by weight percent: TABLE-US-00009 Primary hydrocarbon compound 25-90 wt. % Filler 0-66 wt. % Polymer Modifier 0-30 wt. % Hydrocarbon Resin Process Oil 0-30 wt. % Antioxidant 0-30 wt. % UV Stabilizer 0-30 wt. % Cross-Linker 0-30 wt. % Biocide 0-30 wt. % Coloring Agent 0-30 wt. % Metal Flakes 0-30 wt. % Adhesion Enhancer 0-30 wt. % Fire Retardant 0-30 wt. % Tackifying Agent 0-30 wt. % Softening Agent 0-30 wt. % Wax 0-15 wt. % Acid 0-15 wt. % Internal Reinforcement Fiber 0-40 wt. %; and wherein said weight percentage exclude any internal reinforcement layer in said bitumen compound layer.

3. The surface-reinforced bitumen roofing membrane as defined in claim 1, wherein said bitumen compound layer comprises by weight percent: TABLE-US-00010 Primary hydrocarbon compound 25-80 wt. % Filler 0.5-60 wt. % Polymer Modifier 0.05-25 wt. % Hydrocarbon Resin Process Oil 0.05-20 wt. % Antioxidant 0-5 wt. % UV Stabilizer 0-5 wt. % Cross-Linker 0-10 wt. % Biocide 0-5 wt. % Coloring Agent 0-5 wt. % Metal Flakes 0-5 wt. % Adhesion Enhancer 0-5 wt. % Fire Retardant 0-25 wt. % Tackifying Agent 0-5 wt. % Softening Agent 0-5 wt. % Wax 0-5 wt. % Acid 0-5 wt. % Internal Reinforcement Fiber 0-30 wt. %; and wherein said weight percentage exclude any internal reinforcement layer in said bitumen compound layer.

4. The surface-reinforced bitumen roofing membrane as defined in claim 1, wherein said bitumen compound layer comprises by weight percent: TABLE-US-00011 Primary hydrocarbon compound 25-60 wt. % Filler 0.5-50 wt. % Polymer Modifier 0.05-20 wt. % Hydrocarbon Resin Process Oil 0.05-15 wt. % Antioxidant 0-2 wt. % UV Stabilizer 0-2 wt. % Cross-Linker 0-5 wt. % Biocide 0-2 wt. % Coloring Agent 0-2 wt. % Metal Flakes 0-2 wt. % Adhesion Enhancer 0-2 wt. % Fire Retardant 0-20 wt. % Tackifying Agent 0-2 wt. % Softening Agent 0-2 wt. % Wax 0-2 wt. % Acid 0-2 wt. % Internal Reinforcement Fiber 0-25 wt. %; and wherein said weight percentage exclude any internal reinforcement layer in said bitumen compound layer.

5. The surface-reinforced bitumen roofing membrane as defined in claim 1, wherein said bitumen compound layer comprises by weight percent: TABLE-US-00012 Primary hydrocarbon compound 25-55 wt. % Filler 0.05-45 wt. % Polymer Modifier 0.05-10 wt. % Hydrocarbon Resin Process Oil 0.05-5 wt. % Antioxidant 0-2 wt. % UV Stabilizer 0-2 wt. % Cross-Linker 0-5 wt. % Biocide 0-1 wt. % Coloring Agent 0-2 wt. % Metal Flakes 0-2 wt. % Adhesion Enhancer 0-2 wt. % Fire Retardant 0-15 wt. % Tackifying Agent 0-2 wt. % Softening Agent 0-2 wt. % Wax 0-2 wt. % Acid 0-2 wt. % Internal Reinforcement Fiber 0-20 wt. %; and wherein said weight percentage exclude any internal reinforcement layer in said bitumen compound layer.

6. The surface-reinforced bitumen roofing membrane as defined in claim 1, wherein said bitumen compound layer comprises by weight percent: TABLE-US-00013 Primary hydrocarbon compound 40-80 wt. % Filler 0-60 wt. % Internal Reinforcement Fibers 0-30 wt. % Polymer Modifier 1-25 wt. % Hydrocarbon Resin or Process Oil 0-15 wt. % Antioxidant 0-1 wt. % UV Stabilizer 0-1 wt. % Biocide 0-1 wt. % Fire Retardant 0-11 wt. %; and wherein said weight percentage exclude any internal reinforcement layer in said bitumen compound layer.

