Cover Laminate or Cover Layer System

Abstract

The invention relates to a cover laminate such as a roof laminate or cover layer system (10) comprising at least a first layer (14), which extends on the cover side, in the form of a migration-inhibiting barrier layer or barrier film with respect to bitumen, plasticizer and/or EPS, and a second layer (12), which extends on the side away from the cover, in the form of a first nonwoven,

wherein the first layer is connected to the second layer either by means of a reactive plasticizer-resistant adhesive (16), or, in the case of formation of the first layer as a thermoplastic hot-melt adhesive film, by means of said film.

Claims

1. A cover laminate or cover layer system (10, 30, 100, 300) used for covering or sealing an element such as a structure, in particular a roof, comprising at least a first layer (14, 28), which extends on the element side, in the form of a migration-inhibiting barrier layer or barrier film with respect to at least one material from the group consisting of bitumen expanded polystyrene, plasticizer, and a second layer (12) which extends on the side away from the element in the form of a first nonwoven, wherein the first layer is connected to the second layer either by means of a reactive plasticizer-resistant adhesive (16), or, in the case of formation of the first layer as a thermoplastic hot-melt adhesive film, by means of said film.

2. The cover laminate or cover layer system according to claim 1, characterized in that, along the side of the first layer (14, 28) which extends on the element side, a third layer (24) in the form of a second nonwoven extends.

3. The cover laminate or cover layer system according to claim 2, characterized in that the third layer (24) is connected to the first layer (14, 28) via an adhesive (26) or by formation of the first layer (12) as a thermoplastic hot-melt adhesive film.

4. The cover laminate or cover layer system according to claim 1, characterized in that the adhesive (16, 26) is a reactive plasticizer-resistant hot-melt adhesive.

5. The cover laminate or cover layer system according to claim 1, characterized in that the first and/or second nonwoven (12, 24), in particular the first nonwoven and the second nonwoven, made of at least one material, is based on PES (polyester) or on a homopolymer or copolymer of ethylene and/or propylene or on PA (polyamide) or viscose or on PET (polyethylene terephthalate) or on PUR (polyurethane), in particular on PET (polyethylene terephthalate).

6. The cover laminate or cover layer system according to claim 1, characterized in that the nonwoven (12, 24) has a thickness d.sub.v such that 0.1 mm≦d.sub.v≦5 mm, in particular 0.15 mm≦d.sub.v≦0.3 mm, and/or a grammage G of 5 such that g/m.sup.2≦G≦1000 g/m.sup.2, in particular 20 g/m.sup.2≦G≦50 g/m.sup.2.

7. The cover laminate or cover layer system according to claim 1, characterized in that the reactive plasticizer-resistant hot-melt adhesive (16, 26) is based on PUR (polyurethane) and, in particular, is a 1-component hot-melt adhesive or a multi-component hot-melt adhesive, in particular a 2-component hot-melt adhesive, or the plasticizer-resistant hot-melt adhesive is a polyolefinic thermoplastic adhesive or adhesive melt, in particular based on polyethylene (PE).