7. The surface-reinforced bitumen roofing membrane as defined in claim 1, wherein said bitumen compound layer comprises by weight percent: TABLE-US-00014 Primary hydrocarbon compound 25-60 wt. % Filler 25-60 wt. % Internal Reinforcement Fibers 0-20 wt. % Polymer Modifier 2-20 wt. % Hydrocarbon Resin or Process Oil 0-15 wt. % Antioxidant 0-1 wt. % UV Stabilizer 0-1 wt. % Biocide 0-1 wt. % Fire Retardant 0.05-11 wt. %; and wherein said weight percentage exclude any internal reinforcement layer in said bitumen compound layer.

8. The surface-reinforced bitumen roofing membrane as defined in claim 1, wherein said bitumen compound layer comprises by weight percent: TABLE-US-00015 Primary hydrocarbon compound 40-50 wt. % Filler 35-50 wt. % Internal Reinforcement Fibers 0-20 wt. % Polymer Modifier 4-8 wt. % Hydrocarbon Resin or Process Oil 0-15 wt. % Antioxidant 0-1 wt. % UV Stabilizer 0-1 wt. % Biocide 0-1 wt. % Fire Retardant 0.05-11 wt. %; and wherein said weight percentage exclude any internal reinforcement layer in said bitumen compound layer.

9. The surface-reinforced bitumen roofing membrane as defined in claim 1, wherein said fiber mat is 2-60 mil in thickness.

10. The surface-reinforced bitumen roofing membrane as defined in claim 1, wherein said fiber mat is a woven mat.

11. The surface-reinforced bitumen roofing membrane as defined in claim 1, wherein said fiber mat includes a non-woven mat.

12. The surface-reinforced bitumen roofing membrane as defined in claim 1, wherein said fiber mat includes one or more of polyester, fiberglass, a blend of fiberglass and polyester and wherein a weight ratio of fiberglass to polyester is 0.1:99.9 to 99.9:0.1, carbon fiber, nylon, and/or rayon.

13. The surface-reinforced bitumen roofing membrane as defined in claim 1, including a release liner releasably adhered to an underside of the modified bitumen membrane, said release liner having a thickness of 1-20 mil.

14. The surface-reinforced bitumen roofing membrane as defined in claim 13, wherein said release liner is treated with silicone.

15. The surface-reinforced bitumen roofing membrane as defined in claim 1, including a release liner releasably adhered to a top surface of said fiber mat, said release film has a thickness of 1-20 mil; said bitumen compound layer comprising by weight percent: TABLE-US-00016 Primary hydrocarbon compound 25-80 wt. % Filler 0.5-60 wt. % Polymer Modifier 0.05-25 wt. % Hydrocarbon Resin Process Oil 0.05-20 wt. % Antioxidant 0-5 wt. % UV Stabilizer 0-5 wt. % Cross-Linker 0-10 wt. % Biocide 0-5 wt. % Coloring Agent 0-5 wt. % Metal Flakes 0-5 wt. % Adhesion Enhancer 0-5 wt. % Fire Retardant 0-25 wt. % Tackifying Agent 0-5 wt. % Softening Agent 0-5 wt. % Wax 0-5 wt. % Acid 0-5 wt. % Internal Reinforcement Fiber 0-30 wt. %; and wherein said weight percentage excludes any internal reinforcement layer in said bitumen compound layer.

16. The surface-reinforced bitumen roofing membrane as defined in claim 15, wherein said release liner is treated with silicone.

17. A surface-reinforced bitumen roofing membrane that includes a bitumen compound layer, a fiber mat that is position on or above at least a portion of a top surface of said bitumen compound layer, a bleed blocker layer located between said bitumen compound layer and said fiber mat, and a liquid applied coating that partially or fully encapsulates or impregnates said fiber mat; said bitumen compound layer comprising: said bitumen compound layer comprising by weight percent: TABLE-US-00017 Primary hydrocarbon compound 25-80 wt. % Filler 0.5-60 wt. % Polymer Modifier 0.05-25 wt. % Hydrocarbon Resin Process Oil 0-20 wt. % Fire Retardant 0-25 wt. % Internal Reinforcement Fiber 0-30 wt. %; and wherein said weight percentage excludes any internal reinforcement layer in said bitumen compound layer.

18. The surface-reinforced bitumen roofing membrane as defined in claim 17, wherein said fiber mat extends beyond a first side edge of said bitumen compound layer along a longitudinal length of said bitumen compound layer.

19. The surface-reinforced bitumen roofing membrane as defined in claim 17, wherein said fiber mat is spaced from a first side edge of said bitumen compound layer to form a lap line region along said longitudinal length of said of said bitumen compound layer.

20. The surface-reinforced bitumen roofing membrane as defined in claim 19, wherein a release liner that is releasably positioned on a top surface of said lap line region.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The following is a brief description of the drawings, which are presented for the purposes of illustrating the exemplary objects disclosed herein and not for the purposes of limiting the same.

(2) FIG. 1 illustrates the use of the surface-reinforced bitumen roofing membrane without a polymeric bleed blocker and also illustrates the optional temporary surface film that can be used to protect the membrane from water.

(3) FIG. 2 illustrates the use of the surface-reinforced bitumen roofing membrane with a fiber mat and a polymeric bleed blocker, and also illustrates the optional temporary surface film that can be used to protect the membrane from water.

(4) FIG. 3 illustrates the surface-reinforced bitumen roofing membrane having a non-woven fibrous mat and polymeric bleed blocker, and also illustrates the optional temporary surface film that can be used to protect the membrane from water.

(5) FIG. 4 illustrates the surface-reinforcement bitumen roofing membrane without a bleed blocker layer, and wherein the surface reinforcement optionally extends beyond the width of the modified bitumen membrane, and optionally runs along its entire length.

(6) FIG. 5 illustrates a bitumen compound layer that includes an optional reinforcement layer within the primary hydrocarbon compound.

(7) FIG. 6 illustrates a continuous feed process for applying the fiber mat and release film to the bitumen compound layer during manufacturing of the surface-reinforced bitumen roofing membrane.

DETAILED DESCRIPTION OF VARIOUS NON-EMBODIMENTS OF DISCLOSURE

(8) A more complete understanding of the articles/devices, processes and components disclosed herein can be obtained by reference to the accompanying drawings. These figures are merely schematic representations based on convenience and the ease of demonstrating the present disclosure, and are, therefore, not intended to indicate relative size and dimensions of the devices or components thereof and/or to define or limit the scope of the exemplary embodiments.

(9) Although specific terms are used in the following description for the sake of clarity, these terms are intended to refer only to the particular structure of the embodiments selected for illustration in the drawings and are not intended to define or limit the scope of the disclosure. In the drawings and the following description below, it is to be understood that like numeric designations refer to components of like function.

(10) The singular forms “a,” “an,” and “the” include plural referents unless the context clearly dictates otherwise.

(11) As used in the specification and in the claims, the term “comprising” may include the embodiments “consisting of” and “consisting essentially of.” The terms “comprise(s),” “include(s),” “having,” “has,” “can,” “contain(s),” and variants thereof, as used herein, are intended to be open-ended transitional phrases, terms, or words that require the presence of the named ingredients/steps and permit the presence of other ingredients/steps. However, such description should be construed as also describing compositions or processes as “consisting of” and “consisting essentially of” the enumerated ingredients/steps, which allows the presence of only the named ingredients/steps, along with any unavoidable impurities that might result therefrom, and excludes other ingredients/steps.

(12) Numerical values in the specification and claims of this application should be understood to include numerical values which are the same when reduced to the same number of significant figures and numerical values which differ from the stated value by less than the experimental error of conventional measurement technique of the type described in the present application to determine the value.

(13) All ranges disclosed herein are inclusive of the recited endpoint and independently combinable (for example, the range of “from 2 grams to 10 grams” is inclusive of the endpoints, 2 grams and 10 grams, and all the intermediate values).

(14) The terms “about” and “approximately” can be used to include any numerical value that can vary without changing the basic function of that value. When used with a range, “about” and “approximately” also disclose the range defined by the absolute values of the two endpoints, e.g., “about 2 to about 4” also discloses the range “from 2 to 4.” Generally, the terms “about” and “approximately” may refer to plus or minus 10% of the indicated number.

(15) Percentages of elements should be assumed to be percent by weight of the stated element, unless expressly stated otherwise.