8. The cover laminate or cover layer system according to claim 1, characterized in that the barrier layer or barrier film (14) consists of a material from the group consisting of PA (polyamide), copolyamide, thermoplastic polyamide (TPE-A), PET (polyethylene terephthalate), EVOH (ethylene vinyl alcohol copolymer), PP (polypropylene), PE (polyethylene), PVDC (polyvinylidene chloride), PVDF (polyvinylidene fluoride), PAN (polyacrylonitrile), PEN (polyethylene naphthalate), PC (polycarbonate) or at least contains such a material, or that the barrier layer or barrier film (28), in the form of a thermoplastic hot-melt adhesive film, is based on thermoplastics and/or thermoplastic elastomers, preferably selected from one of the groups consisting of polyethylene (PE), low-density polyethylene (LDPE), ethylene/vinyl acetate copolymer (EVA), polybutene (PB); olefin-based thermoplastic elastomers (TPE-O, TPO) such as ethylene-propylene-diene/polypropylene copolymers; crosslinked olefin-based thermoplastic elastomers (TPE-V, TPV); thermoplastic polyurethanes (TPE-U, TPU) such as TPU with aromatic hard segments and polyester soft segments (TPU-ARES), polyether soft segments (TPU-ARET), polyester and polyether soft segments (TPU-AREE) or polycarbonate soft segments (TPU-ARCE); thermoplastic copolyesters (TPE-E, TPC) such as TPC with polyester soft segments (TPC-ES), polyether soft segments (TPC-EE); styrene block copolymers (TPE-S, TPS) such as styrene/butadiene block copolymers (TPS-SBS), styrene/isoprene block copolymers (TPS-SIS), styrene/ethylene-butylene/styrene block copolymers (TPS-SEBS), styrene/ethylene-propylene/styrene block copolymers (TPS-SEPS); thermoplastic copolyamides (TPE-A, TPA), in particular thermoplastic copolyamides (TPE-A, TPA), and thermoplastic polyurethanes (TPE-U), TPU), wherein, in particular, the barrier layer is a hot-melt adhesive based on polyamide (PA).

9. The cover laminate or cover layer system according to claim 1, characterized in that the barrier layer or barrier film (14, 28) has a thickness ds such that 5 μm≦ds≦100 μm, in particular 15 μm≦ds≦50 μm, and/or is designed to be single-layered or multi-layered.

10. A use of the cover laminate or cover layer system (10, 30, 100, 300) according to claim 1 for sealing a structure, in particular as a roof cover and/or a roof seal, wherein the cover laminate or cover layer system is connected on the side away from the structure to a roofing sheet (22) and/or comprises a self-adhesive or weldable layer (20) on the structure side.

11. The use according to claim 10, characterized in that the roofing sheet (22) consists of at least one material from the group consisting of PVC (polyvinyl chloride), TPE (thermoplastic elastomer), TPO (olefin-based thermoplastic elastomer), TPV (thermoplastic vulcanizate), EPDM (ethylene propylene diene rubber), EVA (ethylene vinyl acetate), PP (polypropylene), PE (polyethylene), PA (polyamide) or at least contains one of these materials.

12. The use according to claim 10, characterized in that the layer (20) consists of at least one material from the group consisting of bitumen, butyl, SBR, elastomer or combinations thereof or of a welding composition based on polymer bitumen.

13. A method for producing a cover laminate or a cover layer system (30, 300) according to claim 1, intended for covering a structure, characterized by the method steps of heating of the first layer (28) in the form of a thermoplastic hot-melt adhesive, which faces the second layer (12), and, in the case of the use of the third layer (24), additional heating of the side of the first layer which faces the third layer, placement of the layers one on top of the other and connecting of the individual layers by pressure, or characterized by the method steps of coating of the sides of the first and of the second layer (12, 24) which face one another, and, in the case of the use of the third layer (24), additional coating of the sides of the first and of the third layer which face one another with an adhesive (16, 26), placing of the layers one on top of the other and curing of the adhesive.

14. The method according to claim 13, characterized in that, for the connection of the second layer (12) to a roofing sheet (22), the cover laminate or cover layer system (10, 100) is heated.

15. The method according to claim 13, characterized in that, as adhesive (16, 26), a reactive plasticizer-resistant hot-melt adhesive is used, which is applied, in particular, by means of a spreading knife, roller application and/or extrusion.

16. The method according to claim 13, characterized in that the nonwoven (12, 24) is to be or is mixed with superabsorbent polymers or swellable polymers.

17. The method according to claim 13, characterized in that the first layer (12) consists of a layer system or is produced from said layer system which consists of a central layer (114) exerting the migration-inhibiting action, along the outer sides of which in each case a covering layer (120, 122) extends, which, in particular, consists of a polyolefin, wherein the covering layer (120, 122) is to be or is preferably connected to the central layer (114) via an adhesive or adhesion-promoting layer (116, 118).

18. The cover laminate or cover layer system according to claim 1, characterized in that the nonwoven (12, 24) is to be or is mixed with superabsorbent polymers or swellable polymers.

19. The cover laminate or cover layer system according to claim 1, characterized in that the first layer (12) consists of a layer system or is produced from said layer system which consists of a central layer (114) exerting the migration-inhibiting action, along the outer sides of which in each case a covering layer (120, 122) extends, which, in particular, consists of a polyolefin, wherein the covering layer (120, 122) is to be or is preferably connected to the central layer (114) via an adhesive or adhesion-promoting layer (116, 118).

Description

[0094] Additional details, advantages and features of the invention result not only from the claims, the features that can be obtained therefrom—individually and/or in combination —, but also from the following description of preferred embodiment examples:

[0095] FIG. 1 shows a first embodiment of a roof laminate or roof layer system,

[0096] FIG. 2 shows a second embodiment of a roof laminate or roof layer system,

[0097] FIG. 3 shows a third embodiment of a roof laminate or roof layer system, and

[0098] FIG. 4 shows a fourth embodiment of a roof laminate or roof layer system.

[0099] In the figures, in which identical elements are provided with identical reference numerals, one can see cover laminates or cover layer systems, extending between a surface to be covered and a sealing cover sheet or sealing sheet or outside sheet—hereafter referred to as a roofing sheet—in order to prevent a migration of materials from the roofing sheet into the surface and vice versa, to the extent that the aging behavior of the roofing sheet is improved in comparison to the previously known roof layer systems, and the roof layer system is not negatively influenced by materials that tend to migrate.

[0100] The migration of bitumen, flux oils and/or plasticizers or of the volatile components thereof and/or expanded polystyrene should be prevented or inhibited. The possibility of diffusion of steam or oxygen should be provided.

[0101] Since the main application case is essentially the sealing of structures, in particular the covering of roofs, the expression roofing sheet laminate or roofing sheet layer system is used below, although the term laminate or layer system is also suitable for other coverings. To that extent, the word “roof” is not to be understood in a limiting sense.

[0102] However, for the sake of simplicity, the word “roof” is frequently used.

[0103] In FIG. 1, a so-called bilaminate 10 is represented, which comprises a nonwoven 12, referred to as second layer, and a barrier film, referred to as first layer 14, which are connected via a reactive plasticizer-resistant adhesive, which is represented in the drawing as layer 16. The first layer 14 can also be a layer system, as explained in reference to FIG. 5.

[0104] The second layer 12, —hereafter also referred to as nonwoven 12—is based on polyester or on a homopolymer or copolymer of ethylene and/or propylene, on a polyamide or on rayon, on PET (polyethylene terephthalate) or on PUR (polyurethane), in particular on PET (polyethylene terephthalate). The use of foams can also be considered.

[0105] The thickness of the second layer 12 is between 0.1 mm and 5 mm, wherein preferably a thickness between 0.15 mm and 0.3 mm is to be indicated. Possible grammages are between 5 g/m.sup.2 and 1000 g/m.sup.2, wherein an m.sup.2 weight between 20 g/m.sup.2 and 50 g/m.sup.2 should be given preference.

[0106] The first layer 14—hereafter also referred to as barrier film 14—is based, in particular, on PA (polyamide), PET (polyethylene terephthalate), copolyamide, thermoplastic polyamide (TPE-A), EVOH (ethylene vinyl alcohol copolymer), PP (polypropylene), PE (polyethylene), PVDC (polyvinylidene chloride), PVDF (polyvinylidene fluoride), PAN (polyacrylonitrile), PEN (polyethylene naphthalate), PC (polycarbonate) and can be designed to be single-layered or multi-layered. Combinations of the materials mentioned can also be considered.

[0107] Particularly preferably, the barrier film 14 consists of or contains at least one material from the group consisting of polyamide, copolyamide, thermoplastic polyamide, polyethylene naphthalate.

[0108] Preferred thicknesses of the first layer 14 are between 5 μm and 100 μm, in particular 15 μm and 50 μm.