(16) Referring now to the drawings which illustrate non-limiting embodiments of the surface-reinforced bitumen roofing membrane in accordance with the present disclosure, FIGS. 1-4 illustrate various non-limiting embodiments of the surface-reinforced bitumen roofing membrane and a non-limiting process for forming the surface-reinforced bitumen roofing membrane in accordance with the present disclosure.

(17) The surface-reinforced bitumen roofing membrane includes at least two layers, namely 1) a bitumen compound layer, and 2) a fiber mat, and can optionally include a) an optional bleed blocker layer that is located between the bitumen compound layer and the fiber mat, b) an optional liquid applied coating that partially or fully encapsulates the fiber mat, c) an optional release liner that is releasably positioned on the bottom surface of the bitumen roofing membrane, and/or d) an optional release film that is releasably positioned on the fiber mat surface or the optional liquid applied coating.

(18) The surface-reinforced bitumen roofing membrane in accordance with the disclosure provides a user (e.g., contractor, etc.) with a ready-made reinforcement layer for a field-applied liquid applied coating; however, the coating applied on the surface-reinforced bitumen roofing membrane at time of manufacture in an in-line process.

(19) The bitumen compound layer can include a rubber-modified bitumen containing SBS, SEBS, SIS, or other rubber polymers. The bitumen compound layer can optionally contain fire retardants and tackifier resins.

(20) The bitumen compound layer optionally includes an internal reinforcement to add reinforcement and internal strength to the bitumen compound layer when the bitumen compound layer is in the rolled or unrolled state. The type of internal reinforcement that can be used in the bitumen compound layer can include, but is not limited to, a polyester reinforcement, a glass fiber reinforcement, and/or a combination of polyester and glass fiber reinforcement. The internal reinforcement (e.g., polyester, fiberglass mat, or combination thereof) is generally different from the fiber mat) and generally has a thickness of 5-20 mil.

(21) The bottom surface of the bitumen compound layer can be formulated to be a self-adhering surface. When the bottom surface of the bitumen compound layer is formulated to be a self-adhering surface, the bottom surface of the bitumen compound layer can include a release liner. The release liner can have a thickness of 1-10 mil, and which release liner can be optionally treated with a polymer (e.g., silicone, etc.). As can be appreciated, a release liner is not necessary with a bitumen compound layer that is not self-adhering, such as a bitumen compound layer that as a bottom surface that includes ground glass, sand, a burn backer, etc.

(22) The top of surface of the fiber mat can include an optional removable surface protective film or release film to protect the membrane surface from water until the coating system can be applied. The release film can have a thickness of 1-20 mil, and which release film can be optionally treated with a polymer (e.g., silicone, etc.) on one or both sides. In a non-limiting embodiment, the release film can be treated with a pressure sensitive adhesive on the side in contact with the fiber mat or the liquid applied coating to keep the release film more secure yet able to be peeled from the fiber mat or liquid applied coating with little or no damage to the fiber mat.

(23) The surface-reinforced bitumen roofing membrane includes a bitumen compound layer formed of a modified bitumen compound. One non-limiting formulation for the bitumen compound layer includes:

(24) TABLE-US-00008 Primary hydrocarbon compound 25-60 wt. % (e.g., 80-100 wt. % bitumen) SBS Rubber 2-20 wt. % Filler (e.g., calcium carbonate) 25-60 wt. % Fire Retardants 0.01-11 wt. % (e.g., alumina trihydrate, and charring agents such as ammonium polyphosphate) Hydrocarbon Resin or processing oil 1-10 wt. %.

(25) The fiber mat that is applied to the bitumen compound layer at least partially functions as a surface reinforcement for the surface-reinforced bitumen roofing membrane. The fiber mat can also be used to form a surface reinforcement layer that includes the liquid applied coating that is applied to the fiber mat. In one non-limiting configuration, the fiber mat is formed of multi-directional fibers (e.g., strands of fire retardant fiberglass, etc.) that are held together with a binder (e.g., acrylic binder, etc.). The fiber mat generally has a thickness of 10-20 mil and the length of the fibers in the fiber mat are generally 1/32-5 in. long.

(26) The fiber mat can optionally include a backing material that is pre-coated on the bottom surface of the fiber mat. The composition of the optional backing material can be bitumen or asphalt, plastic, or other polymer to facilitate in adhering the fiber mat to the bitumen compound layer or the optional bleed blocker layer.