[0109] In particular, the reactive plasticizer-resistant adhesive forming the layer 16 can a hot-melt adhesive based on a 1-component or 2-component system and cures by polyaddition. In the process, 1-component PUR adhesives cure with addition of atmospheric humidity and/or heat. The possibility also exists of combining these mechanisms, so that a first handling strength occurs by hardening due to atmospheric humidity, and the final strength occurs under the influence of heat.

[0110] In order to enable the laminate 10 consisting of the layers 12, 14, 16 to be laid on a boundary surface such as a roof 18, along the outer side of the barrier film 14, a self-adhesive adhesive layer 20 extends, which can be based, for example, on bitumen, butyl, SBR (styrene-butadiene elastomer), elastomers or combinations thereof or on a welding composition based on polymer bitumen. Other suitable adhesive layers can also be considered.

[0111] On the outer side, the roof 18 can comprise a bitumen sheet, an insulation, in particular EPS, or other roof superstructures from the roofing sector. This is subsumed under the term roof.

[0112] The outer side of the bilaminate 10 and thus of the nonwoven 12 is covered by a roofing sheet 22 which, in particular, is based on materials such as PVC (polyvinyl chloride), TPE (thermoplastic elastomer), TPO (olefin-based thermoplastic elastomer), TPV (thermoplastic vulcanizate), EPDM (ethylene-propylene-diene rubber), EVA (ethylene vinyl acetate), wherein, as roofing sheet 22, all those classified in DIN SPEC2000-21 can be considered.

[0113] As roofing sheet 22, one can also consider using film types such as PP (polypropylene), PE (polyethylene), PA (polyamide), PIB (polyisobutylene), PET (polyethylene terephthalate).

[0114] For the production of the bilaminate 10, the nonwoven 12 is first coated with the reactive plasticizer-resistant hot-melt adhesive. This can occur by application by means of rollers. The barrier film 14 is then applied onto the layer 16 formed by the hot-melt adhesive. In order to cure the hot-melt adhesive and thus for the establishment of the connection between the nonwoven 12 and the barrier film 14, an additional energy application is in principle not necessary. Instead, curing can take place over a period of two to three days, for example. However, a targeted energy application can of course be carried out in order to shorten the duration.

[0115] An appropriate laminate 10 is connected to the roof 18 via the self-adhesive adhesive layer 20. The roofing sheet 12 can then be applied onto the nonwoven 12. For this purpose, it is provided, in particular, that the bilaminate 10 is first heated—for example, by IR emitter —, so that roofing sheet composition can flow from the preheated roofing sheet 12 into the nonwoven 12, resulting in high strength due to interlocking between roofing sheet 22 and nonwoven 12.

[0116] The laminate 100, which can be seen in FIG. 2, is a trilaminate and, in addition to the first layer 14, the second layer 12 and the reactive hot-melt adhesive, extending between these layers and referred to as layer 16, it comprises a third layer 24, which extends opposite from the second layer 12 and which is also a nonwoven. The third layer 24 is also connected via a reactive plasticizer-resistant hot-melt adhesive, represented as layer 26, to the barrier film 14, so that reference is made to explanations provided above/. The trilaminate 100 which has been constructed in this manner is connected, in accordance with the bilaminate 20, on the one hand, to the roof 18 via the self-adhesive adhesive layer 20, and, on the other hand, to the roofing sheet 22 in the above-described manner.

[0117] In FIGS. 3 and 4, additional embodiments of a laminate or layer system can be seen, by means of which a migration of materials from one side to the other side or vice versa is to be prevented or inhibited or reduced. The laminates 30, 300 shown in FIGS. 3 and 4 differ from those of FIGS. 1 and 2 in that the nonwoven 12 (FIG. 3) or the nonwovens 12, 24 (FIG. 4) are not connected with a reactive plasticizer-resistant adhesive, but, instead, a barrier film 28 marked by the reference numeral 28 and connected to the nonwoven 12 or to the nonwovens 12, 24 at the same time has adhesive properties, that is to say, at the same time forms the adhesive component. For this purpose, the barrier film 28 is designed, in particular, as a thermoplastic hot-melt adhesive film. The barrier film 28 is connected directly to the nonwovens 12, 24 and not via an adhesive layer to said nonwovens.

[0118] Here, the meltable, migration-inhibiting barrier film 28—also referred to as thermoplastic hot-melt adhesive films—should be based on thermoplastics and/or thermoplastic elastomers, preferably selected from one of the groups consisting of [0119] polyethylene (PE), low-density polyethylene (LDPE), ethylene vinyl acetate copolymer (EVA), polybutene (PB) [0120] olefin-based thermoplastic elastomers (TPE-O, TPO) such as ethylene-propylene-diene/polypropylene copolymers [0121] crosslinked olefin-based thermoplastic elastomers (TPE-V, TPV) [0122] thermoplastic polyurethanes (TPE-U, TPU) such as TPU with aromatic hard segments and polyester soft segments (TPU-ARES), polyether soft segments (TPU-ARET), polyester and polyether soft segments (TPU-AREE) or polycarbonate soft segments (TPU-ARCE) [0123] thermoplastic copolyesters (TPE-E, TPC) such as TPC with polyester soft segments (TPC-ES), polyether soft segments (TPC-EE) [0124] styrene block copolymers (TPE-S, TPS) such as styrene/butadiene block copolymer (TPS-SBS), styrene/isoprene block copolymer (TPS-SIS), styrene/ethylene-butylene/styrene block copolymers (TPS-SEBS), styrene/ethylene-propylene/styrene block copolymers (TPS-SEPS) [0125] thermoplastic copolyamides (TPE-A, TPA), in particular thermoplastic copolyamides (TPE-A, TPA), and thermoplastic polyurethanes (TPE-U, TPU).

[0126] Here, the barrier layer or barrier film 28 can have a thickness ds such that 5 μm≦ds≦100 μm, in particular 10 μm≦ds≦50 μm.

[0127] For the production of the bilaminate 30, the nonwoven 12 and the thermoplastic barrier film 28 are first heated, for example, by IR emitters or heated rollers. In an additional step, the nonwoven 12 and the barrier film 28 is compressed under pressure and cooled. For this purpose, for example, a calendar stack with cooled rollers can be used. Already at temperatures barely below the melting point of the barrier film 28, but, at the latest, when room temperature is reached, the composite has solidified and can be rolled up and packaged.

[0128] In the production of the trilaminate 300, only the nonwoven 24 and the facing side of the barrier film 28 are heated and subjected to the same method as already described.

[0129] Therefore, the invention is characterized by a method for producing a cover laminate or a roof covering, having the method steps of: [0130] heating of the side of the barrier film 28 (FIG. 3) which faces the nonwoven 12 and, in the case of use of an additional nonwoven 24, additional heating of the side of the barrier film 28 which faces the nonwoven 24 (FIG. 4), [0131] placement of the layers (nonwovens 12, 24, barrier film 28) one on top of the other and connecting of the individual layers by pressure,

[0132] wherein the nonwoven 12 is then connected to a roofing sheet 22, in that at least the laminate 30, 300 is heated, for example, by IR emitters or heated rollers, and is then applied to the roofing sheet 22. p

[0133] In order to facilitate the processing during the production of the bilaminate 30 and also of the trilaminate 300, it is possible in various cases to use a carrier film, for example based on PE (polyethylene) and/or PP (polypropylene), which, in the end, or after the respective production step, can be pulled off.

[0134] The bilaminate 10 and 30 and also the trilaminate 100 and 300 can be used as lining for a self-adhesive roofing sheet, so that a unit consisting of roofing sheet 22, bilaminate 10 or 30 or trilaminate 100 or 300 with the self-adhesive adhesive layer 20 extending on the outside is available and can be used.

[0135] However, the invention is characterized in particular in that, as adhesive, by means of which the nonwoven 12 or the nonwovens 12, 24 are connected to the barrier layer 14, instead of a hot-melt adhesive consisting of PUR, a polyolefinic thermoplastic adhesive or a corresponding adhesive melt is used, wherein the latter is based in particular on polyethylene. An advantage of the use of a corresponding adhesive consists in that a good hydrolysis resistance is provided.