(27) The fiber mat generally spans the entire width of the surface-reinforced bitumen roofing membrane. However, the fiber mat can be configured to span less than the full width of the surface-reinforced bitumen roofing membrane to form a lap line region on one or both sides of the surface-reinforced bitumen roofing membrane along the longitudinal length of the surface-reinforced bitumen roofing membrane. The top surface of the one or more lap line regions optionally can be formed of bitumen, rubber-modified bitumen, or the composition of the top surface of the bitumen compound layer. The width of the lap line region (when formed) is generally 1-5 in., and typically 3-4 in. The top surface of the lap line region can include a release liner.

(28) Alternatively, the fiber mat can optionally be made to overhang one (or both) longitudinal edges of the bitumen compound layer to provide a lap reinforcement, or tie in, to an adjacent surface-reinforced bitumen roofing membrane.

(29) The fiber mat can optionally have fire-retardant properties. As such, the fiber mat can be optionally pretreated and/or post-treated with fire-retardant materials (e.g., applied halogenated compounds, graphite compounds, etc.).

(30) An adhesive can optionally be used to secure the fiber mat to the bitumen compound layer or optional bleed blocker layer.

(31) The surface-reinforced bitumen roofing membrane can optionally include a liquid applied coating that partially or fully encapsulates the fiber mat. Such liquid applied coating can be a pre-applied coating or a coating that is applied after the surface-reinforced bitumen roofing membrane has been placed on a building structure (e.g., roof, etc.). The liquid applied coating is used to partially or fully saturate and/or encapsulate the fiber mat. In one method, the liquid applied coating is coated by a contractor in the field after the installation of the surface-reinforced bitumen roofing membrane on a roof system. The liquid applied coating can be applied in the field to the surface-reinforced bitumen roofing membrane by spray coating, mopping, rolling, brushing, etc. the liquid applied coating onto the top surface of the fiber mat.

(32) The optional liquid applied coating is formulated to partially or fully penetrate the fiber mat (e.g., fiberglass mat, etc.). Generally, the liquid applied coating does not a) come into direct contact with the top surface of the bitumen compound layer, orb) does not substantially come into direct contact with the top surface of the bitumen compound layer (e.g., 0-10% and all values and ranges therebetween of the top surface of the bitumen compound layer comes in direct contact with the liquid applied coating) due to the properties of the fiber mat and/or optional bleed blocker layer. The limiting or prevention of the liquid applied coating from contacting the bitumen compound layer results in the limiting or prevention of oils from the bitumen compound layer from diffusing into the liquid applied coating which can result in discoloration of the top surface of the liquid applied coating, blistering in the liquid applied coating, and/or other deleterious effects to the liquid applied coating.

(33) The liquid applied coating can be formed of polyurethane, polyurea, poly (methyl methacrylate), an elastomeric material, and/or silicone.

(34) The dried thickness of the liquid applied coating on the fiber mat is generally 4-6 mil. Generally, the wet thickness of the liquid applied coating can be 64-100 mil.

(35) The liquid applied coating can be pre-applied to the surface-reinforced bitumen roofing membrane by 1) applying the liquid applied coating to the fiber mat after the fiber mat is connected to the bitumen compound layer or optional bleed blocker layer, or 2) applying the liquid applied coating to the fiber mat prior to the fiber mat being connected to the bitumen compound layer or optional bleed blocker layer.

(36) The final thickness of the surface-reinforced bitumen roofing membrane is generally 20-150 mil, typically 40-130 mil, and more typically 80-100 mil.

(37) The surface-reinforced bitumen roofing membrane in accordance with the disclosure removes a step of applying a liquid applied coating on a roof membrane, and then manually rolling out and positioning a fabric reinforcement on the base coat that can wrinkle or tent or later delaminate, blister, or result in a surface defect or surface failure. The resulting roof that uses the surface-reinforced bitumen roofing membrane in accordance with the disclosure can be lighter than a traditional multi-layered roof system containing a base sheet and cap sheet because the liquid applied coating becomes the monolithic cap sheet on the surface-reinforced bitumen roofing membrane in accordance with the disclosure, thus eliminating additional layers as used in traditional roofing systems.

(38) The surface-reinforced bitumen roofing membrane can optionally include a bleed blocker layer that is located between the bitumen compound layer and the fiber mat. The bleed blocker layer is used to provide a barrier between the fiber mat and the bitumen compound layer to inhibit or prevent the bitumen oils from bleeding through the fiber mat and interacting with the liquid applied coating that is applied to the top surface of the fiber mat. The bleed blocker layer can also be used to improve the fire retardancy of the surface-reinforced bitumen roofing membrane. The bleed blocker layer can also be used to improve the weathering properties of the surface-reinforced bitumen roofing membrane. The bleed blocker layer can be formed of an acrylic material, polyvinyl alcohol, nitrile rubber, thermoplastic urethane, polyamide, vinyl acetate, latex, SBR, SBS, SEBS, SIS, natural rubber, low density polyethylene (LDPE), linear low density polyethylene (LLDPE), medium density polyethylene (MDPE), high density polyethylene (HDPE), cast unrented polypropylene (CPP), biaxially oriented polypropylene (BOPP), polyethylene/polyamide (PE/PA), polyester, polyethylene terephthalate, polyurethane, and/or polyamide. The bleed blocker layer can be applied as a liquid coating to the bottom surface of the fiber mat and/or to the top surface of the bitumen compound layer. Alternatively, the bleed blocker layer can be a preformed film (e.g., single ply film, multi-ply film, etc.) that is connected to the bottom surface of the fiber mat and/or to the top surface of the bitumen compound layer. An adhesive can optionally be used to secure the bleed blocker layer to the bottom surface of the fiber mat and/or to the top surface of the bitumen compound layer. In another non-limiting arrangement, the bleed blocker layer can include a fiber surface-reinforced layer (e.g., fiberglass woven or non-woven mat) that is coated with a polymer, or otherwise chemically treated.

(39) FIGS. 1-4 illustrate three non-limiting embodiments of the surface-reinforced bitumen roofing membrane in accordance with the present disclosure.

(40) FIG. 1 illustrates the surface-reinforced bitumen roofing membrane formed by a fiber mat that is connected to a bitumen compound layer, which bitumen compound layer optionally includes a release liner that is releasably connected to a bottom surface of the bitumen compound layer. The fiber mat can be formed of multi-directional fibers that are secured together by a binder. The bitumen compound layer may or may not include a reinforcement layer. The fibers in the fiber mat are optionally formed of fiberglass, and the fiber mat is optionally treated with a fire retardant. The surface-reinforced bitumen roofing membrane also optionally includes a removable release film that is releasably connected to the top mat to protect the membrane against water until the coating can be applied.

(41) FIG. 1 also illustrates that the fiber mat does not extend the full width of the bitumen compound layer to create an optional lap line region on one or both sides of the surface-reinforced bitumen roofing membrane. Although not shown, the lap line region can optionally include a release liner.

(42) FIG. 2 illustrates the surface-reinforced bitumen roofing membrane formed by a fiber mat that is connected to a bleed blocker layer, which bleed blocker layer is connected to the bitumen compound layer, which bitumen compound layer optionally includes a release liner that is releasably connected to a bottom surface of the bitumen compound layer. The fiber mat is formed of multi-directional fibers that are secured together by a binder. The bitumen compound layer may or may not include a reinforcement layer. The fibers in the fiber mat are optionally formed of fiberglass, and the fiber mat is optionally treated with a fire retardant. The surface-reinforced bitumen roofing membrane also optionally includes a removable release film that is releasably connected to the top mat to protect the membrane against water until the coating can be applied.

(43) As can be appreciated, the fiber mat illustrated in FIG. 2 does not need to extend the full width of the bitumen compound layer, thus can only partially extend the full width of the bitumen compound layer as illustrated in FIG. 1 to create a lap line region on one or both sides of the surface-reinforced bitumen roofing membrane, thereby exposing a top surface of the bleed blocker layer. In such an optional arrangement, the lap line region can optionally include a release liner.

(44) FIG. 3 illustrates the surface-reinforced bitumen roofing membrane formed by a fiber mat that is connected to a bleed blocker layer, which bleed blocker layer is connected to the bitumen compound layer, which bitumen compound layer optionally includes release liner that is releasably connected to a bottom surface of the bitumen compound layer. The fiber mat is a non-woven mat that may or may not include binder. The bitumen compound layer may or may not include a reinforcement layer. The fibers in the fiber mat are optionally formed of fiberglass, and the fiber mat is optionally treated with a fire retardant. The surface-reinforced bitumen roofing membrane also optionally includes a removable release film that is releasably connected to the top mat to protect the membrane against water until the coating can be applied.