[0136] However, the invention is also characterized in that, as blocking or barrier layer, a layer based on polyamide is used, wherein a corresponding polyamide melt can be applied directly to the nonwoven 12 or 24, so that an additional adhesive would not be required. The application on the nonwoven 12, 24 can occur by spreading knife and/or roller application and/or by extrusion or coextrusion and/or injection molding.

[0137] When the term barrier layer or barrier film or migration-inhibiting layer is used above, it must be pointed out that this layer itself can consist of a layer system, which is to be referred to as barrier layer or barrier film or migration-inhibiting layer or film. The layer system, which is labeled 14 according to FIGS. 1 and 2, here consists of a central layer 114, which performs the migration-inhibiting action and which consists, in particular, of a material from the group consisting of polyamide, copolyamide, thermoplastic polyamide (TPE-A), polyethylene naphthalate (PET) or contains said material. The layer 114 is covered on both sides by an adhesion promoter layer or an adhesive 116, 118. On the adhesive or adhesion promoter layer 116, 118, a respective covering layer 120, 122 is then applied, which should consist of a polyolefin, wherein, in particular, as material, one should mention a material from the group consisting of PP (polypropylene), PE (polyethylene), LDPE (low-density polyethylene) or HDPE (high-density polyethylene). This layer system, which forms the first layer 14, and which is also referred to as barrier film, is then connected by means of the reactive plasticizer-resistant adhesive 16 to the nonwoven 12 or via the self-adhesive adhesive layer 20 to a substrate.

[0138] As has been explained in reference to FIGS. 1 to 4, in view of FIG. 5, the bilaminate or trilaminate is used particularly in connection with roofing sheets, wherein the nonwoven 12 is interlocked with a corresponding roofing sheet bearing reference numeral 22 in the figures, in order to establish a reliable connection.

[0139] For covering or sealing large surfaces, corresponding cover units or roofing sheet units have to be laid next to one another. In order to seal said units with respect to one another, two different possibilities exist, which can be seen in FIGS. 6 to 8.

[0140] In FIG. 6, corresponding roofing sheet units marked with reference numerals 222 and 224 are arranged next to one another. The adjoining edges are covered by a strip 226, which is then welded to the roofing sheets 22. The strips 226 should be made of the same material as the roofing sheet 22.

[0141] In FIGS. 7 and 8, an embodiment to be emphasized particularly can be seen, the aim being to weld the roofing sheet units 322, 324 to one another. As can be seen in FIG. 8, one of the roofing sheet units, namely the roofing sheet unit 324, comprises a welding edge 326, which is the edge section of the right roofing sheet 22. Thus, the bilaminate or trilaminate 10, 30, 100, 300 extends offset relative to the outer edge 328 of the roofing sheet 22, and the underside of the welding edge 326 is thus exposed. The welding edge 326 is placed on the edge of the roofing sheet 22 of the adjacent roofing sheet unit 322 and then welded to the roofing sheet 22. In this edge area, the bilaminate or trilaminate 10, 30, 100, 300 can extend flush with respect to the outer edge 330 of the roofing sheet 22. A gap of, for example, between 0.5 cm and 2 cm can of course also exist between the bilaminate edge or the trilaminate edge and edge 330 of the roofing sheet 22.

[0142] The gap A between the bilaminate or trilaminate 10, 30, 100, 300 and the outer edge 328 of the welding edge 326 should be in the range of between 5 cm and 6 cm. Offset back relative to the outer edge 332 of the bilaminate or trilaminate 10, 30, 100, 300, the self-adhesive layer 20 should then extend. The gap B is preferably in the range of between 1 cm and 2 cm.

[0143] Although the invention has been explained in a preferential manner in reference to a roof to be covered, the teaching according to the invention is not limited thereby. Instead, the teaching applies to all the application cases in which surfaces are to be covered, that is to say, in particular, any building surfaces, open air surfaces to be sealed or pool surfaces.