(45) As can be appreciated, the fiber mat illustrated in FIG. 3 does not need to extend the full width of the bitumen compound layer, thus can only partially extend the full width of the bitumen compound layer as illustrated in FIG. 1 to create a lap line region on one or both sides of the surface-reinforced bitumen roofing membrane, thereby exposing a top surface of the bleed blocker layer. In such an optional arrangement, the lap line region can optionally include a release liner.

(46) FIG. 4 illustrates the surface-reinforced bitumen roofing membrane formed by a fiber mat that is connected to a bitumen compound layer, which bitumen compound layer optionally includes a release liner that is releasably connected to a bottom surface of the bitumen compound layer. The fiber mat can be formed of multi-directional fibers that are secured together by a binder. As can be appreciated, the fiber mat can be a non-woven mat that may or may not include binder as illustrated in FIG. 3. The bitumen compound layer may or may not include a reinforcement layer. The fibers in the fiber mat are optionally formed of fiberglass, and the fiber mat is optionally treated with a fire retardant. The surface-reinforced bitumen roofing membrane also optionally includes a removable release film that is releasably connected to the top mat to protect the membrane against water until the coating can be applied. The fiber mat extends beyond the width of the bitumen compound layer and runs along the entirety of its length on one side, which will overlap the seam of an abutting modified bitumen sheet, which bitumen compound layer optionally includes release liner that is releasably connected to a bottom surface of the bitumen compound layer. Although not shown, the surface-reinforced bitumen roofing membrane can optionally include a bleed blocker layer, which bleed blocker layer is connected to the bitumen compound layer as illustrated in FIG. 2.

(47) As can be appreciated, the fiber mat illustrated in FIG. 4 can only partially extend the full width of the bitumen compound layer as illustrated in FIG. 1 to create a lap line region on one side of the surface-reinforced bitumen roofing membrane, and the other side of the bitumen compound layer fiber mat extends beyond the width of the modified bitumen. The optional lap line region exposes a top surface of bitumen compound layer, or the top surface of the bleed blocker layer when such bleed blocker layer is used. In such an optional arrangement, the lap line region can optionally include a release liner.

(48) As can be appreciated, any of the surface-reinforced bitumen roofing membranes illustrated in FIGS. 1-4 can include a) the formation of a lap line region on one or both sides of the surface-reinforced bitumen roofing membrane, b) a fiber mat that extends beyond the width of the bitumen compound layer on one or both sides of the surface-reinforced bitumen roofing membrane, or c) one side of the surface-reinforced bitumen roofing membrane includes a lap line region and the other side of the surface-reinforced bitumen roofing membrane the fiber mat that extends beyond the width of the bitumen compound layer.

(49) FIG. 5 illustrates a bitumen compound layer 10 that includes an optional reinforcement layer 30 positioned within the primary hydrocarbon compound 20. As illustrated in FIG. 5, optional reinforcement layer 30 is position in the middle of bitumen compound layer 10; however, it will be appreciated, that reinforcement layer 30 can be located closer to the top or bottom of bitumen compound layer 10. Generally, reinforcement layer 30 is spaced from the top and bottom surface of bitumen compound layer 10.

(50) FIG. 6 illustrates a non-limiting manufacturing process for forming the surface-reinforced bitumen roofing membrane. A continuous feed process is illustrated for applying the optional surface protective film and the fiber mat to the top surface of the bitumen compound layer and an optional release liner to the bottom surface of the bitumen compound layer. The manufacturing process for forming the surface-reinforced bitumen roofing membrane can be by continuous feed or with cut sections of a set length.

(51) It will thus be seen that the objects set forth above, among those made apparent from the preceding description, are efficiently attained, and since certain changes may be made in the constructions set forth without departing from the spirit and scope of the invention, it is intended that all matter contained in the above description and shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense. The invention has been described with reference to preferred and alternate embodiments. Modifications and alterations will become apparent to those skilled in the art upon reading and understanding the detailed discussion of the invention provided herein. This invention is intended to include all such modifications and alterations insofar as they come within the scope of the present invention. It is also to be understood that the following claims are intended to cover all of the generic and specific features of the invention herein described and all statements of the scope of the invention, which, as a matter of language, might be said to fall therebetween.